Alternating 2 Pumps with the EZ Relay

Technical Document

September 2006

Supporting Documentation

Manual Name Reference Number

EZ512-DC-RC MN05013003E

Link to search Eaton Electrical Web site www.eatonelectrical.com

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Overview
The purpose of alternating pump controls is to equalize the run time of each pump in a
multi-pump system. If there are two pumps in the system, there are five different control
schemes to consider.
1. One pump on at all times pump alternation occurs at a specific time of day, such as
midnight.
2. One pump on while switch is closed pump A turns on when a switch closes, and
turns off when the switch opens. The next time the switch closes, pump B is on for
the duration of the switch closure.

Switch 2

Switch 1 Liquid level

Type 3 pump alternation float switches in tank

Fig. 1
3. One pump on when two switches have closed, and off when both have opened
switch 1 closes, and nothing happens. Then, switch 2 closes, and pump A turns on.
Switch 2 opens and pump A remains on. Finally, switch 1 opens and pump A turns
off. The next switch cycle controls pump B in a similar manner.
Lag

Lead

Off

Liquid level

Types 4 and 5 duplex pump float switches in tank

Fig. 2

Page 2 of 5 TD51738
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 4. Lead / lag, first on first off (FOFO) three switches (off, lead, and lag) are used.
When off closes, nothing happens. Next, lead closes and pump A turns on. Finally,
lag closes and pump B turns on. As the level drops, lag opens, and both pumps
remain on. When lead opens, pump A turns off. When off opens, pump B turns off.
During the next switch cycle, pump B is the lead pump, turning on first and turning off
first.
5. Lead / lag, sequence on simultaneous off (SOSO) three switches (off, lead, and
lag) are used. When off closes, nothing happens. Next, lead closes, and pump A
turns on. Finally, lag closes and pump B turns on. As the level drops, lag opens and
both pumps remain on. Lead opens and both pumps remain on. When off opens,
both pumps turn off. During the next switch cycle, pump B is the lead pump, turning
on first.
Control schemes 3-5 above refer to maintaining a level in a tank using float switches as
inputs to the control. The level may be a low level in emptying applications as described
above, or a high level in filling applications. For filling applications, replace the word
drops with rises in descriptions 4 and 5 above. Also, the descriptions above and the
attached configuration programs assume that the float switch is open when the liquid
level is below it, and closed when the liquid level is at or above it.
Regardless of the control scheme, there must be a method of bypassing a selected pump
for maintenance purposes so that it does not turn on as long as the bypass signal is
present.
Pumps generally are monitored by hourmeters, which keep track of the run time. The EZ
relay has built-in hourmeters, which can be used for this purpose. The EZ display can
show both run times on a single screen. Furthermore, these run timers are presettable,
and can cause an output to turn on when either pump reaches its preset maintenance
time. The run time presets used in the attached programs are set to 2 hours for initial
checkout purposes. Once the system is checked out, set the preset values for run timers
O1 and O2 to appropriate values. The run times are viewable on the display by pressing
pushbutton P2 (up arrow). Press P4 (down arrow) to return to the normal status display, if
desired.

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Setup
Parts required:
1. EZ512-xx-Rx
Any EZ512 relay with display and relay output. The display is necessary to view run
times.
2. EZSOFT
Programming software for the EZ relay.

There are two EZ configuration programs attached to this document, named Alternating
2 pumps.e60, and Duplex pump lead-lag.e60. For any of the alternating pump control
schemes described in types 1-3 above, use Alternating 2 pumps.e60. For either of the
duplex control schemes described in types 4 and 5 above, use Duplex pump lead-
lag.e60.

Connections for control schemes 1-3 (Alternating 2 pumps.e60):

Inputs:
I1 Switch 1 for types 2 and 3, not used for type 1
I2 Switch 2 for type 3, not used for types 1 and 2
I3 Not used
I4 Bypass pump A. I4 will turn off and hold off pump A as long as it is activated via
an operator switch. Pump B will handle all the pumping during this period, unless
it is also bypassed.
I5 Bypass pump B. I5 will turn off and hold off pump B as long as it is activated via
an operator switch. Pump A will handle all pumping during this period, unless it is
also bypassed.
I6 Control scheme select 1. Hardwire on or leave open per table below.
I7 Control scheme select 2. Hardwire on or leave open per table below.
I8 Run timer(s) reset. Momentary activation will reset any run timer that has
reached its preset value. Holding I8 on for three seconds will reset both run
timers, regardless of their present values.

Control scheme selection

Type 1 Type 2 Type 3

I6 off on on

I7 off off on

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 Outputs:
Q1 Pump A
Q2 Pump B
Q3 Not used
Q4 Maintenance alarm (run timers)
Connections for control schemes 4 & 5 (Duplex pump lead-lag.e60):
Inputs:
I1 Switch 1 (off)
I2 Switch 2 (lead)
I3 Switch 3 (lag)
I4 Bypass pump A. I4 will turn off and hold off pump A as long as it is activated via
an operator switch. Pump B will handle all the pumping during this period, unless
it is also bypassed.
I5 Bypass pump B. I5 will turn off and hold off pump B as long as it is activated via
an operator switch. Pump A will handle all pumping during this period, unless it is
also bypassed.
I6 Type select. On selects type 4 (FOFO), off selects type 5 (SOSO). Hardwire
on for type 4 operation, or leave open for type 5 operation.
I7 Not used
I8 Run timer(s) reset. Momentary activation will reset any run timer that has
reached its preset value. Holding I8 on for three seconds will reset both run
timers, regardless of their present values.
Outputs:
Q1 Pump A
Q2 Pump B
Q3 Not used
Q4 Maintenance alarm (run timers)

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