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Summary of Contents for Xylem FLYGT FPG 415
- Page 1 Installation, Operation, and Maintenance Manual 887763_6.0 FPG 415...
- Page 3 Table of Contents Table of Contents 1 Introduction and Safety.................... 3 1.1 Introduction......................3 1.2 Safety terminology and symbols..............3 1.3 User safety......................4 1.3.1 Power lock-out................... 5 1.3.2 Qualification of personnel................ 5 1.4 End-of-life product disposal................5 1.5 Spare parts......................6 1.6 Warranty......................6 1.7 Support.......................
- Page 4 Table of Contents 7 Maintenance......................28 7.1 Preventive maintenance................. 28 7.2 Change the battery..................28 8 Troubleshooting......................30 8.1 The unit does not work................... 30 9 Technical Reference....................31 9.1 Dimensions.......................31 9.2 Environmental requirements................. 31 9.3 IP rating......................31 9.4 Electrical data....................32 9.5 RTC battery.......................32 9.6 Terminals......................
- Page 5 This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
- Page 6 1 Introduction and Safety Hazard level Indication A hazardous situation which, if not avoided, could WARNING: result in death or serious injury A hazardous situation which, if not avoided, could CAUTION: result in minor or moderate injury Notices are used when there is a risk of equipment NOTICE: damage or decreased performance, but not personal injury.
- Page 7 Risk of electrical shock or burn. A certified electrician must supervise all electrical work. Comply with all local codes and regulations. All work on the product must be carried out by certified electricians or Xylem authorized mechanics. Xylem disclaims all responsibility for work done by untrained, unauthorized personnel.
- Page 8 1.6 Warranty For information about warranty, see the sales contract. 1.7 Support Xylem only supports products that have been tested and approved. Xylem does not support unapproved equipment. FPG 415 Installation, Operation, and Maintenance Manual...
- Page 9 2 System Description 2 System Description 2.1 Adaptive mixers ADF The mixer is connected to an FPG 415 gateway that has an embedded web server. The operator connects to the web server through the HMI. Parts Number Part Product name Description Mixer •...
- Page 10 2 System Description Number Part Product name Description Gateway FPG 415 • A gateway with an embedded web server. – Digital input signal – Analog input signal – Modbus • All the alarms are sent back to the external control system. •...
- Page 11 2 System Description Parts Number Part Product name Description Mixer • SR 4220 A mixer with an integrated intelligent technology • SR 4230 • SR 4320 Controller APP 412 • Based on process conditions, the controller regulates the mixer. • The operator changes the mixer settings through the local HMI or through a SCADA system over Modbus.
- Page 12 2 System Description Number Part Product name Description FOP 402 HMI - Alternative 1 • A touchscreen HMI that is used for navigation and selection in the menus. • The touchscreen HMI is connected to a web server that is embedded in the controller.
- Page 13 2 System Description Parts Number Part Product name Description Pump • PP 4220 A pump with an integrated intelligent technology • PP 4230 Gateway FPG 415 • A gateway with an embedded web server. – Digital input signal – Analog input signal –...
- Page 14 2 System Description Number Part Product name Description FOP 315 HMI - Alternative 2 • A basic HMI with a jog wheel that is used for navigation and selection in the menus. Computer – HMI - Alternative 3 • The computer gives access to the same menu system as the touchscreen HMI.
- Page 15 2 System Description Number Part Product name Description Controller APP 412 • The controller starts and stops the pump based on input signals. • The operator changes the pump settings through the local HMI or through a SCADA system over Modbus. •...
- Page 16 3 Product Description 3 Product Description 3.1 Product design FPG 415 is a gateway that is connected to Flygt adaptive mixers or to Flygt adaptive ultra low head pumps. The gateway starts and stops the mixer or the pump based on the input signal from the external control system. All the alarms are sent back to the external control system.
- Page 17 3 Product Description 3.4 The data plate 8xxxxxx 1. Brand 2. MAC address 3. Country of origin. Manufacturer. 4. Product 5. Rated supply 6. Approvals 7. Waste disposal symbol 8. Serial number 9. Part number FPG 415 Installation, Operation, and Maintenance Manual...
- Page 18 4 Mechanical Installation 4 Mechanical Installation 4.1 Do not install in an explosive zone NOTICE: Do not use this unit in environments that may contain flammable/explosive or chemically aggressive gases or powders. 4.2 Install the gateway, ADF Snap the unit onto the DIN rail. 4.3 Install the gateway, ADC 1.
- Page 19 4 Mechanical Installation 3. Snap the unit or units onto the DIN rail. FPG 415 Installation, Operation, and Maintenance Manual...
- Page 20 5 Electrical Installation 5 Electrical Installation 5.1 Precautions Before starting work, make sure that the safety instructions have been read and understood. DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized.
- Page 21 5 Electrical Installation Requirements These requirements apply for electrical installation: • All fuses and circuit breakers must have the proper rating, and comply with local regulations. • The cables must be in accordance with the local rules and regulations. 5.2 Cables These requirements apply for power and Ethernet cable installation: •...
- Page 22 5 Electrical Installation Ethernet 2. Connect the Ethernet cable to the Ethernet terminal. It is possible to use the Ethernet terminal for multiple communication options: – Communication with FOP 402 – Communication with SCADA systems through Modbus TCP If the Ethernet terminal is used for multiple communication options, then use an Ethernet switch.
- Page 23 5 Electrical Installation 1 - 4 1 - 4 1. Open 2. Closed Digital outputs 7. Connect the digital output cables to the digital output terminals. The digital outputs are potential free relay outputs. Connect a power supply unit maximum 250 VAC, or 30 VDC, 5 A. The digital outputs are configurable to be normally open or normally closed.
- Page 24 5 Electrical Installation 5.3.2 Connect multiple units When multiple units are installed in the same application, cables are connected in parallel or separately. The backplane connectors are not used when the installation includes gateways only. Connect only one HMI. 1. Connect the FOP 315 HMI cables in parallel. Terminate with a 120 ohm resistor between terminals 2 and 4 at the end that is farthest from the HMI.
- Page 25 5 Electrical Installation NODE ADDRESS 24VDC RS485 ALARM A ALARM B RUN/CLEAN COMMS RS485 NODE ADDRESS MASTER SLAVE ETHERNET NO COM NO COM 5.4 Connect the controller and the gateways Some of the connection terminals are configurable. For more information, see the System Installation and Operation Manual.
- Page 26 5 Electrical Installation 5.4.2 Set the switches Set the switches. Switch Correct setting NODE ADDRESS, 0–9 All the node addresses in the system must be unique and not 0. MASTER/SLAVE – APP 412: MASTER – FPG 415: SLAVE TERM, ON/OFF –...
- Page 27 6 Operation 6 Operation 6.1 Startup and operation For instructions about the system operation, see the System Installation and Operation manual. 6.2 LED indicators ALARM A ALARM B COMMS RS485 NODE ADDRESS Table 1: Normal operation Description Color Indication Power Green The power is on.
- Page 28 6 Operation Description Color Indication Constant red The alarm condition is present. The alarm is acknowledged, or no acknowledgement is required. – There is no alarm. ALARM B Alarm, Class B Flashing red The alarm is not acknowledged. The alarm condition is either present or has ceased.
- Page 29 6 Operation ALARM A ALARM B COMMS RS-485 Indication Flashing red Flashing red – – – communication between the controller and the gateways in the system is lost. The gateways are operating in redundancy mode. FPG 415 Installation, Operation, and Maintenance Manual...
- Page 30 7 Maintenance 7 Maintenance 7.1 Preventive maintenance DANGER: Crush Hazard Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. Make sure that the unit is clean from dust and dirt. Use a wet cloth and soapy water for cleaning.
- Page 31 7 Maintenance 7. Turn on the power to the system. 8. Make sure that the real-time clock (RTC) shows the correct time. FPG 415 Installation, Operation, and Maintenance Manual...
- Page 32 8 Troubleshooting 8 Troubleshooting 8.1 The unit does not work Make sure that all wires are correctly connected according to the cable chart. Cause Remedy The PWR LED is not lit. • Make sure that the unit receives voltage. • Restart the unit. The unit does not communicate with the mixer/ •...
- Page 33 9 Technical Reference 9 Technical Reference 9.1 Dimensions 24VDC RS485 ALARM A ALARM B COMMS RS485 NODE ADDRESS MASTER SLAVE ETHERNET NO COM NO COM 1. 112 mm (4.4 in) 2. 45 mm (1.8 in) 3. 106 mm (4.2 in) 9.2 Environmental requirements Parameter Value...
- Page 34 9 Technical Reference Degree of protection, IP20 Code Description The enclosure is protected against: • Fingers or objects that are less than 80 mm (3.15 in) in length • Objects that are larger than 12.5 mm (0.49 in) in diameter The enclosure is not protected against water.
- Page 35 9 Technical Reference Section Terminal Description TERM Backplane termination switch Standard type A USB socket MASTER, SLAVE MASTER/SLAVE switch Isolated analog input, 4–20 mA Maximum 24 VDC – Scaling: 0–100% Offset: 0–16 mA with 0.1 mA resolution Analog output, 4–20 mA Maximum 24 VDC –...
- Page 36 9 Technical Reference Section Terminal Description Ethernet • Modbus TCP • Web server Backplane The Flygt controller communicates with the Flygt gateways through the backplane. FPG 415 Installation, Operation, and Maintenance Manual...
- Page 40 For more information on how Xylem can help you, go to www.xylem.com Xylem Water Solutions Global Visit our Web site for the latest...
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