Esc 8 tuv 7 pqrs 9 wxyz 0 * # 5 jkl 4 ghi 6 mno 2 abc 1 ,. 3 def 0 A 1.30 m 0.50 m 1.50 m 0.55 m 1.70 m 0.60 m 1.90 m 0.65 m 352.5 A 353.8 A 354.1 A 1.55 m 1827 l/s MAIN STATUS SETTING TREND ALARM ACKN. PUMP 4 PUMP 3 PUMP 2 PUMP 1 2013.08.21 05:56:19 Low level 980.3 l/s m P3 P4 P1 P2 3 0 07:25:58 07:28:10 07:30:26 0.15 kWh/m3 CA 511 0 1 2 3 4 5 6 7 8 9 A B C D E F CA 441 0 1 2 3 4 5 6 7 8 9 A B C D E F CA 442 0 1 2 3 4 5 6 7 8 9 A B C D E F CA 443 CA 781 CAN CA 622 RX/TX ON-OFF 485-term. 0V -485 +485 6 7 8 A B V+ H Shld L V- 1 2 3 5 4 CAN Bus www.sulzer.com Pump controller type ABS PC 441 EN User guide SW 1.70 81307063J (07/2019)
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This manual, as well as the software described in it, is furnished under license and may be used or copied only in accordance with the terms of such license. The content of this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Sulzer. Sulzer assumes no responsibility or liability for any errors or inaccuracies that may appear in this book.
Except as permitted by such license, no part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Sulzer.
Sulzer reserves the right to alter specifications due to technical developments.
Installation guide There is a separate document Installation guidethatdescribeshowtophysicallyinstallthepumpcontroller(printeddocumentintheinstallationpackage,andalsoaPDFonSulzerweb).
4. Youmustknowhowoverflowwillbemeasured:ifitwillbemeasuredusingbothanoverflowdetector(tode-tectthestartoftheoverflow)andalevelsensor(tomeasuretheactualflow),youmustknowtheparameters(exponentsandconstants)tobeenteredassettingssothattheoverflowcanbeaccuratelymeasuredbyacalculation in PC 441.
Reading guide Forinstallation,seetheseparatedocumentsInstallation guidesforrespectiveproduct,PC441,CA511,CA44x,CA622andCA781,whichcanbefoundonSulzerhomepage.Beforeyoumakeanysettings,orusethecontrolpanel,readchapter 1 Overview of functions and usage—itdescribesthegeneralfunctionalityandthe meaning and usage of the controls on the panel.
NOTE! The default settings are listed in the Installation guide.
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Text appearing and declaration in this guide TextinitalicisadescriptionoftextinthedisplayofCA511oradescriptionhowyoufindyourwaythroughthemenusbykeystrokes.Textsinbold,ishowyouhavetodoachangeofthesettingsintheCA511menu.
Most settings in chapter 6onlyapplytothesystemadministrator,butthefollowingalsoapplytothosewhoonlyoperatethecontroller:languageselection,dateandtimesettings,units,backlighttime-out,buzzer,operatorpasscode,start/stoplevels.
Digital in means a signal that is either on or off (high or low),wherehighisanythingbetween5and24voltsDC,andlowisanythingbelow2volts.
Digital outputAnoutputsignalthatiseitheron or off. Atonconditionoutputcurrentissourcedfromthepowersupplyandtheoutputishigh(~V+).Atoff condition the output is low (no output current). Aretypicallyconnectedtorelays.
Analog outputs Anoutputsignalintherange4-20mAor0-20mA. Sourcedfrompowersupply.
Analog inputsareforsensors,andtheseinputssensecurrentintherange4-20mAor0-20mA.
ThePC441canworkstandaloneortogetherwithextensionmodules,buttheextensionmodulescannotworkwithout the PC 441.
.
As a pump monitoring devicethePC441offersthemarketacombinedstandardsolutionforsubmersiblepumpandpumpstationsurveillance.Canbesetupforfull-scalemonitoringofoneoruptofoursubmersiblepumps plus ancillaries.
As a pump controllerthePC441controlsthestart/stopofthepumps,offeringastandardizedsolutionforsewagepumpstationswithuptofourpumps.Avarietyofsolutionsfromstandardon/offcontroluptoad-vancedVFDsupportincludingpumpcapacitycalculation.
As a combined control and monitoring devicethePC441canbeofferedasasolutionsupportingboththeareas above in a single unit.
Modules: 1.CA511-Graphicaloperatorinterface Max 1 of this unit per system
2.CA622-RS485Communicationinterfacemodule Max 1 of this unit per system 3.PC441-Pumpmonitoringand/orcontroller 4.CA781-Analoganddigitaloutexpansionmodule Max 1 of this unit per system
5.CA441-Moisturemonitoringmodule Max 4 of this unit per system 6. CA442-Temperaturemonitoringmodule Max 6 of this unit per system 7.CA443-Motorandsupplypowermonitoringmodule Max 5 of this unit per system
PC 441 is the heart ofthesystem!Othermodules are optional.
1.2 CA 511 operator panelYounavigatethemenusbythearrowbuttons.PresseithertheUp or Down arrow button to switch to the menu view.YouconfirmanoperationwiththeEnterbutton,oracknowledgeanalarm.PressingtheEscape button will cancel the current operation.
Upto4pumpsvia16Din,16Dout,5Ain,4Aout 3 moisture and 5 temperature inputs per pump Temp L2 & L3
-> CA 511
Station P1 P2 P3 P4 P1 P3 P2 P4
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Thedefault(top-level)viewofthedisplaydynamicallyshowstheoperatingstatusofthepumpsandconditionsin the pit. Figure1-2showsthesymbolsandexplainstheirmeanings.Theunitwillalwaysreverttothisviewafter10minutesofinactivityinanyotherview(suchasshowingmenus).
Main menu Figure1-3showstheMainmenu,whichyoureachfromtheoverviewimagebypressingeithertheUp or Down arroworshortcutkeyMainbelowdisplay:
Main Menu Manual ControlManual Control Pump 1Alarm List Pump 2Show Status Pump 3Settings Pump 4Select Language Mixer Drain Pump Cleaner Remote Blocking Esc
Personal alarm, and how to reset it Whenthepumpstationismanned,apersonalalarmcanbeissuedifthemaintenancepersonhasn’tshown
activitywithinacertainperiodoftime.Fordetailsaboutsettingsrelatedtothis,seesection6.3Systemset-tings (assigning Alarm type, Alarm delay and Max time to reset),section 6.12 Settings for digital inputs (as-signing Staff in stationtoaDigitalin),andsection 6.13 Settings for digital outputs (assigning Personal alarm alert to a digital output).
AfterthespecifiedMax time to reset,theassignedoutputisactivatedsoavisualoraudiosignalcanalertthemaintenancepersonthatthealarmtimermustbereset.IfthealarmtimerisnotresetwithinAlarm delay,apersonal alarm is sent out.
1.2.1 Status viewOne of the useful functions in PC 441 is Status view.InthestatusviewshowsPump running time, Number of starts, Capacity and Energy consumption.InthosecasesthereCA441,CA442andCA443areinthesystem,youwillbeabletoseeTemperaturesinthedifferentbearings,monitoringtheVibrations,Power absorbed and Motor current.YouwillalsoseethepowersupplyvoltageL1 – L3iftheisaCA443inthesystem.Allthepumpalarms will show up here in the graphic.
Pump Running TimeNumber of Pump StartsPump CapacityEnergy Consumption
Temp. Upper BearingTemp. StatorTemp. Lower BearingVibrationsPower absorbedMotor CurrentL1-2 406 V L2-3 406 V
588 h2940609 l/s115248 kWh
68 ˚C79 ˚C70 ˚C2.7 mm/s196 kW353.2 AL3-1 401 V
TotalP 1
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 12011.06.23 05:56:19 NO UNACK ALARMS
Figure 1-4 Status view
1.2.2 How to access the status viewStatusviewiseasytobeaccessedbypushingthe“Status”belowthedisplay,andthen“Pump 1”–“Pump 4”ontherightsideofthedisplay.Seepicturebelow.
Pump Running TimeNumber of Pump StartsPump CapacityEnergy Consumption
Temp. Upper BearingTemp. StatorTemp. Lower BearingVibrationsPower absorbedMotor CurrentL1-2 406 V L2-3 406 V
588 h2940609 l/s115248 kWh
68 ˚C79 ˚C70 ˚C2.7 mm/s196 kW353.2 AL3-1 401 V
TotalP 1
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 12011.06.23 05:56:19 NO UNACK ALARMS 2
1Figure 1-5 How to access Status view
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It’spossibletousetheleftandrightarrowkeysatthenumeralkeyboard to step to the other pumps.
Use up and down arrowstostepbetweendays. Upto7daysbackcanbedisplayed.
LeavetheStatusviewbyESC.
1.2.3 Pump alarms under status viewIftheField bus modules CA 441 and CA 442areattachedtothePC441andpumpalarmsappears,whenunder Status viewyouwillbeabletoseeanindicationwherethefaultisphysicallylocatedinthepump.
Motor protector Pumpor other general Pumpfailures from PC 441
DI 2 Electric Area
DI 3 Motor HousingT3 Hi Temp Lo. Bearing
T1 Hi Temp Stator /T4 Hi Temp Stator(T1 & T4 share the same alarm numbers)Stator temperature L2 - L3 withadditional CA 442
To get a presentation of the curve titles in the menu Trend curve,thenpushEnterthenyouhavetheTrend curvepictureonthedisplay,thepicturewillappearwiththedescriptionasbelow:
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
P3 P4P1 P2
ml/sl/s
230040010
0000
12:42:24 12:44:24 12:46:24
[Pit Level][Pit Inflow][Outflow][Closed]
Figure 1-8 DescriptionofthecurvesinTrend curve
The presentation will disappear after a few seconds.
One screen of Trend curves covers 300 samplings and that corresponds to 5 minutes in default settings of 1 second.
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2 CONFIGURETHEPC441
Overview of settingsEachstationhasanuniqueconfigurationsetup,buttheprocedureissimilartosetupthese.ThischapterwillguideyouthroughthebasicsettingsinPC441.Note:Thisdoesnotcoverallconfigurations,youmustconsideryourprerequisites.
The menu item Settingshas21submenuswithmanysettingsthatneedtobeenteredbythesystemadmin-istrator(althoughtheyallhavesensibledefaultvalues).Thefollowing9notesbelowarearecommendedprocedure to setup PC 441.
Each of the 21 submenus under settings are described in separate tables in section 6.
To enter the settings area:
Press down arrowonceandyouareinthemenus,continuetopressdownarrowtoSettings,pressEnter.
ThemajorityofsettingsrequireapasscodeforSystemexceptsomesettingsunderthesub-menuSystem and the start/stop levels under submenus Pump 1-4whichonlyrequireapasscodeforOperator.
• UsethedownarrowkeytoStation application and press Enter. Select Pump controller or Pump monitor byusingtheup/down arrow in the left part of the screen, pressEnteratyourchoice.UsethedownarrowkeytoMain graphics and choose the base screen (Pump pit statusoranypump)
• Fromthebasescreen,pressthekeyforSettingunderthedisplay,scrolldownbyusingthedownar-rowkeytoCommunication and press Enter. Press enter again and select Protocol (Modbus/Comli/ModbusTCP)andpressEnteratyourchoice.Pressleftarrowkeytogobacktotheleftpartofthescreen. Use the down arrow to Com port and press Enter. Select Station ID,PressEnter.TypeinyourStation IDbyusingnumeralkeysorup/downarrowkeys,requiredforAquaWeboranyothersurveillancesystem.SelectBaudrate,Parity and Handshake.Usetheleftarrowkeytogobacktothe left part of the screen and select Service port,pressEnter.SelectBaudrate for the service port.
Under Settings, Digital inputs;chooseforeachinputaccordingtotable2-1andDigital outputstotable2-2.
Digital outputs
OFF
Pump control
Reset motor protector
Pump fail
Too many pumps blocked
One pump fail
Master reset motor protector
Mixer control
Reset motor protector Mixer
Drain pump control
Reset motor protector Drain
Cleaner control
Modem control
Remote control
Personnel alarm
High level
Alarm alert
Not ackn. A-alarm
Not ackn. A/B-alarm
Active A-alarm
Active A/B-alarm
Pump reversing
Active B-alarm
Logic IO
Data register set point
Extern reset alert
Under Settings, Analog inputs,chooseforeachinputaccordingtotable2-3.Analoginput1isfixedtolevelandcannot be changed.
Table 2-3: Table 2-4:
Analog input 2-5
OFF
Motor current P1-P4
Back-pressure
Vibrations
Free choice
Vibrations P1-P4
Xylem MiniCas Sim P1-P4
Outflow meter
Note Analog1ispredefinedtolevelsensor and cannot be changed.
Analog outputs
OFF
Pit level
Pit inflow
Pit outflow
Pit overflow
Pulse channel 1
Pulse channel 2
Pulse channel 3
Pulse channel 4
PID controller
Data register
Table 2-1: Table 2-2:
Digital inputs
OFF
Pump run indication
Manual pump start
Pump not in auto
Start float
Pump failure
Motor protector
High temperature
Leakage
Stop float P1-P4
Low level float
Overflow sensor
High level float
Drain pump float
Run indicator Drain pump
Motor protector Drain pump
Run indicator Mixer
Motor protector Mixer
Staff in station
Alarm reset
Power fail
DI pulse channel 1-4
Block PID controller
Alarm input
Mixer block + Alarm input
Drain pump block + Alarm input
Block remote data
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In AquaProg:
Figure 2-3 Analoganddigitalinputs/outputs
2.3 Configure�the�field�bus�unit�modulesAlltheextensionmodulestoPC441areoptional.ThecommunicationisdonebytheCAN-bus.SeeInstal-lation guide CA 441, CA 442, CA 443(P/N:81307058)onSulzerhomepageformoredetailinformationtosetup Leakage, Temperature and Power monitors.InstallationguidestoCA511(P/N81307061),CA622(P/N81307133)andCA781(P/N81307132)canalsobefoundatSulzerhomepage.
CA 441 Leakage module
AsystemwithPC441cancontainuptofourCA441modules.OneCA441modulecanmonitorleakageinoneorfourpumpsdependingonthesettingoftheaddressknobonthefrontofthemodule,seeInstallation guide CA 441, CA 442, CA 443 (P/N:81307058)formoreinformation.Ifusingonemoduletofourpumps,thereisoneinputforeachpump.IfusingoneCA441moduleforeachpump,therearefourinputstoeachpump.
Inthesettings,youmustspecifythatthemodule(s)areconnectedandwhichtypeofsensortypeyourpumpshave.DefaultisABS standard and can be changed to Xylem (ITT Flygt).
CA 442 Temperature module
PC441supportsuptosixunitsofCA442.OneCA442modulecan monitor temperatures in one or four pumps depending on the settingoftheaddressknobonthefrontofthemodule,seeInstal-lation guide CA 441, CA 442, CA 443(P/N:81307058)formoreinformation.Ifusingonemoduletofourpumps,thereisoneinputforeachpump.IfusingoneCA442moduleforeachpump,therearefourinputstoeachpump.Inthesettings,youmustspecifysensortypes(Klixon/Pt100/PTC).
PC441supportsuptofiveCA443modules,onemoduleforeachpumpandoneforwholesystem.CA443modulescannotbeusedtogetherwithVFD.TheCA443modulesmustbeconnectedbeforepumpcontactorsotheinputsL1-L3nevergetpowerless. Iftheinputsgetpowerless,thephasealarmgoon,andthepumpwillnotstart,seeInstallation guide CA 441, CA 442, CA 443 (P/N:81307058)formoreinformation.
CA781isamodulewhichgivesyoueightextradigitaloutputsandtwoextraanalogoutputs.CA781modulemustbepoweredfrom the same source as PC 441 and cannot be powered from theCAN-busbecauseofitshigherpowerconsumption.PC441supportsoneCA781module.SeeInstallation and user guide (P/N81307123)onSulzerhomepageformoreinformation.
CA 622 RS 485 communication module
PC441cancommunicatedirectlytoVFDs,energymetersandsoftstartersviaCA622module.CA622actsasModbusmaster,communicating with attached Modbus slave devices. See the In-stallation and user guide(P/N81307133)onSulzerhomepageformoreinformationandwhichVFD,energymetersandsoftstartersPC441andCA622support.Ifmissingyourmodel-contactCon-trol&MonitoringatSulzerandwemightbeabletoaddthenewmodel.PC441supportoneCA622inthesystem.
Forexample:Ifthepumpstationispumpingclearwaterandaheavyrainfillsthepitveryfast,thepumpcanstart before the level reach the start level.
Station flow (recommended parameters)
Under Meas. parameters set the Inflow calculation=ONandyourpitshape,alsothefunctionEmptying or Filling the pit must be set. System curve at duty pointisusedifthereisn’tanyOutlet pressure sensor.
Recommended is to setup the Pit area under Station flow.That’sbecausethepumpcalculationsshallpreformas accurate as possible. This are bound to Energy calculation,Pump capacity and Outlet calculations. Best accuracyofpumpcapacitycalculationsandpumpedvolumeiswhenanOutlet pressure sensor is used. See section 3.2 for more information.
Calculation of pump capacity (recommended parameter)
Recommended to set Calculation=ON.Thelevelmustbeinthespanofminimumandmaximumduringthecalculations.Makesurethatthealltimestogetherinstart delay/calculation time/stop delay in total must be in oneandthesamepumpsequence.Seesection 3.2 and forward.
There are several alarms which can be set under Pit alarms.EachalarmisconfigurabletobeA-orB-alarms.Consultyourdrawingsandverifywhichareimportantforyourinstallation.
Pump blocking (optional parameter)
Thepumpcanbeblockedonremote.Thereisatimeoutwhichreleasestheblockingafteracertaintime.BlockingonLow level float and/or High pressure can be set here.
Level sensor check (optional parameter)
Level sensor checkItispossibletocheckthelevelsensorreadingcomparedtotheinstalledfloats.Seethesettings under Level sensorchecksetthisup.
2.5 Settings for pump 1 to pump 4 and their alarmsHereyoucangivethepumpatagname(max20characters).InstalledpumpsmusthaveRelay control pump=YES,otherwisethepumpwillnotshowupinCA511graphics.Alternately;ifpump3andpump4arenotinstalled;Relay control pump=NO that pump disappears from the graphics.
2.6 Common P1 – P4Inthisoptionaremanyusefulfunctionstoavoidfutureproblems,likeMotor protector auto reset,Pump exercis-ing,Pump reversing,anddifferentscenariosforblockingwhenusingPower monitor.
Motor protector auto reset
Canbedone“Conventional”orbyCA622“Motor drive”. Conventional needs a digital output which controls an externalsolenoidtoresetthemotorprotector.
Motor driverequiresCA622andtheresetissenttotheVFDviasoftware
Pump exercising
Itispossibletoexercisesomepumpsifrequired. Amaximumpumpofftimecanbesetandexercisingtime. The level must be within the parameters.
Pump reversing
Several parameters can trigger reversing. See also chapter 5
Figure 2-6 AquaProgviewofcommonP1-P4
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2.6 Common P1 – P4Inthisoptionaremanyusefulfunctionstoavoidfutureproblems,likeMotor protector auto reset,Pump exercis-ing,Pump reversing,anddifferentscenariosforblockingwhenusingPower monitor.
Motor protector auto reset
Canbedone“Conventional”orbyCA622“Motor drive”. Conventional needs a digital output which controls an externalsolenoidtoresetthemotorprotector.
Motor driverequiresCA622andtheresetissenttotheVFDviasoftware
Pump exercising
Itispossibletoexercisesomepumpsifrequired. Amaximumpumpofftimecanbesetandexercisingtime. The level must be within the parameters.
Pump reversing
Several parameters can trigger reversing. See also chapter 5
2.7 Set log settings and eventsThere are 16 analog log channels which can be allocated to 26 log functions. Recommended to use the log channels in order from channel 1 and upwards. To have one or more log channels disabled between active channelswillcostdatatraffictothesurveillancesystem.
The log interval can be set from 1 minute to 1440 minutes.
Table 2-7:
Log functions
Level in pump pit
Inflow
Outflow
Overflow level
Overflow flow
Back-pressure
Motor currents P1-P4
Pump capacity P1-P4
Power factor (Cos)
Temperature stator wiring
Temperature upper bearing
Temperature lower bearing
Vibration
Main voltage
Main frequency
AI free choice
Supply voltage
Pulse channel
Temperature stator wiring L2
Temperature stator wiring L3
PID controller output
Data register
Data register (2-compl)
Actual VFD frequency
Measured pump head
Actual pump head
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Events
Event list stores individual events such as Pump starts/stops,Alarms,alarmtypesandwhenthealarmsoccurandwhenitwasacknowledged.Thecontrollerstores4096time-stampevents.
GointoSettings – Common P1-P4 – Log pump events - Yes
2.8 If using CA 622; set up communications to surrounding units VFD, soft starters and energy metersSeeinstallationguideforCA622howtoconnectthesurroundingunits.Note:AllthesurroundingunitsmusthaveuniqueModbusID’sandsamecommunicationparameters.
2.9 Set up cleaner, mixer or drain (if used)Ifusingcleaner,mixerordrainpump,adigitaloutputmustbesetascorresponding.
Cleaning
Thesettingsforcleaneraretobefound:
Settings – Cleaner
The cleaning can be done at pump start or at pump stop. Flushing time in second NumberofStarts to flushsettheintervaltohowmanystarts/stopsbeforecleaningstarts.
Stop pump when mix [Yes/No] Run indication [Yes/No] Mixer run time Pump starts to mix Time interval to mix Max level for start Min level to start Motor protector Mixer alarms
Drain pump
Drainpumprequiresastartfloatconnectedtoadigitalinputwhichissetasdrain pump float. The settings for drainpumpistobefound:
Levelboundariescanbeenteredforthepumpcapacitycalculation.Level 2: Abovethislevelitisnotusefulormaybenotevenpossibleto calculatetheflow. For instance due to the volume in the incoming mains.Level 1: Belowthislevelitisnotusefulormaybenotevenpossibleto calculatetheflow. Forinstance,dependingonthelevelforthepumpssuctionpoint.
Level 2
Level 1
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Logic used to calculate the pump capacityFirst pump starting.Whenthestartlevelofthefirstpumpisreached,thelastknownfilteredvalueoftheinflowisstoredinthememory.Afteranadjustabletime-delaytheactualpumpcapacitymeasuredbycalculatingthespeedofleveldecreasingtimesthestationpit.Thetimedelayistheretoenablethepumpandsystemtoreachfullcapacitybeforeconductingthemeasurement.Thepumpcapacitycalculationtimeisalsoavaluethatcanbeset/adjusted.Thetimeneededtoachieveanaccuratevaluewilldependonparameterslikeforinstance:sizeofbasin,typeofpumpandthecollectionnetworkdesigntomentionafew.
Logic used to calculate the outflow during a pump cycle
Show Status Pump PitPump pit System OverflowPump 1 -OFF-Pump 2 Remote BlockedPump 3 -OFF- Pump 4 Back-Pressure Block Overflow -OFF- Mixer Pumped Volume Drain Pump Total Pump HeadCleaner 8.17 m Esc
Level based flow solution with a pressure sensor mounted on the mains for actual head compensation
Useeitheragivenstaticheadormountapressuresensorontheoutgoingmainstogettheactualhead.Ifapressuresensorismountedinthemainsdischargepipe,thecontrollerwillautomaticallycompensateforanyvariances in the head. Having a pressure sensor mounted on the mains can also warn for potential problems with a high mains pressure.
Suchaproblemcanoccurdueto:
Airentrapmentinthemains High load from other stations
Abovepumpcurvefi gure 3-5givesfollowingflowsandsettings.
In menu Pump 1-4 > Pump Curve.
(L) Point 1 Hmax tot. head 18.0 m (ft.) Point 1 flow 8.2l/s(GPM) (M) Point 2 Hmid tot. head 15.5 m (ft.) Point 2 flow 14.4l/s(GPM) (H) Point 3 Hmin tot. head 13.0 m (ft.) Point 3 flow 19.0l/s(GPM)
IfsensorismountedaccordingtoEx1(Sensor0-level=Pumpoutlet)setparameterTotal head sensor zero=18 m.
If sensor is mounted according to figure 3-5, 0.4 m below pump outlet set parameter Total head sensor zero = 18 + 0.4 = 18.4 m.
Mid level 2.5 m from lowest levelM = 18 m - 2.5 m = 15.5 m
Overflow at 5 m from lowest level H = 18 m - 5 m = 13 m
Lowest level 0 mL = 18 m - 0 m = 18 m
Diff.0.4 m
10
15.5
18H max
H mid
H
HM
L
H min
Q
Static head 10m
Static head 15.5m
Static head 18m
Q1 Q2 Q3
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3.2.4 System curve Apumpisalmostalwaysseeninasystemofpipelinesandvalves.Thesegivelossesthatthepumpmustovercomeforaspecificflow.Withthesystemcurveisthesumofthestaticheightandpipelinesystemlossesataspecificflow(total head).Youmaythinkthatiftwoequalpumpsparallelcoupledarerunningtheoutflowwillincreasebyafactorof2.Sometimesitturnsout,however,thattheoutflowwillonlyincreasealittle.Thisisbecausethepipelinelossesincreasewithincreasedflowandthusthetotalliftheight.Ifyoudonotcom-pensateforthis,thecalculationoftheoutputflowandpumpedvolumewillbeincorrectinthecaseofseveralpumpsrunning.ThisisespeciallytruewhenwehavegreatpressurelossesinthepipeinrelationtothestaticheightPC441hastwodifferentwaystocompensateforthis.
1. OnewayistomanuallysettheparametersinthemenuFlow compensation under menu Station�flow�>�Meas. parameters. Specifiesthefactorsasapercentageofthepumpcapacitymeasuredwhentheonepumpisrunning (1pumprunning=100%).Setfactorsfor2,3and4pumpsrunning.SettheparametersinthemenuSystem curvetozero,whichturnsoffautomaticcalculation(see2below). Itcanbedifficulttoestimatehowmuchcapacitydecreasesatthedifferentoperationalcases.
2. Enterthedutypointofthesystemcurveforapump. InmenuSystem curve under Station�flow�>�Meas.�parameterssetthedutypointforapump. SystemcurveanddutypointcanbecalculatedmanuallyorbyusinganycalculationprogramssuchasABSELPROfromSulzer. Set the static and total lifting height (static and total head)atthespecificflow.PC441canusethistocalcu-latecompensationfactorsfortheoutflowwhenmorethanonepumpisrunning. AftercalculationmenuFlow compensation shows the calculated factors.
TherearetwodifferentexponentsandtwoconstantswhichcanbesetinPC441,dependingonthemanufac-turer and nature of the weir. Thoseconstantsshallnormallybeprovidedbythemanufactures.Ifyoudon’thavethee2andc2values,youcansete2andc2to0(zero),onlyusetheleftsideoftheequation.Forthebasicweirtypesthec2constantcanbesetto0(zero).
Overflow==he1c1 + he2c2 [m3/s]
Type of weir Exp Constant
Thompson 30° 2.5 0.373
Thompson 45° 2.5 0.569
Thompson 60° 2.5 0.789
Thompson 90° 2.5 1.368
Straight weir 1 m 1.5 1.76 Forstraightweirswithawidthotherthan1m,multiplytheconstantwiththewidthinmeters.Ex.c=b*1.76(bin meters)
NOTE! If”Locked on inflow”ischosen,thePC441taketheoverflowtobethelastcalculationofinflowinthepitminusthecapacityofthepumpswhicharerunning.
1. Normal alternation Pumpsarestartedalternatelyaccordingtoarotatingschedule.Thepumpthatstartedfirstinthepumpcycle,willstartlastonthecycle.Inthiswaytherunningtimeisdividedequallybetweenalternatingpumps.Pumps that are not activated for alternation start and stop on their own start and stop levels. One can choose between alternation at each pump stop or when all pumps are stopped. Alternateateachpumpstopmethodispreferredifthenormalinflowtothepitissohighthatthepumpsdon’thavethecapacitytoemptyit.Ifalternatewhenallpumpsstopmethodisselectedinthissituation,theissuecouldarisethatonepumpisalwaysrunning,hencenoalternationwilltakeplace. Alternatewhenallpumpsstopmethodispreferredifthepumpshavethecapacitytoemptythepitatnormalinflow.Thenallpumpsstopandthestart/stoplevelsalternate.
Example 1 Continuous high inflow. A single pump can’t empty the pit.
3.4.1 Max number of pumps runningIfthepipingsystemcannottakethepressurewhenallpumpsarerunningthereisthepossibilitytosetthemaxnumber of pumps that are allowed to run at the same time. This feature could also be used when there is a limit for the power load in the station.
IfStart Level Tracking is activated the pump controller uses the start levels of the pumps to decide which pumptostart.Thepumpwiththehigheststartlevelexceededhashighestpriorityandwillbestartedfirst.Alternatingpumpshavethesamepriorityandalternateasusual.
IfsettoYES;ReversecyclestartswhenthedigitalinputsignalMotorProtectorgoesactive.Motorprotectorwill be reset before the pump starts reversing. You must enable auto reset motor protector function for the pump.Setthecolddowntimeandpulsetimeintheautoresetmenu.Ifthemotorprotectorresetfailsreversingcycleisaborted.
Pumpreverseisconsideredsuccessfulwhenthepumphasbeenrunningforthesettime[Start rev. delay time]withoutanypumperror. On success the attempt counter is reset. Iftheattemptscounterreachesmaxnumberofattempts,analarmwillbegeneratedandallfurtherreversingstoppeduntilmotorprotectoralarmorpumpfailalarmshasbeenresetmanually.
-Set[Stop pumps before rev.]to[Yes]ifyouwanttheotherpumpstostopandstayblockedwhenreversingcyclerun.
If[Pump rel. when rev]issetto[ON],thepumprelaywillbeactivated1secafterthereversingrelayandwillbedeactivated1secbeforethereversingrelayisdeactivated.Herepumprelayisusedtocontrolthepump(on/off)andreversingrelayisusedtoshifttwophasesbeforereversing.
If[Pump rel. when rev]issetto[OFF]onlyreversingrelayisactivatedduringreversing.Pumprelayisalwaysoffduringthereversingprocess.
CA622communicatewiththeVFDsbyRS485fieldbus.TheCA622unitisconnectedtothesystemviaCANbus.CA622isfittedwithagalvanicallyisolatedRS485communicationportforcommunicationwithperipheralproductssuchVFDs,softstartersandenergymeters.CA622isalwaystheModbusmasterwithallperipherals acting as Modbus slaves.
PC441hasmanypredefinedVFDs,thecorrectonemustbechoseninthemenus.AllthepredefinedVFDsareoptionsinthefirmwareofPC441andCA622.IfyoucannotfindyourbrandandmodelofVFD;makesurethatyouhavethelatestfirmwareversioninPC441andinCA622.OnSulzerhomepageyoucanfindtheInstallation and user guide CA 622(P/N81307133)thereyoucanseeifyourmodelofVFDissupported.
Atstartlevelthepumpwillstartatmaxfrequency,ifthestartlevelishigherthansetpoint.Outputsignaliskeptatmaxfreq.untilthesetlevelisreached.Ifcalculationofpumpcapacityisenabledthepumpwillrunatmaxfrequency,untilthecalculationiscompleted.Ifthepumpisrunningatminfrequencyforanadjustabletimeyoucan set a force speed for pumping out the pit. The pump will go on force speed until stop level is reached (or set level).
• InSettings / Pump xmenu:SetType of pumpto[Speed controlled VFD] IfasecondVFDpumpisused.Setthesametypeforthat.
• Onthenextlevelinthemenu,[Pcap comp. at min Freq](Pumpcapacityatminimumfrequency),thepumpcapacityisalwayscalculatedwhenthepumpisrunningatmaxspeed.Whenthepumpisatlowerspeedthecapacitywillbelower.Enterthecompensationforthathere. Settingthisparameterto50%meansthatthecapacityatminspeed(freq.)ishalfofthemaxspeedcapacity.
• InSettings / Pump xmenu:Setthestart and stoplevelforthepump,thestartlevelshouldbehigherthanthesetlevelonthePIDcontroller.Thestoplevelshouldbelowerthanthesetlevel.
• InSettings / Analog outputs / Analog output 1menu: Set Output functionto[PID controller]. ThesameforAnalogoutput2,ifasecondVFDpumpisused,theoutputshouldbeconnectedtothefrequencyinputontheVFD
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• InSettings / Digital outputs;Setoutput function[Pump relay]asforfixedpumps.Theoutputshouldbeconnectedtothe“Run input”ontheVFD.
• InSettings / PID controller / Set point menu: You can set max and min levels for the set point and a start set point.
• InSettings / PID controller / Output signal menu: Hereyoucansetthemax and minvaluesfortheoutputsignal(min/maxfreq). 0%=4mAand100%=20mA.,withthefrequencybeingdependentonthesettingoftheVFD.
• InSettings / PID controller / PID parameters menu: HereyousettheparametersthatcontrolthebehaviourofthePIDController,thesettingoftheseparameters are outside the scope of this document.
• InSettings / PID controller / Speed control VFD menu Ifthepumpisrunningatminfrequencyforanadjustabletimeyoucansetaforce (lock) speed for pumpingoutthepit.HereyousettheMin pump speed, Lock speed delay and Lock speed for the function. Iflockedspeeddelay = 0 the function is disabled.
3.6.3 Variable frequency drive auto resetAsoffirmwareversion1.70,the“Autoresetmotorprotector”functionalityhasaselectionfor“Conventional”or“Motor drive”protection.
See Settings – Common P1-P4 – Motor protector auto reset
If[Motor drive]isselected,tripdetectionanddriveresetisdoneoverfield-bus(inparallelwithoptionaldis-crete motor protector input and reset output).
The[Max no attempts]errorcounterisresetwhentheautoresetsequenceisconsideredsuccessful.Thishappenswhenthepumpruntimereachestheset[Pause time] (cooling time) before auto reset.
4.1 Digital output: Logic IOOne of the options in the functions of Digital out is Logic IO.Thisfunctionisespeciallyusefulifyouwanttotriggeranoutputsignalwhenmorethenonecriteriaoreventsareneededtobeforfilledforanoutputsignal.Thereareuptofourdifferentcriteriathatcanbeusedtotriggertheoutputsignal.ThoseIObitscaninteractas a True OR, Inverse OR, True AND and Inverse AND functions or as a combination of these for one and the same output. The output signal can be set to Normally closed or Normally open(NC/NO).
See the Comli/Modbus register manualregardingtheIO-bitlist.
Example Intheexamplebelow,DO1inPC441willbeactivatedifanyofthetemperaturealarmsconnectedtoCA442trips.
Toconfigure,firstrefertotheIO-bitsinComli / Modbus manual for PC 441 and further to Pump status on chart 1.2;thereyoufindIO-bit28,29and30whichareforthedifferentIO-bitsfortemperaturealarmsonpump1:
-Settings / Digital outputs / Digital output 1to[Logic IO]andtypeinaccordingtopicturebelow:
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Digital Output 1 Logic IO functionOutput Function IO signal 1 [Logic IO] [True OR]Normaly State IO number 28 [Normaly Open (NO)] IO signal 2 [True OR] IO number 29 IO signal 3 [True OR] IO number 30 IO signal 4 Esc
4.2 Digital output type: data reg. setpoint WiththeDigitalOutputType“Data reg. Setpoint”asetpointcanbetiedtoanyanalogsignal,internalorexter-nal.ByusingtheregistersdefinedintheModbusmanualandenteringtheminthefunctionasintheexamplebelow,youcanachievethisfunction.
Example Wehaveasulphuricgasmonitoringdeviceconnectedtoananaloginputsignal.WeuseA.IN5forthesulphuric meter.InthiscasewewantaswitchonDO1whentheconcentrationofgasisorabove10.0ppm.Wealso
wanttheoutputsignaltoswitchbackat1.0ppm(ahysteresisof9ppm).Thisdigitaloutput1controlsafanwhich evacuates the gas from the station.
NOTE! AccordingtoComli/Modbus reference manual(p/n81307126)wefindthattheregisterforanaloginput5istoread on register 5;seefigure4-2below.Wenoteaswellthatthescalefactoris0.1(i.e. the value in reg.5 is multi-
plied by 0.1 to get actual value in engineering units).
Figure 4-2 AbovetableisanextractfromtheComli/ModbusmanualforPC441– Analog inputs/Output in engineering units.
ThefunctionisconfiguredinthemenuofCA511asfollows:UnderSettings / Digital outputs / PC 441 Main (or CA 781 Exp.-) Module / Digital output 1 to [Data reg. setpoint] according to picture below.
Digital Output 1 Digital Output 1Output Function Data Register [Data reg. Setpoint] 5Normaly State Setpoint ON [Normaly Open (NO)] 100 Setpoint OFF 10 Setpoint Delay 5 s Esc
The Setpoint ON=100 correspond to the value of 10 engineering units and Setpoint OFF=10 correspond to 1.
AboveisanexampleofhowtogetananalogsensorsignaltochangestateonaDigital Output signal via Data reg. setpoint function.
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4.3 Digital output type: external reset alert ExternalresetalertisactiveduringtheconfiguredPre alert time before an automatic reset of motor protector isperformed,oralarmsareresetfromadigitalinputtypeAlarm reset withresetdelay>0.
4.6 Analog output type: data registerWiththeAnalogOutputTypeData register,anyanalogsignal,actualorcalculatedcanbeusedasa0/4-20mAoutputsignal.ByusingtheregistersdefinedintheModbusmanual,youcanachievethisfunction.
Example Wewanttohavea4-20mAanalogoutputsignaltiedtostatortemperature1onpump1.Wealsowanttheoutput signaltobe4mAat0°Cand20mAat150°C.
NOTE! AccordingtoComli/Modbus reference manual(p/n81307126)wefindthatthetemperaturestatorpump1isin register 40;seefigure4-3below.Wenoteaswellthatthescalefactoris0.1(i.e. the value in reg.40 is multi-
plied by 0.1 to get actual value in engineering units).
ThefunctionistosetupinthemenuoftheCA511under;Settings / Analog outputs / PC 441 Main (or CA 781 Exp.-) Module / Analog output 2 to [Data register] according to picture below.
Analogue Output 2 Output RangeSignal Range Data Register [4-20 mA] 40Filter Constant Scaling 0% = 1 s 0Output Function Scaling 100% = [Data Register] 1500
5.1 CommunicationTherearethreeportsforcommunication.OneUSBandtwoRS232,ofthesetwoRS232thereisonlyonewhich can be connected to a modem. The protocols are Modbus (RTU or TCP) or Comli. Other protocol could beavailableifthereisanexternalconverterfromModbusorComlitorequestedprotocol.
5.1.1 Com port (screw terminals 48 – 52)This port is designed for modem communication and supports Modbus (RTU or TCP) or Comli protocols. Other protocolsuchasTCP/IPcanbeusedbyusingmodemwhichconvertsthesignal.TheportisconfiguredasModbusRTUdefaultwithbaudrate:115200,parity:None,Handshake:Off,andProtocolID:1,Messagetimeout:2sOptional:Stationname.
Onthisporttherearepossibilitiestochangethepropertiesofbaudrate(300–115200),protocolID(1–255)andstationID(1–65535),Parity(None,Odd,Even)andhandshake(on/off)aswell.NecessaryforAquaWebconnection is the Station IDsetcorrectlyandthattheprotocolIDissetto1!
5.1.2 Service port (9-pols D-Sub in the front)Thisportfollows“Com port”inprotocolandhasalwaysprotocolID:1therearehoweverpossibilitiestochangethe properties of baud rate separate from Com port.Thisportisconsideringtobeusedfordownloadconfigu-rationandupdatingthefirmwarebyusingAquaProg.
5.1.3 USB port (USB type B in the front)Thisportisfollowingtheprotocolfrom“Com port”andisonlyforupload/downloadconfigurationbyusingAquaProg.
5.1.4 ModemOnly the port at the screw terminals (Com port) is supporting modem. ThereareseveraldifferentmodemswhichcanbeusedonPC441.NormallyisaGSMmodemconnectedtothePC441whichcallsbyGSMtoaSCADAtriggedbyaneventorthataSCADAcallsupforcatchinglogvalues.IfPC441isconnectedtoAquaWeb,thenmusttheSulzerCA-modembeworkingasaAquaWeb client modem.It’salsopossibletoconnectaTCP/IPoranalogmodem.
Analog modem Forfixedtelephoneline.Signalsbeforeanswer,minimum1.Hayessettingsnormallyworkswithdefault. Settings under Communication – Modem – Modem connected in the PC 441 shall be [Analog modem].
Settings under Communication – Modem – Modem connectedinthePC441shallbesetto[CA 52x AquaWeb Client].SetGPRSUsernameandPasswordifrequiredbythesubscriptionprovider.GPRSEventLogandHeartbeatoperatorscanforerrorsearchonly.Defaultoff.
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TCP/IP converter ForfixedTCP/IPline.CommunicationthroughRS232toexternalIPconverter.Thisiscomparabletoadirect line and in the settings under Communication – Modem – Modem connected in the PC 441 shall be [Modem connected NO].
TCP-Server IfyouhaveaSIMcardsubscriptionwithafixedIPaddress,thenyoucanconnectthestationbyGPRSona localnetworkbyusingaSulzermodemandsetthefunctioninmodemsettingstoFIX IP TCP LISTEN–TCP-
server.
FIX IP TCP LISTENrequiresaSIMwithfixedIPaddressfromtheprovideronthestationsothatanexternalSCADAcancontactremotely.
Settings under Communication – Modem – Modem connectedinthePC441shallbesetto[FIX IP TCP LISTEN].
Other types of Profibusgatewayandradiomodemsetc. modem
5.1.5 Com Echo PC 441WhencommunicationwithmultipleunitsoverRS232portthereisapossibilitytoactivatecommunicationechobetweencommunicationsports,alldataonCom:1areechoedtoCom:2andviceversa.AllunitsmusthaveuniqueComli/ModbusID.
Figure 5-2
Ifdial-upmodemisused;ithastobeonunit1.Thisunitistheonlyunitwhichcaninitiatemodemtodial-upalarms.Thatmeansinacombinedalarmfromadditionalcontrollerstogeneratealarmdial-uphastogothrough unit 1. Unit 1 needs a separate alarm input signal from each unit to trigger the alarm call up. Likewise,analarmoutputfromeachunithastobeconnectedtoaseparateinputonunit1,seefigure4-5.Whenusingdirectcommunication;thesefeedbacksignalsarenotneeded.
ActivateComEchointhemenuofCA511:
Settings – Communications – Service Port – Com. Echo – Yes
5.1.6 AlarmsTherearemainlytwowaystohandlealarmsfromPC441;throughmodemordirectcommunication.MostcommonisaGPRS/GSMmodemsolution.ThealarmscanbetransferredtoaSCADAsystemorasaSMStoa mobile phone.
5.2.1 How to set up AquaProgAdetaileddescriptionofAquaProgisoutsidethescopeofthisdocument,pleaseseeAquaProgmanualP/N81300037onwww.sulzer.com.
PC441communicatesbydefaultwithModbus RTU and has Comli ID 1 and Station ID 1. The baud rate is 115200,8 data bits and No Parity.
Tocreateanewsubstationfollowthetextbelow.
Figure 5-3 CreateanewsubstationinAquaProg.
1. Giveyourstationaname
2. Choose“Typeofsubstation”–PC441V1xx
3. ComliIDiscriticalforAquaProg,defaultis1.IfthereiswrongstationID–AquaProgcanhandlethat,butnotwrongComliID.IfyouusetheService Port or the USB–thenit’salwaysComli ID = 1.
Thereisthepossibilityforcertainrescalingofdata,e.g.Running time in seconds can be rescaled to minutes withthefactor60.Thescalefactorcanbebetween0-32767.Withthefactor0norescalingisdone.
Togetherwiththecrossreferencetablethereisapossibilitytosetanindividualscalefactorbetween0and32767,foreachpositioninthecross-referencelist.Whenreadingdata,thevalueisdividedwithcorrespond-ingscalefactor.Whenwritingdatathevaluewillbemultipliedwithcorrespondingscalefactor.Scalefactorisignored when set to 0.
6.2 Overview of settings The menu item Settingshas21submenuswithalargenumberofsettingsthatneedtobeenteredbythesys-temadministrator,althoughtheyallhavesensibledefaultvalues.Thefollowingarethe21submenus:
6.3. Systemsettings
6.4. Pump pit settings
6.5. Pump 1 to 4 settings
6.6. Commonsettingsforpump1,2,3and4
6.7. SettingsforPIDcontroller
6.8. Settingsformixer
6.9. Drainpump
6.10. Cleaner
6.11. Analoglogging
6.12. Settings for digital inputs
6.13. Settings for digital outputs
6.14. Settings for analog inputs
6.15. Settings for analog outputs
6.16. Settings for pulse channels
6.17. Settings for trend curves
6.18. Communication settings
6.19. Settingsforfieldbusmodules
6.20. Common settings
AllsettingsrequireapasscodeforSystemexceptsomesettingsunderthesubmenuSystem and the start/stop levels under submenus Pump 1, Pump 2, Pump 3 and Pump 4,whichonlyrequireapasscodeforOpera-tor.
Eachofthe21submenusaredescribedinseparatetables.TheexactprocedurehowthetablesshouldbeinterpretedisexemplifiedbelowforthesettingsunderthemenuitemSettings > System > System alarms > Power fail in Table6-1.
1. Choose the menu item Setting (or choose Main,selectSettingsbyusingtheUp/down buttons and press Enter). The topmost menu item System will be selected. Press Enter again.
2. Select the menu item System alarmsbyusingtheUp/downbuttons,pressEnter.
3. SelectthemenuitemPowerfail,pressEnter.
4. SelectthemenuitemAlarm type,pressEnter and enter the pass code for System. Choose one of (Inactive, B-Alarm, A-Alarm) and press Enter.
5. Select the menu item Alarm Delay,pressEnter and give the pass code for System. Set the number of seconds and press Enter.
Thepasscodewillbevalidaslongasyoustayinthesettingmenus,forstep5above,youmaynotneedtoenter the pass code. How the buttons on the panel are used is described in Chapter 1 Overview.
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6.3 System settingsTable6-1showsthecompletelistofsystemsettings.
Afterthealternativestoplevelhas been reached the stop of thepumpcanbedelayedbyset-ting the Stop Delay parameter.
PumpStopLevel m,ft
AfterNo.Starts Integer
StopDelay Seconds
P1UseStopLevel? (NO,YES)
...
...... ...
P4UseStopLevel) (NO,YES)
LevelChangeStart/Stop
StartFunctionActive (NO,YES)
System
IfthelevelincreasesatleastLevel Change to Start during the time period Per,thenonepumpwillstart.Ifthelevelcontinuestoincreasethatmuch,thenextpump will start.
No.PumpRuntoStart
(NoLimit, Min1Pump,Min2Pumps,Min
3 Pumps)
No.PumpRuntoStart
(NoLimit, Max1Pump,Max2Pumps,Max3Pumps)
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Submenu Submenu Submenu Setting Value Pass code Comment
LevelChangeStart/Stop
LevelChangetoStart m,ft
System
IfthelevelincreasesatleastLevel Change to Start during the time period Per,thenonepumpwillstart.Ifthelevelcontinuestoincreasethatmuch,thenextpump will start
Time period (Per.) Minutes
Stop FunctionActive? (NO,YES)
IftheleveldecreasesmorethanLevel Change to Stop during the time period Per,thenonepumpwillstop.Ifthelevelcontinuestodecreasethatmuch,theotherpump will stop.
No.PumpRuntoStop
(NoLimit, Min1Pump,Min2Pumps,Min3Pumps,Min
4 Pumps)
No.PumpRuntoStop
(NoLimit, Max1Pump,Max2Pumps,Max3Pumps,Max
4 Pumps))
LevelChangetoStop m,ft
Time Period (Per.) Minutes
Station Flow
Meas. Parameters
-
InflowCalculation (OFF,ON)
System
Pit Shape (Rectangu-lar,Conical)
Pump Function (EmptyingPit,Filling Pit)
Isthepumpfillingoremptyingthepit?
Calc.IntervalInflow Seconds Time interval between measure-ments.
SystemCurve
StaticHeadDutyPoint m,ft Usedforoutflowcalculationifanyparametersaresetto0thefunction is disabled and normal flowcompensationareused.
See Section 3.2.3
TotalHeadDutyPoint m,ft
FlowatDutyPoint Liters/second,GPM
Flow Com-pensation
2 Pumps running Percentage 100%meansthat2pumpsde-liver twice as much as a single pump.50%meansthat2pumpsdeliver not more than a single pump.
Forsubmersedpumps,setMin Level for Calc to be the top of thepump-itimprovesaccu-racy.CalculationstartsafterStart Delay,whenpumpflowsarestabilized,andgoesonforCalculation Time. Stop Delay doesnotaffectpumpcapacitycalculation,butthecalculationoftheinflowis inhibited during Stop Delay afterthepumpstopsastheflowstabilizes.
MaxLevelforCalc. m,ft
MinLevelforCalc. m,ft
StartDelay Seconds
Calculation Time Seconds
StopDelay Seconds
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Submenu Submenu Submenu Setting Value Pass code Comment
Calc.Overflow
OverflowDetect (OFF,OverflowSensor;LevelLimit)
System
Todetectoverflow,anoverflowsensor is much more accurate than a threshold from the level sensor.Bysettingparameters(exponentsandconstants)theoverflowcanalsobeaccuratelymeasuredbyacalculation.‘Lockoninflow’simplyusesthehis-toricalvalueofinflow.
Level Limit is the level at which overflowisexpected.Note:notasaccurateasusinganoverflowswitch.
See Section 3.2
LevelifLimitUsed m,ft
OverflowCalculation (Exp+const,LockonInflow)
Calc.Overflow
Exponent1 Number
System
Overflow=he¹c1 + he2c2 (m3/s or ft3/s)
h=heightofwater(morft)
See Section 3.2.1
Constant 1 Number
Exponent2 Number
Constant 2 Number
BackupRun
Pump 1 BackupStart (OFF,ON)
System
Ifthenormalcontrolviastartandstoplevelsfails,thismayactasanemergencybackup:Ifthehigh-levelfloattriggers,pumps1,2,3and/or4maybeset to start running for a period of Running Time.
used when a pressure sen-sorisinstalledontheoutflowside;whenitindicatestoohighpressureforthepump,itcanbeblocked.AvalueofzeroforBlock Time out means that the blockingwillnevertimeout.
BlockDelay Seconds
BlockLimit bar,psi
BlockTimeout Seconds
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Submenu Submenu Submenu Setting Value Pass code Comment
Athigh/lowfloat,asensoralarmcan be issued if the level sensor gives a vale that is not within Max Deviationfromthespecifiedlevelofthehigh/lowfloat.
Toensurethatvaluesvary,seebelow:
LevelatHighFloat m,ft
MaxDeviation+/- m,ft
CheckatLowFloat (OFF,ON)
LevelatLowFloat m,ft
MaxDeviation+/- m,ft
LevelChangeCheck (OFF,ON) Asensoralarmcanbeinstalledif the level sensor does not change its output value at least Min Level Change in the time period Check Time.
CheckTime Seconds
MinLevelChange+/- m,ft
TariffControl
- TariffControl (OFF,ON)
System
Iftariffcontrolisused,youcansetthepumpstostartempty-ing the pit Pump Prestart Time beforehightariffstarts.Inthiscase,itwillemptythepitdownto Pump Down Level (or to a stoplevel,whicheveristriggeredfirst.
Pause Time is used for two purposes: (1) the cooling time before a new resetisattempted, (2) the counter for Max No. At-tempts is reset when the pump has been running for Pause Time.
...
...... ...
Reset Protector P4 (NO,YES)
Pulse Time Seconds
Pause Time Seconds
MaxNo.Attempts Integer
PumpExercising
ExercisePump1 (NO,YES)
System
Thisisusedto“exercise”thepumpsiftheyhavebeenstandingstill for Max Stand Still Time.
If‘Start if Level >=’islowerthan‘Start if Level <’,thisisthewindowwherethepump(s)mayrun.Intheoppositecase,thepump(s)mayonlyrunoutsidethatwindow.Whentheconditionismet,thepump(s) will run for Running Time.
...
...... ...
ExercisePump4 (NO,YES)
MaxStandStillTime Minutes
Running Time Seconds
StartifLevel>= m,ft
StartifLevel<= m,ft
Pump Reversing
Reversing Pump 1 (NO,YES)
System
This is used to reverse the pump when a pump failure has occurred. The start of the reversing can betriggedbythemotorprotec-tor or the digital input (pump fail) orwhenlowpumpcapacityisdetected.
IfPump Relay When Rev. is set to ONthepumprelaywillbeacti-vated one second after the revers-ingrelayandgoesoffonesecondbeforethereversingrelay.
...
...... ...
Reversing Pump 4 (NO,YES)
Rev. On Pump Fail (NO,YES)
Rev. On Fallen M. prot (NO,YES)
Rev.OnLowP.Cap (NO,YES)
Rev. On Overcurrent (NO,YES)
StartRev.DelayTime MInutes
Rev. Running Time Seconds
MaxNo.Attempts Integer
PumpRelayWhenRev. (OFF,ON)
Stop Pumps Before Rev. (NO,YES)
PowerPumpBlocking
OnOverVoltage (NO,YES)
System Usealarmlimitsfromthesystemalarms menu.
OnUnderVoltage (NO,YES)
On Unbalanced Voltage (NO,YES)
OnHighFrequency (NO,YES)
OnLowFrequency (NO,YES)
BlockOnDelay Seconds
BlockOffDelay Seconds
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6.7 Settings for PID controllerTable6-5showsthecompletelistofsettingsyoucanmakeunderthesubmenu PID Controller.
Table 6-5 Settings for PID�controller,�under�‘Settings�>�PID�Controller’
There is a total of 16 digital (on/off)inputchannels.Thefirst12ones can be chosen from a list of26functions.However,werecommendtokeepthedefaultconfiguration,whichislistedintheinstallationGuide.
Pump Not in Autoisusuallyasignal from a manual switch that disconnects the pump com-pletelyfrombeingcontrolledfrom this unit.
Manual Startmaybeconnectedtoamanualswitch-itsfunctionwill be identical to that of start-ingthepumpbyusingthemenu.
DigitalInput13 to
DigitalInput16
InputFunction
(SameasDigitalIn1 – 12 above with additionalfunctions:
Thelast4digitalinputchannels,thatarenumbered13-16,canbe chosen from a list of 29 func-tions.However,werecommendtokeepthedefaultconfigura-tion,wheretheyareusedfor Input Pulse Ch. 1, Input Pulse Ch. 2, Input Pulse Ch. 3 and Input Pulse Ch. 4 respectively.NormallyState
(NormallyOpen(NO),
NormallyClosed(NC))
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6.13 Settings for digital outputsTable6-11showsthecompletelistofsettingsyoucanmakeunderthesubmenuDigital Outputs. The default configurationforDO1-8islistedintheInstallationGuide.
Table 6-11 Settings for digital�outputs,�under�‘Settings�>�Digital�Outputs’
Submenu Submenu Setting Sub Setting Value Passcode Comment
Call order Backupnumberor Parallel call See Section 4.7.6
PhoneNumber String
CallAttempt1-4assumethatamodemisconnected.Notneededforfixedlineconnections.ForSMS,theGSMnumbermustbe in international format (but theleading‘+’charactermaybeomitted).
SendIdString (NO,YES)
IdStringSendDelay Seconds
The time between the start of the connectionuntiltheID-Stringisbeing sent (if set to YES).
Communica-tionAlarm
Modem ErrorAlarmType (Inactive,B-
Alarm,A-Alarm)
SystemAlarmDelay Seconds
Teleline ErrorAlarmType (Inactive,B-
Alarm,A-Alarm)
AlarmDelay Seconds
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6.19 Settings�for�field�bus�modulesTable6-17showsthecompletelistofsettingsyoucanmakeunderthesubmenu Field Bus Modules.