Abstract:
The present invention is a controller specifically for pumps, making the benefits of variable frequency drive (VFD) technology more accessible to pump users. The present invention incorporates pump-specific system optimization software, an industrial grade drive, and a menu-driven user interface, offering protection, reliability, and ease of use not possible with other variable frequency drives.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to pump controllers, and more particularly to a variable frequency drive based controller for controlling a centrifugal pump within safety parameters by using intelligent pump system monitors. 
     BACKGROUND OF THE INVENTION 
     Variable frequency drives (VFD) are used to adjust motor speed of the pump by controlling the frequency of the electrical power supplied to the motor so as to regulate flow within a pump system. It is known in the prior art to use of a VFD and an external processor to control a centrifugal pump. The VFD is used to vary pump speed and provide speed and torque measurements. Typically, prior art VFD techniques require at least one external sensor (differential pressure, discharge pressure, or flow sensor) and use pump Affinity Laws to characterize (develop performance curve) normal pump performance at a number of different operating points. These expected normal values determined from the pump characterization process are stored in the processor&#39;s memory. Then, during pump operation, performance is again determined using the above method and compared by the processor to the corresponding stored “normal” values to determine if pump operation has become degraded. 
     In other prior art pump control methods, relationships (curves) are developed between TDH and Torque for minimum and maximum allowable flow points over a variety of speeds and used to identify the operating point of the pump and determine if it is operating within an allowable minimum and maximum flow range. Pump performance curves, relationships between BHP, flow and TDH, and between BHP, torque and speed, as well the Affinity laws are used to develop the TDH vs. torque curves. Motor torque and speed values from a VFD are supplied to a processor where TDH, torque and speed relationships are used in a processor to identify the operating point of the pump and determine if the pump is operating within the allowable minimum and maximum allowable flow ranges. This method has been deployed in a VFD. 
     Although the above prior art methods are adequate for their intended purposes, it would be useful to have a pump controller that neither requires an external sensor, nor does it require performance values calculated at multiple speeds to be stored in memory. Also, it would be useful to have a controller that does not require generation of any unique performance curves, i.e. TDH vs. Torque. Such features would simplify the set-up and operation of a VFD controller for a centrifugal pump. 
     SUMMARY OF THE INVENTION 
     A method of controlling operation of a centrifugal pump in a fluid pumping system having a variable frequency drive powering an alternating current (AC) motor which turns said centrifugal pump is disclosed. The method comprises internally monitoring automatically output current and voltage of the VFD to the AC motor without the need for an external sensor; calculating automatically output power based on monitored values of said output current and voltage; checking automatically whether said calculated output power is either above a predetermined high power limit or below a predetermined low power limit for a desired setpoint; and initiating automatically a predetermined response action if said calculated output power is either above said predetermined high power limit or below said predetermined low power limit. 
     A controller implementing the above method is also disclosed. 
     Other advantages of the system of the present invention will be apparent from the following detailed description. The invention is described in more detail hereinafter with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a pumping system with a controller for controlling the pumping system according to the present invention. 
         FIG. 2  is an exemplary illustration of pump data required for program calculations of the controller according to the present invention. 
         FIG. 3  is a flow chart depicting motor data/tune set up of the controller according to the present invention. 
         FIG. 4  is a flow chart depicting control mode set up of the controller according to the present invention. 
         FIG. 5A  is a flow chart depicting a reference source set up associated with process control mode of the controller. 
         FIG. 5B  is a flow chart depicting a reference source set up associated with the speed control mode of the controller. 
         FIG. 6  is a flow chart depicting a Pump Power Monitor (PPM) logic module associated with the controller. 
         FIG. 7  is a flow chart depicting a Pump Variable Monitor (PVM) logic module associated with the controller. 
         FIG. 8  is a flow chart depicting a Pump Condition Monitor (PCM) logic module associated with the controller. 
         FIG. 9  is a flow chart depicting a Digital Input Monitors (DIM) logic module associated with the controller. 
         FIG. 10  is a flow chart depicting an Auto Setpoint Adjustment Monitor (ASAM) logic module associated with the controller. 
         FIG. 11  is a plot of a change in flow rate controlled by the ASAM in an illustrative example according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , there is shown a pumping system  10  having a variable frequency drive (VFD)  20  with a controller  30  for controlling the pumping system according to the present invention. The VFD  20  is coupled to an AC motor  40  which turns a centrifugal pump  50  at a rotational speed (n). The controller  30  operates the VFD  20  to control flow, speed or pressure of the pumping system  10 , and to identify and report pump system problems. As shown, the controller  30  includes a processor  60  connected to memory  70  which contains executable software  80  and algorithms  90  for controlling the motor and pump according to the present invention. 
     It is to be noted that, as used herein, the term “variable frequency drive” is to include adjustable frequency drives (AFDs), Variable Speed Controllers (VSCs), Variable-speed Drives (VSD), AC drives or inverter drives, Variable Voltage Variable Frequency drives (VVVF), or something similar, which operates to control motor speed. It is to be further noted that although the controller  30  of the present invention is shown embedded within the VFD  20 , in other embodiments the controller  30  may be externally connected between the VFD  20  and the motor  40  of pumping system  10 . The latter implementation permits use of the controller  30  with virtually any type of VFD devices. It is still other embodiments, VFDs having an embedded controller, or vice verse, may be modified with at least the executable software  80  to control the motor  40  and pump  50  according to the present invention. One suitable VFD  20  having an embedded controller  30  in which to modified with at least the executable software  80  of present invention is the New Reliance Electric™ GV6000 AC Drive from Rockwell Automation, Inc. (Milwaukee, Wis.). 
     The processor  60  may be a large scale integrated (LSI), VLSI, or better integrated circuit controlled by software programs allowing operation of arithmetic calculations, logic and I/O operations. Other processors, including application-specific integrated circuit (ASIC), System-on-a-chip (SoC), and digital signal processors (DSPs) are also contemplated. Memory  70  such as a random access memory, (RAM), flash memory, or other addressable memory is included within the controller  30  for storing data values as well as pump set-up parameters and operating conditions. As will be explained hereafter in greater details, the processor  60  performs processing according to the present invention by activating the executable software  80  which responds to user inputs via a user interface  100 , as well as to data  110  and the algorithms  90  to perform a myriad of arithmetic calculations for comparison with operating values. Based on the results of those calculations and the comparison with operating values, the software  80  functions to generate an alarm signal  120  indicative of an alarm condition associated with a particular operating parameter(s), and/or generates a signal which alters the current motor speed (n) to correct for an abnormal operating condition when the difference between the calculated and stored parameter values in the data  110  exceed a predetermined numeric value. 
     The controller  30  operates to generate a control signal  130  to VFD logic  140  within the VFD  20  indicative of a request to reduce or increase motor speed (n) in order to correct for detected abnormal condition. The VFD  20  then generates a signal  150  to the motor  40  corresponding to a change in voltage and/or frequency to cause the motor speed (n) to change in an amount proportional to the controller generated control signal  130 . The software  80  of the present invention will now be explained in greater details with refer made also to  FIG. 2 . 
     Basic Start-Up Flow Description 
       FIG. 2  is a flow chart depicting the basic start flow  200  provided by the software  80  to set-up the controller  30  according to the present invention. As shown, in step  202 , motor data/tune information is entered via the user interface  100  and stored as data  110  in the controller  30 . In this step, the user inputs the nameplate motor data, start/stop methods, performs a rotational check, and auto tunes the controller  30 . This is explained in greater details in a later section with reference to  FIG. 3 . In step  204 , control setup information is entered via the user interface  100  and stored as data  110  in the controller  30 . In this step, the user inputs the type of control used by the controller  30 , either speed mode or process mode. 
     It is to be noted that the software  80  of the present invention operates the controller  30  in either a speed or process mode. In the speed mode, the controller  30  maintains a specific motor speed (n) entered by the user, i.e. the setpoint, and operates in either open loop, i.e. no speed feedback or in closed loop with speed feedback  160 . Without speed feedback the controller  30  puts out a constant frequency but the actual speed of the motor/pump can vary due to motor slippage caused by load. With speed feedback  160 , the controller  30  operates in closed loop control and will continuously adjust the output frequency of the VFD  20 , i.e., signal  150 , to maintain the setpoint speed. It is to be appreciated that the controller  30  also include a number of other analog inputs  152  and analog outputs  154  as well as the a number of digital inputs  156  and digital outputs  158  for more specific needs, which are discussed in later sections. As input, the speed feedback  160  can come from either an optional external sensor  170 , e.g., a tachometer, or an internal speed feedback parameter that is an estimate of true speed calculated by the variable frequency drive (VFD) using the VFD manufacturer&#39;s algorithms provided with the VFD. By default, the controller  30  is set to use internal feedback in the speed mode, i.e., “Sensorless Vector” control. 
     In the process control mode, the controller  30  uses the input from an optional external process sensor(s)  180  as feedback and will continuously adjust speed to maintain the process variable setpoint(s). The process sensor(s)  180  can be any typical sensor such as pressure, flowmeter, temperature, etc. Note that flow measurements may be obtained using conventional flow measuring devices such as ventures, orifice plates, mag meters and the like. With the user interface  100 , the user can enter the process setpoint directly in the data  110  of the controller  30  indicated in the desired units (i.e., gpm, psi, degrees, ft of head, etc.). The controller  30  will then continuously adjust speed to maintain the desired process setpoint. 
     If the user selects speed mode in step  204 , the software  80  proceeds to step  206 , the setpoint setup. If the user selects process mode in step  204 , the software  80  via the user interface  100  prompts the user to set up the process type and scale the feedback sensor before proceeding to step  206  for entering the setpoint setup information. This is explained in greater details in a later section with reference to  FIG. 4 . In step  206 , the user will setup the reference source and setpoint for the selected control (Speed or Process) mode entered in step  204 . This is explained in greater details in a later section with reference to  FIG. 5A  (Setpoint for Process Mode) and  FIG. 5B  (Setpoint for Speed Mode). 
     In step  208 , intelligent pump system (IPS) monitor setup information is entered via the user interface  100  and stored as data  110  in the controller  30 . The available IPS monitors are Pump Power Monitor (PPM), Process Variable Monitor (PVM), Pump Condition Monitor (PCM), Digital Input Monitors (DIM), and the Automatic Setpoint Adjustment Monitor (ASAM). Each of the IPS monitors is explained in greater details in later sections with reference to  FIGS. 6-10 . 
     In step  210 , the user enters information via the user interface  100  to configure the input/output signals and stored as data in the controller  30 . In particular, in this step, the user may configure analog inputs  152  and analog outputs  154  as well as the digital inputs  156  and digital outputs  158  for more specific needs. At this point, the basic start flow  200  provided by the software  80  to set-up the controller  30  according to the present invention is now finished, and the controller  30  is now ready to operate with the use of the IPS monitors. However, it is to be appreciated that the controller  30  is ready for operation after step  206  without enabling the IPS monitors, if such is a desire. 
     Motor Data/Tune 
     Reference now is made to  FIG. 3 , which is a flowchart showing in greater detail the motor data/tune information  300  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  in step  202  ( FIG. 2 ) to set-up the controller  30  according to the present invention. In step  302 , the user may enter the speed units that the user interface  100  will display, either in revolutions per minute (RPM) or hertz (Hz). The default is RPM. In step  304 , the user may enter the units from which the controller  30  will reference power, either horsepower (HP) or kilowatts (kW). The default is HP. In step  306 , the user enters the power rating found on the motor name plate (NP Power). In step  308 , the user enters the full load amp rating found on the motor nameplate (NP FLA). In step  310 , the user enters the voltage rating found on the motor nameplate (NP VOLTS). In step  312 , the user enters the frequency found on the motor nameplate (NP HERTZ). In step  314 , the user enters the rpm found on the motor nameplate (NP RPM). In step  316 , the user enters the maximum speed the pump needs to run (MAXIMUM SPEED). This will be used as a reference for the process variable monitor (PVM). 
     In step  318 , the user enters the minimum speed the pump should run (MINIMUM SPEED). This will be used as a reference for the process variable monitor (PVM). In step  320 , the user enters the desired time for the controller  30  to give the motor  40  to reach the process setpoint after a start or speed increase command (ACCELERATION TIME). In step  322 , the user enters the rate of deceleration for all speed decreases (DECELERATION TIME). In step  324 , the user selects the signal source which commands the controller  30  to start and stop (START/RUN SIGNAL SOURCE). In step  326 , the user selects “Yes” to configure a digital input for a function loss (FUNCTION LOSS) of the START/RUN SIGNAL SOURCE. If configured for a function loss, the controller  30  will not operate when the digital input is open. In step  328 , the user selects to verify that the direction of pump rotation is correct (ROTATION CHECK). If the pump&#39;s rotation is incorrect, the user selects “No” and the controller  30  will correct the rotation. In step  330 , the user selects to initiate a non-rotational motor stator resistance test for autotuning which gives the controller  30  the best possible motor control (STATIC AUTOTUNE). 
     Control Mode 
     Reference now is made to  FIG. 4 , which shows in greater detail the control mode information  400  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  in step  204  ( FIG. 2 ). In step  402 , the user selects the mode of operation, either Speed Mode or Process Mode (CONTROL MODE). In step  404 , the user selects the type of sensor used to control the process (Flow, Temperature, Pressure, Level, or Other)(SENSOR TYPE). This sensor is connected to an analog input designated herein as Analog Input m. In step  406 , the user selects the desired units of measure for the process (UNITS). In step  408 , the user selects whether to use a differential pressure sensor to measure the flow (DIFFERENTIAL PRESSURE SENSOR). The default is no, and is an optional step in the setup of the controller  30 . In step  410 , the user selects the feedback signal sense (FEEDBACK SIGNAL SENSE). The user selects “Normal” if the process condition will increase with pump speed. The user selects “Inverse” if the process condition will decrease with pump speed. The default is normal, and is an optional step in the start-up of the controller  30 . 
     In step  412 , the user selects the type of analog input signal (ANALOG INPUT m SIGNAL). The user selects “Current” to use a current sensor, or select “Voltage” to use a voltage sensor. The default is current. In step  414 , the user enters the maximum analog input signal of Analog Input m (e.g. 20 mA or 10 VDC)(ANALOG IN m HIGH). In step  416 , the user enters the process value that corresponds to the maximum analog input signal of Analog Input m (e.g. 300 psi=20 mA)(AINm SENSOR HIGH). In step  418 , the user enters the minimum input signal of Analog Input m (e.g. 4 mA or 2 VDC)(ANALOG IN m LO). In step  420 , the user enters the process value that corresponds to the minimum input signal of Analog Input m (e.g. 0 psi=4 mA)(AINm SENSOR LOW). In step  422 , the user then goes to the setpoint setup in step  206  ( FIG. 2 ), which is explained hereafter in greater details. 
     Setpoint for Process Mode 
     Reference now is made to  FIG. 5A , which shows in greater detail the process mode setpoint information  500  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selected in step  206  ( FIG. 2 ). In step  502 , the user selects from where the process setpoint is referenced (REFERENCE SOURCE). The choices available are the user interface  100 , a process reference (e.g., sensor  180 ), a remote reference (e.g., one of the digital inputs  156  providing input from a connected network source), and a sensor connected to an analog input  152  designated herein as Analog Input n. In the follow example, Analog Input n is selected. In step  504 , the user then enters the units of measure for the sensor connected to Analog Input n (AINn SENSOR UNITS). In step  506 , the user selects “Current” if the sensor connected to Analog Input n is a current sensor, or “Voltage” if the sensor connect to Analog Input n is a voltage sensor (ANALOG INPUT n). In step  508 , the user enters the maximum input signal of the sensor connect to Analog Input n (e.g. 20 mA or 10 VDC)(ANALOG IN n HI). In step  510 , the user enters the process value that corresponds to the maximum input signal of the sensor connected to Analog Input n (e.g. 300 psi=20 mA)(AINn SENSOR HIGH). In step  512 , the user enters the minimum input signal of the sensor connected to Analog Input n (e.g. 4 mA or 2 VDC)(ANALOG IN n LO). In step  514 , the user enters the process value that corresponds to the minimum input signal of the sensor connected to Analog Input n (e.g. 0 psi=4 mA)(AINn SENSOR LOW). 
     Had the user selected either the user interface  100 , the process reference (e.g., sensor  180 , or one of the inputs  152 ), or the remote reference (e.g., one of the digital inputs  156 ) in step  502 , steps  504 - 514  would have been skipped by the software  80 . If the user selects process reference, then in step  516  the user is prompted by the software  80  to enter the value for process reference (PROCESS REF 1 ). This value PROCESS REF 1  is then the process setpoint value for controller  30 . If the user selects remote reference, then in step  518  the user selects the interface connection (e.g. port number, network address, etc.) of the remote reference providing the process setpoint value (REMOTE REFERENCE). After step  514 ,  516 , or  518 , the user is then prompted by the software  80  in step  520  to set the availability of manual override control from the user interface  100  (MANUAL OVERRIDE FROM OIM). Manual override mode is used to disable the control algorithm of the controller  30  and operate the pump in speed mode. Either the Auto/Manual button on the user interface  100  or digital inputs, if so configured, can activate the manual override mode. Once the manual override mode has been activated, it can only be deactivated by the source that enabled it. Manual override can be configured to work one of two ways, depending on the setting of the controller  30 . Either all of the IPS monitors will be disabled when manual override is activated, or all of the IPS monitors that were enabled prior to Manual Override will default to “Message Only,” except for those that are set to “Shut Down.” Once Manual Override mode has been disabled, the system returns to its original state, and all timers and alarms are reset. 
     In step  520 , the user select “Yes” to enable the manual override functionality (i.e., Auto/Manual button) on the user interface  100 , or “No” to disable this functionality. Next, if the user had selected “Yes” in step  520 , then in step  522 , the user is requested to select which speed reference is to be used on manual override (PRELOAD MANUAL OVERRIDE). If the user selects “Yes” then when the Auto/Manual button on the user interface  100  is activated, the software will load the current operating speed as the reference speed. If the user selects “No” then software will load the speed reference being entered manually by the user via the user interface when manual override is activated. If one of the digital inputs  156  is used to activate manual override mode while the system is running in process mode or speed mode, then the reference speed is determined by the preselected digital input. As mentioned above, after entering the above setpoint information, the controller  30  is ready to run with no pump protection from the IPS monitors, if such is a desire. 
     It is to be appreciated that in process control mode the present invention does not compare the actual operating point of the centrifugal pump (based on motor torque and motor speed) to minimum and maximum flow operating ranges. Rather the present invention in process control (PI) mode compares the controlled process variable (i.e., psi, flow, etc.) to a desired set point, and adjusts speed to maintain the desired set point. If the required set point for the controlled process variable cannot be attained within the present invention&#39;s preset maximum and minimum speed limits, a response action will be initiated. In addition, power at each speed may be compared to minimum and maximum power limits to determine whether the centrifugal pump is operating within its power limits. 
     An internal proportional integral control algorithms (PI regulator) is provided to manage the speed output response of the present invention to a change in a process setpoint or a change in the controlled variable. There are two ways the PI regulator can be configured to operate: Process trim, which takes the output of the PI regulator and sums it with a master speed reference to control the process; and Process control, which takes the output of the PI regulator as the speed command. No master speed reference exists, and the PI output directly controls the present invention output. 
     The user is able to input two P and I variables. Process I-time (a value between 0.00-100.00 sec) specifies the time required for the integral component to reach 100% of the process error (i.e., feedback). Process P-Gain (a value between 0.00-100.00) sets the value for the process regulator proportional component and is used in the following equation: Process Err Out×Process P-Gain=Process Output. However, the Process P-Gain should not be considered a stability factor which prevents overcorrecting and instability. Generally, although proportional control can reduce error substantially, it cannot by itself reduce the error to zero (i.e., instability will remain). The error can, however, is reduced to zero by adding the integral term (Process I-time) to the control function. The PI integrator in a closed loop seeks to hold its average input at zero, but it does not “prevent” overcorrecting as oscillation about the setpoint (above and below) can occur when correcting the average input to zero. 
     Internal sensors of the VFD are provided to monitor the output frequency and amperes, and also to store in memory the nameplate motor frequency. However, the present invention does not utilize this information in the software  80  to automatically maintain a desired flow rate ratio as mentioned above. In sharp contrast, the present invention in process variable monitor (PVM), as explained hereafter in a later section, monitors the speed required to maintain a required process setpoint (i.e., a desired flow rate) detected by a flow rate meter, and to detect a process no longer controllable within set operating speed limits and automatically initiate a user selected response action. In pump power monitor (PPM), which is also explained hereafter in a later section, in either process control mode or speed control mode, internally monitors current and voltage, and calculates VFD output power and check to see that its not above or below predetermined normal limits for a desired setpoint. Accordingly, no current reading (i.e., current value) is used in a programmed relationship between current, frequency, and flow rate, thereby making the system much easier to setup and operate. 
     The process control mode allows the present invention to take a reference signal (setpoint) and an actual signal (feedback) and automatically adjust the speed to match the actual signal to the reference. Proportional control (P) adjusts the output based on the size of the error (larger error=proportionally larger correction). Integral control (I) adjusts the output based on the duration of the error. The integral control by itself is a ramp output correction. This type of control gives a smoothing effect to the output and will continue to integrate until zero error is achieved. By itself, integral control is slower than many applications require, and, therefore, is combined with proportional control (PI). The purpose of the PI regulator is to regulate a process variable such as position, pressure, temperature, or flow rate, by controlling speed. 
     Setpoint for Speed Mode 
     Reference now is made to  FIG. 5B , which shows in greater detail the speed mode setpoint information  550  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selected in step  206  ( FIG. 2 ). In step  552 , the user selects from where the speed setpoint is referenced (REFERENCE SOURCE). The choices available are the user interface  100 , a remote reference, and analog input. In the follow example, analog input is selected. In step  554 , the user then selects whether the analog input designated as Analog Input x is ether Analog Input m or Analog Input n. In step  556 , the user selects “Current” if the sensor connected to Analog Input n is a current sensor, or “Voltage” if the sensor connected to Analog Input x is a voltage sensor (AINx TYPE). In step  558 , the user enter the maximum input signal of the sensor connected to Analog Input x (e.g. 20 mA or 10 VDC)(ANALOG IN x HI). In step  560 , the user enters the speed value that corresponds to the maximum input signal of the sensor connect to Analog Input x (e.g. 60 Hz=20 mA)(AINn SENSOR HIGH). In step  562 , the user enters the minimum input signal of the sensor connect to Analog Input x (e.g. 4 mA or 2 VDC)(ANALOG IN x LO). In step  564 , the user enters the speed value that corresponds to the minimum input signal of the sensor connect to Analog Input x (e.g. 10 Hz=4 mA)(AINx SENSOR LOW). 
     Had the user selected either the user interface  100 , the speed reference, or the remote reference in step  552 , steps  554 - 564  would have been skipped by the software  80 . If the user selects speed reference, then in step  566  the user is prompted by the software  80  to enter the value for speed reference (SPEED REF 1 ). This value SPEED REF 1  is then the speed setpoint value for controller  30 . If the user selects remote reference, then in step  568  the user selects the interface connection (e.g. port number, network address, etc.) of the remote reference providing the speed setpoint value (REMOTE REFERENCE). After step  564 ,  566 , or  568 , the user is then prompted by the software  80  in step  570  to set the availability of manual override control from the user interface  100  (MANUAL OVERRIDE FROM OIM). Just as with the process mode setpoint information, the user select “Yes” to enable the manual override functionality (i.e. AUTO/MAN button) on the user interface  100 , or “No” to disable this functionality. Next, if the user had selected “Yes” in step  570 , then in step  572 , the user is requested to select which reference speed to use on manual over (PRELOAD MANUAL OVERRIDE). If the user selects “Yes” then in manual override the software will load the current operating speed as the reference speed. If the user selects “No” then software will load the speed reference being entered manually by the user via the user interface  100  when manual override is activated. If a digital input is used to activate manual override mode while the system is running in process mode or speed mode, then the reference speed is determined by the preselected digital input. As mentioned above, after entering the above setpoint information, the controller  30  is ready to run with no pump protection from the IPS monitors, if such is a desire. The software monitors are now discussed in greater detail hereafter. 
     IPS Monitors 
     It is to be appreciated that the IPS (intelligent pump system) monitors are software agents that provide monitoring and protection features to the pump system. In one embodiment, the IPS monitors are software based and implemented directly onboard the VFD  20 , utilizing the VFD&#39;s internal processing and power measurement capabilities. Such an embodiment eliminates the need for external power measurement sensors and external processing device. In other embodiments, the IPS monitors can also be implemented using an external processor with the power signal from the VFD or an external processor and external power sensors. 
     Turning back to  FIG. 2 , if the user wished to activate one of the IPS monitors, then in step  208  from a quick start menu  212  which is provided on the user interface  100 , the user selects which IPS monitor to activate. As shown on the quick start menu, the available IPS monitors are Pump Power Monitor (PPM)  600 , Process Variable Monitor (PVM)  700 , Pump Condition Monitor (PCM)  800 , Digital Input Monitors (DIM)  900 , and the Automatic Setpoint Adjustment Monitor (ASAM)  1000 . The PPM  600  is discussed in greater details hereafter with reference made to  FIG. 6 . 
     Pump Power Monitor 
     The Pump Power Monitor (PPM) is used in either process or speed control mode to detect pump operation at power levels above or below predetermined normal levels. The present invention only requires storage of one speed and the corresponding high and low power limits at that speed. With that information, the present invention dynamically computes upper and lower power limits, and will provide a response, such as stopping the motor, if actual power is outside one of the limits. In particular, the present invention uses the affinity relationship that power is proportional to the speed cubed to determine the upper and lower power limits at a new pump speed. It is to be appreciated that the computations are formed as a function of speed and not frequency of the motor with fixed power loses taking into account. Also, The present invention does not require an external sensor, nor does it require performance values calculated at multiple speeds to be stored. Accordingly, the present invention does not require generation of any unique performance curves, i.e. TDH vs. Torque. In addition, the power limits can be selected from the pump&#39;s standard performance curves or specific values provided with pump selection/specification documents in order to protect the pump. Limits can also be selected by the customer that not only protect the pump, but may be required to protect the process. An optional motor efficiency factor can be entered as well as time delay values to allow the pump to attempt to attain normal operation and prevent spurious alarms or warnings. A list of user selectable actions that the VFD can execute upon detection of an out of limits condition is also provided. 
       FIG. 6  shows in greater detail the setup information of the PPM  600  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selecting the PPM of the present invention in step  208  from the quick start menu  212  ( FIG. 2 ). Next, in step  602 , the user sets PPM LIMITS value to either “Static” to monitor two fixed power limits, or “Dynamic” to monitor power based on power limits set and adjusted by Affinity Laws. In static mode, the power limits are fixed values and are not dynamically scaled. If static mode is used, the appropriate upper and lower power limit settings for the fixed values can be obtained from the pump performance curve or pump selection data. In dynamic mode, the power limits (PPM Hi Limit, PPM Lo Limit) are dynamically adjusted for speed based on pump Affinity Law calculations. In step  604 , the user sets a PPM SPEED value which is the speed used to calculate the dynamic power limits based on the Affinity Laws. It is also used along with the existing pump speed and pump Affinity Laws to recalculate the power limits based on current pump speed if the dynamic mode for the pump limits is enabled in step  602 . An example of this recalculation is provided in a later section. 
     In step  606 , the user enters optionally the maximum operating power before an action is taken (PPM Hi Level). The high power limit is typically set for the lowest of: power at the end of the pump performance curve; maximum rated motor power; or power rating of the magnetic coupling of a magnetic drive pump or canned motor pump. In step  608 , the user enters the maximum time the power can be equal to or above the PPM Hi Level (PPM HILIMIT TIME), if so entered. In step  610 , the user enters the minimum operating power before an action is taken (PPM Lo Level). The low power limit is typically set for the highest of the performance curve of the pump or the power required at minimum continuous recommended flow. In step  612 , the user enters the maximum time the power can be equal to or below the PPM Lo Level (PPM LoLimit Time) before any selected response actions is initiated. The delay time should be set to accommodate normal process fluctuations but which does not allow the pump to operate at low power (low flow) conditions that may result in damage to the pump. 
     The PPM also provides a user settable time delay (PPM START DELAY) before protective action based on limit settings is initiated by the controller  30  in order to allow the pump  50  to attain normal operation during startup and to help avoid spurious responses caused by normal process fluctuations. In step  614 , the user enters the amount of time before any PPM action can be taken at start-up or restart of the motor and pump. The high and low power limits are disabled during this time period. Also, a default value is provided but should be adjusted per application characteristics. It is to be noted that the PPM Start Delay is separate from an IPS Start Delay, and runs concurrently with it. The IPS Start Delay, since common to all IPS monitors, is explained in greater details in a later section. As such, the PPM Start delay enables the use of a different (longer) time delay with power monitoring protection for the startup of applications such as self-priming that may require the longer time periods before attaining normal operating conditions. 
     In step  616 , the user selects the action that the PPM takes when an out of limit event occurs (PPM RESPONSE). The selectable responses are No Action (default), Message Only, Pump Shutdown, Speed Override, and Process Override, wherein Table 1 shows the available action that the PPM can initiate. 
     Finally, in step  618 , the user may enter optionally a percent of motor efficiency (if known) to enable the estimation of power to the pump based on motor efficiency. The default is 100%. Power measurements provided by the VFD are indicative of power output from the VFD to the motor. The motor efficiency affects the actual power delivered to the pump. Since it is of interest to know power delivered to the pump by the motor, the motor efficiency should be accounted for if known. 
     
       
         
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                 Action 
                 Description 
               
               
                   
               
             
             
               
                 No Action 
                 PPM feature is disabled 
               
               
                 Message Only 
                 Messages displayed on the user interface in a Drive Status field 
               
               
                   
                 1) “PPM Hi Warn” - Power is above the high power limit 
               
               
                   
                 2) “PPM Lo Warn” - Power is below the low power limit 
               
               
                 Pump Shutdown 
                 Pump is stopped. 
               
               
                   
                 1) “PPM Hi Shtdn”- Status message displayed if PPM high power limit initiated the 
               
               
                   
                 shutdown 
               
               
                   
                 2) “PPM Lo Shtdn” - Status message displayed if PPM low power limit initiated the 
               
               
                   
                 shutdown 
               
               
                   
                 3) “Faulted PPM Shutdown”- fault pop-up box is displayed 
               
               
                   
                 4) “PPM Shutdown”- Message stored in the fault queue 
               
               
                 Speed Override 
                 Control mode changes to Speed mode. Speed setpoint changed to alternate programmable 
               
               
                   
                 preset speed. 
               
               
                   
                 1) “PPM Hi SpdOv” - Status message displayed if a high power condition initiated the 
               
               
                   
                 override 
               
               
                   
                 2) “PPM Lo SpdOv” - Status message displayed if a low power condition initiated the 
               
               
                   
                 override 
               
               
                   
                 3) “PPM Spd Override” -- Message is stored in the alarm queue 
               
               
                 Process Override 
                 Valid only in Process Mode. Process setpoint changed to alternate programmable preset 
               
               
                   
                 process setpoint. 
               
               
                   
                 1) “PPM Hi PrcOv” - Status message displayed if the high power condition initiated the 
               
               
                   
                 override 
               
               
                   
                 2) “PPM Lo PrcOv” - Status message displayed if the low power condition initiated the 
               
               
                   
                 override 
               
               
                   
                 3) “PPM Prc Override”- Message is stored in the alarm queue 
               
               
                   
               
             
          
         
       
     
     The PPM operates by internally monitoring the output power from the VFD to the pump motor. No external sensor is needed. The motor efficiency factor can be entered to enable a better estimation of the power directly to the pump. The PPM is used to detect pump operations at power levels above or below either pre-set expected normal levels or upper and lower power dynamically changing limits continuously calculated using Affinity laws. Abnormal power levels may indicate pump equipment problems or operating conditions that may be detrimental to the pump and/or the process. For example, the PPM can be used to detect underload and overload conditions such as dry running, blocked lines, cavitation or excessive wear and rubbing. Upon detection of power levels that are outside of the power limits, an appropriate action, selected from the list of PPM Response Actions, such as provided in Table 1, can be automatically initiated. Adjustable time delays entered during the PPM setup are provided to allow the pump to attain normal operating process fluctuations. A retry feature is provided to allow the controller to attempt to re-establish normal operation after a preset time delay. The retry feature since available to all of the IPS monitors is explained in a later section. 
     The PPM displays on the user interface  100  power directly in power units as horsepower or kilowatts. This allows the upper and lower limits to be determined directly from the pump manufacturer&#39;s pump performance curves or pump selection data without having to operate the pump at extremes to determine these power limits. It is to be noted that prior art power level monitoring methods typically require limits to be set using motor amperage values or percentages of full load, neither of which typically are supplied as part of pump performance specifications. With such prior art methods, this may require operating the pump at potentially detrimental extremes to measure the values in order to obtain the power limit settings. With the present invention, setting power limits without having to operate the pump to determine them adds both simplicity to the setup and protection to the pump upon initial startup or commissioning. 
     As mentioned above, the PPM is intended to protect the pumping equipment and process from conditions detectable by over (too high) and under (too low) power measurement. VFD&#39;s typically incorporate equipment protection techniques onboard. But, these techniques are generally “overload” protection based on amperage or torque measurement or estimation. It is also to be appreciated that the use of variable frequency drives with centrifugal pumps presents a challenge in setting normal high and low power limits since those values (limits) can be dependent upon the speed at which the pump is operating. If the limits are set at one operating speed and the speed changes due to process requirements, the fixed limits may no longer be adequate to provide equipment protection or provide useful pump diagnostic information. 
     The PPM provides the dynamic mode feature that will automatically (dynamically) adjust the high and low power limits utilizing Pump Affinity Laws for centrifugal pumps that define the relationship between pump power at a given speed and the power at any other speed. This feature allows high and low power limits to be set using the limits known at any one speed. The limits will then be automatically adjusted by the power monitor for any new speed. To illustrate this feature of the PPM, the following example is provided. 
     As mentioned above, and as used in this example, the following information entered by the user during PPM set-up and provided by the VFD is as abbreviated and noted as follows: “N 1 ” is the operating speed at which the upper and lower power limits are known. “P 1  UL” is the upper (high) power limit at N 1 . Note, if operating power exceeds this value, the selected action PPM RESPONSE is initiated. “P 1  LL” is the lower power limit at N 1 . Note, if operating power falls below this value, the selected action PPM RESPONSE is initiated. “Start Up Time Delay” in seconds is the time period after the motor is started that must expire before any action can be initiated by the power monitor. “High Limit Time Delay” in seconds is the time period that operating power must exceed the high limit before action can be initiated. Also, Start up delay must have expired before this delay is utilized. “Low Limit Time Delay” in seconds is the time period that operating power must be below the low limit before action can be initiated. Also, Start up delay must have expired before this delay is utilized. “Motor Efficiency” in percentage (%) is optional, and has a default of 100%. 
     It is to be noted that shaft output power is calculated by motor efficiency x VFD output power. “PPM Limits adjustment enable” in static mode limits are fixed values, and in dynamic mode the limits are automatically re-calculated for operating speed using Affinity Laws for centrifugal pumps. “N 2 ” is the current motor speed which is an internal VFD parameter continuously updated by the VFD. The “Speed Feedback” VFD parameter is used to estimate actual motor speed. It is used without requiring external encoder feedback to estimate actual motor speed. This is a different parameter than “Output Frequency” that keeps track of the VFD&#39;s output frequency. Actual motor operating speed can be different from the VFD&#39;s output frequency value due to motor loading and slippage. The present invention is setup to use “Sensorless Vector Control” operating mode. This mode allows speed estimation using the speed feedback parameter to be closer to actual operating speed than the typical “Volts/Hertz” mode. “P 2  Upper Limit” is calculated by the processor using the Affinity law for centrifugal pumps for power, i.e 
               (       P   1       P   2       )     =       (       N   1       N   2       )     3           
where P 1  is the upper power limit at N 1  RPM entered by the user and P 2  is the new upper power limit calculated at N 2  (the current operating speed) by the VFD. The equation can be re-arranged for implementation as
 
               P   2     =       P   1     ×         (       N   2       N   1       )     3     .             
“P 2  Lower Limit” is calculated by the processor using the Affinity law for centrifugal pumps for power, i.e.
 
               (       P   1       P   2       )     =       (       N   1       N   2       )     3           
where P 1  is the lower power limit at N 1  RPM entered by the user and P 2  is the new lower power limit calculated at N 2  (the current operating speed) by the VFD. The equation can be re-arranged for implementation as
 
               P   2     =       P   1     ×         (       N   2       N   1       )     3     .             
Shaft power out is the power value calculated by the VFD using (motor efficiency x VFD power out). This is the power value that high and low power limits are compared against to determine if an out of limits condition exists.
 
     With the above in mind, in use, the user knows from the Manufacturer&#39;s performance data that the pump is available for operation at 1800 RPM which is entered as N 1 . The End of Curve (EOC) flow (maximum flow rate) is 1,500 gpm. The power at EOC is 40 Hp. This value is entered as the High power limit (P 1  UL). The minimum allowable flow rate is stated as 150 gpm. The power at minimum allowable flow is 25 Hp. This value has been entered as the Low power limit (P 1  LL). The pump is now actually operating at 1600 RPM. With the PPM in dynamic mode, the High power limit (P 1  UL) at the new speed is automatically re-calculated using the equation: 
               P   ⁢           ⁢   1   ⁢     UL   new       =     P   ⁢           ⁢   1   ⁢     UL   old     ×         (       N   2       N   1       )     3     .             
Using this equation, the new High power limit (P 1 UL new ) at 1600 RPM=40 HP×(1600/1800)^3=28.09 HP. The new Low power limit is also automatically re-calculated using the equation
 
               P   ⁢           ⁢   1   ⁢     LL   new       =     P   ⁢           ⁢   1   ⁢     LL   old     ×         (       N   2       N   1       )     3     .             
The new Low power limit (P 1 LL new ) at 1600 RPM=25 HP×(1600/1800)^3=17.55 HP. Since speed may be continuously changing to attain desired process operating conditions, the power limits are also automatically re-adjusted based on any new speed. Next, the Process Variable Monitor (PVM) is discussed in greater detail.
 
Process Variable Monitor
 
     The PVM can be used while operating in Process control (PI) mode to detect a process no longer controllable within the set operating limits of the controller  30 . This may be due to a change in process fluid or system characteristics, loss of adequate suction, or equipment failure or wear.  FIG. 7  shows in greater detail the setup information of the PVM  700  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selecting the PVM of the present invention in step  208  from the quick start menu  212  ( FIG. 2 ). In step  702 , the user enters the positive and negative threshold (in percent) that the process variable being monitored must remain within before the PVM triggers a specified action (PVM THRESHOLD). In step  704 , the user enters the amount of time the process variable being monitored must be outside the threshold value before the PVM triggers a specified action (PVM ON TIME). In step  706 , the user enters the amount of time the process variable being monitored must be inside the threshold value before the PVM resets (PVM OFF TIME). Finally, in step  708 , the user selects the specified action that the PVM takes when an out of limit event occurs (PVM RESPONSE), which are listed in Table 2 below. 
     The PVM operates by monitoring the speed required to maintain the required process setpoint. The motor data/tune information includes, inter alia, the maximum and minimum speeds that the pump should run in the process to maintain the desired flow rate. Such information is used as the minimum and maximum references for the PVM. Accordingly, the PVM detects when a process is no longer controllable within the present operating speed limits, and can initiate an alternative pre-established process setpoint, switch to speed mode at a pre-established speed setpoint or take other action as listed in Table 2 to optimize plant output and pump availability. If the required setpoint for the controlled process variable (i.e., psi, flow, etc.) cannot be attained within the IPS Tempo&#39;s preset maximum and minimum speed limits, the PVM response action will automatically be initiated. Adjustable time delays entered during setup are provided to allow the pump to attain normal process fluctuations. A retry feature is provided to all the IPS monitors to re-establish normal operation after a preset time delay. As mentioned above in a previous section, the present invention stores motor data/tune information. 
     
       
         
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                 Action 
                 Description 
               
               
                   
               
             
             
               
                 No Action 
                 PPM feature is disabled 
               
               
                 Message Only 
                 Messages displayed on the user interface in a Drive Status field 
               
               
                   
                 3) “PVM Hi Warn” - Maximum speed and setpoint is not attained 
               
               
                   
                 4) “PVM Lo Warn” - Minimum speed and setpoint is not attained 
               
               
                 Pump Shutdown 
                 Pump is stopped. 
               
               
                   
                 1) “PVM Hi Shtdn”- Status message displayed if PVM maximum speed condition initiated 
               
               
                   
                 the shutdown 
               
               
                   
                 2) “PVM Lo Shtdn” - Status message displayed if PVM minimum speed condition initiated 
               
               
                   
                 the shutdown 
               
               
                   
                 3) “Faulted PVM Shutdown”- fault pop-up box is displayed 
               
               
                   
                 4) “PVM Shutdown”- Message stored in the fault queue 
               
               
                 Speed Override 
                 Control mode changes to Speed mode. Speed setpoint changed to alternate programmable 
               
               
                   
                 preset speed. 
               
               
                   
                 1) “PVM Hi SpdOv” - Status message displayed if the max spped condition is initiated 
               
               
                   
                 2) “PVM Lo SpdOv” - Status message displayed if a minimum speed condition is initiated 
               
               
                   
                 3) “PVM Spd Override” -- Message is stored in the alarm queue 
               
               
                 Process Override 
                 Valid only in Process Mode. Process setpoint changed to alternate programmable preset 
               
               
                   
                 process setpoint. 
               
               
                   
                 1) “PVM Hi PrcOv” - Status message displayed if the maximum speed condition initiated 
               
               
                   
                 the override 
               
               
                   
                 2) “PVM Lo PrcOv” - Status message displayed if the minimum speed condition initiated 
               
               
                   
                 the override 
               
               
                   
                 3) “PVM Prc Override”- Message is stored in the alarm queue 
               
               
                   
               
             
          
         
       
     
     To determine flowrate, an external flowmeter is used. The flowmeter can be a direct flowrate reading device or a differential pressure style flowmeter. However, it is to be noted that the present invention does not perform TDH calculations as mentioned above. Also, there is no response taken by the controller  30  to ensure that the speed signal produced is only for a speed that will produce a flow rate resulting in a pump pressure with a non-positive slope. 
     Pump Condition Monitor 
     The PCM can be used to detect abnormal pump or process conditions by monitoring the signal from a sensor connected to one of the IPS Tempo&#39;s analog input channels. The PCM can then initiate the appropriate action selected from a list of available response actions when an abnormal pump or process operating conditions is detected. The PCM can be used while operating in either process control mode or speed control mode. Examples of monitored conditions include: Vibration, Lube health, Temperature, Pressure, and Flow. 
       FIG. 8  shows in greater detail the setup information of the PCM  800  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selecting the PCM of the present invention in step  208  from the quick start menu  212  ( FIG. 2 ). In step  802 , the user selects the source of the signal that the PCM checks (Analog 2  Value is the default)(PCM SOURCE). The source for the monitored sensor signal can be from either of the two analog input channels, Anlg 1  or Anlg 2 . The sensor signal from an analog input channel can optionally be further scaled by using one of the four scale blocks of the controller  30  prior to processing by the PCM. In steps  804 - 812 , the user sets up the selected analog input. Since these step are same as steps  506 - 514  performed during the setup of the Setpoint for Process Mode ( FIG. 5A ), no further discussion is provided. 
     In step  814 , the user selects either “Boundary mode or “Level” mode (Level is the default)(PCM MODE). There are two operating modes for the PCM: Level (signal threshold) and Boundary. The signal threshold Level mode provides two separate adjustable levels. It acts based upon the sensor signal crossing one or both preset levels in the same direction (rising or falling), i.e., “High” and “Higher” or “Low” and “Lower.” Each level can initiate a separate response. The Boundary mode action is based upon the sensor signal rising above the preset “Max” value or dropping below the preset “Min” value. Accordingly, in step  816 , the user specifies the minimum PCM limits in Boundary mode or Level  1  limits in Level mode (PCM LEVEL  1 /MIN). In Level mode, it is the first of the two levels to be crossed to initiate a PCM response. In Boundary mode, it is the value that the sensor signal must be below for any PCM response action to be initiated. In step  818 , the user specifies the maximum PCM limits in Boundary mode or Level  2  limits in Level mode (PCM LEVEL  2 /MAX). In Level mode, it is the second of the two levels to be crossed to initiate a PCM response. In Boundary mode, it is the value that the sensor signal must exceed before any PCM response action to be initiated. 
     In step  820 , the users enters the maximum time that the monitored signal can be outside Level  1  before the action is initiated (PCM LEVEL  1  TIME). In step  822 , the user enters the maximum time that the monitored signal can be outside Level  2  before the action is initiated (PCM LEVEL  2  TIME). In step  824 , the user selects the action that the PCM takes when an out of limit event (outside of Level  2 ) occurs (PCM LVL  2  ACTION). In step  826 , the user selects the action that the PCM takes when an out of limit event (outside of Level  1 ) occurs (PCM LVL  1  ACTION). The actions are listed in Table 3 below. 
     
       
         
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
               
                 Action 
                 Description 
               
               
                   
               
             
             
               
                 No Action 
                 PPM feature is disabled 
               
               
                 Message Only 
                 Messages displayed on the OIM in the Drive Status field 
               
               
                   
                 1) “PCM Hi Warn” -- Status message is displayed if the maximum boundary (Boundary) or 
               
               
                   
                 “Level 2” (Level) are exceeded 
               
               
                   
                 2) “PCM Lo Warn” -- Status message is displayed if “Level 1” (Level) is exceeded of if the 
               
               
                   
                 value has dropped below the minimum boundary (Boundary) 
               
               
                 Pump Shutdown 
                 Pump is stopped 
               
               
                   
                 1) “PCM Hi Shtdn” -- Status message is displayed if the monitored condition is above 
               
               
                   
                 “Level 2” (Level) or “Max” (Boundary) 
               
               
                   
                 2) “PCM Lo Shtdn” -- Status message is displayed if the monitored condition is above 
               
               
                   
                 “Level 1” (Level) or below “Min” (Boundary) 
               
               
                   
                 3) “Faulted F.142 PCM Shutdown” -- IPS Tempo fault pop-up box is displayed 
               
               
                   
                 4) “PCM Shutdown” -- Message is stored in the fault queue 
               
               
                 Speed Override 
                 Control mode changes to Speed mode. The speed setpoint is change to an alternate 
               
               
                   
                 programmable preset speed 
               
               
                   
                 1) “PCM Hi SpdOv” -- Status message is displayed if the monitored condition above “Level 
               
               
                   
                 2” (Level) or “Max” (Boundary) initiated the override 
               
               
                   
                 2) “PCM Lo SpdOv” -- Status message is displayed if the monitored condition above “Level 
               
               
                   
                 1” (Level) or below “Min” (Boundary) initiated the override 
               
               
                   
                 3) “PCM Spd Override” -- Message is stored in the alarm queue 
               
               
                 Process Override 
                 Valid only in Process Mode. The process setpoint is change to an alternate programmable 
               
               
                   
                 preset process setpoint. 
               
               
                   
                 1) “PCM Hi PrcOv” -- Status message is displayed if the monitored condition above “Level 
               
               
                   
                 2” (Level) or “Max” (Boundary) initiated the override 
               
               
                   
                 2) “PCM Lo PrcOv” -- Status message is displayed if the monitored condition above “Level 
               
               
                   
                 1” (Level) or below “Min” (Boundary) initiated the override 
               
               
                   
                 3) “PCM Prc Overide” -- Message is stored in the alarm queue 
               
               
                   
               
             
          
         
       
     
     In step  828 , the user specifies the amount of time (for either level) that must elapse before the out of range condition is considered reset (PCM OFF TIME). The PCM Level and Off Time delays are provided to avoid spurious PCM responses caused by normal process fluctuations. A retry feature is provided to allow the controller to attempt to re-establish normal operation after a preset time delay. The retry feature is discussed in a later section. 
     Digital Input Monitors 
     Digital Input Monitors (DIM) are used to detect and respond to conditions or events indicated by discrete (On/Off) switching devices connected to one of the three digital input channels. Such discrete switching devices are, for example, limit switches, level switches, pressure switches, temperature switches, flow switches, relay contacts, and the like. Each DIM can be used in Process control (PI) mode or Speed control mode. 
       FIG. 9  shows in greater detail the setup information of each of the DIMs  900  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selecting one of the DIMs of the present invention in step  208  from the quick start menu  212  ( FIG. 2 ). In step  902 , the user enters the amount of time required to activate the DIM (DIMN ON TIME). This is the adjustable time period that must expire after a DIM input senses the “On” state before the selected DIM response is initiated. In step  904 , the user enters the amount of time required to deactivate the DIM 6  (DIMN OFF TIME). This is the adjustable time period that must expire after a DIM input senses the “Off” state before the DIM “On” state is re-established. In step  906 , the user set the operation of the DIM (INVERT DIMN OPERATION) The user selects “No” for normal operation (high equals On), and selects “Yes” for inverted operation (low equals On). In step  908 , the user selects the action that the DIM takes upon activation (DIM 6  RESPONSE). The available response are listed in Table 4 below. 
     
       
         
               
               
             
           
               
                 TABLE 4 
               
               
                   
               
               
                 Action 
                 Description 
               
               
                   
               
             
             
               
                 No Action 
                 PPM feature is disabled 
               
               
                 Message Only 
                 Messages displayed on the OIM in the Drive Status field 
               
               
                   
                 1) “DIMn Hi Warn” -- DIMn at “High” (1) state 
               
               
                   
                 2) “DIMn Lo Warn” -- DIMn at “Low” (0) state 
               
               
                 Pump Shutdown 
                 Pump is stopped 
               
               
                   
                 1) “DIMn Hi Shtdn” -- Status message is displayed if a “High” (1) state on digital input n 
               
               
                   
                 initiated the shutdown 
               
               
                   
                 2) “DIMn Lo Shtdn” -- Status message is displayed if a “Low” (0) state on digital input n 
               
               
                   
                 initiated the shutdown 
               
               
                   
                 3) “Faulted DIMn Shutdown” -- Controller fault pop-up box is displayed 
               
               
                   
                 4) “DIMn Shutdown” -- Message is stored in the fault queue 
               
               
                 Speed Override 
                 Control mode changes to Speed mode. The speed setpoint is change to an alternate 
               
               
                   
                 programmable preset speed 
               
               
                   
                 1) “DIMn Hi SpdOv” -- Status message is displayed if a “High” (1) state on digital input n 
               
               
                   
                 initiated the override 
               
               
                   
                 2) “DIMn Lo SpdOv” -- Status message is displayed if a “Low” (0) state on digital input n 
               
               
                   
                 initiated the override 
               
               
                   
                 3) “DIMn Spd Override” -- Message is stored in the alarm queue 
               
               
                 Process Override 
                 Valid only in Process Mode. The process setpoint is change to an alternate programmable 
               
               
                   
                 preset process setpoint. 
               
               
                   
                 1) “DIMn Hi PrcOv” -- Status message is displayed if a “High” (1) state on digital input n 
               
               
                   
                 initiated the override 
               
               
                   
                 2) “DIMn Lo PrcOv” -- Status message is displayed if a “Low” (0) state on digital input n 
               
               
                   
                 initiated the override 
               
               
                   
                 3) “DIMn Prc Override” -- Message is stored in the alarm queue 
               
               
                   
               
             
          
         
       
     
     The DIM operates by monitoring the “ON” and “OFF” status of the digital inputs of the controller  30 . The ON and OFF states of the digital inputs are determined by the voltage levels applied to them as defined in the I/O specification. Upon detection of a DIM ON state, the response action of the controller  30  that was selected during the DIM setup is initiated. Time delays are provided and configured during DIM setup. Time delays enable the pump to attain normal operating conditions during pump starting. They also allow the pump to avoid spurious DIM responses caused by normal operation after a DIM has initiated a response action and a preset time period has expired. 
     Auto Setpoint Adjustment Monitor 
     The Auto Setpoint Adjustment Monitor (ASAM) is used to automatically modify (adjust) a process control or speed setpoint in response to a signal from an analog sensor (e.g., sensor  170  or  180 )( FIG. 1 ) connected to one of the analog input channels (Analog In n) of the controller  30  that utilizes a customizable input-output relationship defined by multiple input/output data value pairs provided in a scaling table. In particular, the sensor signal is acted upon by a programmable multi-point scaling operation defined by the scaling table that determines the effect of the signal on the process control or speed setpoint. The multi-point scaling table consists of ten pairs of values. Each pair contains an “Input Signal %” that can range from 0% to 100% and an “Output Scaler %” that can range from 0% to 150%. The signal from the analog input (Analog In n), in the range of 0% to 100% as defined by Analog In n Lo and Analog In n Hi during the setup procedure of the controller  30 , is compared to the “Input Signal %” values in the scaling table. The “Output Scaler %” in the scaling table pair at which the Analog Input n % matches the “Input Signal %” becomes the setpoint multiplier value. Interpolation is used to calculate values that fall between points in the scaling table. In order to use the ASAM it must be enabled, speed or process control setpoint selected, and the multi-point scaling table populated with value pairs that result in the desired setpoint scaling profile. This is accomplished using the ASAM setup menu selected from the quick start menu  212  ( FIG. 2 ). 
       FIG. 10  shows in greater detail the setup information of the ASAM  1000  requested by the software  80  and entered into data  110  of the controller  30  by the user via the user interface  100  if selecting the ASAM of the present invention in step  208  from the quick start menu  212  ( FIG. 2 ). In step  1002 , the user Select “On” to enable the ASAM (MPS ENABLE), wherein the default is “Off” which disables the ASAM. As mentioned above, enabling the ASAM allows it to modify the process or speed setpoint by applying a scaling multiplier calculated using a multi-point scaling table, which is explained in greater detail in a later section in reference to Table 5. In steps  1004 - 1012 , the user sets up the selected analog input. Since these step are same as steps  506 - 514  performed during the setup of the Setpoint for Process Mode ( FIG. 5A ), no further discussion is provided. In step  1014 , the user selects either “Speed” for speed mode, “Process” for process mode, or “Both” for controlling the active mode, either speed or process mode (SETPOINT TYPE). 
     In step  1016 , the user enters into the scaling table values for the conversion of input values to output values of the selected process or speed reference, which is determined by selected control mode (speed or process). The scaling table comprises percent (%) values range from 0% to 100% of the ten input signal (MPS INPUTn (n=1 to 10)) and are the values that are compared with the values from an analog input (Analog In n) of the controller  30  that can also range from 0% to 100%. When a match is found, the output signal % paired with the matched input signal % becomes the output signal % scaling multiplier that is applied to the setpoint. Interpolation is used to determine values that fall between points in the conversion profile. Also, input values n+1 must be greater than input value n. The first input value does not need to be 0, and any value lower than the first input value will automatically be interpolated between 0 and that value in the scaling table. 
     Finally, in step  1018 , the user enters values into the scaling table for the conversion of output values to control setpoint values of the selected control mode (process or speed mode). The percent (%) values of the ten output signals (MPS OUTPUTn (n=1 to 10)) can ranges from 0% to 150%. These values are used as scaling multipliers for the speed or process control setpoint. To effectively apply the ASAM, the input and output signal % values must be properly selected. This involves understanding the relationships between the measured parameter used to modify the speed or process setpoint and the resulting impact on the process and pump due to the setpoint change. System requirements can determine the amount of speed or process setpoint change that is allowable. For example, systems containing a static head component may limit speed to a value sufficient to overcome the static head and maintain adequate pump flow. 
     The following is an example of an application of the ASAM. The task monitored and performed safely by the ASAM is to empty a tank at a decreasing flow rate as the tank level decreases. The following system information is as follows: tank height is 50 feet; initial flow rate is 100 gpm; a flow feedback sensor attached to first analog input channel of the controller  30 ; and a tank level/pressure sensor is calibrated in feet is installed to measure the tank level. For this task, it is desired to permit the initial flow rate of 100 gpm until the tank level reaches 25 feet (50% maximum level). Starting at level of 25 feet, however, it is desired to reduce the flow rate by 15% (15 gpm) for each 10% (5 feet) reduction in level in order to provide a more controlled pump out and/or help prevent pump cavitation. The solution to the task is as follows. 
     First, the user configures a second analog input channel for the tank level sensor, and attaches the tank level sensor to second analog input in order to monitor the tank level. Second, the controller  30  is set to process control mode, and finally, the ASAM is enabled and the scaling table is configured using the information in Table 5 below. 
     The In % and Out % values shown in Table 5 are entered into the ASAM&#39;s MSP Input and Output value pairs in steps  1016  and  1018 , respectively. The MPS Input and Output values can be modified as required to generate a desired operating setpoint profile. In this example, the ASAM In % represents the tank level in % of maximum level/pressure sensor value. The Out % represents the flow rate multiplier for the corresponding In % level sensor. 
     
       
         
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 5 
               
             
             
               
                   
               
               
                 (Scaling table) 
               
             
          
           
               
                   
                   
                   
                   
                   
                 Resulting 
               
               
                   
                   
                   
                   
                   
                 Flow Rate 
               
               
                   
                   
                   
                   
                   
                 Setpoint 
               
               
                   
                 Tank 
                   
                 ASAM In % 
                 ASAM 
                 (ASAM 
               
               
                 Tank 
                 Level 
                   
                 (% Tank 
                 Out % 
                 Out % × Initial 
               
               
                 Level 
                 (Sensor 
                 ASAM 
                 Level 
                 (Flow Rate 
                 Flow Rate) 
               
               
                 (Feet) 
                 %) 
                 Data Pair 
                 Sensor) 
                 Multiplier) 
                 (gpm) 
               
               
                   
               
             
          
           
               
                 5 
                 10 
                 1 
                 10 
                 40 
                 40 
               
               
                 10 
                 20 
                 2 
                 20 
                 55 
                 55 
               
               
                 15 
                 30 
                 3 
                 30 
                 70 
                 70 
               
               
                 20 
                 40 
                 4 
                 40 
                 85 
                 85 
               
               
                 25 
                 50 
                 5 
                 50 
                 100 
                 100 
               
               
                 30 
                 60 
                 6 
                 60 
                 100 
                 100 
               
               
                 35 
                 70 
                 7 
                 70 
                 100 
                 100 
               
               
                 40 
                 80 
                 8 
                 80 
                 100 
                 100 
               
               
                 45 
                 90 
                 9 
                 90 
                 100 
                 100 
               
               
                 50 
                 100 
                 10 
                 100 
                 100 
                 100 
               
               
                   
               
             
          
         
       
     
     Thus, as the tank level varies, the ASAM Out % value adjusts (scales) the flow rate setpoint. In this case, the flow rate setpoint is reduced by 15 gpm for each 5 foot drop below the feet level.  FIG. 11  plots the change in flow rate controlled by the ASAM in this example. 
     In view of the above, it is to be noted that the ASAM is useful in applications such as “Load Out,” where a suction pressure sensor is used to indicate the level in the vessel to be unloaded or the NPSH available to the pump. The ASAM provides a more controlled unload as well as reduces the possibility of cavitation due to insufficient NPSH available by slowing down the pump as the tank empties. 
     Global Actions 
     Finally, the present invention has global actions that can be initiated by all of the IPS Monitors  600 ,  700 ,  800 ,  900 ,  1000  and are configured separately from the individual monitors. These global actions include Energize Digital (Discrete) Output Relay, and Auto retry. For Energize Digital (Discrete) Output Relay, any of the digital output relays (Alarms  120 , digital outputs  158 ) of the controller  30  can be activated. These digital output relays can be used to initiate other use defined actions such as, for example, condition annunciation using external lamps, beacons, sirens, condition signaling to an external controller, energizing other equipment (i.e., starting an additional pump), and the likes. 
     Auto retry will cause the controller  30 , after a preset time delay, to attempt to re-establish normal operation (i.e., the speed or process setpoint prior to the detection of the condition that initiated the action). When auto restart is enabled by the user setting a value greater than zero for the number of restarts of the auto retry (Auto Rstrt Tries), and an auto reset fault occurs, the controller  30  will stop and remain in the fault condition. After the number of seconds in the user defined delay of the auto retry (Auto Restrt Delay) has elapsed, the controller  30  will automatically reset the faulted condition. The controller  30  will then issue an internal start command to restart. If another auto-resettable fault occurs, the cycle will repeat up to the number of attempts specified by the user (Auto Rstrt Tries) during set up. 
     If the controller  30  faults repeatedly for more than the number of attempts specified in Auto Rstrt Tries with less than five minutes between each fault, the controller  30  will remain in the faulted state. The fault Auto Rstrt Tries will be logged in the fault queue. The auto restart feature is disabled when the controller  30  is stopping and during autotuning. It is to be noted that a DC Hold state is considered stopping. The following conditions will abort the auto retry process: issuing a stop command from any control source; issuing a fault reset command from any active source; removing the enable input signal; setting Auto Restrt Tries to zero; occurrence of a fault that is not auto-resettable; removing power from the IPS Tempo; and exhausting an auto-reset/run cycle. 
     The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein, may be suitably practiced in the absence of the specific elements which are disclosed herein.