Download pdf - Pump controller type ABS PC 441

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1.30 m0.50 m

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MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 12013.08.21 05:56:19 Low level

980.3 l/s

mP3 P4P1 P2

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CA 443CA 781

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CAN Bus

www.sulzer.com

Pump controller type ABS PC 441

EN User guide SW 1.70

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Copyright © 2019 Sulzer. 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. 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.

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CONTENTS

ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS 1

1 OVERVIEW OF FUNCTIONS AND USAGE 31.1 Field bus status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 CA 511 operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2.1 Status view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2.2 How to access the status view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2.3 Pump alarms under status view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.2.4 Trend curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 CONFIGURE THE PC 441 92.1 Setgeneralconfiguration,system,IDandcommunicationsettings . . . . . . . . . . . . . . . . . 92.2 Configurethedigitalinputs,digitaloutputs,analoginputsandanalogoutputs . . . . . . . 112.3 Configurethefieldbusunitmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.4 Configurethepumppitparameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.5 Settings for pump 1 to pump 4 and their alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.6 Common P1 – P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.7 Set log settings and events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.8 IfusingCA622;setupcommunicationstosurroundingunitsVFD,softstartersand

energymeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.9 Setupcleaner,mixerordrain(ifused) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 DETAILED DESCRIPTION OF THE FUNCTIONS 213.1 Pump controller and/or monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.2 Pumpcapacityandin/outflowofthepit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.2.1 Auto-setlimitlowpumpcapacityalarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.2.2 Pit shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.2.3 Pump curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.2.4 Systemcurve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.2.5 Energyefficiency:kWh/volumeunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.3 Overflowflowcalculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.3.1 Howtocalculateoverflowsbyusingconstantsandexponents . . . . . . . . . . . . . . . . . . . 373.4 Pump alternation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.4.1 Maxnumberofpumpsrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.5 Pump reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403.5.1 Othersettingsregardingpumpreversing:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403.6 Speedcontrolledpumps(VFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.6.1 ConfigurePC441forVFDpump(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.6.2 PIDsettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.6.3 Variablefrequencydriveautoreset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 FURTHER EXPLANATIONS ABOUT SOME DIGITAL/ANALOG OUTPUT/INPUT TYPES 434.1 Digitaloutput:LogicIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434.2 Digitaloutputtype:datareg.setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444.3 Digitaloutputtype:externalresetalert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.4 Digitalinputtype:blockremotedate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.5 Digitalinputtype:mixeranddrainpumpblocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.6 Analogoutputtype:dataregister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.7 Analogueinput:Secondarypitlevelsensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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5 COMMUNICATION AND AQUAPROG 475.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.1.1 Com port (screw terminals 48 – 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.1.2 Serviceport(9-polsD-Subinthefront) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.1.3 USBport(USBtypeBinthefront) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.1.4 Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.1.5 Com Echo PC 441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.1.6 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.2 AquaProg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.2.1 HowtosetupAquaProg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.3 Cross reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6 SETTINGS 516.1 Select language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516.2 Overview of settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516.3 Systemsettings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526.4 Pump pit settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546.5 Pump 1 to 4 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586.6 Commonsettingsforpump1,2,3and4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636.7 SettingsforPIDcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646.8 Settingsformixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656.9 Drainpump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656.10 Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666.11 Analoglogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666.12 Settings for digital inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676.13 Settings for digital outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.14 Settings for analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.15 Settings for analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696.16 Settings for pulse channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.17 Settings for trend curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716.18 Communication settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726.19 Settingsforfieldbusmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.20 Common settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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ABOUTTHISGUIDE,AUDIENCEANDCONCEPTS

ThisguidedescribesthepumpcontrollerPC441andtheoperatorpanelCA511.Thepumpcontrollerscanei-therbeusedstand-aloneorcommunicateallvaluesandconditionstoacentralScadasystemorawebbasedalarmandmonitoringsolutionlikeAquaWebfromSulzer.

Installation guide There is a separate document Installation guidethatdescribeshowtophysicallyinstallthepumpcontroller(printeddocumentintheinstallationpackage,andalsoaPDFonSulzerweb).

Audience ThisguideisintendedforsystemadministratorsandoperatorsofPC441pumpcontrollerwithoperatorpanelCA511orPCprogramAquaProg.

Prerequisites Thisguideassumesthatyoualreadyareacquaintedwiththosepumpsyouaresettocontrolandhavethesen-sorsandoperatorpanelCA511connectedtoPC441.

Thesystemadministratormustalsoknowanddecideonthefollowing:

1. Thepumpcontrollercaneitheruseananaloglevel-sensor,whichmeasuresthewaterlevelinthepit,forprecisecontroloverstartandstoplevels,oritcanusesimplefloatswitchesplacedatstartandstoplevels.

• Floatswitchescanbeusedinadditiontoananaloglevel-sensor,asabackup,andasanad-ditional alarm input.

• Ananaloglevel-sensorhasseveraladvantagesoverfloatswitches:itismorerobust(cannotgetstuckorbemechanicallyjammed);itismoreaccurate;itismoreflexible(youcaneasilychangethestartandstoplevels);youcangetreadingsofthewaterlevelinthepit,theinflow,overflowandthepumpcapacity;youcanoptimisethepumpperformanceinvariousways,includingexer-cising,alternativestoplevels,tariffcontroletc.

• Itisalsopossibletoemployanalternativestoplevel,usuallyalowerlevelthannormal,thatiseffectiveonceafteranumberofpumpstarts.Thiscanbeusefulifitisdesirableto“completely”emptythepitonceinawhile.

2. Youneedtoknowifthepump(s)shouldbeexercisedincaseoflongidleperiods.Iftheinstallationhastwopumpsormore,youneedtodecideifthepumpsshouldalternate.

3. Iftheelectricityhasdailyvaryingtariffs,youmustknowthetimesofhigh/lowtariffs.

4. Youmustknowhowoverflowwillbemeasured:ifitwillbemeasuredusingbothanoverflowdetector(tode-tectthestartoftheoverflow)andalevelsensor(tomeasuretheactualflow),youmustknowtheparameters(exponentsandconstants)tobeenteredassettingssothattheoverflowcanbeaccuratelymeasuredbyacalculation in PC 441.

5. Youneedtoknowwhichalarmclass,A-alarmorB-alarm(seeGlossaryandconventions),toassigneachalarm.

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.

Thesystemadministratormustensurethatallsettingsaccordingtochapter 6 Settingsaresuitableforyourapplication.

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.

Glossary and conventions

Todesignateamenuiteminahierarchy,ananglebracketisusedtoseparatethelevels.Example:Settings > SystemmeansthemenuitemyoureachbyfirstchoosingthemenuitemSettings,whichhasanumberofsubmenus,whereyouchoosethemenuitemSystem.

Textinblueindicatesahypertextlink.Ifyoureadthisdocumentonacomputer,youcanclickontheitem,whichwilltakeyoutothelinkdestination.

Pump exercising:Longidleperiodsinacorrosivecontaminatedenvironmentarenotgoodforpumps.Asacountermeasure,theycanbe“exercised”atregularintervals,whichwillreducecorrosionandotherdetrimentaleffects.

Cos j: Cosine of the phase angle j between the motor current and the voltage.

Alarm class:ThealarmclasscanbeeitherA-alarmorB-alarm.A-alarmsarethosethatrequireimmediateac-tion,sooperationalstaffinthefieldshouldbealertedregardlessofthetimeofday.B-alarmsarelessimpor-tant,butshouldbetakencareofduringnormalworkhours.

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.

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1 OVERVIEWOFFUNCTIONSANDUSAGE

PC441isdesignedtocontrol1-4pumps.Itcanoperateapumpstationstandaloneand/orasapumpmonitor.ForconfigurationandoperatorinteractionthegraphicoperatorpanelCA511maybeused.WiththeAquaProgsoftware(evaluationversionavailable)aPCcanbeusedforconfigurationandbackupofsettings.Byaddingamodem,afullremotealarmandmonitoringsolutioncanbeachievedwithjustanAquaWebrentalcontractorbymostSCADAsystems.Optionalmonitoringmodulesforleakage,temperatureandelectricalparametersgivesahighlyscalablesolutionforoptimalcostandperformance.

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. 3. 4.

5. 6. 7.

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8.Sulzerwirelessmodem Max 1 unit per system

Thebaseunit,PC441,communicateswiththeextensionmodulesviaCANcommunication. Seetheinstallationguidehowtoconnecttheextensionmodules.Afullyextendedsystemcanlooklikethis:

8.

Modem

Figure 1-1

RS-232 port for a computer(service port or com echo see 3.8.5)

Power indicator

Field bus indicator

Alarm indicator

USB (service port)

Agreenlampattheveryleftindicatesthattheunitispowered(eitherbatteryormains). Theredalarmindicatorwillblinkwheneverthereisanunacknowledgedalarm.

1.1 Field bus status indicatorPumpcontroller,operatorpanelandmonitoringmodulescommunicatesviaaCANbus.

Fixedgreenlight=connectedOK Flashinggreenlight=searchingformodules Flashingredlight=InvalidIDsetonmodule

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.

Figure 1-2

0 A

1.30 m0.50 m

1.50 m0.55 m

1.70 m0.60 m

1.90 m0.65 m

352.5 A 353.8 A 354.1 A

1.55 m1827 l/s3.8 bar


PUMP 4

PUMP 3

PUMP 2

PUMP 12019.01.23 05:56:19 Low level

980.3 l/s

mP3 P4P1 P2

3

007:25:58 07:28:10 07:30:26

0.15 kWh/m3Height of water in pit

Overflow detectorInward flow to pit

Trend curve

Shows operation(animated)

Height of water(animated)

High-level float sensor

Low-level float sensor

Outward flow from pitBack-pressure

Current consumption for pump

Total pump efficiencyStart / Stop levels

Thedisplayanditsinformationfieldsinthedefaulttop-levelview.

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).

WhenPC441issettouselessthan4pumps,theviewadaptstoshowactualnumberofpumps.

Power and alarm ThetwoleftmostsymbolsontheCA511panelareforpowerandalarmindication: indicator

• Buttons at bottom gives direct access to the most common menus.

• Bottomrightmost“Ackn.”.Buttonwillacknowledgethemostcur-rentalarmdisplayedonstatusrowattopofdisplay.

• Right buttons will start or stop the pump. (Toggle actual state.) Bykeepingbuttonpressed,forcedpumprunbelowstoplevelispossible.

Right-hand buttons Thebuttonstothelowerrightofthedisplayhavethefollowingfunctions:

• To leave the overview image of the pump pit and go into the menus,presseithertheUp or Down arrow button.

• Yougo“into”amenuitembypressingeithertheRight/Forward button or the Enter button.

• Youconfirm(orperform/execute)anoperationwiththeEnter button ( ).

• Toexitthecurrentoperation,orleavethemenusandgobacktooverviewimageofthepumppit,presstheEscape button.

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

Figure 1-3 Thetop-levelmenuofthePC441graphicaldisplay.

Howtoselectlanguageandmakeallsettings(menuitemsSelect language and Settings) are described in chapter 6 Settings.

How to enter values Press Enter to enable editing of a value. and strings

0 A

1.30 m0.50 m

1.50 m0.55 m

1.70 m0.60 m

1.90 m0.65 m

352.5 A 353.8 A 354.1 A

1.55 m1827 l/s


PUMP 4

PUMP 3

PUMP 2

PUMP 12013.08.21 05:56:19 Low level

980.3 l/s

mP3 P4P1 P2

3

007:25:58 07:28:10 07:30:26

0.15 kWh/m3

Esc

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5jkl

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2abc

1,.

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Use the Left/Right buttons to choose the insertion point.

Use the Up/Down buttons to increase/decrease a value or letter. Valuesandstringscanalsobealteredthroughthealphanumerickeyboard.

Anasterisk(*)gives=adot(.).

Finishtheeditingbypressingenter.

Esc

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5jkl

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2abc

1,.

3def

• GreenlightisthepowerLED.

• Theredalarmindicatorflasheswheneverthereisanunacknowledgedalarm,andthedisplaytellsyouthetypeofthealarm.Whenthealarmisacknowledged,thelightturnssteadyred,andremainslituntiltherearenoactivealarms,thisfunctionsthesameasthePC441alarmindicatorLED.

Direct functions, Thebuttonsatthebottomandtotherightofthedisplayhavethefollowingfunctions: bottom and right displays

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Passcodes Therearethreesecuritylevels:

1. Dailyoperations,suchasacknowledginganalarmorstoppingapump,donotrequireanypasscodeorauthorization.

2. Operationalsettings,suchassettingthestartorstoplevelsforthepump,requireapasscodeatthelevelofOperator;

3. Configurationsettingsthataffectthebasicfunctionalityoraccess,suchasthetypeoflevelsensor,requirea passcode at the level of System.

Thefactorydefaultpasscodesare1and2respectively,butthecodescanbechangedunderthemenuitemSettings > System.WheneverapasscodeforOperatorisrequested,youmaysupplyeitherthepasscodeforOperatororSystem.

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.

Toresetthetimer,justpushanybuttononthecontrolpanel.

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


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


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

T2 Hi Temp Up. Bearing

DI 1 Oil Chamber / or Leakage Pumpfrom PC 441

Figure 1-6 Pump sensor indications in Status view

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How to access Trend curve

1.2.4 Trend curveAnotherusefulfunctioninPC441isTrend curve.Hereyoucangetanoverviewofpitlevel,inflowandoutfloworanyotherparameteryouchooseovertime.Fourdifferenttrendcurvescanbedisplayedatthesametime.Thereisalsoapossibilitytoadjusttheintervalsamplingforthecurves.Defaultsettingis1samplepersecond.


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

Figure 1-7 Trend curve

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To get a presentation of the curve titles in the menu Trend curve,thenpushEnterthenyouhavetheTrend curvepictureonthedisplay,thepicturewillappearwiththedescriptionasbelow:


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.

2.1. Setgeneralconfiguration,system-andcommunicationsettings

2.2. ConfiguredesignatedIOfunctionsatDI,DO,AIandAOaccordingtotheelectricalwiringdrawing

2.3. ConfigureI/Omodules,CA441,CA442,CA443,CA622,CA511andCA781

2.4. Pump pit parameters and alarms

2.5. Setpump1-4settingsandtheiralarms

2.6. CommonP1-P4

2.7. Set log settings and events

2.8. Setupcommunicationstosurroundingunits(VFD,softstartersand/orenergymeters(ifused)

2.9. Setupcleaner,mixerordrain(ifused)

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.

AllthesettingscanbedonelocallyformthemenusorbyAquaProg.TheadvantageofAquaProgisyoucansavetheconfigurationatyourPCandeasilyrestorethecontrollerifneeded.

2.1 �Set�general�configuration,�system,�ID�and�communication�settingsSetupthebasicsystemparametersandcommunicationparametersbyusingthemenusinCA511:

Basic system parameters

• Fromthebasescreen,pressthekeyforSettingunderthedisplay,pressEntertwiceandgivethepassword (default 2).Scrollontheleftpartofthescreentoyourlanguagebyusingtheup/downarrowkeys,pressEnteratyourchoice.

• 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)

• UsethedownarrowkeytoSelect units,metricorUSunits,pressEnteratyourchoice.

• UsethedownarrowkeytoDate format,pressEnter.Chooseyourdateformat.

• UsethedownarrowkeytoSet date,Set time,andallothersettingsunderthisparameter.

• Set System alarmsaccordingtoyourpreferences.

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Communication parameters

• 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.

• Selectmodemtype

Nowit’spossibletoconnecttoAquaProgthroughserviceportorUSB.

In AquaProg:

Figure 2-2 CommunicationFigure 2-1 Systemsettings

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2.2 �Configure�the�digital�inputs,�digital�outputs,�analog�inputs�and�analog� outputsSetdesignatedIO-functionsaccordingtotheelectricalwiringdrawing.Seeyourdrawingsofthestation.

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).

EachmodulefromCA442-1(“-1”referstotheaddressontheknob)toCA442-4hasa4-20mAVibrationinput,oneforeachpump.ThevibrationinputsaredisabledinunitsCA442-5andCA442-6.

0 1 2 3 4

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CA 441

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5 6 7 8 9 A B

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CA 442

0 1 2 3 4

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I I I

CA 443

0 1 2 3 4

5 6 7 8 9 A B

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CA 441

0 1 2 3 4

5 6 7 8 9 A B

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I I I

CA 442

0 1 2 3 4

5 6 7 8 9 A B

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I I I

CA 443

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CA 443 Power monitor module

PC441supportsuptofiveCA443modules,onemoduleforeachpumpandoneforwholesystem.CA443modulescannotbeusedtogetherwithVFD.TheCA443modulesmustbeconnectedbeforepumpcontactorsotheinputsL1-L3nevergetpowerless. Iftheinputsgetpowerless,thephasealarmgoon,andthepumpwillnotstart,seeInstallation guide CA 441, CA 442, CA 443 (P/N:81307058)formoreinformation.

CA 511 Graphical operator interface panel

PC441supportsoneCA511.ItisnotpossibletouseoneCA511toseveralPC441s.CA511isconnectedtoPC441viaCAN-busandhasaCAN-busterminationontheback.Thefirmwarever-sioninCA511mustconformtotheversioninPC441.Alwaysusethelatestfirmwaretoensurefullfunctionality.

CA 781 Output expansion module

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.

WhenusingCA622inthesystem,thevaluesfrommanyparameterscanbereadoutbytheRS485busdirectfromVFD/softstartersorenergymetersandstoredinthecontroller.Thesevaluescanalsobelogged.PC441togetherwithCA622canalsocontroltheon/off,speedandreversingofthepumps.ConsulttheInstallationanduserguideCA622(P/N81307133)onSulzerhomepageformoreinformationaboutwhichVFD/softstarters/energymetersPC441andCA622supports.

0 1 2 3 4

5 6 7 8 9 A B

C D

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I I I

CA 441

0 1 2 3 4

5 6 7 8 9 A B

C D

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I I I

CA 442

0 1 2 3 4

5 6 7 8 9 A B

C D

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I I I

CA 443

Esc

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0 A

1.30 m0.50 m

1.50 m0.55 m

1.70 m0.60 m

1.90 m0.65 m

352.5 A 353.8 A 354.1 A

1.55 m1827 l/s


PUMP 4

PUMP 3

PUMP 2

PUMP 12013.08.21 05:56:19 Low level

980.3 l/s

mP3 P4P1 P2

3

007:25:58 07:28:10 07:30:26

0.15 kWh/m3

CA 511

CA 781

CAN

CA 622

RX/TX

ON-OFF485-term.

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2.4 Configure�the�pump�pit�parametersTable 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

Level sensor type (required parameter, default level sensor)

Analogsensororstart/stopfloats.Analogsensorisrecommendedifyouwanttotrackthecapacityofthepumps and pumping volume.

Max number of pumps running (optional parameter)

Ifyourpipesystemcannothandletoohighflows/pressureoryourpowergridhaslimitations,reducenumberofpumps running at the same time. See section 3.4.1

Alternation (optional parameter)

Normalorasymmetrical

Normal:Thepumpsstartinsequencefrom1-4.Thereisalwaysonepumpstartatthefirst(lowest)startlevel.

Asymmetrical:Thepumpsaredividedintwogroupsthereonegroupisworkingmorefrequentlythantheothergroup. See also section 3.4

Alternative stop level (optional parameter)

Thisfunctionistoaidreductionofsedimentsinthepitandavoidingfloatingcrust

Start/stop on fast change (optional parameter)

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.

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Overflow (optional parameter)

Overflowcanbedetectedbyanoverflowdetector(MD137)orbythecertainlevel.Seemoreinformationaboutoverflowin section 3.3.

Backup running (optional parameter)

BackuprunningstartwhenaHigh-level floatgetsactivated.Youcanspecifywhichpumpsshallparticipateinbackuprun,andhowlongthepumpshallrun.

Pit alarms (some parameters are recommended)

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.

Tariff control (optional parameter)

Thisfunctionistoreduceenergyconsumptioninhoursofhighcostofenergy.Youcansetthisupforseparatedaysintheweek.

Level above sea (optional parameter)

Ifyoutypeinavaluehere,thisvaluewillbeaddedinthepitlevelbutnotaffectthestart/stoplevels.

In AquaProg:

Figure 2-4 Pump pit settings

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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.

Importantparametertosetupforeachpump:

Typeofpump(fixedorVFD) Runningindication(digitalinput,motorcurrentorfieldbusmoduleCA622) Start/stop level Pump alarms Pump curve

Optionalparameters:

Time settings Pumpblocking Pumpblockingonalarms Dryrundetection

Type of pump:

• Fixedpumps A digital output starts the pump

• Speedcontrolledpump(PID/VFD) Start a VFD which has predefined frequency

Pump parameters:

• Set the nominal current for the pump

• Set the power factor for the pump

Usefulparameterstodetectdryrunandheavyload

Select run indication:

• Digitalinput

• Motor current Require current transformers connected to an analog input

• ModbusCA622 RS 485 communication to/from VFD or soft starter

Start/stop levels for each pump

Recommendedtohavedifferentstartlevelsforallthepumps.Samestoplevelforallthepumpsisfine.

Time settings (optimal parameter)

Setthemaximumruntimeforthepumps

QH curve (pump curve)

Togetaccuratevaluesforpumpcapacityandpumpedvolume,thisparameterisimportant.Seechapter5formore information about pump curve.

Mixer prestart

IfMixerfunctionisselectedandthePC441isactingasa[Pump controller],theMixerwillbestartedbeforethefirstpumpisstarted.Thisallowsthemixertimetospeedupbeforeanypumpisstarted.

ThisistrueiftheMixerispumpstartcountcontrolled. IftheMixeristimecontrolled,itwillstartindependentofpumpstart. Inbothcasesminandmaxlevelformixstartmustbeperformed. Configurethepumpstartdelayinmenu:

Settings / Pump x / Time settings/ Threshold on delay. Youmustsetthisdelayonthepumpwiththeloweststartlevel.

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Pump alarmsThereareseveralpumpalarmstoconfigure.EachalarmisconfigurabletobeA-orB-alarms.Thefirstpart,table2-6below,istosetupthetypesofalarm(A-orB)andalarmdelay.

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

Max reverse attempts

Pump blocking (auto or manual reset)

Allalarmsheremustbeacknowledgedonsiteorremotelyforthepumptostartagain.

Pump blocking on alarms (pump blocked until alarm acknowledge)

Allthealarmsherewillblockthepumpwhenthealarmisactive.Whenthecriteriaforthealarmhavereturnedtonormalstate,thepumpstartsautomaticallyagain.

Dry run detection

Parameterswhichmustbesetifdryrunshallbedetected.

In AquaProg:

Figure 2-5 Pump alarms

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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

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.

Thelogsarekeptinthecontrollerfor15daysandtheoldestwillbedeletedwhenthememoryisfull.

Thesettingsare:

Logsignal Logfunction Loginterval

There are 34 Log signals which can be logged.

The Log functionscanbesetasfollows:

Closed Actualvalue Averagevalue Min value Maxvalue

Closed: Nologging Actualvalue: Amomentarilyvaluewillbestoredatthelogsequence. Averagevalue: Anaveragevalueduringthelogintervalwillbestored. Minandmaxvalue: Theminorthemaxvalueintheintervalwillbestored.

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.

Theeventlistisalwaysactiveforalarms.Toactivateeventlistforpumpstarts/stops,

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.

Mixer

Thesettingsformixeristobefound:

Settings – Mixer control

Themixercanbestartedafteracertainnumberofregularpumpstartsorafteratimeinterval.Thereisalsoacriteriatosettheleveltobewithinacertainspan.Themixerruntimemustalsotobeset.

Thesettingsare:

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:

Settings – Drain pump

Thedrainpumprunsonlyontimesettings,thereisnostopfloatforthedrainpump.

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3 DETAILEDDESCRIPTIONOFTHEFUNCTIONS

3.1 Pump controller and/or monitorPC441canbeusedasacontrollerwithmonitoringcapabilityorsolelyasamonitoringdevice.

Setup PC 441 as pump controller:

-InSettings / System menu: Set Station applicationto[Pump controller](=default).

The PC 441 monitor and control the pumps.

Setup PC 441 as pump monitor:

WhenthePC441isconfiguredasaPump monitor: Allpumpcontrolfunctions(start/stoppumps)aredisabledonlymonitoringfunctions areactive.Ifalevelsensorisconnectedinflow,outflow,pumpcapacityandpumped volumecanbecalculated.Pumpscanbeblockedincaseoferrorconditions. Alarmscanbegeneratedandthentriggeralarmcalls(GSM/GPRS/SMS). PC441cancontrolaMixer/Cleaner/Drainpumpatthesametimeasitmonitorspumps.

• InSettings / System menu:SetStation Applicationto[Pump monitor].

Formonitorfunctiontoworkyouneedtoconnectsomekindofpumprunningindicator.Motorcurrentoradigital signal can be used as run indicator.

First select type:

• InSettings / Pump x /. Set Pump run Indicationto[Digital input]or[Motor current]

If[Motor current]:

• InSettings / Analog inputs;SetInput functionto[Current pump x] (ifthereisnoCA443inthesystem)

If[Digital input]:

• InSettings / Digital inputs;SetInput functionto[Run indicator] and select pump number.

If you want to block pumps in case of errors:

• InSettings / Digital outputs;SetOutput functionto[Pump fail output] and select pump number.

Connecttheoutputtotheexternalpumpcontrollogicasblockingsignal.ThesignalwillgoactivewhenPC441detects an error condition for the pump.

If you want to have the possibility to manually start a pump from the CA 511 panel:

• InSettings / Digital outputs:SetOutput functionto[Pump relay] and chose pump number.

Connecttheoutputtotheexternallogictoforcethepumptorunwhenthesignalisactive.Thesignalwillgoactivewhenyoupressthemanualbuttononthepanelandstayactiveuntilit’sreleased.

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3.2 Pump�capacity�and�in/outflow�of�the�pit

In-/outflow and pump capacity calculationFunction

• Calculatestheinflowusinglevelchangepertimeunitandsurfacearea.

• Calculatesthepumpcapacityeverytimeapumprunsbyitself.

• Pumpandsystemdatacanbeenteredforamoreexactcalculation.

• Anevenhigherflowcalculationaccuracyisobtainedifapressuresensorismountedon the mains outlet.

• Outflowcalculationcompensationforrpm.

• Outflowcanbetakenfromaflowmeter.

Value

• Servicethepumpbeforebreakdown,avoiding/reducingoverflows.

• Avoidwastingenergyusingpumpswithdegradedefficiency.

• Servicecanbeplannedtooccurduringnormalworkinghours.

• Noexternalflowmeterrequired.

• Accurateoverflowmeasurement

The PC 441 supports several approaches to flow calculation and combinations thereof

1. Flowisbasedonmanuallyenteredcapacityvaluesforeachpump.Thisdataisthenusedtotheoreticallycalculatethepumpedvolumebymultiplyingcapacitydatawithrunninghours. Pros: Simpleset-up Cons: Noactualpumporsystemhealthcheck

2. Flowisbasedonaflowmeasuringdevicemountedonthemains. Pros: Simpleset-upwithaccurateflowmeasurementifmountingcriteriaaremet Cons:Noinformationoninflowandcollectionsystembehaviour

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3. Volumeisbasedoninflowcalculationincombinationwithaflowmeasurementonthemains. Pros: Anaccurateflowmeasurementifmountingcriteriaaremet Collectionsystembehaviourcannowbemonitored Cons: Somemoresystemset-upisrequired

4. Avolume-basedinflowandoutflowcalculationalsoconsideringpumpandsystemcurves. Pros: Acosteffectiveflowmonitoringsolutionalsoenablingcollectionsystemflowmonitoring Cons: Accesstobasin,pumpandsystemcurvesdatarequired

5. Avolumebasedinflowandoutflowcalculationincombinationwithapressuremonitoringofthemains. Pros: AcosteffectiveflowmonitoringsolutionalsoenablingcollectionsystemMonitoringwithaneven higheraccuracyandlesssystemset-uprequired Themainspressurereadingalsosimplifiestheflowcalculationtimesset-up Nosystemcurveinformationhastobeset-up Cons: Accesstobasinandpumpcurvesdatarequired

Parameter settings for an accurate in-/outflow and pump capacity calculation

Function

• Calculatetheinflowusinglevelchangepertimeunittimes surface area

• Calculatethepumpcapacityeverytimeonepumprunsbyitself

• Pumpcurves,rpmcompensationandsystemdatacanbe enteredformoreexactcalculation

• Apumpmonitoringsequencecanbemanuallyinitiatedviathe pump status menu

Value

• Avoidwastingenergyusingpumpswithdegradedefficiency

• Servicepumpbeforebreakdown

• Servicecanbeplannedtooccurduringnormalworkinghours

• Noexternalflowmeterrequired

Pump and system curves

• Pump curves can be entered

• Thesystemcurveiscalculatedfromtheonlinemeasurement togetherwithgivendataforstatichead,totalheadandflowatgivendutypoint.

• Thesystemcurvedoesnotneedtobeenteredifamainspressuresensorismounted,onlytheheightdifferencebetweenpumpinletandpressuresensorhas tobeentered!

Pump capacity monitoring and pumped volume recording via an external flow signal

Function

• Pumpedvolumeandpumpcapacitycalculationcanbedoneusinganexternalflowmeter

• Theinternallevel/volumebasedcalculationforinflowcanbecombinedwiththeexternalflowsignal

Logging of pumped volume

• Continuous accumulation over time

• Daytotalforlast7days

• Canbecombinedwithenergymeasurementforpumpefficiencycalculations

• Canbeusedforcomparingflowsbetweenstationsinacollectionnetwork,pinpointingpossibleproblemsofwateringressoroverflowswithinthecollectionsystem

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Calculation of pumped volume

Function

• Pumpedvolume=Calculated pump capacity times Pump running hours

• Pumpedvolumecalculationtakesinconsiderationthepumpcurves,systemcurveaswellfortherpm and mains pressure. (if applicable)

Figure 3-1 Calculatedflowwithandwithoutpumpandpumpsystemcurveentered

Logging of pumped volume

• Continuous accumulation

• Totalizedvaluesperdayandsevendaysbackintime

• Flowcalculationsbasedonvolumetriccalculationsadjustedtopumpcurves,systemcurvesrpmandmainspressuredependingonconfiguration

Continuous volumetric calculations Byenteringtheshapeandsizeofthepumppit,togetherwithanaccuratelevelmeasuringdevice,theunitwillalwaysknowthemomentaryvolumeinthepit.

Anewpumpcapacitycalculationisperformedeverytimethepumpstartsalonewithnootherpumprunning.Ifoneormorepumpsarealreadyrunning,thecontrollerwillusetheexistingnominalpumpcapacityfortheoutflowcalculation.

Inflowiscalculatedatapresetinterval.Outflowisrecalculatedeverysecondandthevaluesarepresentedandupdated according to the parameters set.

Ifananaloginputsignalissetas“Outflowmeter”thissignalwillbeusedforcalculationsofoutflowandpumpcapacity.

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

Theoutflowcalculationisbasedonthecalculatedpumpcapacitytimestherunninghoursofthepump.Toenhancetheaccuracyevenfurtherthepumpcurveforeachpumpcanbeentered.Thecurveisthenusedtoadjustthecalculatedvaluetomatchtheactualhead.Whentheleveldropstheheadincreasesandmostlyalsothepumpcapacity.Thiswillthenbeadjustedinaccordancetothepumpcurvedataentered.IfconnectedtoaVFD,therpmcanalsobeusedtocompensatetheoutflowcalculation.

Logic used to re-calculate the inflow during a pump cycle

Asearliermentionedtheinflowiscontinuouslycalculatedbasedonthelevelchangepertimeunitwhennopump is running.

Whenoneorseveralpumpsarerunningthecontrollerknowstheassumedoutflowbasedonthecalculatedpumpcapacityandifenteredalsoadjustedtothepumpcurve,systemcurveandrpm.Thisnowmeansthatthecontrollerknowswithwhatratethelevelshoulddecreasebasedonthepumpcapacityalreadycalculated.

Iftheleveldecreaseswithaslowerrateitisthenassumedthattheinflowhasincreasedtobalancethecalcula-tion.

Thecalculatedoutflowisalsoafunctiononnumberofpumpsrunning.

Calculation scenarios when a new pump capacity value is NOT accepted

Basic calculation rules

1. Thelevelmustbebetweenthehighandlowlevelset-points.

2. Thepumpcapacitycalculationsequencestartswhenthepump start signal is given. The level value after a conducted measurement must be below that point.

Basis for the calculation of indicated pump capacity

1. Fiverollingmeasurementsarecontinuouslyperformed,where the two with highest deviation is deleted.

2. Basedonthreevaluesleftisanaveragecapacityvaluecalculated.

3. Shownarethefollowingcalculatedvalues:

• Nominalcapacity(averageofthe3outof5calculations). The nominal value is used for the alarm handling.

• Lastpumpcapacity(lastperformedcalculation)

• Averagecapacitytodaytosevendaysago

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The important parameters for a level-based flow measurement are easily entered in the software.

NOTE!! Ifapressuresensorismountedonthemainsnosystemcurveinformationneedstobeentered.Forcorrectmonitoringtheleveldifferencebetweenpumpsuctionpointandpressuresensoronthemainsmustbegiven.

Lifting elevation = 18 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

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Settings

Valuablepumpperformanceinformationisgiveninthepumptechnicaldatasheet.

Totalheadfromsensorzerolevelisanoldsettingactuallyreferringtothestatichead.Thisonlyneedstobesetifnosystemcurveinformationisenteredornomainspressuresensorisconfigured.

Figure 3-2 Exampleofpumpcurve

Figure 3-3 Technical data in data sheet

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Calculatedoutflowbasedonagiven static head

OR

Note! Whenapressuresensorismountedonthemainsthesetting”Sensoroffsettopumps”needstobesetforanaccuratecalculation.Inthiscase0.4m.

Indicationofcurrenttotalpump headPUMP 1

PUMP 2

PUMP 3

PUMP 4

ACKN.ALARMTRENDSETTINGSTATUSMAIN

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

Thiswillthennaturallyhaveanimpactonthecalculationsbutmoreimportantlyonthecostofpumping.





Whenapressuresensorismountedontheoutgoingmains,theoffsetbetweenthepressuresensorandtheintakeofthepumphastobeenteredtogetthecorrectactualhead.

PUMP 1

PUMP 2

PUMP 3

PUMP 4

ACKN.ALARMTRENDSETTINGSTATUSMAIN

Station Flow Outlet PressureMeas. Parameters Sensor offset to pumpsPit Area 4.00 mOutlet Presssure

Esc

Distancebetweenpressure sensor and suction point of pump

Actualcurrentpump head

Current mains pressure

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Example of calculation cycle:

1. Nopumpisrunning,levelincreasingduetoinflowthatisthencalculatedbasedonthearea/levelandtimesettings.

2. Start level reached.

3. Currentinflowstored.

4. Timedelaybeforepumpcapacitymeasurement,thistoenabletheflowtopickupspeeddependingonsizeofpit,pump,headandcollectionnetworkdesign.

5. Measurespeedoflevelreductionduringapresettimetoapumpcapacityvalueisnowobtained.

6. Thiscapacityvalueisnowadjustedtothepumpcurve(ifentered).

7. Releasetheinflowcalculation.

8. Theinflowisnowafunctionofthepumpcapacityandenteredpumpcurve.

9. Ifyetapumpstartstheoutflowandinflowisthenalsoadjustedaccordingtothesystemcurve.

10. Ifapumpisrunningandthereisastablelevelreading,thiswouldindicatethattheinflowmatchestheoutflow.

11. Ifthelevelincreasesitindicatesthattheinflowishigherthanthepumpcapacity.

Chart example is based on a full run cycle for P1. Charts like these are available through the Sulzer AquaWeb tool.

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Calculation functionality check routines

1. Thelevelreadingstaysonaconstantvalue-PC441hasabuilt-inleveldeviationmonitoringfeature.

2. Thelevelreadingisonaconstantlevelduetoaoverflowsituation-AspeciallydesignedoverflowdetectionsensortypeMD131canbeusedtodetectthis.

3. Theactuallevelforthehighlevelalarmfromafloatcanbeentered,thislevelcanthenbeusedtocomparewiththelevelsensorreading.Ifacertaindeviationfromthisset-pointisdetectedasensorfailurealarmcanbe raised.

Point 1 and 3 are covered in the below settings

Point2iscoveredbyinstallingthe MD131sensor

CalculationCompilation of above

Whenonepumpstartsalone:

• Theactualinflowvaluewhenthepumpstartsistemporarilystoredandtheindicatedinflowvaluefrozen.

• Theoutflowvalueisnowrampedupforaconfigurabletimeframe.“Startdelay”

• Thepumpcapacityiscalculatedduringaconfigurabletimeframe.“Calculationtime”

• Theinflowindicationlockisreleased.Theinflowisnowafunctionofpumpcapacity,levelandifentered,thepumpcurve.

• Theoutflowisrampeddownforaconfigurabletimeframeafterpumpstop.“Stopdelay”

Pump capacity calculation rules

• Thelevelmustbeover“MinLevelforCalculation”

• Thelevelmustbeunder“MaxLevelforCalculation”

• The level after calculation must be lower than when the calculation started.

Increased calculation accuracy

Toimprovethecalculationaccuracyandalarmhandling,especiallywithvaryingstartlevels,werecommendthat the pump curves are entered.

Foramoreaccurateoutflowcalculation,thestationssystemcurvecanbeentered!InthiscasethecontrollerwillrecalculateandadjusttheOutflowcalculationbasedonthemomentarylevel!

Presentation of the Pump Capacity calculation

ThepumpcapacityispresentedasaNominalandLastSamplevalue.

Nominal

• Thenominalvalueisre-calculatedfromfivevaluestopoint1inthe“Pumpcurve”setting.Ofthese,fivevaluesarefilteredbytakingoffthetwomostdivergentandcalculateanaverageofthethreeremaining.

Last Sample

• Asitsounds,thelastcalculation,unfiltered.

OverflowdetectionsensorMD131givesanexactindication to the controller whenanoverflowoccurs.

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3.2.1 Auto-set limit low pump capacity alarmThisfeaturetoauto-setthelowcapacityalarmthresholdto80%ofdetectedpumpcapacity.Theauto-setsequencetakes5-8pumpstartswithpumpcapacitycalculations.

Detect pump ramp-up time and Forced pump capacity calculation logic

Duringdetectionoflowpumpcapacitythresholdispossibletomanuallyactivatea“Detectpumpramp-uptime”and/or“Forcepumpcapacitycalculation”inthemenusforeachpump.

Settings – Pump X – Pump X Alarms – Low pump capacity – Autoset limit

Option: Detect pump ramp-up time

Thecontrollercalculatesthetimeittakesfromthepumpstartuntilfullflowisreached.Thepumpcapacitycalculationisdelayedduringthistime+thecommonsetting“startdelay”.

Option: Forced pump capacity calculation

Willstopthepumpaftercalculationofpumpcapacitybeforestoplevelisreached.

Start Auto set

Select Yestostartthesequence,Notointerruptongoingsequence.

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3.2.2 Pit shapeThecontinuousflowmeasurementisbasedonthefactthatthePC441cancalculatethevolumebymeasuringtheleveldifferenceduringasetcalculationtime.Forthiscalculationistoexactitisnecessarythatthearea/levelshouldbealwaysknown.Thiscanbeachievedbysettingthelevelandareaforalllevelwherethepitchangesshape,upto9breakpoints+theareaatzeropointcanbeset.

Rectangular Cone Cone

Figure 3-4 Exampleofpitshapes.

Togetacorrectcalculationatalllevelseventhepitshapehastobesetasthecalculationisdifferentfordiffer-entgeometricalshapes.Ashapethatendsinapointissetasconical,ifitendsasawedge(2parallelsides)itissetasrectangularshape,seefigureabove.

Example for area calculation:

Rectangle Circle

A = L * W Ex. A = pi * r2 Ex.

A =Area A =? A =Area A =?L =Length L =2.20Meter pi =3.14... D =2.50meterW =Width W =1.75meter R =Radius=D/2 R =2.5/2=

1.25 meter

A =2.2*1.75 A =3.14*(1.25)2

A=3.85m2 A=4.91m2

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3.2.3 Pump curve Theoutflowofthepitiscalculatedwhenthepumpsarerunning.Itisbasedonthecapacityforthepumpsandisaccumulatedtoapumpedvolume.Ifaleveldifferenceinthepit,duringpumping,giveschangesinthepumpcapacityaccordingtothepumpcurve,thisshouldbesetinthePC441.Theoutflowwillinthiscasebecompensatedwiththeactuallevelinthepitaccordingtothepumpcurve,whichgivesamoreaccurateac-cumulated volume.

Figure 3-5

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 l/s0

2

4

6

8

10

12

14

16

18

20

22

Hea

d of

pum

p

mWp.

HM

L

Actualheadofpump=Totalheadofpump-actuallevel

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.

NOTE! Ifpossibleaddthedynamichead(pipelosses)tothetotalheadforthepumps;thismayincreasetheaccuracyoftheevaluationstremendously,especiallywhenfrictionallossesofthepipesarerelativelyhigh.

AsasimpleapproachyoucanfindtheheadsacquaintedtothemeasuredflowsbyusingtheQHcurveofthepumpperformancechart.ThisperformancechartyoucanobtainfromABSELsoftware.

Figure 3-6 Pumpcurvewithdynamicheadadded





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.

NOTE! Forthistowork,eachpumpmusthavetheirpumpcurveenteredinthefollowingmenu(s),Menu pump 1-4 > Pump curve.

Figure 3-7 Flow compensation 3 pumps. Enterthepoint“A”tothesystemcurvemenus.

NOTE! Theeasiestandmostreliablewaytoobtainthesystemcurveandtheoperatingpointsforsoloandmultiplepumpsoperatingatvaryingstaticheadistouseacombinedpipeworklossesandpumpselectionsimulationsoftwarepackage,e.g.SulzerABSEL.Ifthesystemcurveand(ifapplicable)thevariationofthestaticheadareknownfromstudiesoftheconsultingengineers,therelevantvaluescandirectlybeenteredintothepro-gram.ABSELalsoallows,toperformaverydetailedpipeworkfrictionlossanalysis.Therelevantpumpanditsimpellerdiameterareselectedandallresultingdutypointsasintersectionofpump(pumpsinparallel)curvescanbeshownandtransferredintothePC441pumpcurveinput.Seetheexampleonthenextpage.

A

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Example Figure3-8showshowthePC441handlesthecalculationswhenthepumpcurvesand systemcurveareset:

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: [Whenonepumpisrunning])

Static Head Duty Point: 4.00 meters

Total Head Duty Point: 4.8 meters

Flow at Duty Point: 740 l/s

1 pump running 3 pumps runningFor this pump 740 l/s Totalflow1720l/s

Whenonly1pumpisrunningthereisnoneedforanycompen-sationfactor,gives100 %.

Meaning1720-1300=420l/s Fortheindividualpump1720/3=573l/s. That gives a compensation factor of 77 %.

2 pumps running 4 pumps running

Totalflow1300l/s Totalflow2000l/s

Meaning1300-740=660l/smorethan1pump operating. Fortheindividualpump1300/2=650l/s. That gives a compensation factor of 88 %.

Meaning2000-1720=280l/s Fortheindividualpump2000/4=500l/s. That gives a compensation factor of 69 %.

3.2.5 Energy�efficiency:�kWh/volume�unitEnergyefficiency(kWh/volume)isacalculatedvalue,fromaccumulatedpowerconsumptionandaccumulatedoutflow.Powerconsumptionisavailablewhenapowermonitorisattachedtothesystem.Correctvolumeac-cumulationrequiressetupofpumpcapacitycalculation(e.g.providingpitarea),seesection 3.2regardingflowcalculation.

EnergyefficiencyandallotheraccumulatedvaluesarekeptinPC441asagrandtotalandasdailyvalues,sevendaysprior.Theenergyefficiencyvalueshowninmaindisplay,istoday’svalue,thatresetsatmidnightandupdatesonactualpumpperformance.Thisaveragedayvaluegivesagoodreflectionofactualpumpenergyusageandstationperformance.

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3.3 Overflow�flow�calculationThereareseveralmethodsthatcanbeusedtomeasureandcalculateoverflowflow:

1. Useaconventionalflowmeter. Advantage InmostcasesforstandardPLC-systemsthiswillincreasetheaccuracyonthemeasurement. Drawbacks Expensiveandcansufferfromdetritusdryingontothesensorcausingmeasurementissues,whenthepitis

operatinginnormalconditions.Thesensorhastobecleanedregularlytoensurecorrectmeasurements.

2. Usethesamesensorthatisusedforthelevelmeasurementinthepitandaweirandstarttheflowmeas-urement on analog set point.

Advantage Theinvestmentcostislowandthesensorwillnotneedtobecleanedregularly. Drawbacks Thesystemmusthaveaverygoodresolutionontheinputtobeabletomeasuretheoverflowcorrectlyand

averyaccurate0-pointotherwisethemeasurementwillbeinaccurate.

3. Usethesamelevelsensorthatisusedforthelevelmeasuringinthepitandaweir,andusealevelswitchtostarttheoverflowmeasurement.

Advantage TheInvestmentcostislowandthesensornotrequireregularcleaning.Theaccuracyofthe0-pointdoesnotaffectthemeasurementsduetotheswitchbeingusedasa0-point.

� Drawbacks: Theanaloginputneedstohaveaverygoodresolutiontobeabletomeasurethesignal.ThePC441hasnoproblemwiththis,e.g.forasensorwitharangeof10m,thePC441hastheresolutionof<0.7mm.

The third method is preferred and used in the PC 441

Adigitaloverflowswitch,likeSulzerMD131connectedtoadigitalinputindicatesifanoverflowisoccurringindependentofwhatthelevelsignalshows.ThePC441locksthisactuallevelandthePC441startscalculat-ingtheoverflowlevel/flowfromthisvalue.

Thismeansthatthelevelismeasuredwithaveryhighaccuracyfromthecorrect0-point.Ifanexactflowmeasurement is needed a weir or channel should be used.

Figure 3-9

Overflow

Analog pit level sensor

Inflow

OverflowswitchMD131

ThePC441programhasallthefunctionsrequiredforcalculatingflowinweirsandchannels.Theoverflowismeasuredseparatelyforeachpumppit.Numberofoverflows,overflowtime,overflowlevelandtheflowarelogged.

Thelevelssensorisusedastheactuallevelsignalwhentheswitchisactivateditsetsthe0-pointfortheflowmeasurement.IfnolevelswitchorMD131isconnectedtothePC441the0-pointfortheoverflowcanbesetin“Settings / Pump pit / Calc. overflow / Overflow detect“manually.Overflowwillberegisteredwhenthelevelexceedspresetoverflowlevelonthelevelsensor.

NOTE! Thissetpointhasnofunctionifadigitalinput(overflowswitch)issetforoverflowindicationinthepumppit.

Adelaycanbesettopreventdisturbancesorwavestriggeringtheswitch.Afterthisdelaytheflowmeasure-mentstartsandthetimeoftheoverflowisrecorded.Acounterkeepstrackofhowmanytimesthepithasoverflowed.Theoverflowtimeisonlytriggedwhenthelevelishigherthanthestored(set)0-point.Ifafloatsensorisusedforapumppit,whichhasnolevelsensor,theoverflowtimecountsallthetimethefloatisactive.

Theoverflowalarmwillstopafterthefloatgoesbacktonormalandthestopdelaytoavoiderrorsinthecounterandtocompensateforthestartdelay.

NOTE! Overflowalarm and counterisonlyactivatedifalarmisenabled.

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3.3.1 How�to�calculate�overflows�by�using�constants�and�exponents

• InSettings / Pump pit / Calc. overflow/youcantypeintheconstantandexponentsmanually.

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.

3.4 Pump alternationPC441hasseveraldifferentmethodsinordertoalternatepumps.

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.

Startlevelpump1=2.0m Startlevelpump2=3.0m Stoplevelpump1=1.0m Stoplevelpump2=1.5m

Method used: Alt. each pump stops Alt. when all pumps stop

Pit level increaseAtlevel2.0m Pump 1 start Pump 1 start

Atlevel3.0m Pump 2 start Pump 2 start

Pit level decreaseAtlevel1.5m Pump 2 stop Pump 2 stop


Pit level decreaseAtlevel1.5m Pump 1 stop Pump 2 stop


Ifalternatewhenallpumpsstopmethodisused,pump1willneverstop

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Example 2 Temporary high inflow.

Startlevelpump1=2.0m Startlevelpump2=3.0m Stoplevelpump1=1.0m Stoplevelpump2=1.5m

Method used: Alt. each pump stops Alt. when all pumps stop

Pit level increaseAtlevel2.0m Pump 1 start Pump 1 startAtlevel3.0m Pump 2 start Pump 2 start

Pit level decreaseAtlevel1.5m Pump 2 stop Pump 2 stopAtlevel1.0m Pump 1 stop Pump 1 stop

Pit level increaseAtlevel2.0m Pump 1 start Pump 2 startAtlevel3.0m Pump 2 start Pump 1 start

Pit level decreaseAtlevel1.5m Pump 2 stop Pump 1 stopAtlevel1.0m Pump 1 stop Pump 2 stop

Ifalternateeachpumpsstopmethodisused,pump1alwaysstartsfirst.

2. Asymmetrical alternation Thedifferencebetweenasymmetricalandnormalalternationisthatthepumpsaredividedintotwoalter-natinggroups,primaryandsecondarygroup.Withineachgroupthepumpsarealternatingasinnormalalternation. Normallypumpsinprimarygroupstartfirst.Afteraadjustablenumberofpumpstopsinprimarygrouppumpsinthesecondarygroupstartfirst.Thestopcounterresetsandatnextpumpcycleprimarypumpsstartfirstagain.Ifthepumpsintheprimarygroupdonothavethecapacitytopumpdownandthepitlevelcontinuestoincrease,thepumpsinthesecondarywillstartindependentofthestopcounter.

• Pumpsdividedintwoalternationgroups,primaryandsecondary.

• Agroupcanhave1to3pumpswithin.

• Adjustablenumberofstartsinprimarygroupbeforesecondarygroupstart.

Example:

Primarygroupcontainspump1–3,andstartstwicebeforesecondarygroupstartswhichonlycontainspumpnumber 4.

Function:

• Uneven running times

• Jog runs of spare pump

• Runpumpsthathasatendencytoblockmoreoften

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Value

• Sparepumpingoodconditionwhenmainpump/sbreaksdown

• Extendtheserviceintervalsandlowerthemaintenancecosts

• Reducestheriskforoverflow!

• Increasedavailability

Pump 1 Pump 2 Pump 3 Pump 4

Start Sequence

1 2 3

4 5 6 7

8 9 10

11 12 13 14

3. Runtime alternation Inadditiontoabove,pumpcanbealternateddependentonthereruntime.Atexceededmaximumruntimethepumpwillstopandanalternativepumpwillbestarted.Thepumpwillonlystopifthereisatleastonealterna-tivepumpthatisreadytorun.

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.

Ifmaxnumberofpumpsarerunningthesystemwillnotallowanyotherpumpstostart

Apumpisrunningwhentherelayofthepumpisactivatedorthereisarunconfirmationfromthepump.

Ifmaxnumbersofpumpsarerunningandtherunconfirmationislostorsomeothererrorsthatblockthepumpoccur. The following will happen.

• Alarmfortheerrorwillbeindicated.

• Thefaultypumpwillbestopped.

• Ifalternationisactive,afteradelayanewpumpwillbestarted.

• Ifalternationisnotactiveanewpumpwillstartatthenextstartlevel.

IfStart Level Tracking is activated the pump controller uses the start levels of the pumps to decide which pumptostart.Thepumpwiththehigheststartlevelexceededhashighestpriorityandwillbestartedfirst.Alternatingpumpshavethesamepriorityandalternateasusual.

Abovecanbeusedifthepumpshavedifferentcapacitiesandonepumpwithhighcapacityshallpumpaloneathighpitlevelsandapumpwithlowcapacityatlowerlevels.

Example 1 Startleveltracking=On Alternation=Off MaxPumpRunning=1 Startlevelpump1=1.0m Startlevelpump2=2.0m Startlevelpump3=3.0m

Atlevel1.0mpump1start. Atlevel2.0mpump1stopandpump2starts Atlevel3.0mpump2stopandpump3starts

Aboveisvalidforpumpsthatemptythepit.Ifthepumpsarefillingthepitthefunctionisinverted.

Example 2 Startleveltracking=On. MaxPumpRunning=1

Startlevelpump1=1.0mAlternationOn Startlevelpump2=2.0mAlternationOn Startlevelpump3=3.0mAlternationOff

Atlevel1.0mpump1orpump2startsdependingofwhichonestartedlastpumpcycle. Atlevel2.0mnothinghappens. Atlevel3.0mpump1orpump2stop(theonerunning)andpump3starts.

Thisexampleshowthepossibilitytohaveanumberofpumpalternatingatlowinflowsandtostartapowerfulpumpwhentheinflowishigh

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3.5 Pump reversingIntheSettings / Common P1-P4 / Pump reversingspecifieswhichpumporpumpsshallusethereversingfunction.

Thereversingcanbetriggeredon:

• Digitalinput“PumpFail”

• Tripped motor protector (after auto reset)

• High motor current

• Lowpumpcapacity

• Preset number of pump starts

Ifmorethanthesetthresholdfornumberofreversetriggersoccurswithinapresettimeframe(default5/60minutes),nofurtherreverseattemptsaredonewithinthesetblocktime(default24h),ifmanualresetnotisrequired.AcknowledgeoftheMaxreverseattemptsalarmoramanualreversefromlocalcontrolpanelclearspotentialreverseblockconditions.

Reversing when digital in pump fail active

IfsettoYES;ReversecyclestartswhendigitalinputsignalPumpFailgoesactive.Thesignalmustgobacktoinactivestatebeforethepumpstartreversing.Ifnotreversingcycleisaborted.

Reversing when Fallen motor-protector

IfsettoYES;ReversecyclestartswhenthedigitalinputsignalMotorProtectorgoesactive.Motorprotectorwill be reset before the pump starts reversing. You must enable auto reset motor protector function for the pump.Setthecolddowntimeandpulsetimeintheautoresetmenu.Ifthemotorprotectorresetfailsreversingcycleisaborted.

Reversing when Low pump capacity

IfsettoYES;Reversecyclestartsonalarmforlowpumpcapacity.Forthisfunctiontoworkyouneedtoen-ablethelowpumpcapacityalarminthepumpalarmsmenu.Afterreversing,thefunctionisdisableduntilaminimumof10newpumpcapacitiescalculationshavebeencompleted.Whenenablingthepumpcapacitycalculation,theusermustsetthenominalcapacityforthepump:

-InmenuStatus / Pump X / Pump capacity

Reversing on overcurrent

Reversecyclestartswhenalarmforhighmotorcurrentisactivated.Forthisfunctiontoworkyouneedtoen-ablethealarminthepumpalarmmenu.Usethealarmdelaytimetodelaythestartofreversing(don’ttriggeron pump start current).

Reversing on start count

Thereverscyclecanbetriggedafterspecifiednumberofstartsforeachpumptoeliminateclogsandensureproperfunction.IfthisfunctionissettoYES,thesubmenuappears,andselectablenumberofstartscanbespecifiedforeachpump.Inthissubmenu,thecurrentstartcountersaredisplayed.

3.5.1 Other settings regarding pump reversing:InmenuSettings / Common P1-P4 / Pump reversing

-Set[Reversing pump x]to[Yes].

-Set[Start rev. delay time].Thetimetoholdthepumpinoffpositionbeforethestartofpumpreversing

-Set[Rev. run time]. The reversing run time.

-Set[Max no. attempts]Afterthereversing,thepumpwillstartagain.Ifthepumpfailsagain,anewreversingcyclewillbegin.Hereyousetmaxnumberofattempts.

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.

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3.6 Speed controlled pumps (VFD)PC441cancontrolpumpsconnectedtoVFDintwoways,bytheAnalogoutputsorbytheoptionalRS-485moduleCA622.ThemoduleCA622offersalotofadvantagesoverrunningtheVFDbyuseoftheanalogsignals.Theinstallationtimeandcostwillbereducedandtheaccuracyinpumpcalculationswillincrease.

To control the pumps from the analog outputs

PC441mainunitcancontrolmaxtwopumpsonVFDbecausethereareonlytwoanalogoutputsonthePC441.WiththeexpansionunitCA781comestwoadditionalanalogoutputswhichmakeitpossibletocontroltwoextraVFDpumps,fourpumpsintotal,atthesametime.

VFDpumpsaremainlycontrolledbystart/stoplevelandthedigitaloutputslikefixedspeedpumps.TheanalogoutputsignalscontrolthespeedintheVFDunit(s)whichdrivesthepumps.NormalstartandstoplevelsareusedtostartandstoptheVFDpump(s).

Thebuilt-inPIDcontrollerisusedaccordingtotheconstantlevelcontrolmethodandoutputsfrequencysetpointstotheVFD.ThePIDcontrollerwillraisethefrequencywhenthewaterlevelrisesabovethesetlevelandlowerthefrequencywhenthewaterlevelfallsbelowthesetlevel.Insomecases,thecontrollogicwilloverridetheoutputsignalfromthePIDcontroller.

To control the pumps via the CA 622 module

CA622communicatewiththeVFDsbyRS485fieldbus.TheCA622unitisconnectedtothesystemviaCANbus.CA622isfittedwithagalvanicallyisolatedRS485communicationportforcommunicationwithperipheralproductssuchVFDs,softstartersandenergymeters.CA622isalwaystheModbusmasterwithallperipherals acting as Modbus slaves.

PC441hasmanypredefinedVFDs,thecorrectonemustbechoseninthemenus.AllthepredefinedVFDsareoptionsinthefirmwareofPC441andCA622.IfyoucannotfindyourbrandandmodelofVFD;makesurethatyouhavethelatestfirmwareversioninPC441andinCA622.OnSulzerhomepageyoucanfindtheInstallation and user guide CA 622(P/N81307133)thereyoucanseeifyourmodelofVFDissupported.

ConfiguretheCA622moduleinPC441under–Settings–communication–Fieldbusunits–CA622–YES

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).

Ifthepumpisexercised,thepumpwillrunonmaxfrequency.WhenreversingthepumpthespecifiedReverseSpeedvaluewillbeused(50%default).Inhightariffpre-pumpdownmodethepumpwillrunonthesameforcespeedasspecifiedforminfreq.timeout.

IfthereismorethanonepumpconnectedtoVFD,thepumpswillbesynchronized.Theoutputsignalswillalwaysbethesameifthescalingisthesame.TheVFDisresponsibleforspeedingupandslowingdownthepump.PC441doesn’thandleramptimes.TheminandmaxfrequencyforthepumpnormallyissetontheVFD. ThePIDControlleralsohasadjustableminandmaxvaluefortheoutputsignalthatcanbeused.

ThereisapossibilitytorunVFDpumpswithtwodifferentSet Points,connectedtodayandnightsettings. PIDoperatorsettingsarefoundunderStatus:Status / PID controller.

3.6.1 Configure�PC�441�for�VFD�pump(s)

• 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.

NOTE! Thisisimportantforoutflowandpumpedvolumecalculation.

• 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.

3.6.2 PID settings

• InShow status/PID controllermenu,SettheSet pointvalueaccordingtoyoursetlevel.

• 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).

Ifresetfailsmorethan“Maxnoattempts”(default3times),analarmfor“Motorprotectorreseterror”isgener-atedandpumpisblockeduntilalarmisacknowledged.

The[Max no attempts]errorcounterisresetwhentheautoresetsequenceisconsideredsuccessful.Thishappenswhenthepumpruntimereachestheset[Pause time] (cooling time) before auto reset.

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4 FURTHEREXPLANATIONSABOUTSOME DIGITAL/ANALOGOUTPUT/INPUTTYPES

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).

ThisIOcanbeusedtogetaspecificoutputsignalforoneorseveralindicatorsfromCA441orCA442e.g.hightemperature,leakage,oranyothersIO-bitsofyourchoice.

• Anexampleofwherethisfunctioncanbeusefuliswhenyouwanttohaveonedigitaloutputsignaltobeactiveforaspecificalarminanypumps,forexampleHightemperaturealarm.

ThefollowingdiagramisanexamplehowthreeIO-bitinteractwitheachotherinthefunctionofLogicIO:

IO-bit 1 “OR”

IO-bit 2 “OR”

IO-bit 3 “AND” Output

0 0 0 0

InthisexamplethereareonlythreeIO-bitsinvolved.ButyouhavetheoptiontouseuptofourIO-bits.

0 0 1 0

0 1 0 0

0 1 1 1

1 0 0 0

1 0 1 1

1 1 0 0

1 1 1 1

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:

Figure 4-1 AbovechartisanextractfromtheComli/ModbusmanualforPC441-Pumpstatus.

TheninthemenuinCA511gointo:

-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

TheresultwillbethatDO1willbeactivatedifanyofthealarmsfortemperaturearetriggered.

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.

Andthentypeinthesetpointvalue100forONstateandthevalue10forOFFstate

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.

Example: Thepumpsareblockedbecauseoneorseveralalarms.

Aremotealarmresetmaycauseablockedpumptostart.Ifservicestaffarenearbytheycouldbenotifiedbyasirenorflashinglightconnectedtothedigitaloutput,thatapossiblepumpstartispending.

4.4 Digital�input�type:�block�remote�dateWhenthisdigitalinputisactivated,allchangesinthesettingsmaderemotelythroughthemodemportbyAquaProgoranySCADAsystemisblocked.ChangesmadelocallybyAquaProgviatheserviceportarenotblocked.Thisisforasafetyprecautiontoblockanychangesdoneremotely.

Option:Allowsetclock:Yes/No

4.5 Digital�input�type:�mixer�and�drain�pump�blockingThereisafunctionwhereyoucansetadigitalinputtoblockthemixerordrainpump.Itispossibletosetanalarmwithfreealarmtextforeachinput.Whenthesignalisactivatedthemixer/drainpumpwillstopandblock.Ifanalarmisenabled,itwillbecomeactive.

InmenuSettings / Digital Inputs / Digital In x

SetInputfunctionto[Mixer block]or[Drain pump block].Inthesamemenusetuseralarmtextandalarmpriority.

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).

Figure 4-3 AbovetableisanextractfromtheComli/ModbusmanualforPC441– Analoginputs/Outputinengineeringunits

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

Esc

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Scaling100%shouldcorrespondtothedatavalueat20mA,inthiscase1500for150°C.

AboveisanexampleofhowtoconfigureaPt100Statortemperaturetransmittedoutputasa4-20mAsignalviaAnalogoutput.

4.7 Analogue input: Secondary pit level sensorThisinputisacomparisontotheactuallevelsensor.Usefulindualcommunicatingpits.Apit-alarmcanbesetasdeviationfromtheactuallevelsensorandthesecondarypitlevel.Thislevelsensorisonlyforcomparison.

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5 COMMUNICATIONANDAQUAPROG

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].

GSM modem ForGSMconnection,signalsbeforeanswer,minimum1. Hayessettingsnormallyworkswithdefault.SetPINcodeifSIMcardisequippedwithone.Settingsunder

Communication – Modem – Modem connected in the PC 441 shall be set to [GSM modem].

NOTE! ThePINcodecanbedeletedwithacellphone.

GPRS modem BasedoninternalTCP/IPstackinCinterion(formerSiemens)GSM/GPRSmodules.Alldataaccessisviathe HayescommandsdefinedbyCinterion.MostcommonisdynamicIPaddressing.GPRSdefaultisthepump

controllerconnectstoTCPserverinSulzerAquaWebsystem.IfScadasystemshouldconnecttostationseeTCP-serversection.CommunicationviaGSMandGPRSusesthesamenetwork.Ifsubscriptionallows,bothcanbeusedoneatatime.SetPINcodeifSIMcardisequippedwithone(deletedonAquaWebSIMcards).

� AquaWeb�client� �UsedonlywhenasubscriptiononAquaWebexistorwhenthecustomerhasadifferentAPN.IfuseadifferentAPN, theSCADAsystemmusthandletheHeartbeat.

Heartbeatinterval10min(default).Canbeadjustedbutcanraisecostsifsettolow. ServerTCPport;MustbethesameasinGPRSServer(default2000forAquaWeb). ServersIPaddress;ThePublic/globalIP(normallyinfirewall/router)addresstotheGPRSServermustbeastaticIPaddress. APNisprovidedbySIMcardsupplier.GPRSAPNpart1andGPRSpart2.IfAPNstringislongitcanbedi-videdbetweenthetwoparts.(DefaultAPNisaquaweb.cxn).SMSfallback:0046708728550forAquaWebonly!

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

Connectamodemaccordingtofigure4-4totheComportonPC441.OnCA511pressArrow down/Settings/Arrow right/Communication/Enter.

Figure 5-1 ConnectPC441to9-PoleD-Sub.Cablecanbeordered,itemno43320588.

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.

WhenusingtheGSMfunctionalitytosendSMS,therearepossibilitiestosetupfourattemptstocallout.Theseattemptscanbesetasparallelcalls;callmultiplenumbersinasequence.Orasbackupcall;callfirstnumberintheattemptlistandthenwaitforacknowledgementbeforetryingwithsamenumberagainintotalthreetimes,andthencallnextnumberintheattemptlist.Assoonasthesubstationgetsanacknowledgementofanalarmcallout;itwillterminatetheoutgoingcalls.AlarmswillbesentoutatON/OFFstateandA-alarmsorA+B-alarmsdependingofsettings.

From Modbus master RS232

PC 441 unit 1Comli / Modbus ID 1



*Output (X) from unit 2: SumAlarmto an input (Z) on unit 1

*Output (X) from unit 3: SumAlarmto an input (Y) on unit 1

And so on...

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5.2 AquaProgAquaProgisWindowsbasedsoftwarespeciallydesignedforsettingandmonitoringofSulzersubstations.CommunicationwiththecontrollerisestablishedviaRS232,USBorModem(analogorGPRS)connectionbetweensubstationandcomputer.TocommunicatetoPC441therehastobeAquaProgversion4.86orlater.

Features

• ConfiguringsubstationPC441togetherwithCA441-443

• Checkingandacknowledgingalarms

• Checkingevents

• Collecting log data

• ShowingthedisplayandLEDofthesubstation

• Showingthestatusofthein-andoutputsofthesubstation

• Collectingandsendingtheconfigurationdataofthesubstation

• Substation software upgrade

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.

4. Cyourcomportandthepropertiesaccordingtoyoursubstation

5. Modbus is default

6. PressOK

Afterthisconfiguration,youcancallthesubstationandchangethepropertiesasnormal.

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5.3 Cross reference tableCrossreferenceisavailableinfirmware1.22orlaterandinAquaProgversion4.90orlater.

Crossreferencetablecanbeset-upinAquaProgtooptimisethedataflowinComli/Modbustothesupervisorysystem.Register0-254(telegramtype0and2)canbedefinedtoholdpreferreddatabyacrossreferencetableandcanbesetfordataofanyregister.SeefurtherinformationinComli/Modbus register manual.

Thereisthepossibilityforcertainrescalingofdata,e.g.Running time in seconds can be rescaled to minutes withthefactor60.Thescalefactorcanbebetween0-32767.Withthefactor0norescalingisdone.

CertainsupervisorysystemsonlyhandlepositivevalueswhenusingtheComliprotocol.Settingscanbeselectedfor2’scompliment+/-32767orpureintegers0-65535.Ifpositivenumbersareusedwill0bereturnedfor negative values.

TheextendedComlitelegram(max65535reg.)isnotaffectedbythecross-reference.

Togetherwiththecrossreferencetablethereisapossibilitytosetanindividualscalefactorbetween0and32767,foreachpositioninthecross-referencelist.Whenreadingdata,thevalueisdividedwithcorrespond-ingscalefactor.Whenwritingdatathevaluewillbemultipliedwithcorrespondingscalefactor.Scalefactorisignored when set to 0.

Fordataindoubleregisters(32bits),thehighestregisternumbershouldbeusedtogetherwithscalefactors.Writingtothehighestdoubleregisternumberwillalsosetdatainthelowerregisternumberifscalefactorisset.Ifscalefactorissettozero,eachregisterishandledindividually.

Manyregistersallownegativevalues(signed2-complementdata).Thiscancausesomesystemstotreatnegativedataaslargepositivenumbers(ex.–1isreadas65535bythesystem).

Toavoidanyissuesthereisapossibilitytoindividuallysetcrossreferenceregisterstoonlypositivedata.Negativevalueswillgivezeroreadout.

NOTE! CrossreferencetableareonlyavailabletosetupinAquaProg.InthemenusofCA511youhavepossibilityto activate or deactivate the table.

IO-bits IO0-255canberedirectedtoanyIOnumberwhencrossreferencetableisenabled. IO-bit0-255isalsoavailableinregister312-327.Crossreferenceenabledisusefulinsystemsthatoptimise

data screens into single messages.

Toactivatethecrossreferencetableinmenu:

-Settings / Communication / Protocol / Register Cross Ref;SettoON[orOFF]

ByusingAquaProgyoucanalsosaveanddownloadyourcrossreferencetabletootherPC441units.

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6 SETTINGS

6.1 Select language1. Choose the menu item Select language and press Enter twice.

2. Enter the pass code Operator (default is 2). Press Enter.

3. ScrolltothelanguageofyourchoicebyusingtheUp/down buttons.

4. Press Enter and then the Left/backward arrow.

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.

Table 6-1 System�settings,�under�the�menu�item�‘Settings�>�System’

Submenu Submenu Setting Value Passcode Comment

__

SelectLanguage Select a language Operator Same as the setting described in Section 6.1

StationApplicationPump Controller

SystemPump Monitor PumpMonitor:SeeSection 3.1

Select Units (Metricunits,US units) System

Metric:m,m2,m3,Liters/second(liters/s),bar,mm,ºC US:ft,ft2,gal,GPM(gal/min),psi,raºF

DateFormat(YYYY.MM.DD,DD.MM.YYYY,MM.DD.YYYY)

System

SetDate Date

System

Set Time Time

LCDBacklightTimeout Minutes Ifyouenteravalueof0,the

backlightwillalwaysbeon.

LevelDisplayGraphics m,ft

HideStart-StopLevels No,Yes

AlarmAlertOnTime Minutes

AlarmAlertPause Time Minutes

MainPower3~Voltage Volts Usedassetpointsforsystemalarms.MainFrequency Hz

SystemAlarms

Power FailAlarmType (Inactive,

B-Alarm,A-Alarm)

System

AlarmDelay Seconds

IncomingPhaseMissing

AlarmType (Inactive, B-Alarm,A-Alarm)

AlarmDelay Seconds

LowSupplyVoltage


AlarmDelay Seconds

Limit Volts

Hysteresis Volts

NV ChecksumError


NV Checksum Error is issued if thechecksumforthenonvolatilememoryindicateserror.

AlarmDelay Seconds

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SystemAlarms

PersonalAlarm


System

AlarmDelay Seconds

MaxTimetoReset Minutes

Afterthistime,themaintenanceperson must reset the timer (bypushinganybutton),oraPersonalAlarmissentoutafterAlarm Delay

WrongPhaseOrderAlarmType (Inactive,

B-Alarm,A-Alarm)

Signals from main power monitor CA443-0.

Limitsherearethedeviationsfrom the settings in the Main power and the Main frequency menu.

Limitsalsousedassetpointsforpumpblocking.

AlarmDelay Seconds

Over3~Voltage


AlarmDelay Seconds

Limit(+) Percentage

Hysteresis Percentage

Under3~Voltage


AlarmDelay Seconds

Limit(-) Percentage


Unbalanced 3~Voltages


AlarmDelay Seconds

Limit(+/-) Percentage


HighFrequency


AlarmDelay Seconds

Limit(+) Percentage


LowFrequency


AlarmDelay Seconds

Limit(-) Percentage


Set Password

Operator Integer OperatorFor Operator access. The code maybe1to4digitslong.Thefactorydefaultcodeis1.

System Integer System

ForSystem(administrator)ac-cess.Thecodemaybe1to4digitslong.Thefactorydefaultcode is 2.

LogandAlarmReset

AnalogLogCancel

SystemResetAll

Alarm&EventsCancel

ResetAll

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6.4 Pump pit settingsTable6-2showsthecompletelistofsettingsunderthesubmenuPump Pit.

Table 6-2 Pump�pit�settings,�under�‘Settings�>�Pump�Pit’

Submenu Submenu Submenu Setting Value Pass code Comment

LevelSensorType SelectType (Analog, Start/Stop Floats) System

MinTimeRelayChanges Min Time Seconds System

Tominimizepowersurgesorspikescausedbypumpsstart-ingorstoppingsimultaneously,thereshouldalwaysbeamini-mumtimebetweentworelaysswitching states.

MaxNo.PumpsRunning

SetMaxNo.Pumps

(Max1Pump, Max2Pumps, Max3Pumps,NoLimit) System

Set the number of pumps that are allowed to run at the same time.

StartLevelTracking (OFF,ON)Ifactivatedthepumpswiththehighest start level reached have highestpriorityandwillrunfirst.

Pump Alternation

-

TypeofAlternation (OFF,Normal,Asymmetrical)

System

Alternateafter (EveryPumpStop,LastPumpStop)

Pump1Alternate? (NO,YES)

...

...... ...

Pump4Alternate? (NO,YES)

Runtime Alternation? (NO,YES) Inadditiontothenormalor

asymmetricalalternation,youcan set the controller to switch pump when that pump has beenrunningcontinuouslyforacertain period of time.

Runtime to Alternation Minutes

AsymmetricalAltern.

P1inPrimaryGroup? (NO,YES)Willswitchtothesecondarypumpsonlyafteracertainnumberofstopsoftheprimarypumps.

... ..

...

...

P4inPrimaryGroup? (NO,YES)

No.StoptoGroupAlt. Integer

AlternativeStopLevel

FunctionActive? (NO,YES)

System

Letthepumprunbelowitsnor-mal stop level.

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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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.

See Section 3.2.3

3 Pumps running Percentage

4 Pumps running Percentage

PitArea

Level0 Fixedat0m,ft

Youcanspecifytheshapeofthepitbyspecifyingtheareaat10differentlevelsfromthebottomofthepit,level0,tothetop,level9.

Area0 m2,ft2

...

...... ...

Level9 Fixedat9m,ft

Area9 m2,ft2

Calc.PumpCapacity

Pump Cap. Cal-culation (OFF,ON)

System

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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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.

...

...... ...

Pump 4 BackupStart (OFF,ON)

Backup Running Time Seconds

PitAlarms

HighLevel


System

AlarmDelay Seconds

Limit m,ft

Hysteresis m,ft

LowLevel


AlarmDelay Seconds

Limit m. ft

Hysteresis m,ft

HighLevelFloat


Blockal.ifpumpruns(No,Min1pump,Min2pumps,...Min 4 pumps)

Ifpump(s)runningnormallywhentheHighLevelFloatwillgenerateaB-alarm.

AlarmDelay Seconds

LowLevelFloatAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

HighInflow


AlarmDelay Seconds

Limit Liters/second,GPM

Hysteresis Liters/second,GPM

LowInflow


AlarmDelay Seconds



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PitAlarms

BackupStartAlarmType (Inactive,

B-Alarm,A-Alarm)

System

AlarmDelay Seconds

RemoteBlockingAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

High Pressure


AlarmDelay Seconds

Limit bar,psi

Hysteresis bar,psi

LowPressure


AlarmDelay Seconds

Limit bar,psi

Hysteresis bar,psi

OverflowAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

HighPressureBlockAlarmType (Inactive,

B-Alarm,A-Alarm)

The pressure threshold for the alarm is set in the menu below forPumpBlocking.

AlarmDelay Seconds

DrainPumpFloatAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

Sensor ErrorAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

To few pumps available


AlarmDelay Seconds

No.PumpsAvailable

(Min1Pump,Min2Pumps,Min3Pumps,Min

4 Pumps)

M. prot reset errorAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

Pump Blocking

RemoteBlockingRemoteBlocking (OFF,ON)

System

AvalueofzeroforBlock Time outmeansthattheblockingwillnever time out.BlockTimeout Seconds

LowLevelFloat BlockonFloatActive (OFF,ON)

Back-Pressure

BlockonHighPressure (OFF,ON) Note:Back-Pressuremaybe

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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LevelSensorCheck

CheckatHighFloat (OFF,ON)

System

Checksthatthelevelsensorisfunctioningproperly.Checkscanbemadeathighfloat,atlowfloatandtoensurethattheoutput varies.

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.

Foreachdayoftheweek,youcanspecifytwotimeperiodsofhightariff(byspecifyingitsOnandOfftimes).

- Pump Prestart Time Minutes

- PumpDownLevel m,ft

PeakMondaytoPeakSunday

Peak1OnAftermidn. Minutes

Peak1Off Minutes

Peak2On Minutes

Peak2Off Minutes

LevelAboveSea SetLevelm.a.s. m,ft System

Ifthedisplayofcurrentlevelsshould be absolute levels above sea,enterthelevelofthepumppit above sea level.

6.5 Pump 1 to 4 settingsTable6-3showsthecompletelistofsettingsunderthesubmenusPump 1, Pump 2, Pump 3 and Pump 2.

Table 6-3 Pump�1�to�4�settings,�under�‘Settings�>�Pump�1’,’Settings�>�Pump�2’,�‘Settings�>�Pump�3’,�and�‘Settings�>�Pump�4’

Submenu Submenu Submenu Setting Value Passcode Comment

RelayControlPump PumpConnected? (NO,YES) SystemIfapumpisnotconnected,therelayisstilloperatingaccordingto start/stop levels.

TypeofPump

Fixed

SystemSpeed Controlled

VFD

P. Cap Comp atminFreq

(PumpCapacity Compensation at

minimumFrequency)

Percent See Section 3.6

Start/StopLevels

StartLevel m,ft

Operator

Note:Theselevelsareonlyusedduringlowtarifftimesiftariffcontrol is used.StopLevel m,ft

RandomStartLevel+/- m,ft Thestartlevelisrandomized±this range around Start Level.

Hi.TariffStartLevel m,ft Duringhightarifftimes,theselevels are used as the start and stop levels.Hi.TariffStopLevel m,ft

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Pump ParametersNominalCurrent Amperes

SystemNominalPowerFactor Number

PumpRunIndicationPumpRunIndication (OFF,DigitalInput,

Motor Current)System

Themeans/sensorbywhichapump is regarded as running.

Current Threshold Amperes Pump is regarded as running above threshold.

Time Settings

ThresholdOnDelay Seconds

System

Delaybeforechangeofsetpointstatus.ThresholdOffDelay Seconds

MaxRuntimeStop Pump (OFF,ON)

MaxContinu-ous Runtime Minutes

Pumps are stopped when Max Continuous Runtime is reached. The timer is reset each time a start level is reached.

PumpCurve(QH)

Point1HmaxTot. Head m,ft

System

Lowestlevel(pumpoutlet) Highest head See Section 3.2.2Point 1 Flow Liters/second,GPM

Point 2 Hmid Tot. Head m,ft Mid level

See Section 3.2.2Point 2 Flow Liters/second,GPMPoint 3 Hmin

Tot. Head m,ft Highest level in the pit. Lowesthead See Section 3.2.2Point 3 Flow Liters/second,GPM

Total Head Sen-sor Zero m,ft

Oftenthesensor0-pointislowerthentheoutletofthepump.Inthiscasethedifferencemustbeadded to the head. See Section 3.2.2

Pump Alarms

Phase MissingAlarmType (Inactive,

B-Alarm,A-Alarm)

System

AlarmDelay Seconds

DryRunAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

NoRunConfirmAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

Fallen Motor ProtectorAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

M. Prot. Reset ErrorAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

High Motor Current


AlarmDelay Seconds

Limit Amperes

Hysteresis Amperes

LowMotorCurrent


AlarmDelay Seconds

Limit Amperes

Hysteresis Amperes

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Pump Alarms

HighVibrations


System

AlarmDelay Seconds

Limit mm/s,inch/s

Hysteresis mm/s,inch/s

LowPumpCapacity


Analarmisissuedifthemeasuredcapacityisbelowthisthreshold.

AlarmDelay Seconds



PumpNotInAutoAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

Pump ErrorAlarmType (Inactive,

B-Alarm,A-Alarm) Digitalinputpumpfailactivated.AlarmDelay Seconds

MaxCont.RunTimeAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

PumpAlarmBlockedAlarmType (Inactive,

B-Alarm,A-Alarm)

AlarmDelay Seconds

Leakage

DigitalInput/ MiniCas(1)

AlarmType (Inactive, B-Alarm,A-Alarm) Leakagesensorconnectedtoa

digital input or MiniCas simula-tion on Analog Input.AlarmDelay Seconds

DI1 Oil Chamber


SignalsfromCA441.IfoneCA441 is monitoring several pumps onlyDI1oilchambercanbeused.

AlarmDelay Seconds

DI2 ElectricArea


AlarmDelay Seconds

DI3MotorHousing


AlarmDelay Seconds

High Tem-perature

DigitalInput/ MiniCas(1)


System

Temperature sensor connected to a digital input or MiniCas[1]

simulation on Analog Input.AlarmDelay Seconds

T1/T4 Stator


SignalsfromCA442.AlarmslimitsareonlyusedforsensortypePt100.KlixonandPTCusefixedlimits.

IfoneCA442ismonitoringseveralpumpsonlyT1statorcanbe used.

AlarmDelay Seconds

AlarmLimit(Pt100) °C,°F

Hysteresis(Pt100) °C,°F

T2 Upper Bearing


AlarmDelay Seconds



T3LowerBearing


AlarmDelay Seconds



(1)Xylem;MiniCas=External monitoring relay

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Pump Alarms

High Tem-peratur

Temp. StatorL2


System

FromadditionalCA442: Same set point are used for AlarmLimitandHysteresisas T1/T4 (Pt100)

AlarmDelay Seconds

Temp. StatorL3


AlarmDelay Seconds

PumpBlockAutoReset

Stop On High Temp.

T1/T4 Stator or DigitalInputor

MiniCas[1] simulation on Analog Input

(NO,YES)

System

Ifactivatedthepumpwillbeblockedaslongthealarmlimitisexceeded.

Use alarm limits from the pump alarms menu.

Independentonalarmtype.

T2 Upper Bearing (NO,YES)

T3LowerBearing (NO,YES)

Manual Reset Required

(NO, YES for T1/T4 DigitalIn,

YES for all Temp.)

IfsettingisYES,thepumpwillbeblockeduntiltheconditionisbacktonormalandthereaftermanuallyresetfromthemenuMain Menu – Manual Control

– Pump x – Reset Temp. Protection

BlockDelay Seconds

StopOnVibrationsStopOnVibrations (NO,YES)

Ifactivatedthepumpwillbeblockedaslongasthealarmlimitisexceeded.Usealarmlim-its from the pump alarms menu. Independentonalarmtype

BlockDelay Seconds

StoponLeakage

DI1OilChamb. (CA441)or

MiniCas[1] simulation on Analog In or DigitalInput

(NO,YES)

DI2(CA441)ElectricArea (NO,YES)

DI3(CA441) Motor Housing (NO,YES)

BlockDelay Seconds BlockdelayworksonON/OFFconditions.

PumpBlockOnAlarm

-

High Motor Current (NO,YES)

SystemIfsettingisYES,thepumpwillbeblockeduntilthealarmisacknowledged.

LowMotorCurrent (NO,YES)

Fallen Motor Protector (NO,YES)

LowPumpCapacity (NO,YES)

DryRun (NO,YES)

NoRunConfirm (NO,YES)

Pump Error (NO,YES)

HighVibrations (NO,YES)

Blockon High Temperature

DigitalInputorMiniCas[1] simulation

on Analog Input(NO,YES)

T1/T4(CA442)Stator (NO,YES)T2(CA442)

Upper Bearing (NO,YES)

T3(CA442)LowerBearing (NO,YES)

BlockonLeakage

DigitalInputorMiniCas[1] simulation

on Analog Input(NO,YES) System

IfsettingisYES,thepumpwillbeblockeduntilthealarmisacknowledged.

DI1(CA441) Oil Chamber (NO,YES)

DI2(CA441)ElectricArea (NO,YES)

DI3(CA441) Motor Housing (NO,YES)

(1)Xylem;MiniCas=External monitoring relay

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DryRunDetect

LowCosBlockPump (NO,YES)

SystemTo detect that the pump is run-ningdry,athresholdonlowcosphi is used.

BlockDelay Seconds

BlockifCos< Number

BlockTimeout Seconds

Pump Tag Pump name String Max11characterstonamethepump.

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6.6 Common settings for pump 1, 2, 3 and 4.Table6-4showsthecompletelistofsettingsyoucanmakeunderthesubmenu Common P1-P4.

Table 6-4 Common�settings�for�pump�1,�2,�3�and�4,�under�‘Settings�>�Common�P1-P4’


LogPumpEvents Default:OFF (OFF,ON) System

AutoResetM.Protect

Reset Protector P1 (NO,YES)

System

Pulse Time is the duration of the reset pulse.

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


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’


Set Point

ExternalSetPoint

(OFF, AnalogInput2, AnalogInput3,AnalogInput4,AnalogInput5)

System

See Section 3.6.1

SetPointTracking (OFF,ON)

Startup Set Point(LastSetPoint,StartValue,Ex-ternal Set Point)

SetPointStartValue m,ft

MaxSetPoint m,ft

Min Set Point m,ft

Output Signal

Start Up State (LastState,Auto,Manual,Blocked)

System

OutputwhenBlocked (FreezeOutput,BlockSignalValue)

BlockOutput Percent

MaxOutputSignal Percent

Min Output Signal Percent

MaxOutputChange Percent/Seconds

PIDParameters

ControllerDirection (Reverse,Direct)

System

P(Amplification) Number

I(Integrationtime) Seconds

D(Derivationtime) Seconds

OutputAtZeroDev. Percent

SpeedControlVFD

Min Pump Speed Percent

SystemLockSpeed Percent

LockSpeedDelay Seconds

Reverse Speed Percent

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6.8 Settings for mixerTable6-6showsthecompletelistofsettingsyoucanmakeunderthesubmenuMixer.

Table 6-6 Settings for mixer,�under�‘Settings�>�Mixer’


- Stop Pumps whenMix (NO,YES)

System

- RunIndication (OFF,DigitalInput)

- MixerRunTime Seconds

- PumpStartstoMix IntegerThemixeriseitherstartedafterPump Starts to Mix,orafterTime Interval to Mix. Entering zerodisablesthecorrespondingtrigger.

- TimeIntervaltoMix Minutes

- MaxLevelforStart m,ft Ifmax>minlevel,thisisthewindowwherethemixermayrun.Ifmax<minlevel,themixermayonlyrunoutsidethatwindow.- MinLevelforStart m,ft

Motor Protector

AutoReset (OFF,ON)

SystemSee Auto Reset M. Protect

Table6-6.

Pulse Time Seconds

Pause Time Seconds


MixerAlarms

NorunConfirmAlarmType (Inactive,

B-Alarm,A-Alarm)

System

AlarmDelay Seconds

Fallen Motor Protector


AlarmDelay Seconds

M. Prot. Reset Error


AlarmDelay Seconds

6.9 Drain pumpTable6-7showsthecompletelistofsettingsyoucanmakeunderthesubmenuDrain Pump.

Table 6-7 Drain�pump,�under�‘Settings�>�Drain�Pump’


- RunIndication (OFF,DigitalInput)

System

- StartDelay Seconds

- StopDelay Seconds

Motor Protector

AutoReset (OFF,ON)See Auto Reset M. Protect

Table6-6.

Pulse Time Seconds

Pause Time Seconds


DrainPumpAlarms

NoRunConfirmAlarmType (Inactive,

B-Alarm,A-Alarm)

System

AlarmDelay Seconds

Fallen Motor Protector


AlarmDelay Seconds

M. Prot. Reset ErrorAlarmType (Inactive,

B-Alarm,A-Alarm)AlarmDelay Seconds

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6.10 CleanerTable6-8showsthecompletelistofsettingsyoucanmakeunderthesubmenuCleaner.

Table 6-8 Cleaner,�under�‘Settings�>�Cleaner’


- Flushat: (PumpStart,Pump Stop)

System- Flushing Time Seconds

- No.StarttoFlush Integer

6.11 Analog loggingTable6-9showsthecompletelistofsettingsyoucanmakeunderthesubmenuAnalog Logging.

Table 6-9 Analog�logging,�under�‘Settings�>�Analog�Logging’


LogChannel1toLogChannel16

LogSignal

(Closed, PitLevel, PitInflow, PitOutflow,

OverflowLevel, OverflowFlow, Back-Pressure, MotorCurrent, PumpCapacity, PowerFactor, Temp.Stator,

Temp.UpperBearing, Temp.LowerBearing,

Vibrations, MainVoltage,

MainFrequency, FreeChoice,

SupplyVoltage, PulseChannel,

Temperature Stator WiringL2,

Temperature Stator WiringL3,

PidControlleroutput, DataRegister, DataRegister(2-compl.),

ActualVFDfrequencyP1-P4,

TotalHead, ActualHead)

System

Atotalof16analogchannelswhoseoutputsyoucanchoosefrom the list.

Pulse Channelareusedforrain,flowandenergyvalues.

TemperaturesignalsareonlymeaningfulifyouusePT100sensors.

Forsomesignalsyouhavetochoose pump number or pulse channel.

LogFunction

(Closed, ActualValue, AverageValue, MinValue, MaxValue)

LogInterval Minutes

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6.12 Settings for digital inputsTable6-10showsthecompletelistofsettingsyoucanmakeunderthesubmenuDigital Inputs.

Table 6-10 Settings for digital�inputs,�under�‘Settings�>�Digital�Inputs’


DigitalInput1 to

DigitalInput12InputFunction

(OFF, Pumprunindication, Manuelpumpstart, Pumpnotinauto,

Startfloat, Pumpfailure, Motorprotector, Hightemperature,

Leakage, StopfloatP1-P4, Lowlevelfloat, Overflowsensor, Highlevelfloat, Drainpumpfloat,

Runind.drainpump, M.prot.drainpump, Runindicationmixer, Motorprot.mixer, Staffinstation Alarmreset, Powerfail,

DIpulsechannel1-4 BlockPIDcontroller,

Alarminput, Mixerblock+Alarm

input, Drainpumpblock+

Alarminput Blockremotedata)

System

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:

InputPulseCh.1, InputPulseCh.2, InputPulseCh.3, InputPulseCh.4,)

System

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

DigitalOutput1 to

DigitalOutput8

Output Function

(OFF, Pumpcontrol,

Resetmotorprot., Pumpfail,

Toomanypumpsblocked,

Onepumpfail, Masterresetm.prot.,

Mixercontrol, Resetm.prot.mixer, Drainpumpcontrol, Res.m.protdrain, Cleanercontrol, Modemcontrol, Remotecontrol, Personalalarm,

Highlevel, Alarmalert,

Notackn.A-alarm, Notackn.A/B-alarm,

ActiveA-alarm, ActiveA/B-alarm, Pumpreversing, ActiveB-alarm,

Externalresetalert

System

LogicIO,IO1–IO4

(OFF, TrueOR,

InverseOR, TrueAND,

InverseAND)

See Section 4.1

Datareg.setpoint)

DataRegister 0-4529

See Section 4.2SetpointON Integer

Setpoint OFF Integer

Setpoint Delay Seconds

NormallyState (NormallyOpen(NO), NormallyClosed(NC))

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6.14 Settings for analog inputsTable6-12showsthecompletelistofsettingsyoucanmakeunderthesubmenu Analog Inputs.

Table 6-12 Settings for analog�inputs,�under�‘Settings�>�Analog�Inputs’


AnalogInput1

Signal Range (4-20mA,0-20mA)

System

Dedicatedforthelevelsensor.

Filter Constant Seconds

Scaling0%= m,ft

Scaling100%= m,ft

ZeroOffset m,ft

AnalogInput2 to

AnalogInput5


IfCA442isconnectedtoapumpthevibrationinputsignalfromCA442 will be used instead of the analog inputs in this menu.

IfCA443isconnectedtoapumpthemotorcurrentfromCA443will be used instead of the analog inputs in this menu.

(NA=notavailable)

InputFunction

(OFF, NA,

Motorcurrentpump1, Motorcurrentpump2, Motorcurrentpump3, Motorcurrentpump4,

Back-pressure, Vibrations, Freechoice,

Vibrationspump1, Vibrationspump2, Vibrationspump3, Vibrationspump4,

XylemMiniCasSim.P1, XylemMiniCasSim.P2, XylemMiniCasSim.P3, XylemMiniCasSim.P4)

Outflowmeter

6.15 Settings for analog outputsTable6-13showsthecompletelistofsettingsyoucanmakeunderthesubmenuAnalog Outputs.

Table 6-13 Settings for analog�outputs,�under�‘Settings�>�Analog�Outputs’

Submenu Submenu Setting Value Sub settings Passcode

PC 441 Main Module AnalogOutput1


Scaling0% Scaling100%

System


Output Function

(OFF, Pitlevel, Pitinflow, Pitoutflow, Pitoverflow,

Pulsechannel1, Pulsechannel2, Pulsechannel3, Pulsechannel4, PIDcontroller

DataRegister)

DataRegister0-4529 Scaling0% Scaling100%

See Section 4.3

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Submenu Submenu Setting Value Sub settings Passcode

PC 441 Main Module AnalogOutput2



System


Output Function


Pulsechannel1, Pulsechannel2, Pulsechannel3, Pulsechannel4, PIDController)

DataRegister


See Section 4.3

CA781 Exp.Module

AnalogOutput1




Output Function



DataRegister


See Section 4.3

AnalogOutput2




Output Function



DataRegister


See Section 4.3

813

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6.16 Settings for pulse channelsTable6-14showsthecompletelistofsettingsyoucanmakeunderthesubmenuPulse Channels.

Table 6-14 Settings for pulse channels,�under�‘Settings�>�Pulse�Channels’


Pulse Chan-nel 1

to Pulse

Channel 4

Function

Precipitation

1 Pulse mm,inch

System

The menus adapt to the choice youmadeforthefunctionofChannel 1 and Channel 2.

AlarmHighPrecip. (Inactive,B-Alarm,A-Alarm)

AlarmDelay Seconds

Limit l/s/ha,inch/h

Hysteresis l/s/ha,inch/h

Energy

1 Pulse kWh

AlarmHighPower (Inactive,B-Alarm,A-Alarm)

AlarmDelay Seconds

Limit kW

Hysteresis kW

Flow

1 Pulse m3,gal

AlarmHighPower (Inactive,B-Alarm,A-Alarm)

AlarmDelay Seconds

Limit m3/h,GPM

Hysteresis m3/h,GPM

AlarmLowFlow (Inactive,B-Alarm,A-Alarm)

OnlyavailableforChannel1andChannel 2.

AlarmDelay Seconds

Limit m3/h,GPM

Hysteresis m3/h,GPM

6.17 Settings for trend curvesTable6-15showsthecompletelistofsettingsyoucanmakeunderthesubmenuTrend Curves.

Table 6-15 Settings for trend curves,�under�‘Settings�>�Trend�Curves’


- Sample Time Seconds System

Trend Curve 1 to

Trend Curve 4

Signal

(Closed, PitLevel, PitInflow, PitOutflow,

OverflowLevel, OverflowFlow, Back-Pressure, MotorCurrent, PumpCapacity, PowerFactor, Temp.Stator,

Temp.UpperBearing, Temp.LowerBearing,

Vibrations, MainVoltage,

MainFrequency, FreeChoice,

SupplyVoltage)

System

Atotalof4trendcurvesyoucanchoose from the list.

MaxValue Number Themaximumandminimumvalues are used to set the scales of the graphs.MinValue Number

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6.18 Communication settingsTable6-16showsthecompletelistofsettingsyoucanmakeunderthesubmenuCommunication.

Table 6-16 Communication settings,�under�‘Settings�>�Communication’


ProtocolSelect Protocol

(Modbus,Comli,Modbus TCP)

System

Protocol for both the ports and the USB connections.

(ON,OFF)Cross Refer-ence Table See Section 4.9

Service PortBaudrate

(OFF, 300Baud, 600Baud, 1200Baud, 2400Baud, 4800Baud, 9600Baud, 19200Baud, 38400Baud, 57600Baud,

115200 Baud)

SystemSee Section 4.7.2

Comport Echo (OFF,ON) See Section 4.7.5

Com Port

StationId Integer

System

Uniquenumberforthesta-tion needed for connection to AquaWeb.

Baudrate

(OFF, 300Baud, 600Baud, 1200Baud, 2400Baud, 4800Baud, 9600Baud, 19200Baud, 38400Baud, 57600Baud,

115200 Baud)See Section 4.7.1

Parity (None,Odd,Even)

Handshake (OFF,ON)

ProtocolId Integer

Message Time out Seconds

StationName String

Modem

- Modem Connected

(NO,AnalogModem,GSMModem,GPRSModemCA521,FIXIPTCPLISTEN)

System

Modemisnotneededforfixedline connections.

- Signals Be-foreAnswer Integer

See Section 4.7.4

- HayesBe-fore Calling String

- HayesAfterDisconnect String

- ModemPINCode String

- ModemPUKCode String

- SMSC Service CenterNo String

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Modem GPRSSettings

HeartBeatInterval Minutes

System See Section 4.7.4

ServerTCPPortNo Number

ServerIPAddress String

GPRSAPNPart1 String

GPRSAPNPart2 String

SMSFallback (OFF,ON)

FallbackSMSNumber String

GPRSUserName String

GPRSPassword String

GPRSEventlog (OFF,ON)

H. Beat Opera-tor Scan (OFF,ON)

AlarmCallUp

MaxNo.Calls/Alarm Integer

System

Themaximumnumberofat-temptstocall.ItcyclesthroughCallAttempt1-4(seesettingsbe-low) until Max No. Calls/Alarms is reached.

IntervalCallAttempts Seconds The time between call attempts.

AlarmCallAcknowledge

(NoAckn., RingSignal,

WritetoReg.333,AllDataCom.)

AlarmAckn.WriteR333 (OFF,ON)

Thisisforthelocalindication.IfYES,itisacknowledgedwhenthecentralsystemhastakencare of the alarm.

ConnectIdString String

CallAttemptsCallAttempts1

to CallAttempts4

AlarmReceiver (OFF,CentralSystem,SMSGSMPDU)

System

Typeofalarmreceiver.IffOFF,itskipstothenextCallAttemptinthe list.

Condition AlarmCall

(A-AlarmON,A-AlarmON/OFF),A+B-AlarmON,A+B-AlarmON/OFF)

Acallisattemptedonlyiftheconditionistrue.On/Offindicateswhetherthealarmgoesonoroff.Example:A+B-Alarm On/OFF meanseitherAorBalarmthateithergoesonoroff.

TimeoutCallAckn. Seconds Thetimeuntilitskipsthisattemptandtriesthenextone.

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.

Table 6-17 Settings�for�field�bus�modules,�under�‘Settings�>�Field�Bus�Modules’


LeakageMonitors CA441

CA441-1 P1orP1-P4

- Used and Con-nected (NO,YES)

System

OnlysetthistoYES if the units are connected to Canbus and usedasleakagemonitor.

- Pumps Connected (4PumpsP1-P4,Pump1)

IfonepumpisselectedDI1-DI3isusedforthatpump.AtfourpumpsDI1correspondstoP1...DI4toP4.

- DI1SensorType

(OFF, ABSStandard, ABSExtended,

Xylem)

- ... ...

...

...

- DI4SensorType


Xylem)

AlarmCom.Failure

AlarmType (Inactive,B-Alarm,A-Alarm)

AlarmDelay Seconds

Sensor Alarms

DI1SensorError

Alarm Type:(Inactive,B-Alarm,A-Alarm)

Alarm Delay:Seconds)

...

...... ...

DI4SensorError



LeakageMonitors CA441

CA441-2Pump 2

to CA441-4Pump 4


System

OnlysetthistoYES if the units are connected to Canbus and usedasleakagemonitor.

- DI1SensorType


Xylem)

- ... ...

...

...

- DI4SensorType


Xylem)

AlarmCom.Failure


AlarmDelay Seconds

Sensor Alarms

DI1SensorError



...

...... ...

DI4SensorError



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Temperature Mon.CA442

CA442-1P1orP1-P4

- Used and Con-nected

(4PumpsP1-P4,Pump1)

System

OnlysetthistoYES if the units are connected to Canbus and used as temperature monitor.

- Pumps Connected (NO,YES)

IfonepumpisselectedT1-T3isusedforthatpump.Atfourpumps T1 corresponds to P1...T4 to P4.

- T1SensorType (OFF,KlixonPTC,PT100)

- ... ...

...

...


Vibrations

Scaling0%= mm/s,inch/s



AlarmCom.Failure


AlarmDelay Seconds

Sensor Alarms

T1 Sensor Error



...

...... ...

T4 Sensor Error



CA442-2Pump 2

to CA442-4Pump 4


OnlysetthistoYES if the units are connected to Canbus and used as temperature monitor.

Temperature Mon.CA442

CA442-2Pump 2

to CA442-4Pump 4


System

- ... ...

...

...


Vibrations




AlarmCom.Failure


AlarmDelay Seconds

Sensor Alarms

T1 Sensor Error



...

...... ...

T4 Sensor Error



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Power Moni-torsCA443

CA443-0Main Power


System

OnlysetthistoYES if the units are connected to Canbus and used as power monitor.

Current Measuring

Transf. Con-nected to

(None, L1,

L1andL2, L1,L2andL3)

Allcurrentmeasuringisdonethrough current transformers.

TR.NominalCurrent Amperes

TR. Second-aryCurrent Amperes

CurrentOffset Amperes

CurrentDeadband Amperes


Phase Com-pensations Value

VoltagesMeasuring

Phases Connected

(None, L1,

L1andL2, L1,L2andL3,

NA, Volt.fromCA443-1)

(NA=notavailable)Ext.Transf.Connected (NO,YES)

OffsetVoltage Voltage


AlarmCom.Failure


AlarmDelay Seconds

High-legDelta (NO,YES)

CA443-1Pump 1

to CA443-4Pump 4


System

OnlysetthistoYES if the units are connected to Canbus and used as power monitor.

Current Measuring

Trans. Connected to

(None, L1,

L1andL2, L1,L2andL3)

Allcurrentmeasuringisdonethrough current transformers.

TR.NominalCurrent Amperes

TR. Second-aryCurrent Amperes

CurrentOffset Amperes

CurrentDeadband Amperes

Filter Con stand Seconds

Phase Com-pensations Value

VoltagesMeasuring

Phases Connected

(None, L1,

L1andL2, L1,L2andL3,

Volt.fromCA443-0)

Ifvoltagemeasuring

Ext.Transf.Connected

(NO; YES:PrimaryVoltage,SecondaryVoltage)

OffsetVoltage Voltage


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Power Moni-torsCA443

CA443-1Pump 1

to CA443-4Pump 4

AlarmCom.Failure


SystemAlarmDelay Seconds

High-legDelta (NO,YES)

AO/DO Expantion CA781

- Used and Connected (NO,YES)

SystemAlarmCom.

Failure


AlarmDelay Seconds

FieldBusAlarmAlarmType (Inactive,B-

Alarm,A-Alarm) SystemAlarmDelay Seconds

6.20 Common settingsTable6-18showsthecompletelistofsettingsyoucanmakeunderthesubmenuCommon.

Table 6-18 Common settings,�under�‘Settings�>�Common’

Submenu Submenu Setting Value Pass-code

Comment

No.DecimalsFlow

InflowDecimals (None,1,2,3,4)

System

OutflowDecimals (None,1,2,3,4)

Pump Capac-ityDec. (None,1,2,3,4)

OverflowDecimals (None,1,2,3,4)

Pulse Flow Decimals (None,1,2,3,4)

Sulzer Pump Solutions Ireland Ltd., Clonard road, Wexford, IrelandTel. +353 53 91 63 200, www.sulzer.com

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