Download APP541 Installation manual

Installation manual
APP 541
Esc
Autamatic Pump Pilot
895684_app541_inst_eng_rev1_00
OK
Reset
APP 541
This manual is applicable to the following APP 541 versions:
Hardware:
Operator panel:
I/O-module:
Com-module:
AFH1801 Rev 1.02
AHH1801 Rev 1.02
TMX1801 Rev 1.00
System Software: 2.20
Application:
1.00
© Copyright 2005 ITT Flygt AB. All rights reserved. No part of this manual may be reproduced or copied
without the written permission of ITT Flygt AB.
ITT Flygt AB
P.O.Box 2058
SE-291 02 Kristianstad
Sweden
Tel +46 44 20 59 00
June 2005
This document may be changed without any prior notice.
Contents
Contents
1.
2.
3.
4.
5.
6.
7.
Read this first................... 4
1.1. Product documentation ..............
1.2. Safety rules for the owner/
operator ......................................
1.3. Guarantee ....................................
1.4. This manual .................................
1.4.1. Symbols used .............................
1.4.2. Abbreviations ............................
4
4
4
4
4
4
Introduction..................... 5
Mechanical installation.... 6
3.1. Installation in explosive areas ..... 6
3.1.1. Installation in an equipment
cubicle ....................................... 6
3.2. Level sensor installation .............. 6
3.2.1. 4-20 mA level sensor .................. 6
3.2.2. ENM-10 level regulator ............... 6
3.3. Mounting instructions ................. 7
3.3.1. Notice about mounting front seal
according to IP 65 .................... 7
3.3.2. I/O-module ................................. 7
Electrical installation ....... 8
4.1. Power supply ............................... 8
4.1.1. Earthing (grounding) .................. 9
4.1.2. Overvoltage protection ............... 9
4.2. Emergency operation .................. 9
4.3. Connections ................................. 9
4.3.1. Digital inputs .............................. 9
4.3.2. Inversion of inputs ...................... 9
4.3.3. Analogue input ........................... 9
4.3.4. Digital outputs ........................... 9
4.4. Communication ......................... 10
4.4.1. Connection to a modem
or radio .................................... 10
4.4.2. Connection to a PC using a
fixed line .................................. 10
Wiring diagram
100-240 V AC .................
Wiring diagram 24 V DC
Fault tracing...................
Specification ..................
11
12
13
14
3
Read this first
1. Read this first
1.4.1. Symbols used
Before starting installation of the APP 541 read this
chapter carefully. It contains general information on
documentation, safety and guarantee.
Safety instruction
1.1. Product documentation
Risk of personal damage.
Documentation delivered with the APP 541. Check that
this manual version is applicable to the delivered
APP 541 version (see cover inlet).
Safety instruction
Risk of personal damage dangerous voltage.
1.2. Safety rules for the owner/
operator
Special attention value
• All government regulations, local health and safety
directives must be observed.
Risk of apparatus or component damage.
• All danger due to electricty must be avoided.
1.4.2. Abbreviations
1.3. Guarantee
CS = Central system
• Modifications or changes to the unit/installation
should be done only after consulting ITT Flygt.
RTU = Remote Terminal Unit
SCADA = Supervision Control And Data Acqvicition
• Genuine spare parts and accessiories authorized by
the manufacturer are essential for compliance with
the terms of the guarantee. The use of other parts
may invalidate the guarantee.
1.4. This manual
In order to avoid repetition of information, this manual
describes how one pump P1, should be read or entered.
If a second pump or more pumps, are included in the
installation, the corresponding steps must be repeated
on those too.
4
Introduction
2. Introduction
The APP 541 is a pump controller that consists of two
parts, i.e. a DIN rail-mounted I/O module and a
operator panel.
The APP 541 can use a modem, GSM or radio to
communicate with a SCADA system e.g. the AquaView.
A special communication module is available for this
purpose.
Observe all precautions for handling
electrostatically sensitive devices before
opening the unit.
The front surface of the APP 541 has a high
degree of protection against moisture and
dirt, but should always be installed so that it
will not be unnecessarily exposed to water or
the risk of external physical damage.
The APP 541 may be used only in the manner
specified by the manufacturer.
The manufacturer does not allow any
internal modifications to be made in the unit.
Always keep this manual in the vicinity of the
installed unit.
5
Mechanical installation
3. Mechanical installation
3.1. Installation in explosive areas
3.2. Level sensor installation
The unit must never be installed in an
explosive or flammable environment.
N.B. See separate operation and installation manual
for details of installation in the pump sump.
For instructions concerning installation of the
level sensors in such an environment see
section 3.2. Level sensor installation.
3.2.1. 4-20 mA level sensor
The sensor shield must be connected to the earth
(ground) terminal of the APP 541 as shown in the
diagram under “Analogue input” on page 9.
If the pump is installed in an explosive
environment, its thermal overload switch
must be connected
The sensor may be installed in an explosive or
flammable environment, provided that an external
Ex barrier is used.
3.1.1. Installation in an equipment cubicle
3.2.2. ENM-10 level regulator
Ensure that the operating temperature of the cubicle is
between 0 and 50° C. Heating will normally be required
in winter if the cubicle is located outdoors or in a
similarly cold environment.
The cubicle temperature may become too high in
summer if ventilation is inadequate. Heating of the
cubicle is also recommended to avoid condensation.
High level switch
Low level switch
Installation of the ENM-10 level regulator in the pump
sump.
ENM-10 level regulators may be installed in an explosive
or flammable environment, provided that an
intrinsically safe Ex barrier is used.
6
Mechanical installation
3.3. Mounting instructions
3.3.1. Notice about mounting front seal according
to IP 65
The enclosure is designed for mounting into a
rectangular hole in a larger cabinet door.
Be careful not to get any grease in your eyes
and avoid prolonged skin contact. Wash your
hands afterwards.
A rubber gasket will seal against the front surface of the
cabinet door. Studs welded to the rear of the front plate
must enter into holes in the cabinet door.
To assure a front seal according to IP 65 the front unit
has to be mounted on to a rigid and smooth surface.
• Use the paper template to mark off the opening to
be made in the cubicle door.
• Tape the template to the cubicle door. Mark with a
centre-punch the positions of holes 5 and 8 in the
template.
If otherwise mounted on to a textured surface and/or
flexible steel plate cabinet, it is normally necessary to
apply a thick layer of grease on the sealing surfaces to
obtain sealing according to IP 65.
• First drill a small pilot hole at every punch mark.
Then open up the screw holes marked 5 in the
template to 5 mm.
Suitable grease is "Gleitmo 1810v". After application
wipe gently all overflowing grease away.
• Drill 8 mm dia. holes marked 8 in the template for
the corners of the opening in the cabunet door.
200
184
5
8
Do never use grease containing silicone since
this might seriously damage sensitive electric
contact surfaces inside the cabinet!
8
3.3.2. I/O-module
5
8
The I/O-module has clamps at the rear.
• Place the unit in a suitable location on a DIN rail.
135
119
• Connect the cables supplied between the operator
panel and the I/O-module. Secure the cable so that
they will not be nipped.
8
Note: The Ethernet cable is a crossover UTP RJ 45 cat 5e.
The cable length is 1.8 m (max length 3 m).
8
8
5
5
• Then tape with masking tape between the outsides
of the holes 8. See the drawing.
8
8
8
8
• Use a jigsaw or some other suitable tool to make
the opening for the operator panel in the cubicle
door.
• Place the operator panel in the opening. Fit the
washers and nuts, and tighten them firmly.
7
Electrical installation
4. Electrical installation
4.1. Power supply
Warning
A separate fuse must protect the APP 541 power supply.
Flygt recommends the use of a miniature circuit breaker
that opens on all poles.
Do not open machine with the grounding
wire disconnected.
One I/O module is designed to operate on 100 to 240 V
AC power supply.
The unit can also operate on 24 V DC as backup power
supply and can charge the backup battery when the
mains power supply is on.
More than one live circuit.
The electric wiring should be done only by an
authorized electrician. All electrical
installation work must be carried out with
the equipment disconnected from the power
supply, without any possibility of being made
live, and in accordance with local
regulations.
An ON / OFF isolating switch must be
provided adjacent to the installation to
enable the APP 541 to be isolated from the
power supply. This isolating switch must be
located close to the APP 541 and must be
easily accessible to the user.
And there is one model designed to operate at 24 v DC.
The I/O module also supplies power to the operator
panel.
N:B. Max. current availabe to the modem:
24 VDC, 180 mA, 4.5 Watt
The isolating switch should be marked to
show that it belongs to the APP 541.
When installing electronic measuring and control
systems, it is important that the cabling be specified
and run so as to minimize interference by electric and
magnetic fields.
The many potential sources of such interference include
relay coils, solenoid valves, switches, thyristor units,
earth (ground) currents and static electrical discharges.
Susceptibility to interference also varies with the
electrical environment, i.e. due to factors such as cable
lengths, screening and whether or not interference
suppression is provided. Many problems can be
prevented by good design.
Cables carrying signals of different types (for example,
analogue and digital signals) must be run separately.
Power and signal cables must never be run in close
proximity to one another.
8
Electrical installation
4.1.1. Earthing (grounding)
4.3. Connections
An equipment earthing (grounding) conductor must be
connected to terminal 3 (see Wiring diagram).
The terminal blocks on the APP 541 are described below
and are shown in the “Wiring diagram 100-240 V AC”
on page 11.
The earthing conductor should be connected to the best
possible earth, such as an earthed mounting plate or an
earth rod. Remember that the earthing conductor must
be as short as possible.
4.3.1. Digital inputs
The digital inputs are connected to terminals 28 -59 (see
the “Wiring diagram 100-240 V AC” on page 11).
Each input has its own power supply.
The shields of all shielded cables must be earthed.
4.1.2. Overvoltage protection
4.3.2. Inversion of inputs
Flygt recommends that the mains power supply unit be
provided with overvoltage protection (with lightning
protection). Since this will make the APP 541 less
sensitive to overvoltage, it will enable it to be used in
more severe environments.
The digital input signals can be inverted to change the
operating mode from closing to opening, or vice versa.
0 indicates no inversion. This is the default state.
See the User manual.
4.3.3. Analogue input
The protection should be connected in series with the
power supply, preferably to a separate earth (ground),
such as an earth rod, although connection to the earth
busbar in the distribution box may sometimes suffice.
The analogue input (4-20 mA) is connected to terminala
4 - 5 (see the Wiring diagram) and has its own power
supply. The input can carry a maximum total voltage of
16 V.
A 6-10 mm2 earthing wire should be used to connect
the overvoltage protection to earth.
4.2. Emergency operation
1
When the control unit is in the normal running mode a
relay (1) will be activated. If the control unit should fail,
due to software, hardware or power supply fault, the
relay will be deactivated (0).
2
3
This relay can be connected between a high level switch,
a timer and a power supply relay controlling the pump.
This function will provide an emergency function that
will run the station on the high-level switch even if the
control unit is out of operation.
4 5 6 7 8 9 10
+
-
• Emergency operation is delayed by 5 seconds after
the supply has been switched on.
• External Manual-0-Auto switch is located close to
the operator panel.
Analogue terminals for:
3
4
5
7-8
9-10
Shield
Red +
Black Input for current transformer with 0-1 A AC
output
Input for current transformer with
0-1 A AC output
4.3.4. Digital outputs
The digital outputs are connected to terminals 11-22
(see the Wiring diagram).
The outputs are potential-free, relays with a max. rating
of 2 A at 230 V AC or 30 V DC.
9
Electrical installation
4.4. Communication
To install the communication module, in the operator
panel, follow the instructions below:
N:B: Make sure that the power supplay is isolated!
2
1
1. Release the four screws (1) holding the rear cover to
the front of the unit.
2. Lift off the rear cover (2).
Unpack the communication module (3).
3
4
3. Place module (3) in the position (4), (see above).
4. Make sure it is securely in position.
5. Refit the rear cover.
4.4.1. Connection to a modem or radio
Connect the enclosed dedicated modem cable from the
modem/radio to the RS232 connector on the COM1.
Connect the modem/radio to its own power supply.
4.4.2. Connection to a PC using a fixed line
Connect a dedicated null-modem cable from the PC to
the RS232 connector on the COM1.
N.B. A common misunderstanding is to confuse the use
of a modem cable and a null-modem cable. Normally a
modem cable has a male contact in one end and female
contact in the opposite end. The null-modem cable has
normally female contacts in both ends.
Note that they are different connected internally to the
contact pins. Be sure to use the right cable for each
purpose.
N.B. For configuration, see the User manual.
10
Wiring diagram 100-240 V AC
5. Wiring diagram 100-240 V AC
Power supply (see section 4.1):
Power supply, phase, neutral and ground:
100-240V AC, 50/60 Hz. (1, 2, 3)
Analogue inputs (see section 4.3.3):
B Level sensor input, 4-20 mA. (4, 5, 6)
C Current transformer for pump 1/3, 0-1 A AC (7, 8)
D Current transformer for pump 2/4, 0-1 A AC (9, 10)
Digital outputs (see section 4.3.4):
E Start pump 1 (11, 12)
F Start pump 2 (13, 14)
G Start pump 3 (15, 16)
H Start pump 4 (17, 18)
I Common alarm output (19, 20)
J Emergency operation (21, 22)
Operator panel (see section 3.3.1):
K Operator panel 24 V DC (23, 24)
L Communication to operator panel (25)
Power supply (see section 4.1):
M Battery backup 24 V DC (Option) (26, 27)
Digital inputs (see section 4.3.1):
N Motor protector to pump 1. (28, 29). If not used,
jumper the input.
O Start-feedback from pump 1. (30, 31)
Q
R
S
Start feedback from pump 2. (34, 35)
Motor protector to pump 3. (36, 37)..
Start feedback from pump 3. (38, 39)
T
U
V
X
Y
Z
Motor protector to pump 4. (40, 41)
Start feedback from pump 4. (42, 43)
General purpose input 1. (44, 45)
General purpose input 2. (46, 47)
General purpose input 3. (48, 49)
General purpose input 4. (50, 51)
AA General purpose input 5. (52, 53)
AB General purpose input 6. (54, 55)
AC General purpose input 7. (56, 57)
AD General purpose input 8. (58, 59)
U
AD
52 53 54 55 56 57 58 59
t8
e
os
pu
in
pu
rp
al
r
ne
al
G
en
er
G
en
er
AC
G
rp
en
os
er
e
al
in
pu
pu
t5
rp
G
en
os
er
e
in
al
p
pu
ut
rp
6
os
e
in
pu
t7
pu
t4
in
pu
t3
in
os
e
os
e
rp
al
pu
al
AB
AA
Z
rp
in
p
os
e
G
en
er
al
pu
rp
os
e
pu
rp
pu
ut
1
P4
k
ac
ee
db
G
en
er
al
pr
M
M
ct
e
ot
tf
B
ba atte
ck ry
up
ot
or
pr
ot
ec
St
to
ar
rP
tf
1
ee
db
M
ot
ac
or
k
P1
pr
ot
ec
to
St
ar
rP
tf
2
ee
db
ac
k
P2
M
ot
or
pr
ot
ec
St
to
ar
rP
tf
3
ee
db
ac
k
P3
or
ot
4
P
or
Y
44 45 46 47 48 49 50 51
36 37 38 39 40 41 42 43
28 29 30 31 32 33 34 35
X
V
pu
t2
T
S
Motor protector to pump 2. (32, 33)
in
R
Q
P
ar
26 27
O
St
N
M
P
G
en
er
A
pu
e
G
APP 541
A
B
C
10
D
11
12
E
H
N.B. Terminals 6, 8 and 10 are connected together internally.
N.B. Terminals 29, 31, 33.......59 are connected together internally.
N.B. I and J are activatded at normal operation.
11
ne
io
25
24
V
23 24
er
21
22
J
r
er
at
op
nc
y
ge
on
m
19 20
I
l
n
18
m
pu
ar
t
17
G
al
ar
m
p
m
m
pu
ar
t
15 16
D
pe C
ra to
to
rp
a
t
ou
F
4
3
p
2
p
um
tp
13 14
To
O
pa pe
ne ra
l to
9
O
8
Em
7
Co
6
St
5
St
4
ar
Cu
3
St
lS
ve
gn
Le
Si
2
al
V
30
Su
1
5
11
er
Po
w
/2
pp
ly
AC
APP 541
en
so
r
G inp
rr
ND
e
40- n
20
1A t T
r
m
Cu AC ans
A
fo
rr
rm
0- ent
er
1A T
P1
AC ran
/P
sf
3
or
m
e
r
St
P2
ar
/P
tp
4
um
p
1
MIO 501
K
L
Wiring diagram 24 V DC
Wiring diagram 24 V DC
A
Ground (3)
Analogue inputs (see section 4.3.3):
B Level sensor input, 4-20 mA. (4, 5, 6)
C Current transformer for pump 1/3, 0-1 A AC (7, 8)
D Current transformer for pump 2/4, 0-1 A AC (9, 10)
Digital outputs (see section 4.3.4):
E Start pump 1 (11, 12)
F Start pump 2 (13, 14)
G Start pump 3 (15, 16)
H Start pump 4(17, 18)
I Common alarm output (19, 20)
J Emergency operation (21, 22)
Operator panel (see section 3.3.1):
K Operator panel 24 V DC (23, 24)
L Communication to operator panel (25)
Power supply (see section 4.1):
M Power supply 24 V DC input or
Battery backup 24 V DC (Option) (26, 27)
Digital inputs (see section 4.3.1):
N Motor protector to pump 1. (28, 29)
O Start-feedback from pump 1 (30, 31)
Q
R
S
Start feedback from pump 2. (34, 35)
Motor protector to pump 3. (36, 37).
Start feedback from pump 3. (38, 39)
T
U
V
X
Y
Z
Motor protector to pump 4 (40, 41)
Start feedback from pump 4. (42, 43)
General purpose input 1. (44, 45)
General purpose input 2. (46, 47)
General purpose input 3. (48, 49)
General purpose input 4. (50, 51)
AA General purpose input 5. (52, 53)
AB General purpose input 6. (54, 55)
AC General purpose input 7. (56, 57)
AD General purpose input 8. (58, 59)
AD
ut
in
p
se
pu
in
po
ur
lp
a
er
al
en
er
t8
7
in
pu
t6
os
e
rp
o
rp
pu
en
G
G
G
en
er
al
pu
rp
o
se
se
in
pu
t5
4
3
ut
os
e
en
er
al
G
AC
52 53 54 55 56 57 58 59
in
p
2
ut
in
p
os
e
AB
AA
Z
ur
p
ur
p
al
p
er
en
er
en
G
G
os
e
ur
p
G
en
er
al
p
ur
p
os
e
in
p
ut
ut
1
P4
ac
k
db
al
p
G
en
er
pr
M
M
ct
e
ot
fe
e
B
ba atte
ck ry
up
ot
or
pr
ot
ec
St
to
ar
rP
tf
1
ee
db
M
ot
ac
or
k
P1
pr
ot
ec
to
St
ar
rP
tf
2
ee
db
ac
k
P2
M
ot
or
pr
ot
ec
St
to
ar
rP
tf
3
ee
db
ac
k
P3
or
ot
4
P
or
Y
44 45 46 47 48 49 50 51
36 37 38 39 40 41 42 43
28 29 30 31 32 33 34 35
X
V
pu
U
in
p
T
S
Motor protector to pump 2. (32, 33)
al
p
R
Q
P
ar
t
26 27
O
St
N
M
P
APP 541
A
B
8
C
9
10
D
11
12
E
G
18
H
N.B. Terminals 6, 8 and 10 are connected together internally.
N.B. Terminals 29, 31, 33.......59 are connected together internally.
N.B. I and J are activatded at normal operation.
12
op
rm
en
cy
al
a
er
g
m
19 20
21
I
22
J
io
24
n
V
O DC
pe
ra to
to
rp
an
To
el
O
pa pe
ne ra
t
l
or
17
er
at
ou
t
15 16
on
p
ar
t
pu
m
um
ar
tp
F
4
3
p
2
13 14
Em
7
Co
m
6
St
5
St
4
p
V
30
3
pu
m
2
ar
t
11
1
5
Po
w
er
/2
Su
pp
ly
AC
APP 541
St
Le
ve
l
Si Sen
gn
s
al or
Cu
G inp
r
ND
40- ren
20
1A t T
r
m
Cu AC ans
A
fo
rr
rm
0- ent
er
1A T
P1
AC ran
/P
sf
3
or
m
e
rP
St
ar
2/
tp
P4
um
p
1
MIO 501
23 24
K
25
L
Fault tracing
6. Fault tracing
Power on LED does not
light up.
Alarm status LED red.
Is power supply off?
No
Alarm status LED
Red
Yes Check the external
mains switch and
mains fuse or
miniature circuit
breaker.
Check Alarm log menu
Alarm:
High temperature,
P1 - P4
Contact FLYGT service
agent
No
Go to next Alarm.
Yes
Yes
Thermal overload switch in
motor winding has
tripped due to
high temperature.
No
Pump fails to start
No
Contact FLYGT service
agent
Pump is damaged (e.g.
bearing failure, winding
fault); pump impeller is
jammed
Contact FLYGT service
agent
Blocked, displays steady
light (Pump status
indicator, red LED)
Yes
Check that Manual
0-Auto selector is
set to Auto.
If not Manual-0Auto is used,
jumper the auto
input.
Alarm:
Tripped, P1 - P4
Check that Auto is
selected in from P1
Status to P4 Status
menu as
appropriate. Alter if
necessary
External motor
protection has tripped
Thermal overload switch
must be wired as shown in
wiring diagram.
If not used jumper the
input.
No
Go to next Alarm.
Yes
Yes
No
Contact FLYGT service
agent
Alarm:
Max run, P1 - P4
No
Contact FLYGT service
agent
13
Yes
Check external motor
protector .
Pump is running on
two phases
Pump is damaged
(e.g. bearing failure,
winding fault); pump
impeller is jammed
Check start and stoplevels from Start level 1,
Stop level 1 to Start level
4 and Stop level 4 menus
as appropriate.
Check time setting in Max
run time menu and adjust
if necessary.
Pump impeller is
damaged and delivering
insufficient flow.
Level sensor is faulty.
High-level switch or start/
stop switch is faulty.
Specification
7. Specification
Digital inputs
Relay outputs
Analogue inputs
Processor
Battery back-up for the real time clock
Current consumption
Fuses
Rated voltage
Relay output
Rated output for modem
Operating temperature
Storage temperature
Humidity (non-condensing)
Degree of protection
EMC emission standard
EMC immunity standard
LVD electrical safety
Display
Push buttons
Indications
Dimensions control pane (l × w × h)
Dimensions I/O-module (l × w × h)
Weight of operator panel
Weight of I/O-module
Mounting
Terminals
Cable from I/O unit to operator panel
Level sensor types
Total of 16: Pump fault, circuit tripped, start feedback, high level switch,
thermal overload switch, external Manual-0-Auto switch,
external alarm, general purpose
Total of 6: Start pump, common alarm, emergency operation.
Total of 3: Analogue level, 4–20 mA, analogue current CT 0-1 A AC
16-bits Motorola HCS12
3 V Lithium, Battery will normally last for 8 years.
< 50 mA
100/240 V AC: T3. 15 A
24 V DC: 1.1A
100-240 V AC 50/60 Hz or 24 V DC (18 - 36 V DC)
Max. load 240 V AC/2 A
24V DC 180mA (when RTU is powered with 100/240 V AC).
Operating temperature -20° C to + 50° C. The LCD display will respond more
slowly at temperatures below 0° C
-10° C to + 70° C
90 % RH
IP 65 Front, IP 20
EN 61000-6-3
EN 61000-6-2
EN 61010-1
LCD 2 x20 character
8
12 LEDs
220 x 150 x 25 mm
210 x 149 x 47 mm
1 kg
0.9 kg
Cabinet
Signal: 1.5 mm2
Power: 2.5 mm2
Ethernet cable is a crossover UTP RJ 45 cat 5e. The cable length is 1.8 m (max
length 3 m).
External level sensor 4-20 mA
External level regulator ENM-10
14
www.flygt.com