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ABS advanced pump controller PC 441

EN Installation Guide

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ABS advanced pump controller PC 441, Installation guide

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Copyright © 2013 Sulzer Pump Solutions AB. All rights reserved.

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 Pump. Sulzer Pump assumes no responsibility or liability for any errors or inac-curacies 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 Pump.

Sulzer Pump reserves the right to alter specifications due to technical developments.

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ABS advanced pump controller PC 441, Installation guide

1 INSTALLATION

1.1 Mount the controllerMount the controller on a 35 mm DIN rail. The physical dimensions of the con-troller is: 86 x 160 x 60 mm (3.39 x 6.30 x 2.36 inch) (H x W x D). If it doesn’t easily snap onto the rail, you can pull the small tab at the bottom side of the unit, using a small screwdriver.

1.2 Make all connectionsThere are a total of 48 terminals that may be connected to power, sensors, switches, relays and a modem; these terminals are numbered from 1 to 52 ac-cording to the following figure:

WARNING Ensure that all power is off, and that all output devices to be connected to the controller also are turned off before you connect anything!

Table 1 shows all connections to terminals 1-26 at the bottom side of the control-ler. The usage of the configurable Digital In and Analogue In shown in the table is the default configuration.

“Digital In” means a signal that is either on or off — high or low, where high is between 5 and 34 volts DC. Digital In may be connected to either passive devices, such as switches, or active devices that are powered and deliver signals. Figure 1 shows how to connect such devices to the Digital In terminals.

Table 2 shows all connections to terminals 27–52 at the top side of the controller. The usage of the configurable DO 1 to DO 8 and AO 1 to AO 2 shown in the table is the default configuration. “DO” stands for “Digital Outputs”, which are voltage outputs.

The power must be DC between 9 and 34 volts. Figure 2 shows how to connect a power-fail switch to Digital In 3 (terminal 5) and how to connect a battery pack for uninterrupted operation.

The modem should be connected according to Figure 8.

For CAN bus (Field bus) see section 1.3 Can bus.

RS-232 port for a computer

Terminals at the top side of the controller, numbered 27 to 52

Terminals at the bottom side of the controller, numbered 1 to 26

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Table 1. Terminals at the bottom side of the pump controller

Factory Settings Namei #

Voltage supply, 10–32 V DC ⇒V+ 1

V - 2

Overflow level Digital In 1 → 3

HIgh level float Digital In 2 → 4

Power failure Digital In 3 → 5

Personal in station (local mode) Digital In 4 → 6

Motor protector pump 1 Digital In 5 → 7

Pump 1 not in auto Digital In 6 → 8

Spare pump 1 Digital In 7 → 9

Motor protector pump 2 Digital In 8 → 10

Pump 2 not in auto Digital In 9 → 11

Spare pump 2 Digital In 10 → 12

Motor protector pump 3 Digital In 11 → 13

Pump 3 not in auto Digital In 12 → 14

Spare pump 3 Digital In 13 → 15

Motor protector pump 4 Digital In 14 → 16

Pump 4 not in auto Digital In 15 → 17

Low level float Digital In 16 → 18

19

V+ ← 20

Level sensor Analogue Inii 1 → 21

P1 Motor current Analogue Inii 2 → 22

P2 Motor current Analogue Inii 3 → 23

P3 Motor current Analogue Inii 4 → 24

P4 Motor current Analogue Inii 5 → 25

V- 26

i. “Digital In” means a signal that is either on or off (high or low), where high is anything between 5 and 32 volts DC and low is anything below 2 volts. All digital inputs are con-figurable in the menu Settings > Digital Inputs, but the configuration shown here is the default one.

ii. “Analogue In” means Analogue Input. They are all sensing the current in the range 4–20 mA or 0–20 mA. This is configured in the menu Settings > Analogue Inputs.

Figure 1. The Digital In terminals may be connected to either passive devices, such as switches, or active devices that are powered and deliver signals. Connect devices according to the figure.

VoltageSupply

SignalOutput

Signalground

VoltageSupply

PC 441

Digitalinputs

X

Y

V+Push-button/switch

Signalling device

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Table 2. Terminals at the top side of the pump controller

# Namei Factory Settings

27 V - 0V

28 → DOi 1. Alarm alert

29 → DOi 2. Pump 1

30 → DOi 3. Pump 2

31 → DOi 4. Pump 3

32 → DOi 5. Pump 4

33 → DOi 6. Personal alarm alert

34 → DOi 7. Relay Mixer

35 → DOi 8. High level

36

37 → + AOii 1.Pit level

38 ← - AOii 1.

39 → + AOii 2.Off

40 ← - AOii 2.

41

42 V +↔ CAN_V+

43 CAN_H

44 ↔ CAN_SHLD

45 CAN_L

46 V - 0V

47

48 ← CTS

49 → RTS

50 → TX

51 ← RX

52 0V

i. DO means Digital Output. It is a voltage output. See the menu Settings > Digital Outputs for configuration of these outputs.

ii. AO means Analogue Output. See Settings > Analogue Outputs for configuration of these outputs.

Figure 2. The power must be DC between 9 and 34 volts, but if it also charges batteries, it should be 27.2 V. Connect a power-fail switch to Digital In 3 (terminal 5) according to the figure. For uninterrupted operation in case of power failure, connect a battery pack according to the figure.

VoltageSupply

PC 441

Digital input: "Power fail"

Relay

Backup battery pack

+

+

Fuse

AC

DC

Batterycharger

27.2 V

V+

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Figure 3. Analogue input connection (level sensor)

Figure 4. Digital output connection (external relay)

Figure 5. Analogue output connection

V+

PC 441PINS

AnalogueIn I

Level sensor +-

4-20 mA

V+

V-

PC 441PINS

0V

DOI

Relay

Loads are connected series

AO1+

AO1-

PC 441PINS

With analogue connected to V-

PLC

V-

A A+ - + - +

-V-

V+

0/4 - 20 mA

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1.3 CAN bus (Field bus) A CAN network is of multidrop type witch means that all units are connected in parallel on the same cable. PC 441 is the master on the bus to which display devices like CA 511 and any monitoring devices are connected (type CA 441 / 442 / 443).

The CAN cable uses 5 wires. Two wires are used for communication CAN_L and CAN_H. One wired is shield CAN_SHLD and two wires are used as bus power V+ and 0V. Bus power allow devices to get power directly from the bus.

Figure 6. CAN connection

1.3.1 Using bus power

Max bus power output from PC 441 is 350 mA (V+). CA 511 can be bus powered directly from PC 441. Other modules must use an external power supply.

A few rules:

□ If CA 511 is the only device connected on the bus. Bus power CA 511 directly from PC 441.

□ If other devices (like CA 441 ..) also are connected. Don’t use bus power from PC 441 for these devices. Connect an external power supply (V+ and 0V) to the first device in the chain.

□ If some modules are placed far away from the main unit, it’s a good idea to use a separate power supply for these units.

1.3.2 CAN termination

The CAN bus shall be terminated at both cable ends. PC 441 is bus master and has a built-in termination that are always active and should therefore always be placed in one of the endpoints of the cable. For other devices you can activate the selectable termination with a switch marked CAN TERM Active termination for the device placed on the other endpoint of the cable. All other devices between should have their termination switch in Off position.

Figure 7. CAN network with connection

CA 511 CA 441 / 442 / 443

0V CAN_L SHLD CAN_H V+0V CAN_L SHLD CAN_H V+1 2 3 4 51 2 3 4 5

PC 441

V+ 4243444546

CA 44x

CAN_HSHLD

CAN_L0V

~-

+Power supply

CAN TERMON

CAN TERMOFF

CAN TERMOFF

CAN TERMOFF

CA 44x CA 44xCA 44x CA 511 PC 441

AlwaysON

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1.3.3 CAN ID

In a CAN network every unit must have a unique address or ID-number. PC 441 and CA 511 use a fixed ID on the bus and no ID settings are needed for these devices.

On the CA 44x one part of the address is set default depending on device, the other part of the address is set by a hexadecimal switch, marked “ID”. Choose address by pump number as in table below or instructions in system manual. If the device has a unique address and contact with the network master, the CAN LED is still green. For error codes of the CAN LED see system manual.

When used with PC 441 use the following addresses to achieve correct func-tions.

Table 3. CA 441 Leakage Monitor

CAN SUB ID Monitoring function

0 Not used with PC 441

1 Pump 1 or pumps 1-4

2 Pump 2

3 Pump 3

4 Pump 4

5 - > F Not used with PC 441

Table 4. CA 442 Temperature Monitor

CAN SUB ID Monitoring function

0 Not used with PC 441

1 Pump 1 or pumps 1-4

2 Pump 2

3 Pump 3

4 Pump 4

5 - > F Not used with PC 441

Table 5. CA 443 Power Monitor

CAN SUB ID Monitoring function

0 Main power monitor

1 Pump 1

2 Pump 2

3 Pump 3

4 Pump 4

5 - > F Not used with PC 441

0 1 2 3 4

5 6 7 8 9 A B

C D

E F

I I I I I I I I I I I I

I I

I I

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Figure 8. Depending on the type of modem, connect according to the figure. Modem cable 43320588.

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2 CONNECTION OF XYLEM PUMPS TO ABS PC 441

It is possible to connect Xylem pumps in parallel with ABS pumps.

For connection of sensors there are three cases depending on sensor configura-tion in the pump.

Case A: CLS sensor or combination of sensors in seriesIn this case you have to use the analog inputs on the PC441. For advanced motor current monitoring or if out of analog inputs on the PC 441 use the CA 443 mod-ule for current monitoring. See the CA 44x Installation Guide.

If the sensors are not connected in series, connect the sensors to temperature and leakage monitors respectively, see case B and C below. However the CLS is always connected to an analog input of the PC 441.

ATTENTION! In this case feeding power must not exceed 13.7 volts DC at any time.

Overvoltage can cause permanent damage to the pump controller. Ideal power is between 11.5 and 13.7 Volts DC

Pay special attention to the polarity of the CLS. Faulty connection will cause none or malfunction.

Select input type “ITT MiniCas Sim” on the PC 441 for this functionally.

Case B: Only temp sensorsChose “Klixon” Thermo switch/PTC or “Pt100” mode in the settings menus for CA 442

FLS/FLS10

CLSThermoswitch

Anal

oge

inpu

t 2 -

5

V+Ai(n)

Power input12V DC

Xylem pumpABS PC 441

CLS or any combination of sensors like:•CLS and FLS or•CLS and Thermo switch or•Thermo switch and FLS•CLS and Thermo switch and FLS

Klixons/Pt100

CANT(n)+T(n)-

Power inputDC

Xylem pump

ABS PC 441

ABS CA 442

CAN

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ABS advanced pump controller PC 441, Installation guide

Case C: Only leakage sensors from the FLS seriesChose “Xylem” mode in the settings menus for CA 441.

FLS/FLS10CAN

Di(n)+Di(n)-

Power inputDC

Xylem pump

ABS PC 441

ABS CA 441

CAN

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3 TECHNICAL DATA

3.1 Technical data PC 441

Ambient operation temperature -20 to +50 °C (-4 to +122 °F)

Ambient storage temperature -30 to +80 °C (-22 to +176 °F)

Degree of protection IP 20, NEMA: Type 1

Housing material PPO and PC

Flame rated V0 (E45329)

Pollution degree 2

Mounting DIN Rail 35 mm

Dimension HxWxD: 86 x 160 x 60 mm (3.39 x 6.30 x 2.36 inch)

Humidity 0-95 % RH non condensing

Power supply 9-34 VDC SELV or Class 2

Power consumption < 5.0 W (without digital output load)

Installation category CAT II

Digital outputs Max load

8 DO. Positive logic. Sourcing from power supply 1A/output. Max total current for all 8 outputs together is 4 A.

Digital inputs Input resistance Input voltage

16 DI. Positive logic 10 kohm 5-34 V . Trig level ~ 4 V

Max pulse rate digital in 13-16 500 Hz (pulse channels)

Analogue outputs Max load Resolution Current limit

2 AO. 0/4-20 mA Sourcing from power supply 500 ohm@12 V, 1100 ohm@24 V 15 bits 0.5 uA ~22 mA

Analogue inputs Input resistance Resolution

5 AI. 0/4-20 mA 136 ohm. PTC protected AI1 :14 bits (level sensor). AI2-5 : 10 bits

Communication ports 1 RS232 Service port 1 RS232 port for telemetry interface (modem) 1 USB2 Service port

Field Bus (to CA 511/CA 441 ………) 1 CAN Port . Max current load 350 mA

Max altitude 2000 m

Approval

3.2 CleaningHow to clean the unit

Power off the unit. Only outside/front shall be cleaned by using a dry, soft cloth. A good choice would be the microfiber type of cloth. Gently wipe the PC 441 front in order not to scratch the overlay. If the dry cloth did not completely remove the dirt, do not press harder in an attempt to scrub it off. If necessary, moisten the cloth by adding a small amount of water with thin solution of mild detergent and try again. Never use detergent with polish or solvent which can have an impact of the plastic surface.

Declaration of conformity

Declaration of ConformityAs defined by: EMC-Directives 2004/108/EC and 92/31/EEC, Low Voltage Directive 2006/95/EC, Directive for CE-Marking 93/68/EEC

EN EC Declaration of Conformity SV EG-försäkran om överensstämmelseDE EG-Konformitätserklärung NO EUs SamsvarserklæringFR Déclaration de Conformité CE DA EC-OverensstemmelseserklæringNL EC-Overeenkomstigheidsverklaring FI EU-VaatimustenmukaisuusvakuutusES Declaración de confirmidad CE ET EÜ Vastavuse deklaratsioonPT Declaracão de conformidade CE PL Deklaracja zgodnosci WE IT Dichiarazione di conformità CE CS Prohlášení o shodšĕ ES

EL Δήλωση εναρμόνισης EK SK EC Vyhlásenie o zhodeTR AT Uygunluk Beyanı HU EK Megfelelőségi nyilatkozat

Sulzer Pump Solutions AB, Rökerigatan 20, SE-121 62 Johanneshov, Sweden

EN: Name and address of the person authorised to compile the technical file to the authorities on request: DE: Name und Adresse der Person, die berechtigt ist, das technische Datenblatt den Behörden auf Anfrage zusammenzustellen:FR: Nom et adresse de la personne autorisée pour générer le fichier technique auprès des autorités sur demande :NL: Naam en adres van de persoon die geautoriseerd is voor het op verzoek samenstellen van het technisch bestand:ES: Nombre y dirección de la persona autorizada para compilar a pedido el archivo técnico destinado a las autoridades:PT: Nome e endereço da pessoa autorizada a compilar o ficheiro técnico para as autoridades, caso solicitado:IT: Il nome e l’indirizzo della persona autorizzata a compilare la documentazione tecnica per le autorità dietro richiesta::EL: Όνομα και διεύθυνση του ατόμου που είναι εξουσιοδοτημένο για τη σύνταξη του τεχνικού φακέλου προς τις αρχές επί τη απαιτήσει:TR: Yetkili makamlara istek üzerine teknik dosyayı hazırlamaya yetkili olan kişinin adı ve adresi:SV: Namn och adress på den person som är auktoriserad att utarbeta den tekniska dokumentsamlingen till myndigheterna:NO: Navn og adresse på den personen som har tillatelse til å sette sammen den tekniske filen til myndighetene ved forespørsel:DA: Navn og adresse på den person, der har tilladelse til at samle den tekniske dokumentation til myndighederne ved anmodning om dette:FI: Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite:ET: Isiku nimi ja aadress, kelle pädevuses on koostada nõudmise korral ametiasutustele tehnilist dokumentatsiooni:PL: Nazwisko i adres osoby upoważnionej do przygotowania dokumentacji technicznej w przypadku, gdy jest ona wymagana przez władze:CS: Jméno a adresa osoby oprávnĕné na vyžádání ze strany úřadů vytvořit soubor technické dokumentace:SK: Meno a adresa osoby oprávnenej na zostavenie technického súboru pre úrady na požiadanie:HU: Asmens, įgalioto valdžios institucijoms pareikalavus sudaryti techninę bylą, vardas, pavardė ir adresas:

Frank Ennenbach, Director Product Safety and Regulations, Sulzer Pump Solutions AB, Gråbrödersgatan 2, S-211 21 Malmö, Sweden

EN: Declare under our sole responsibility that the products: SV: Försäkrar under eget ansvar att produkterna:DE: Erklärt eigenverantwortlich dass die Produkte: NO: Erklærer på eget ansvar, at følgende produkterFR: Déclarons sous notre seule responsabilité que les produits: DA: Erklærer på eget ansvar, at følgende produkter:NL: Verklaren geheel onder eigen verantwoordelijkheid dat de produkten: FI: Vakuutamme yksinomaan omalla vastuullamme, että seuraavat tuotteetES: Declaramos bajo nuestra exclusiva responsabilidad que los productos: ET: Deklareerime ainuvastutajana, et tooted:PT: Declaramos sob nossa unicia responsabilidade que los produtos: PL: Deklaruje z pelna odpowiedzialnoscia, ze urzadzenia typu:IT: Dichiariamo sotto la nostra esclusiva responsabilità che i prodotti: CS: Prohlašuje na vlastní odpovědnost, že výrobky:EL: Δηλώνουμε με αποκλειστική μας ευθύνη ότι τα προϊόντα: SK: Vyhlasujeme na našu zodpovednost’, že výrobky:TR: Sorumluluk tamamen bize ait olarak beyan ederiz ki aşağıdaki ürünler: HU: Felelösségünk teljes tudatában kijelentjük, hogy a termékek:

ABS advanced pump controller PC 441

EN: to which this declaration relates are in conformity with the following standards or other normative documents:DE: auf die sich diese Erklärung bezieht, den folgenden und/oder anderen normativen Dokumenten entsprechen:FR: auxquels se réfère cette déclaration sont conformes aux normes ou à d’autres documents normatifs:NL: waarop deze verklaring betrekking heeft, in overeenstemming zijn met de volgende normen of andere normatieve documenten:ES: objeto de esta declaración, están conformes con las siguientes normas u otros documentos normativos:PT: aque se refere esta declaracáo está em conformidade com as Normas our outros documentos normativos:IT: ai quali questa dichiarazione si riferisce sono conformi alla seguente norma o ad altri documenti normativi:EL: τα οποία αφορά η παρούσα δήλωση είναι σύμφωνα με τα ακόλουθα πρότυπα ή άλλα κανονιστικά έγγραφα:TR: bu beyanın konusunu oluşturmakta olup aşağıdaki standart ve diğer norm belgelerine uygundur:SV: som omfattas av denna försäkran är i överensstämmelse med följande standarder eller andra regelgivande dokument:NO: som dekkes av denne erklæringen, er i samsvar med følgende standarder eller andre normative dokumenter:DA: som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder eller andre normative dokumenter:FI: joihin tämä vakuutus liitty, ovat seuraavien standardien sekä muiden sääntöämääräävien asiakirjojen mukaisia:ET: mida käespöev deklaratsioon puudutab, on vastavuses järgmiste standardite ja muude normatiivdokumentidega:PL: do których odnosi sie niniejsza deklaracja sa zgodne z nastepujacymi normami lub innymi dokumentami normatywnymi:CS: na které se toto prohlášeni vztahuje, jsou v souladu s následujícími normami nebo jinými normativními dokumenty:SK: na ktoré sa vz ahuje toto vyhlásenie, zodpovedajú nasledujúcim štandardom a iným záväzným dokumentom:HU: amelyekre ez a nyilatkozat vonatkozik, megfelelnek a következőszabványokban és egyéb szabályozó dokumentumokban leírtaknak:

Safety: EN 61010-1:2001 EMC: EN 61000-6-1:2001, EN 61000-6-2:2003, EN 61000-6-3:2001, EN 61000-6-4:2001

Stockholm 2012-07-01

Per Askenström Sulzer Pump Solutions AB

| Sulzer Pump Solutions Ireland Ltd. | Clonard Road, Wexford, Ireland | | Phone +353 53 91 63 200 | Fax +353 53 91 4235 | www.sulzer.com |

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