Sulzer ABS PC 441 User Manual

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Installation manual (14 pages)

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Pump controller type ABS PC 441

2013.08.21

980.3 l/s

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1.30 m

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CA 511

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CA 441

User guide SW 1.70

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Low level

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PUMP 1

1827 l/s

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1.50 m

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1.90 m

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0.55 m

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STATUS

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CA 443

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Page 1 Pump controller type ABS PC 441 2013.08.21 05:56:19 Low level 1.55 m 0.15 kWh/m3 PUMP 1 980.3 l/s  1827 l/s  1.30 m  1.50 m  1.70 m  1.90 m  0.50 m  0.55 m ...
Page 2 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.
Page 3: Table Of Contents
CONTENTS ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS OVERVIEW OF FUNCTIONS AND USAGE Field bus status indicator ..........4 CA 511 operator panel .
Page 4 4.7.6 Alarms ............. . . 48 AquaProg .
Page 5: About This Guide, Audience And Concepts
ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS This guide describes the pump controller PC 441 and the operator panel CA 511. The pump controllers can ei- ther be used stand-alone or communicate all values and conditions to a central Scada system or a web based alarm and monitoring solution like AquaWeb from Sulzer. Installation guide There is a separate document Installation guide that describes how to physically install the pump controller (printed document in the installation package, and also a PDF on Sulzer web). Audience T his guide is intended for system administrators and operators of PC 441 pump controller with operator panel CA 511 or PC program AquaProg.
Page 6 Text appearing and declaration in this guide Text in italic is a description of text in the display of CA 511 or a description how you find your way through the menus by key strokes. Texts in bold, is how you have to do a change of the settings in the CA 511 menu. Most settings in chapter 5 only apply to the system administrator, but the following also apply to those who only operate the controller: language selection, date and time settings, units, backlight time-out, buzzer, operator pass code, start/stop levels. Glossary and conventions To designate a menu item in a hierarchy, an angle bracket is used to separate the levels. Example: Settings > System means the menu item you reach by first choosing the menu item Settings, which has a number of submenus, where you choose the menu item System. T ext in blue indicates a hypertext link. If you read this document on a computer, you can click on the item, which will take you to the link destination. Pump exercising: Long idle periods in a corrosive contaminated environment are not good for pumps. As a countermeasure, they can be “exercised” at regular intervals, which will reduce corrosion and other detrimental effects.
Page 7: Overview Of Functions And Usage
OVERVIEW OF FUNCTIONS AND USAGE PC 441 is designed to control 1-4 pumps. It can operate a pump station stand alone and/ or as a pump monitor. For configuration and operator interaction the graphic operator panel CA 511 may be used. With the AquaProg software (evaluation version available) a PC can be used for configuration and back up of settings. By adding a modem, a full remote alarm and monitoring solution can be achieved with just an AquaWeb rental contract or by most SCADA systems. Optional monitoring modules for leakage, temperature and electrical parameters gives a highly scalable solution for optimal cost and performance. The PC 441 can work standalone or together with extension modules, but the extension modules cannot work without the PC 441. PC 441 is the heart of the system! Other modules are optional. As a pump monitoring device the PC 441 offers the market a combined standard solution for submersible pump and pump station surveillance.
Page 8: Field Bus Status Indicator
8. Sulzer wireless modem Max 1 unit per system The base unit, PC 441, communicates with the extension modules via CAN communication. See the installation guide how to connect the extension modules. A fully extended system can look like this: Up to 4 pumps via 16 Din, 16 Dout, 5 Ain, 4 Aout 3 moisture and 5 temperature inputs per pump Temp L2 & L3 -> CA 511 Station Modem USB (service port) RS-232 port for a computer (service port or com echo see 3.8.5)
Page 9 The default (top-level) view of the display dynamically shows the operating status of the pumps and conditions in the pit. Figure 1-2 shows the symbols and explains their meanings. The unit will always revert to this view after 10 minutes of inactivity in any other view (such as showing menus). When PC 441 is set to use less than 4 pumps, the view adapts to show actual number of pumps. Power and alarm The two leftmost symbols on the CA 511 panel are for power and alarm indication: indicator • Green light is the power LED. • The red alarm indicator flashes whenever there is an unacknowledged alarm, and the display tells you the type of the alarm. When the alarm is acknowledged, the light turns steady red, and remains lit until there are no active alarms, this functions the same as the PC 441 alarm indicator LED. Direct functions, The buttons at the bottom and to the right of the display have the following functions: bottom and right displays • Buttons at bottom gives direct access to the most common menus. 2013.08.21 05:56:19 Low level 1.55 m 0.15 kWh/m3...
Page 10: Status View
Passcodes There are three security levels: 1. D aily operations, such as acknowledging an alarm or stopping a pump, do not require any passcode or authorization. 2. O perational settings, such as setting the start or stop levels for the pump, require a passcode at the level of Operator; 3. C onfiguration settings that affect the basic functionality or access, such as the type of level sensor, require a passcode at the level of System. The factory default passcodes are 1 and 2 respectively, but the codes can be changed under the menu item Settings > System. Whenever a passcode for Operator is requested, you may supply either the passcode for Operator or System. Personal alarm, and how to reset it W hen the pump station is manned, a personal alarm can be issued if the maintenance person hasn’t shown activity within a certain period of time. For details about settings related to this, see section 5.3 System set- tings (assigning Alarm type, Alarm delay and Max time to reset), section 5.12 Settings for digital inputs (as- signing Staff in...
Page 11: Pump Alarms Under Status View
It’s possible to use the left and right arrow keys at the numeral key board to step to the other pumps. Use up and down arrows to step between days. pqrs wxyz Up to 7 days back can be displayed. Leave the Status view by ESC. 1.2.3 Pump alarms under status view If the Field bus modules CA 441 and CA 442 are attached to the PC 441 and pump alarms appears, when under Status view you will be able to see an indication where the fault is physically located in the pump. DI 2 Electric Area T2 Hi Temp Up.
Page 12 To get a presentation of the curve titles in the menu Trend curve, then push Enter then you have the Trend curve picture on the display, the picture will appear with the description as below: PUMP 1 PUMP 2 [ Pit Level ] [ Pit Inflow] [ Outflow] [ Closed] PUMP 3 PUMP 4 12:42:24 12:44:24 12:46:24 MAIN STATUS SETTING TREND ALARM ACKN.
Page 13: Configure The Pc 441
CONFIGURE THE PC 441 Overview of settings Each station has an unique configuration setup, but the procedure is similar to setup these. This chapter will guide you through the basic settings in PC 441. Note: This does not cover all configurations, you must consider your prerequisites. The menu item Settings has 21 submenus with many settings that need to be entered by the system admin- istrator (although they all have sensible default values). The following 9 notes below are a recommended procedure to setup PC 441. 2.1. Set general configuration, system- and communication settings 2.2. C onfigure designated IO functions at DI, DO, AI and AO according to the electrical wiring drawing 2.3. Configure I/O modules, CA 441, CA 442, CA 443, CA 622, CA 511 and CA 781 2.4. Pump pit parameters and alarms 2.5. Set pump 1 - 4 settings and their alarms 2.6.
Page 14 Communication parameters • From the base screen, press the key for Setting under the display, scroll down by using the down ar- row key to Communication and press Enter. Press enter again and select Protocol (Modbus/Comli/ Modbus TCP) and press Enter at your choice. Press left arrow key to go back to the left part of the screen. Use the down arrow to Com port and press Enter. Select Station ID, Press Enter. Type in your Station ID by using numeral keys or up/down arrow keys, required for AquaWeb or any other surveillance system. Select Baudrate, Parity and Handshake. Use the left arrow key to go back to the left part of the screen and select Service port, press Enter. Select Baudrate for the service port. •...
Page 15: C Onfigure The Digital Inputs, Digital Outputs, Analog Inputs And Analog Outputs
C onfigurethedigitalinputs,digitaloutputs,analoginputsandanalog outputs Set designated IO-functions according to the electrical wiring drawing. See your drawings of the station. Under Settings, Digital inputs; choose for each input according to table 2-1 and Digital outputs to table 2-2. Table 2-1: Table 2-2: Digital inputs Digital outputs Pump run indication Pump control Manual pump start Reset motor protector Pump not in auto Pump fail Start float...
Page 16: Configure The Field Bus Unit Modules
In AquaProg: Figure 2-3 Analog and digital inputs / outputs Configurethefieldbusunitmodules All the extension modules to PC 441 are optional. The communication is done by the CAN-bus. See Instal- lation guide CA 441, CA 442, CA 443 (P/N:81307058) on Sulzer home page for more detail information to setup Leakage, Temperature and Power monitors. Installation guides to CA 511 (P/N 81307061), CA 622 (P/N 81307133) and CA 781 (P/N 81307132) can also be found at Sulzer home page. CA 441 Leakage module A system with PC 441 can contain up to four CA 441 modules. One CA 441 module can monitor leakage in one or four pumps depending on the setting of the address knob on the front of the module, see Installation guide CA 441, CA 442, CA 443 CA 441 (P/N: 81307058) for more information. If using one module to four...
Page 17 CA 781 module. See Installation and user guide (P/N 81307123) on Sulzer home page for more information. CA 622 RS 485 communication module PC 441 can communicate directly to VFDs, energy meters and V+ H Shld L soft starters via CA 622 module. CA 622 acts as Modbus master, CAN Bus communicating with attached Modbus slave devices. See the In- stallation and user guide (P/N 81307133) on Sulzer home page for more information and which VFD, energy meters and soft starters PC 441 and CA 622 support. If missing your model -contact Con- CA 622 trol & Monitoring at Sulzer and we might be able to add the new RX/TX model. PC 441 support one CA 622 in the system. When using CA 622 in the system, the values from many...
Page 18: Configure The Pump Pit Parameters
Configurethepumppitparameters Table 2-5: Pit settings Level sensor type Max number of pump running Min time between relay change Alternation Alternative stop level Start/stop on fast change Station flow* Calculation of pump capacity* Overflow Backup running Pit alarms Pump blocking Level sensor check Tariff control Level above sea * MUST for accurate pump capacity calculation...
Page 19 Overflow (optional parameter) Overflow can be detected by an overflow detector (MD 137) or by the certain level. See more information about overflow in section 3.3. Backup running (optional parameter) Backup running start when a High-level float gets activated. You can specify which pumps shall participate in backup run, and how long the pump shall run. Pit alarms (some parameters are recommended) There are several alarms which can be set under Pit alarms. Each alarm is configurable to be A- or B-alarms. Consult your drawings and verify which are important for your installation. Pump blocking (optional parameter) The pump can be blocked on remote. There is a time out which releases the blocking after a certain time. Blocking on Low level float and/or High pressure can be set here. Level sensor check (optional parameter) Level sensor check It is possible to check the level sensor reading compared to the installed floats. See the settings under Level sensor check set this up.
Page 20: Settings For Pump 1 To Pump 4 And Their Alarms
Settings for pump 1 to pump 4 and their alarms Here you can give the pump a tag name (max 20 characters). Installed pumps must have Relay control pump=YES, otherwise the pump will not show up in CA 511 graphics. Alternately; if pump 3 and pump 4 are not installed; Relay control pump=NO that pump disappears from the graphics. Important parameter to setup for each pump: Type of pump (fixed or VFD) Running indication (digital input, motor current or field bus module CA 622) Start/stop level Pump alarms Pump curve Optional parameters: Time settings Pump blocking Pump blocking on alarms Dry run detection Type of pump: •...
Page 21 Pump alarms There are several pump alarms to configure. Each alarm is configurable to be A- or B-alarms. The first part, table 2-6 below, is to setup the types of alarm (A- or B) and alarm delay. Table 2-6: Pump alarms Phase missing Dry run No run confirmation Fallen motor protector Motor protector reset error High motor current Low motor current Leakage High temperature High vibration Low pump capacity Pump not in auto Pump error Max continuous runtime Alarm blocked...
Page 22: Common P1 - P4
Common P1 – P4 In this option are many useful functions to avoid future problems, like Motor protector auto reset, Pump exercis- ing, Pump reversing, and different scenarios for blocking when using Power monitor. Motor protector auto reset Can be done “Conventional” or by CA 622 “Motor drive”. Conventional needs a digital output which controls an external solenoid to reset the motor protector. Motor drive requires CA 622 and the reset is sent to the VFD via software Pump exercising It is possible to exercise some pumps if required.
Page 23: Set Log Settings And Events
Set log settings and events There 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 channels will cost data traffic to the surveillance system.
Page 24: If Using Ca 622; Set Up Communications To Surrounding Units Vfd, Soft Starters And Energy Meters
Events Event list stores individual events such as Pump starts/stops, Alarms, alarm types and when the alarms occur and when it was acknowledged. The controller stores 4096 time-stamp events. The event list is always active for alarms. To activate event list for pump starts/stops, Go into Settings – Common P1-P4 – Log pump events - Yes If using CA 622; set up communications to surrounding units VFD, soft starters and energy meters See installation guide for CA 622 how to connect the surrounding units. Note: All the surrounding units must have unique Modbus ID’s and same communication parameters.
Page 25: Detailed Description Of The Functions
DETAILED DESCRIPTION OF THE FUNCTIONS Pump controller and/or monitor PC 441 can be used as a controller with monitoring capability or solely as a monitoring device. Setup PC 441 as pump controller: - In Settings / System menu: Set Station application to [Pump controller] (=default). The PC 441 monitor and control the pumps. Setup PC 441 as pump monitor: When the PC 441 is configured as a Pump monitor: All pump control functions (start/stop pumps) are disabled only monitoring functions are active. If a level sensor is connected inflow, outflow, pump capacity and pumped volume can be calculated. Pumps can be blocked in case of error conditions.
Page 26: Pump Capacity And In/Outflow Of The Pit
Pumpcapacityandin/outflowofthepit In-/outflow and pump capacity calculation Function • Calculates the inflow using level change per time unit and surface area. • Calculates the pump capacity every time a pump runs by itself. • Pump and system data can be entered for a more exact calculation. • An even higher flow calculation accuracy is obtained if a pressure sensor is mounted on the mains outlet. • Outflow calculation compensation for rpm. • Outflow can be taken from a flow meter. Value • Service the pump before breakdown, avoiding/reducing overflows. • Avoid wasting energy using pumps with degraded efficiency. • Service can be planned to occur during normal working hours. • No external flow meter required. • Accurate overflow measurement The PC 441 supports several approaches to flow calculation and combinations thereof 1.
Page 27 3. V olume is based on inflow calculation in combination with a flow measurement on the mains. Pros: An accurate flow measurement if mounting criteria are met Collection system behaviour can now be monitored Cons: Some more system set-up is required 4. A volume-based inflow and outflow calculation also considering pump and system curves. Pros: A cost effective flow monitoring solution also enabling collection system flow monitoring Cons: Access to basin, pump and system curves data required 5. A volume based inflow and outflow calculation in combination with a pressure monitoring of the mains. Pros: A cost effective flow monitoring solution also enabling collection system Monitoring with an even higher accuracy and less system set-up required The mains pressure reading also simplifies the flow calculation times set-up No system curve information has to be set-up Cons: Access to basin and pump curves data required Parameter settings for an accurate in-/outflow and pump capacity calculation Function • Calculate the inflow using level change per time unit times surface area •...
Page 28 Calculation of pumped volume Function • Pumped volume = Calculated pump capacity times Pump running hours • P umped volume calculation takes in consideration the pump curves, system curve as well for the rpm and mains pressure. (if applicable) Figure 3-1 Calculated flow with and without pump and pump system curve entered Logging of pumped volume • Continuous accumulation • Totalized values per day and seven days back in time • Flow calculations based on volumetric calculations adjusted to pump curves, system curves rpm and mains pressure depending on configuration Continuous volumetric calculations By entering the shape and size of the pump pit, together with an accurate level measuring device, the unit will always know the momentary volume in the pit.
Page 29 Logic used to calculate the pump capacity First pump starting. When the start level of the first pump is reached, the last known filtered value of the inflow is stored in the memory. After an adjustable time-delay the actual pump capacity measured by calculating the speed of level decreasing times the station pit. The time delay is there to enable the pump and system to reach full capacity before conducting the measurement. The pump capacity calculation time is also a value that can be set/ adjusted. The time needed to achieve an accurate value will depend on parameters like for instance: size of basin, type of pump and the collection network design to mention a few. Logic used to calculate the outflow during a pump cycle The outflow calculation is based on the calculated pump capacity times the running hours of the pump. To enhance the accuracy even further the pump curve for each pump can be entered. The curve is then used to adjust the calculated value to match the actual head. When the level drops the head increases and mostly also the pump capacity. This will then be adjusted in accordance to the pump curve data entered. If connected to a VFD, the rpm can also be used to compensate the outflow calculation. Logic used to re-calculate the inflow during a pump cycle As earlier mentioned the inflow is continuously calculated based on the level change per time unit when no pump is running.
Page 30 The important parameters for a level-based flow measurement are easily entered in the software. NOTE!! I f a pressure sensor is mounted on the mains no system curve information needs to be entered. For correct monitoring the level difference between pump suction point and pressure sensor on the mains must be given. Lifting elevation = 18 m Overflow at 5 m from lowest level H = 18 m - 5 m = 13 m Mid level 2.5 m from lowest level M = 18 m - 2.5 m = 15.5 m...
Page 31 Settings Valuable pump performance information is given in the pump technical data sheet. Total head from sensor zero level is an old setting actually referring to the static head. This only needs to be set if no system curve information is entered or no mains pressure sensor is configured. Figure 3-2 Example of pump curve Figure 3-3 Technical data in data sheet...
Page 32 Level based flow solution with a pressure sensor mounted on the mains for actual head compensation Use either a given static head or mount a pressure sensor on the outgoing mains to get the actual head. If a pressure sensor is mounted in the mains discharge pipe, the controller will automatically compensate for any variances in the head. Having a pressure sensor mounted on the mains can also warn for potential problems with a high mains pressure.
Page 33 4. T ime delay before pump capacity measurement, this to enable the flow to pick up speed depending on size of pit, pump, head and collection network design. 5. Measure speed of level reduction during a preset time to a pump capacity value is now obtained. 6. This capacity value is now adjusted to the pump curve (if entered). 7. Release the inflow calculation. 8. The inflow is now a function of the pump capacity and entered pump curve. 9. If yet a pump starts the outflow and inflow is then also adjusted according to the system curve. 10. I f a pump is running and there is a stable level reading, this would indicate that the inflow matches the outflow. 11. If the level increases it indicates that the inflow is higher than the pump capacity. Chart example is based on a full run cycle for P1. Charts like these are available through the Sulzer AquaWeb tool.
Page 34 Calculation functionality check routines 1. The level reading stays on a constant value - PC 441 has a built-in level deviation monitoring feature. 2. T he level reading is on a constant level due to a overflow situation - A specially designed overflow detection sensor type MD 131 can be used to detect this. 3. T he actual level for the high level alarm from a float can be entered, this level can then be used to compare with the level sensor reading. If a certain deviation from this set-point is detected a sensor failure alarm can be raised. Point 1 and 3 are covered in the Point 2 is covered by installing the below settings MD 131 sensor...
Page 35: Pit Shape
3.2.1 Pit shape The continuous flow measurement is based on the fact that the PC 441 can calculate the volume by measuring the level difference during a set calculation time. For this calculation is to exact it is necessary that the area / level should be always known. This can be achieved by setting the level and area for all level where the pit changes shape, up to 9 break points + the area at zero point can be set. Rectangular Cone Cone Figure 3-4 Example of pit shapes. To get a correct calculation at all levels even the pit shape has to be set as the calculation is different for differ- ent geometrical shapes. A shape that ends in a point is set as conical, if it ends as a wedge (2 parallel sides) it is set as rectangular shape, see figure above. Example for area calculation: Rectangle Circle A = L * W A = pi * r A = Area A = ? A = Area A = ? L = Length L = 2.20 Meter pi = 3.14...
Page 36: Pump Curve
3.2.2 Pump curve The outflow of the pit is calculated when the pumps are running. It is based on the capacity for the pumps and is accumulated to a pumped volume. If a level difference in the pit, during pumping, gives changes in the pump capacity according to the pump curve, this should be set in the PC 441. The outflow will in this case be compensated with the actual level in the pit according to the pump curve, which gives a more accurate ac- cumulated volume. mWp. Lifting elevation = 18 m Overflow at 5 m from lowest level H = 18 m - 5 m = 13 m Mid level 2.5 m from lowest level M = 18 m - 2.5 m = 15.5 m Lowest level 0 m Diff.
Page 37: System Curve
It can be difficult to estimate how much capacity decreases at the different operational cases. 2. E nter the duty point of the system curve for a pump. In menu under Stationflow>Meas.parameters set the duty point for a pump. System curve System curve and duty point can be calculated manually or by using any calculation programs such as ABSEL PRO from Sulzer. Set the static and total lifting height (static and total head) at the specific flow. PC 441 can use this to calcu- late compensation factors for the outflow when more than one pump is running. After calculation menu Flow compensation shows the calculated factors. NOTE! For this to work, each pump must have their pump curve entered in the following menu(s), Menu pump 1-4 >...
Page 38: Energy Efficiency: Kwh/Volume Unit
Example Figure 3-8 shows how the PC 441 handles the calculations when the pump curves and system curve are set: 4 pumps in parallel selected for 2000 l/s @ 10 m Figure 3-8 System curve (Settings – Pump pit – Station Flow – Meas. Parameters – System Curve: [When one pump is running]) Static Head Duty Point: 4.00 meters Total Head Duty Point: 4.8 meters...
Page 39: Overflow Flow Calculation
T he Investment cost is low and the sensor not require regular cleaning. The accuracy of the 0-point does Advantage not affect the measurements due to the switch being used as a 0-point. Drawbacks: T he analog input needs to have a very good resolution to be able to measure the signal. The PC 441 has no problem with this, e.g. for a sensor with a range of 10 m, the PC 441 has the resolution of < 0.7 mm. The third method is preferred and used in the PC 441 A digital overflow switch, like Sulzer MD 131 connected to a digital input indicates if an overflow is occurring independent of what the level signal shows. The PC 441 locks this actual level and the PC 441 starts calculat- ing the overflow level / flow from this value. This means that the level is measured with a very high accuracy from the correct 0 - point. If an exact flow measurement is needed a weir or channel should be used. Inflow Overflow Analog pit level sensor...
Page 40: How To Calculate Overflows By Using Constants And Exponents
3.3.1 Howtocalculateoverflowsbyusingconstantsandexponents • In Settings / Pump pit / Calc. overflow/ you can type in the constant and exponents manually. There are two different exponents and two constants which can be set in PC 441, depending on the manufac- turer and nature of the weir. Those constants shall normally be provided by the manufactures. If you don’t have the e2 and c2 values, you can set e2 and c2 to 0 (zero), only use the left side of the equation. For the basic weir types the c2 constant can be set to 0 (zero). Overflow = = Type of weir Constant 0.373 Thompson 30 ° 0.569 ° Thompson 45 0.789 ° Thompson 60 1.368 ° Thompson 90 Straight weir 1 m 1.76...
Page 41 Example 2 Temporary high inflow. Start level pump 1 = 2.0 m Start level pump 2 = 3.0 m Stop level pump 1 = 1.0 m Stop level pump 2 = 1.5 m Method used: Alt. each pump stops Alt. when all pumps stop Pit level increase At level 2.0 m Pump 1 start Pump 1 start At level 3.0 m Pump 2 start Pump 2 start Pit level decrease At level 1.5 m...
Page 42: Max Number Of Pumps Running
Value • Spare pump in good condition when main pump/s breaks down • Extend the service intervals and lower the maintenance costs • Reduces the risk for overflow! • Increased availability Pump 1 Pump 2 Pump 3 Pump 4 Start Sequence 3. Runtime alternation In addition to above, pump can be alternated dependent on there runtime. At exceeded maximum run time the pump will stop and an alternative pump will be started. The pump will only stop if there is at least one alterna- tive pump that is ready to run. 3.4.1 Max number of pumps running If the piping system cannot take the pressure when all pumps are running there is the possibility to set the max number 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.
Page 43: Pump Reversing
Pump reversing In the Settings / Common P1-P4 / Pump reversing specifies which pump or pumps shall use the reversing function. The reversing can be triggered on: • Digital input “Pump Fail” • Tripped motor protector (after auto reset) • High motor current • Low pump capacity • Preset number of pump starts If more than the set threshold for number of reverse triggers occurs within a preset time frame (default 5/60 minutes), no further reverse attempts are done within the set block time (default 24h), if manual reset not is required. Acknowledge of the Max reverse attempts alarm or a manual reverse from local control panel clears potential reverse block conditions.
Page 44: Speed Controlled Pumps (Vfd)
CA 622 communicate with the VFDs by RS 485 field bus. The CA 622 unit is connected to the system via CAN bus. CA 622 is fitted with a galvanically isolated RS 485 communication port for communication with peripheral products such VFDs, soft starters and energy meters. CA 622 is always the Modbus master with all peripherals acting as Modbus slaves. PC 441 has many predefined VFDs, the correct one must be chosen in the menus. All the predefined VFDs are options in the firmware of PC 441 and CA 622. If you can not find your brand and model of VFD; make sure that you have the latest firmware version in PC 441 and in CA 622. On Sulzer home page you can find the Installation and user guide CA 622 (P/N 81307133) there you can see if your model of VFD is supported. Configure the CA 622 module in PC 441 under – Settings – communication – Field bus units – CA 622 – YES At start level the pump will start at max frequency, if the start level is higher than set point. Output signal is kept at max freq. until the set level is reached. If calculation of pump capacity is enabled the pump will run at max frequency, until the calculation is completed. If the pump is running at min frequency for an adjustable time you can set a force speed for pumping out the pit. The pump will go on force speed until stop level is reached (or set level).
Page 45: Pid Settings
3.6.2 PID settings • In Show status/PID controller menu, Set the Set point value according to your set level. • In Settings / PID controller / Set point menu: You can set max and min levels for the set point and a start set point. • In Settings / PID controller / Output signal menu: Here you can set the max and min values for the output signal (min/max freq).
Page 47: Further Explanations About Some Digital/Analog Output/Input Types
F URTHER EXPLANATIONS ABOUT SOME DIGITAL/ANALOG OUTPUT/INPUT TYPES Logic IO One of the options in the functions of Digital out is Logic IO. This function is especially useful if you want to trigger an output signal when more then one criteria or events are needed to be for filled for an output signal. There are up to four different criteria that can be used to trigger the output signal. Those IO bits can interact as a True OR, Inverse OR, True AND and Inverse AND functions or as a combination of these for one and the same output.
Page 48: Digital Output Type: Data Reg. Setpoint
Digital Output 1 Logic IO function Output Function IO signal 1 [Logic IO] [True OR] Normaly State IO number [Normaly Open (NO)] IO signal 2 [True OR] IO number IO signal 3 [True OR] IO number IO signal 4  ...
Page 49: Analog Output Type: Data Register
Analog output type: data register With the Analog Output Type Data register, any analog signal, actual or calculated can be used as a 0/4-20 mA output signal. By using the registers defined in the Modbus manual, you can achieve this function. Example W e want to have a 4-20mA analog output signal tied to stator temperature 1 on pump 1. We also want the output signal to be 4mA at 0°C and 20mA at 150°C. NOTE! According to Comli/Modbus reference manual (p/n 81307126) we find that the temperature stator pump 1 is in register 40; see figure 4-3 below. We note as well that the scale factor is 0.1 (i.e. the value in reg.40 is multi- plied by 0.1 to get actual value in engineering units). A bove table is an extract from the Comli/Modbus manual for PC 441 –...
Page 50: Digital Out: External Reset Alert
Settings under Communication – Modem – Modem connected in the PC 441 shall be [Analog modem]. For GSM connection e.g. CA 521. Signals before answer, minimum 1. GSM modem H ayes settings normally works with default. Set PIN code if SIM card is equipped with one. Settings under Communication – Modem – Modem connected in the PC 441 shall be set to [GSM modem]. NOTE! The PIN code can be deleted with a cell phone. GPRS modem B ased on internal TCP/IP stack in Cinterion (former Siemens) GSM/GPRS modules. All data access is via the H ayes commands defined by Cinterion. Most common is dynamic IP addressing. GPRS default is the pump controller connects to TCP server in Sulzer AquaWeb system. If Scada system should connect to station see TCP-server section. Communication via GSM and GPRS uses the same network. If subscription allows, both can be used one at a time. Set PIN code if SIM card is equipped with one (deleted on AquaWeb SIM cards). NOTE! The PIN code can be disabled with a cell phone.
Page 51: Com Echo Pc 441
Heart beat interval 30 min (default). Can be adjusted but can raise costs if set to low. Server TCP port; Must be the same as in GPRS Server (default 2000 for AquaWeb). Servers IP address; The Public/global IP (normally in fire wall/router) address to the GPRS Server must be a static IP address. APN is provided by SIM card supplier. GPRS APN part 1 and GPRS part 2. If APN string is long it can be divided between the two parts. (Default is AquaWeb APN). SMS fallback: 0046708728550 for AquaWeb only! Settings under Communication – Modem – Modem connected in the PC 441 shall be set to [GPRS modem CA 521]. Set GPRS User name and Password if required by the subscription provider. GPRS Event Log and Heart beat operator scan for error search only. Default off. TCP-Server I f you have a SIM card subscription with a fixed IP address, then you can connect the s tation by GPRS on a local network by using CA 521 and set the function in modem settings to FIX IP TCP LISTEN – TCP-server FIX IP TCP LISTEN requires a SIM with fixed IP address from the provider on the station so that an external SCADA can contact remotely.
Page 52: Alarms
When using the GSM functionality to send SMS, there are possibilities to set up four attempts to call out. These attempts can be set as parallel calls; call multiple numbers in a sequence. Or as back up call; call first number in the attempt list and then wait for acknowledgement before trying with same number again in total three times, and then call next number in the attempt list. As soon as the substation gets an acknowledge- ment of an alarm call out; it will terminate the outgoing calls. Alarms will be sent out at ON/OFF state and A-alarms or A+B-alarms depending of settings. AquaProg AquaProg is Windows based software specially designed for setting and monitoring of Sulzer substations. Communication with the controller is established via RS 232, USB or Modem (analog or GPRS) connection between substation and computer. To communicate to PC 441 there has to be AquaProg version 4.86 or later. Features • Configuring substation PC 441 together with CA 441 - 443 • Checking and acknowledging alarms • Checking events • Collecting log data •...
Page 53: Cross Reference Table
1. Give your station a name 2. Choose “Type of substation” – PC441V1xx 3. C omli ID is critical for AquaProg, default is 1. If there is wrong station ID – AquaProg can handle that, but not wrong Comli ID. If you use the Service Port or the USB –then it’s always Comli ID = 1. 4. C your com port and the properties according to your substation 5. Modbus is default 6. Press OK After this configuration, you can call the substation and change the properties as normal. Cross reference table Cross reference is available in firmware 1.22 or later and in AquaProg version 4.90 or later. Cross reference table can be set-up in AquaProg to optimise the data flow in Comli/Modbus to the supervisory system. Register 0-254 (telegram type 0 and 2) can be defined to hold preferred data by a cross reference table and can be set for data of any register. See further information in Comli/Modbus register manual. There is the possibility for certain rescaling of data, e.g. Running time in seconds can be rescaled to minutes with the factor 60. The scale factor can be between 0-32767. With the factor 0 no rescaling is done.
Page 55: Settings
SETTINGS Select language 1. Choose the menu item Select language and press Enter twice. 2. Enter the pass code Operator (default is 2). Press Enter. 3. Scroll to the language of your choice by using the Up/down buttons. 4. Press Enter and then the Left/backward arrow. Overview of settings The menu item Settings has 21 submenus with a large number of settings that need to be entered by the sys- tem administrator, although they all have sensible default values. The following are the 21 submenus: 5.3.
Page 56: System Settings
System settings Table 5-1 shows the complete list of system settings. Table 5-1 Systemsettings,underthemenuitem‘Settings>System’ Submenu Submenu Setting Value Passcode Comment Same as the setting described in Select Language Select a language Operator Section 5.1 Pump Controller Station Application System Pump Monitor Pump Monitor: See Section 3.1 Metric: m, m , Liters/second (Metric units, (liters/s), bar, mm, ºC Select Units System US units) US: ft, ft...
Page 57 Submenu Submenu Setting Value Passcode Comment (Inactive, Alarm Type B-Alarm, A-Alarm) Alarm Delay Seconds After this time, the maintenance Personal Alarm person must reset the timer Max Time to Reset Minutes (by pushing any button), or a Personal Alarm is sent out after Alarm Delay (Inactive, Alarm Type B-Alarm, A-Alarm) Wrong Phase Order Alarm Delay Seconds (Inactive, Alarm Type B-Alarm, A-Alarm) Alarm Delay Seconds Over 3~ Voltage Limit (+)
Page 58: Pump Pit Settings
Pump pit settings Table 5-2 shows the complete list of settings under the submenu Pump Pit. Table 5-2 Pumppitsettings,under‘Settings>PumpPit’ Submenu Submenu Submenu Setting Value Pass code Comment (Analog, Level Sensor Type Select Type System Start/Stop Floats) To minimize power surges or spikes caused by pumps start- ing or stopping simultaneously, Min Time Relay Changes Min Time Seconds System there should always be a mini- mum time between two relays...
Page 59 Submenu Submenu Submenu Setting Value Pass code Comment If the level increases at least Level Change to Start m, ft Level Change to Start during the time period Per, then one pump will start. If the level continues to increase that much, the next Time period (Per.) Minutes pump will start Stop (NO, YES) Function Active?
Page 60 Submenu Submenu Submenu Setting Value Pass code Comment To detect overflow, an overflow sensor is much more accurate (OFF, Overflow Overflow Detect than a threshold from the level Sensor; Level Limit) sensor. By setting parameters (exponents and constants) the overflow can also be accurately measured by a calculation. ‘Lock Level if Limit Used m, ft on inflow’ simply uses the his- Calc. Overflow System torical value of inflow. Level Limit is the level at which overflow is expected. Note: not as accurate as using an overflow (Exp + const,...
Page 61 Submenu Submenu Submenu Setting Value Pass code Comment (Inactive, Alarm Type B-Alarm, A-Alarm) Backup Start Alarm Delay Seconds (Inactive, Alarm Type B-Alarm, A-Alarm) Remote Blocking Alarm Delay Seconds (Inactive, Alarm Type B-Alarm, A-Alarm) Alarm Delay Seconds High Pressure Limit bar, psi Hysteresis bar, psi (Inactive, Alarm Type B-Alarm, A-Alarm) Alarm Delay Seconds Low Pressure Limit bar, psi Hysteresis bar, psi (Inactive,...
Page 62: Pump 1 To 4 Settings
Submenu Submenu Submenu Setting Value Pass code Comment Check at High Float (OFF, ON) Checks that the level sensor is functioning properly. Checks can be made at high float, at Level at High Float m, ft low float and to ensure that the output varies. Max Deviation +/- m, ft At high/low float, a sensor alarm can be issued if the level sensor Check at Low Float (OFF, ON) gives a vale that is not within Max Deviation from the specified Level Sensor Check System...
Page 63 Submenu Submenu Submenu Setting Value Passcode Comment Nominal Current Amperes Pump Parameters System Nominal Power Factor Number (OFF, Digital Input, The means/sensor by which a Pump Run Indication Motor Current) pump is regarded as running. Pump Run Indication System Pump is regarded as running Current Threshold Amperes above threshold. Threshold On Delay Seconds Delay before change of set point...
Page 64 Submenu Submenu Submenu Setting Value Passcode Comment (Inactive, Alarm Type B-Alarm, A-Alarm) Alarm Delay Seconds High Vibrations Limit mm/s, inch/s Hysteresis mm/s, inch/s (Inactive, Alarm Type B-Alarm, A-Alarm) An alarm is issued if the Alarm Delay Seconds Low Pump Capacity measured capacity is below this threshold. Limit Liters/second, GPM Hysteresis Liters/second, GPM (Inactive, Alarm Type B-Alarm, A-Alarm) Pump Not In Auto Alarm Delay Seconds (Inactive,...
Page 65 Submenu Submenu Submenu Setting Value Passcode Comment (Inactive, Alarm Type Temp. B-Alarm, A-Alarm) From additional CA 442: Stator L2 Alarm Delay Seconds Pump High Tem- Same set point are used for System Alarms peratur Alarm Limit and Hysteresis as (Inactive, Alarm Type Temp. T1/T4 (Pt100) B-Alarm, A-Alarm) Stator L3 Alarm Delay Seconds T1/T4 Stator or If activated the pump will be Digital Input or (NO, YES)
Page 66 Submenu Submenu Submenu Setting Value Passcode Comment Low Cos Block Pump (NO, YES) To detect that the pump is run- Block Delay Seconds Dry Run Detect System ning dry, a threshold on low cos Block if Cos < Number phi is used. Block Timeout Seconds Max 11 characters to name the Pump Tag Pump name String pump.
Page 67: Common Settings For Pump 1, 2, 3 And 4
Common settings for pump 1, 2, 3 and 4. T able 5-4 shows the complete list of settings you can make under the submenu Common P1-P4. Table 5-4 Commonsettingsforpump1,2,3and4,under‘Settings>CommonP1-P4’ Submenu Submenu Setting Value Passcode Comment Log Pump Events Default: OFF (OFF, ON) System Reset Protector P1 (NO, YES) Pulse Time is the duration of the reset pulse. Pause Time is used for two purposes: Reset Protector P4...
Page 68: Settings For Pid Controller
Settings for PID controller T able 5-5 shows the complete list of settings you can make under the submenu PID Controller. Table 5-5 Settings for PIDcontroller,under‘Settings>PIDController’ Submenu Submenu Setting Value Passcode Comment (OFF, Analog Input 2, External Set Point Analog Input 3, Analog Input 4, Analog Input 5) Set Point Tracking (OFF, ON) Set Point System (Last Set Point, Startup Set Point Start Value, Ex- ternal Set Point) Set Point Start Value m, ft Max Set Point...
Page 69: Settings For Mixer
Settings for mixer T able 5-6 shows the complete list of settings you can make under the submenu Mixer. Table 5-6 Settings for mixer,under‘Settings>Mixer’ Submenu Submenu Setting Value Passcode Comment Stop Pumps (NO, YES) when Mix Run Indication (OFF, Digital Input) Mixer Run Time Seconds The mixer is either started after Pump Starts to Mix Integer Pump Starts to Mix, or after System Time Interval to Mix. Entering zero disables the corresponding Time Interval to Mix Minutes trigger.
Page 70: Cleaner
5.10 Cleaner T able 5-8 shows the complete list of settings you can make under the submenu Cleaner. Table 5-8 Cleaner,under‘Settings>Cleaner’ Submenu Submenu Setting Value Passcode Comment (Pump Start, Flush at : Pump Stop) System Flushing Time Seconds No. Start to Flush Integer 5.11 Analog logging T able 5-9 shows the complete list of settings you can make under the submenu Analog Logging. Table 5-9 Analoglogging,under‘Settings>AnalogLogging’ Submenu Submenu Setting Value Passcode Comment (Closed, Pit Level, Pit Inflow, Pit Outflow, Overflow Level,...
Page 71: Settings For Digital Inputs
5.12 Settings for digital inputs T able 5-10 shows the complete list of settings you can make under the submenu Digital Inputs. Table 5-10 Settings for digitalinputs,under‘Settings>DigitalInputs’ Submenu Submenu Setting Value Passcode Comment (OFF, Pump run indication, Manuel pump start, Pump not in auto, Start float, Pump failure, Motor protector, There is a total of 16 digital (on/ High temperature, off) input channels. The first 12 Leakage, ones can be chosen from a list Stop float P1-P4, of 26 functions. However, we Low level float,...
Page 72: Settings For Digital Outputs
5.13 Settings for digital outputs T able 5-11 shows the complete list of settings you can make under the submenu Digital Outputs. The default configuration for DO 1-8 is listed in the Installation Guide. Table 5-11 Settings for digitaloutputs,under‘Settings>DigitalOutputs’ Submenu Submenu Setting Sub Setting Value Passcode Comment (OFF, Pump control, Reset motor prot., Pump fail, Too many pumps blocked, One pump fail, Master reset m.prot., Mixer control, Reset m.prot. mixer, Drain pump control, Res. m.prot drain, Cleaner control, Modem control, Remote control, Personal alarm, High level, Alarm alert, Not ackn. A-alarm,...
Page 73: Settings For Analog Inputs
5.14 Settings for analog inputs T able 5-12 shows the complete list of settings you can make under the submenu Analog Inputs. Table 5-12 Settings for analoginputs,under‘Settings>AnalogInputs’ Submenu Submenu Setting Value Passcode Comment Signal Range (4-20 mA, 0-20 mA) Filter Constant Seconds Analog Input 1 Scaling 0% = m, ft Dedicated for the level sensor. Scaling 100% = m, ft Zero Offset m, ft Filter Constant Seconds (OFF, NA, Motor current pump 1, If CA 442 is connected to a pump...
Page 74 Submenu Submenu Setting Value Sub settings Passcode Signal Range (4-20 mA, 0-20 mA) Filter Constant Seconds (OFF, Pit level, Pit inflow, Scaling 0 % Pit outflow, Scaling 100 % Pit overflow, Pulse channel 1, PC 441 Analog Output 2 Pulse channel 2, Main Module Output Function Pulse channel 3, Pulse channel 4, PID Controller) Data Register 0-4529 Scaling 0 % Data Register Scaling 100 % Section 4.3 Signal Range (4-20 mA, 0-20 mA) Filter Constant...
Page 75: Settings For Pulse Channels
5.16 Settings for pulse channels T able 5-14 shows the complete list of settings you can make under the submenu Pulse Channels. Table 5-14 Settings for pulse channels,under‘Settings>PulseChannels’ Submenu Submenu Submenu Setting Value Passcode Comment 1 Pulse mm, inch (Inactive, B- Alarm High Precip. Alarm, A-Alarm) Precipitation Alarm Delay Seconds Limit l/s/ha, inch/h Hysteresis l/s/ha, inch/h 1 Pulse (Inactive, B- Alarm High Power The menus adapt to the choice Alarm, A-Alarm) you made for the function of...
Page 76: Communication Settings
5.18 Communication settings T able 5-16 shows the complete list of settings you can make under the submenu Communication. Table 5-16 Communication settings,under‘Settings>Communication’ Submenu Submenu Setting Value Passcode Comment (Modbus, Comli, Protocol for both the ports and Select Protocol Modbus TCP) the USB connections. Protocol System Cross Refer- (ON, OFF) Section 4.9 ence Table (OFF, 300 Baud, 600 Baud, 1200 Baud, 2400 Baud,...
Page 77 Submenu Submenu Setting Value Passcode Comment Heart Beat Interval Minutes Server TCP Port No Number Server IP Address String GPRS APN Part 1 String GPRS APN Part 2 String SMS Fallback (OFF, ON) Modem GPRS Settings System Section 4.7.4 Fallback SMS String Number GPRS User Name String GPRS Password String GPRS Event log (OFF, ON) H.
Page 78: Settings For Field Bus Modules
5.19 Settingsforfieldbusmodules T able 517 shows the complete list of settings you can make under the submenu Field Bus Modules. Table 5-17 Settingsforfieldbusmodules,under‘Settings>FieldBusModules’ Submenu Submenu Submenu Setting Value Passcode Comment Only set this to YES if the units Used and Con- (NO, YES) are connected to Canbus and nected used as leakage monitor. If one pump is selected DI1 - DI3 (4 Pumps P1- is used for that pump. At four Pumps Connected P4, Pump 1) pumps DI1 corresponds to P1...
Page 79 Submenu Submenu Submenu Setting Value Passcode Comment Only set this to YES if the units Used and Con- (4 Pumps P1- are connected to Canbus and nected P4, Pump 1) used as temperature monitor. If one pump is selected T1 - T3 is used for that pump. At four Pumps Connected (NO, YES) pumps T1 corresponds to P1...T4...
Page 80 Submenu Submenu Submenu Setting Value Passcode Comment Only set this to YES if the units Used and Con- (NO, YES) are connected to Canbus and nected used as power monitor. (None, Transf. Con- L1, nected to L1 and L2, L1, L2 and L3) TR. Nominal Amperes Current TR. Second- Current All current measuring is done Amperes ary Current Measuring...
Page 81: Common Settings
Submenu Submenu Submenu Setting Value Passcode Comment (Inactive, B- CA 443-1 Alarm Type Alarm Com. Alarm, A-Alarm) Pump 1 Failure Power Moni- System Alarm Delay Seconds tors CA 443 CA 443-4 High-leg Pump 4 (NO, YES) Delta Used and (NO, YES) Connected AO/DO (Inactive, B- Expantion System Alarm Type Alarm Com.

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Sulzer ABS PC 441 User Manual

About this Guide, Audience and Concepts

1 Overview of Functions and Usage

2 Configure the Pc 441

3 Detailed Description of the Functions

4 Further Explanations about some Digital/Analog Output/Input Types

5 Settings

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