Transcript
81307060G (09/2014)
Pump Controller Type ABS PC 441
EN
Installation Guide www.sulzer.com
Pump controller type ABS PC 441, Installation guide
Copyright © 2014 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.
81307060G
Sulzer reserves the right to alter specifications due to technical developments.
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Pump controller type ABS PC 441, Installation guide
1
INSTALLATION
1.1 Mount the controller Mount the controller on a 35 mm DIN rail. The physical dimensions of the controller is: 86 x 160 x 60 mm (3.39 x 6.30 x 2.36 inch) (H x W x D). If it doesn’t easily snap onto the rail, you can pull the small tab at the bottom side of the unit, using a small screwdriver.
1.2 Make all connections There are a total of 48 terminals that may be connected to power, sensors, switches, relays and a modem; these terminals are numbered from 1 to 52 according to the following figure:
RS-232 port for a computer
Terminals at the top side of the controller, numbered 27 to 52
Terminals at the bottom side of the controller, numbered 1 to 26
WARNING Ensure that all power is off, and that all output devices to be connected to the controller also are turned off before you connect anything! Table 1 shows all connections to terminals 1-26 at the bottom side of the controller. The usage of the configurable Digital In and Analogue In shown in the table is the default configuration. “Digital In” means a signal that is either on or off — high or low, where high is between 5 and 34 volts DC. Digital In may be connected to either passive devices, such as switches, or active devices that are powered and deliver signals. Figure 1 shows how to connect such devices to the Digital In terminals. Table 2 shows all connections to terminals 27–52 at the top side of the controller. The usage of the configurable DO 1 to DO 8 and AO 1 to AO 2 shown in the table is the default configuration. “DO” stands for “Digital Outputs”, which are voltage outputs. The power must be DC between 9 and 34 volts. Figure 2 shows how to connect a power-fail switch to Digital In 3 (terminal 5) and how to connect a battery pack for uninterrupted operation. The modem should be connected according to Figure 8.
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For CAN bus (Field bus) see section 1.3 Can bus.
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Pump controller type ABS PC 441, Installation guide
Table 1.
Terminals at the bottom side of the pump controller Factory Settings
Namei
#
Voltage supply, 10–32 V DC ⇒
V+
1
V-
2
Overflow level
Digital In 1
→
3
HIgh level float
Digital In 2 Digital In 3
→ →
4
Power failure Personal in station (local mode)
Digital In 4 Digital In 5
Pump 1 not in auto
Digital In 6
→ → → → → → → → → → → → →
6
Motor protector pump 1 Spare pump 1
Digital In 7
Motor protector pump 2
Digital In 8
Pump 2 not in auto
Digital In 9
Spare pump 2
Digital In 10
Motor protector pump 3
Digital In 11
Pump 3 not in auto
Digital In 12
Spare pump 3
Digital In 13
Motor protector pump 4
Digital In 14
Pump 4 not in auto
Digital In 15
Low level float
Digital In 16
5
7 8 9 10 11 12 13 14 15 16 17 18 19
← → → → → →
V+ Level sensor
Analogue Inii 1
P1 Motor current
Analogue In 2
P2 Motor current
Analogue In 3
P3 Motor current
Analogue Inii 4
P4 Motor current
Analogue Inii 5
ii ii
20 21 22 23 24 25 26
V-
i. “Digital In” means a signal that is either on or off (high or low), where high is anything between 5 and 32 volts DC and low is anything below 2 volts. All digital inputs are configurable in the menu Settings > Digital Inputs, but the configuration shown here is the default one. ii. “Analogue In” means Analogue Input. They are all sensing the current in the range 4–20 mA or 0–20 mA. This is configured in the menu Settings > Analogue Inputs.
PC 441 Push-button/switch
X Signalling device
Voltage Supply
Signal Output
Y
Digital inputs
Signal ground
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Figure 1. The Digital In terminals may be connected to either passive devices, such as switches, or active devices that are powered and deliver signals. Connect devices according to the figure.
V + Voltage Supply
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Pump controller type ABS PC 441, Installation guide
Table 2.
Terminals at the top side of the pump controller
#
Namei
Factory Settings
27
V - 0V
28
→
DOi 1.
Alarm alert
29
→ →
DOi 2.
Pump 1
DO 3.
Pump 2
→ → → → →
DOi 4.
Pump 3
DO 5.
Pump 4
DO 6.
Personal alarm alert
DOi 7.
Relay Mixer
DOi 8.
High level
→ ← → ←
+ AOii 1.
42
V +↔
CAN_V+
43
30 31 32 33 34 35
i
i i
36 37 38 39 40
Pit level
- AOii 1. + AOii 2.
Off
- AOii 2.
41
45 46
CAN_H CAN_SHLD
44 ↔
CAN_L
V-
0V
← → → ←
CTS
47 48 49 50 51 52
RTS TX RX 0V
i. DO means Digital Output. It is a voltage output. See the menu Settings > Digital Outputs for configuration of these outputs. ii. AO means Analogue Output. See Settings > Analogue Outputs for configuration of these outputs.
Relay
PC 441 V + Voltage Supply
Figure 1. The power must be DC between 9 and 34 volts, but if it also charges batteries, it should be 27.2 V.
Digital input: "Power fail"
Battery charger
Connect a power-fail switch to Digital In 3 (terminal 5) according to the figure.
AC
For uninterrupted operation in case of power failure, connect a battery pack according to the figure.
DC
27.2 V Backup battery pack
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Fuse
+ +
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Pump controller type ABS PC 441, Installation guide
PC 441 PINS Level sensor
Figure 1.
+ -
4-20 mA
V+ Analogue In I
Analogue input connection (level sensor)
PC 441 PINS V-
0V DOI
V+
Relay Figure 1.
Digital output connection (external relay)
V+
Loads are connected series 0/4 - 20 mA
PC 441 PINS +
AO1+
A
-
+
A
-
PLC + With analogue connected to V-
Figure 1.
-
V-
Analogue output connection
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V-
AO1-
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Pump controller type ABS PC 441, Installation guide
1.3 CAN bus (Field bus) A CAN network is of multidrop type witch means that all units are connected in parallel on the same cable. PC 441 is the master on the bus to which display devices like CA 511 and any monitoring devices are connected (type CA 441 / 442 / 443). The CAN cable uses 5 wires. Two wires are used for communication CAN_L and CAN_H. One wired is shield CAN_SHLD and two wires are used as bus power V+ and 0V. Bus power allow devices to get power directly from the bus. CA 511 1
0V
CA 441 / 442 / 443
CAN_L SHLD CAN_H V+ 2 3 4 5
1
0V
CAN_L SHLD CAN_H V+ 2 3 4 5
PC 441 V+ CAN_H SHLD CAN_L 0V
42 43 44 45 46
CA 44x
~
Figure 1.
Power supply
+
CAN connection
1.3.1 Using bus power Max bus power output from PC 441 is 350 mA (V+). CA 511 can be bus powered directly from PC 441. Other modules must use an external power supply. A few rules: □□
If CA 511 is the only device connected on the bus. Bus power CA 511 directly from PC 441.
□□
If other devices (like CA 441 ..) also are connected. Don’t use bus power from PC 441 for these devices. Connect an external power supply (V+ and 0V) to the first device in the chain.
□□
If some modules are placed far away from the main unit, it’s a good idea to use a separate power supply for these units.
1.3.2 CAN termination The CAN bus shall be terminated at both cable ends. PC 441 is bus master and has a built-in termination that are always active and should therefore always be placed in one of the endpoints of the cable. For other devices you can activate the selectable termination with a switch marked CAN TERM Active termination for the device placed on the other endpoint of the cable. All other devices between should have their termination switch in Off position. CAN TERM ON
CAN TERM OFF
CAN TERM OFF
CAN TERM OFF
Always ON
CA 44x
CA 44x
CA 44x
CA 511
PC 441
CAN network with connection
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Figure 1.
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Pump controller type ABS PC 441, Installation guide
1.3.3 CAN ID
I I I
I I I
I I I
3 4 5
I
B C D
F 0 1 I
2
E
In a CAN network every unit must have a unique address or ID-number. PC 441 and CA 511 use a fixed ID on the bus and no ID settings are needed for these devices.
6
I
I I I
A
I
On the CA 44x one part of the address is set default depending on device, the other part of the address is set by a hexadecimal switch, marked “ID”. Choose address by pump number as in table below or instructions in system manual. If the device has a unique address and contact with the network master, the CAN LED is still green. For error codes of the CAN LED see system manual. 7 8 9
When used with PC 441 use the following addresses to achieve correct functions. Table 3.
CA 441 Leakage Monitor
CAN SUB ID
Monitoring function
0
Not used with PC 441
1
Pump 1 or pumps 1-4
2
Pump 2
3
Pump 3
4
Pump 4
5->F
Not used with PC 441
Table 4.
CA 442 Temperature Monitor
CAN SUB ID
Monitoring function
0
Not used with PC 441
1
Pump 1 or pumps 1-4
2
Pump 2
3
Pump 3
4
Pump 4
5->F
Not used with PC 441
Table 5.
CA 443 Power Monitor
CAN SUB ID
Monitoring function Main power monitor
1
Pump 1
2
Pump 2
3
Pump 3
4
Pump 4
5->F
Not used with PC 441
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0
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Pump controller type ABS PC 441, Installation guide
OV
Depending on the type of modem, connect according to the figure. Modem cable 43320588.
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Figure 1.
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Pump controller type ABS PC 441, Installation guide
2
CONNECTION OF XYLEM PUMPS TO ABS PC 441 It is possible to connect Xylem pumps in parallel with ABS pumps. For connection of sensors there are three cases depending on sensor configuration in the pump.
Case A: CLS sensor or combination of sensors in series In this case you have to use the analog inputs on the PC441. For advanced motor current monitoring or if out of analog inputs on the PC 441 use the CA 443 module for current monitoring. See the CA 44x Installation Guide. If the sensors are not connected in series, connect the sensors to temperature and leakage monitors respectively, see case B and C below. However the CLS is always connected to an analog input of the PC 441.
ATTENTION! In this case feeding power must not exceed 13.7 volts DC at any time. Overvoltage can cause permanent damage to the pump controller. Ideal power is between 11.5 and 13.7 Volts DC Pay special attention to the polarity of the CLS. Faulty connection will cause none or malfunction. Select input type “ITT MiniCas Sim” on the PC 441 for this functionally. ABS PC 441
FLS/ FLS10
Power input Analoge input 2 - 5
12V DC
Xylem pump
Thermo switch
V+
Ai(n)
CLS
CLS or any combination of sensors like: •CLS and FLS or •CLS and Thermo switch or •Thermo switch and FLS •CLS and Thermo switch and FLS
Case B: Only temp sensors Chose “Klixon” Thermo switch/PTC or “Pt100” mode in the settings menus for CA 442 ABS PC 441
DC
Power input Xylem pump
CAN ABS CA 442
Klixons/ Pt100
T(n)81307060G
CAN
T(n)+
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Pump controller type ABS PC 441, Installation guide
Case C: Only leakage sensors from the FLS series Chose “Xylem” mode in the settings menus for CA 441. ABS PC 441
DC
Power input Xylem pump
CAN ABS CA 441
Di(n)+
CAN
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Di(n)-
FLS/ FLS10
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Pump controller type ABS PC 441, Installation guide
3
TECHNICAL DATA
3.1 Technical data PC 441 Ambient operation temperature
-20 to +50 °C
(-4 to +122 °F)
Ambient storage temperature
-30 to +80 °C
(-22 to +176 °F)
Degree of protection
IP 20, NEMA: Type 1
Housing material
PPO and PC
Flame rated
V0 (E45329)
Pollution degree
2
Mounting
DIN Rail 35 mm
Dimension
HxWxD: 86 x 160 x 60 mm (3.39 x 6.30 x 2.36 inch)
Humidity
0-95 % RH non condensing
Power supply
9-34 VDC SELV or Class 2
Power consumption
< 5.0 W (without digital output load)
Installation category
CAT II
Digital outputs
8 DO. Positive logic. Sourcing from power supply. 1A/output. Max total current for all 8 outputs together is 4 A.
Max load Digital inputs Input resistance Input voltage
16 DI. Positive logic 10 kohm 5-34 V . Trig level ~ 4 V
Max pulse rate digital in 13-16
500 Hz (pulse channels)
Analogue outputs Max load Resolution Current limit
2 AO. 0/4-20 mA Sourcing from power supply 500 ohm@12 V, 1100 ohm@24 V 15 bits 0.5 uA ~22 mA
Analogue inputs Input resistance Resolution
5 AI. 0/4-20 mA 136 ohm. PTC protected AI1 :15 bits (level sensor). AI2-5 : 10 bits
Communication ports
1 RS232 Service port 1 RS232 port for telemetry interface (modem) 1 USB2 Service port
Field Bus (to CA 511/CA 441 ………)
1 CAN Port . Max current load 350 mA
Max altitude
2000 m
Approval
3.2 Cleaning Power off the unit. Only outside/front shall be cleaned by using a dry, soft cloth. A good choice would be the microfiber type of cloth. Gently wipe the PC 441 front in order not to scratch the overlay. If the dry cloth did not completely remove the dirt, do not press harder in an attempt to scrub it off. If necessary, moisten the cloth by adding a small amount of water with thin solution of mild detergent and try again. Never use detergent with polish or solvent which can have an impact of the plastic surface.
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81307060G
How to clean the unit
Declaration of conformity
Declaration of Conformity As defined by: EMC-Directives 2004/108/EC and 92/31/EEC, Low Voltage Directive 2006/95/EC, Directive for CE-Marking 93/68/EEC EN
EC Declaration of Conformity
SV
EG-försäkran om överensstämmelse
DE
EG-Konformitätserklärung
NO
EUs Samsvarserklæring
FR
Déclaration de Conformité CE
DA
EC-Overensstemmelseserklæring
NL
EC-Overeenkomstigheidsverklaring
FI
EU-Vaatimustenmukaisuusvakuutus
ES
Declaración de confirmidad CE
ET
EÜ Vastavuse deklaratsioon
PT
Declaracão de conformidade CE
PL
Deklaracja zgodnosci WE
IT
Dichiarazione di conformità CE
CS
Prohlášení o shodšĕ ES
EL
Δήλωση εναρμόνισης EK
SK
EC Vyhlásenie o zhode
TR
AT Uygunluk Beyanı
HU
EK Megfelelőségi nyilatkozat
Sulzer Pump Solutions AB, Rökerigatan 20, SE-121 62 Johanneshov, Sweden EN: DE: FR: NL: ES: PT: IT: EL:
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Yetkili makamlara istek üzerine teknik dosyayı hazırlamaya yetkili olan kişinin adı ve adresi: Namn och adress på den person som är auktoriserad att utarbeta den tekniska dokumentsamlingen till myndigheterna: Navn og adresse på den personen som har tillatelse til å sette sammen den tekniske filen til myndighetene ved forespørsel: Navn og adresse på den person, der har tilladelse til at samle den tekniske dokumentation til myndighederne ved anmodning om dette: Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite: Isiku nimi ja aadress, kelle pädevuses on koostada nõudmise korral ametiasutustele tehnilist dokumentatsiooni: Nazwisko i adres osoby upoważnionej do przygotowania dokumentacji technicznej w przypadku, gdy jest ona wymagana przez władze: Jméno a adresa osoby oprávnĕné na vyžádání ze strany úřadů vytvořit soubor technické dokumentace: Meno a adresa osoby oprávnenej na zostavenie technického súboru pre úrady na požiadanie: Asmens, įgalioto valdžios institucijoms pareikalavus sudaryti techninę bylą, vardas, pavardė ir adresas:
Frank Ennenbach, Director Product Safety and Regulations, Sulzer Management AG , Neuwiesenstrasse 15, 8401 Winterthur, Switzerland EN: DE: FR: NL: ES: PT: IT: EL: TR:
Declare under our sole responsibility that the products: Erklärt eigenverantwortlich dass die Produkte: Déclarons sous notre seule responsabilité que les produits: Verklaren geheel onder eigen verantwoordelijkheid dat de produkten: Declaramos bajo nuestra exclusiva responsabilidad que los productos: Declaramos sob nossa unicia responsabilidade que los produtos: Dichiariamo sotto la nostra esclusiva responsabilità che i prodotti: Δηλώνουμε με αποκλειστική μας ευθύνη ότι τα προϊόντα: Sorumluluk tamamen bize ait olarak beyan ederiz ki aşağıdaki ürünler:
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Försäkrar under eget ansvar att produkterna: Erklærer på eget ansvar, at følgende produkter Erklærer på eget ansvar, at følgende produkter: Vakuutamme yksinomaan omalla vastuullamme, että seuraavat tuotteet Deklareerime ainuvastutajana, et tooted: Deklaruje z pelna odpowiedzialnoscia, ze urzadzenia typu: Prohlašuje na vlastní odpovědnost, že výrobky: Vyhlasujeme na našu zodpovednost’, že výrobky: Felelösségünk teljes tudatában kijelentjük, hogy a termékek:
Pump controller type ABS PC 441 EN: DE: FR: NL: ES: PT: IT: EL: TR: SV: NO: DA: FI: ET: PL: CS: SK: HU:
to which this declaration relates are in conformity with the following standards or other normative documents: auf die sich diese Erklärung bezieht, den folgenden und/oder anderen normativen Dokumenten entsprechen: auxquels se réfère cette déclaration sont conformes aux normes ou à d’autres documents normatifs: waarop deze verklaring betrekking heeft, in overeenstemming zijn met de volgende normen of andere normatieve documenten: objeto de esta declaración, están conformes con las siguientes normas u otros documentos normativos: aque se refere esta declaracáo está em conformidade com as Normas our outros documentos normativos: ai quali questa dichiarazione si riferisce sono conformi alla seguente norma o ad altri documenti normativi: τα οποία αφορά η παρούσα δήλωση είναι σύμφωνα με τα ακόλουθα πρότυπα ή άλλα κανονιστικά έγγραφα: bu beyanın konusunu oluşturmakta olup aşağıdaki standart ve diğer norm belgelerine uygundur: som omfattas av denna försäkran är i överensstämmelse med följande standarder eller andra regelgivande dokument: som dekkes av denne erklæringen, er i samsvar med følgende standarder eller andre normative dokumenter: som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder eller andre normative dokumenter: joihin tämä vakuutus liitty, ovat seuraavien standardien sekä muiden sääntöämääräävien asiakirjojen mukaisia: mida käespöev deklaratsioon puudutab, on vastavuses järgmiste standardite ja muude normatiivdokumentidega: do których odnosi sie niniejsza deklaracja sa zgodne z nastepujacymi normami lub innymi dokumentami normatywnymi: na které se toto prohlášeni vztahuje, jsou v souladu s následujícími normami nebo jinými normativními dokumenty: na ktoré sa vz ahuje toto vyhlásenie, zodpovedajú nasledujúcim štandardom a iným záväzným dokumentom: amelyekre ez a nyilatkozat vonatkozik, megfelelnek a következőszabványokban és egyéb szabályozó dokumentumokban leírtaknak:
Safety: EMC:
EN 61010-1:2010 EN 61000-6-1:2007, EN 61000-6-2:2005, EN 61000-6-3:2007+A1:2011, EN 61000-6-4:2007+A1:201
Stockholm 2014-09-01
Per Askenström Sulzer Pump Solutions AB
Sulzer Pump Solutions Ireland Ltd, Clonard Road, Wexford, Ireland Tel +353 53 91 63 200, Fax +353 53 91 42 335, www.sulzer.com
2014 Copyright © Sulzer
