Sulzer ABS CP 112 User manual

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Control Panel Type ABS CP 112/212
EN User Guide
81307017C (11/2014)
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Control panel type ABS CP 112/212, User 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.
Sulzer reserves the right to alter specications due to technical developments.

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Control panel type ABS CP 112/212, User Guide
CONTENTS
About this guide, audience and concepts 4
1 Overview of functions and usage 5
2 Menus: Status and settings 7
2.1 Select language ..............................................................7
2.2 Menus: status information and all settings ..........................................7
3 Technical data and EMC compatibility 11
3.1 Technical data ...............................................................11
3.2 Maximum load ..............................................................11
3.3 Electromagnetic compatibility ...................................................11

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ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS
This guide describes the pump control panels CP 112 ⁄ 212. The difference be-
tween the two products is that CP 112 is intended for one pump whereas CP 212
can control two pumps. CP 112 does not include any circuit breaker, whereas
CP 212 includes a 3-pole circuit breaker for each pump.
Audience This guide is intended for users of control panel CP 112 ⁄ 212. There is a sepa-
rate document Installation Guide that describes how to physically install the
control panel (printed document in the installation package, and also a PDF on
the CD).
Prerequisites This guide assumes that you already are acquainted with those pumps you are
set to control and the sensors connected to CP 112 ⁄ 212.
The control panel can either use an analogue level-sensor, which measures the
water level in the pit, for precise control over start and stop levels, or it can use
simple oat switches placed at start and stop levels. It is also possible to use
only a start oat, and let the pump(s) stop after a certain time or when the meas-
ured phase angle of the motor current indicates that the pump is running dry.
An analogue level-sensor has the advantage over oat switches that it is more
robust (can not get stuck or be mechanically jammed), is more accurate, and is
more exible (you can easily change the start and stop levels). Also, you can get
a reading of the water level in the pit.
Float switches can be used in addition to an analogue level-sensor, as a backup,
and as an additional alarm input.
It is also possible to employ an alternative stop level, usually a lower level than
normal, that is effective once after a number of pump starts. This can be useful if
it is desirable to “completely” empty the pit once in a while.
You need to know if the pump(s) should be exercised in case of long idle periods.
If the installation has two pumps, you need to know if the pumps should alter-
nate.
Reading guide For installation, see the separate document Installation Guide, which covers both
CP 112 ⁄ 212 and CP 116 ⁄ 216. Before you make any settings, or use the control
panel, read Chapter 1 Overview of functions and usage; it describes the general
functionality and the meaning and usage of the controls on the panel. Finally,
make sure that all settings according to Chapter 2 Menus: status and settings
are suitable for your application. The default settings are listed in the Installation
Guide.
Glossary and conventions Text in blue indicates a hypertext link. If you read this document on a computer,
you can click on the item, which will take you to the link destination.
Pump exercising: Long idle periods in a corrosive contaminated environment
are not good for pumps. As a countermeasure, they can be “exercised” at regular
intervals, which will reduce corrosion and other detrimental effects.
Cos φ: Cosine of the phase angle φ between the motor current and the voltage.
About this Guide, Audience and Concepts

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1 OVERVIEW OF FUNCTIONS AND USAGE
CP 112 and CP 212 are control panels for one and two pumps respectively.
These units have the same functionality in terms of their capability to control
pumps and manage alarms — the only difference is that CP 212 is intended for
two pumps whereas CP 112 is intended for one pump.
Figure 1-1 shows the panel. The main view of the two-row display dynamically
shows the pit status (the level in the pit or the status of start oats) and if there
are any alarms. The unit will always revert to this view after 10 minutes of inactiv-
ity in any other view.
Figure 1-1 For each pump (P1 and P2), there is an indicator lamp showing whether the
pump is running (green) or not (red), and below that, a switch that controls whether the
pump is in Auto mode (A), is turned off (0), or you attempt to start it manually (H).
A green lamp at the very left indicates that the unit is powered (either battery or mains).
The red alarm indicator will blink whenever there is an unacknowledged alarm. When the
alarm is acknowledged, the light turns steady red, and remains lit until there are no active
alarms.
The ESC button will cancel or reset the current menu operation, or revert to the main view.
The menu selection knob has two functions: by rotating it in either direction, you scroll and
select menu items; by pressing it, you enter into a menu, conrm a choice/operation, or
acknowledge an alarm.
Power and alarm indicator The two leftmost indicator lamps show:
○ A green light indicates that the unit is powered.
○ The red alarm indicator blinks whenever there is an unacknowledged alarm,
and the display tells you the type of the alarm. When the alarm is acknowl-
edged, the light turns steady red, and remains lit until there are no active
alarms.
Pump switches CP 212 has two switches, CP 112 has one switch, with which you can manually
start or stop the pump(s). It is a 3-way switch with the following functions:
○ The leftmost position (H) is a momentary state, which will attempt to start the
pump, overriding the pump controller.
○ The middle state (A) sets the pump in Auto, which means that the control
panel is controlling the pump.
○ The rightmost state (0) turns the pump off (disables it).
Pump indicator lamps Above each switch, an indicator lamp shows:
○ A green light indicates that the pump is running.
○ A blinking green light indicates: attempting to start the pump.
○ A red light indicates pump failure.
Escape/Cancel The ESC button will cancel or reset the current menu operation, or revert to the
main view.
RS-232 port for a computer
(service port)
Power indicator
Alarm indicator
Manual start / Auto / Off
Pump 1, Pump 2
CP 112: only P1
Indicator lamp for pump (green/red)
Escape / Cancel
Menu selection knob Buzzer
Control panel type ABS CP 112/212, User Guide
2,88 m
Level
No Alarm

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The menu selection knob The menu selection knob has two functions:
● By rotating the knob in either direction, you do one of the following:
○ Scroll through menu items.
○ Change the value of a menu item (the value is either a number or an item in a
list of alternatives; to conrm/save the change, press the knob).
● By pressing the knob, you do one of the following:
○ Enter into a menu.
○ (You will then see a blinking cursor where a value can be changed.)
○ Conrm/save/perform a choice or an operation.
○ Acknowledge an alarm.
○ Turn the buzzer/alarm off (until a new alarm occurs).
When the display shows that there is an unacknowledged alarm, press the knob
to bring up a prompt to acknowledge the alarm, and if you press the knob once
more, it acknowledges the alarm.
When the display shows that there is an active alarm, press the knob to bring up
a list of details about the alarms; rotate the knob to scroll the list. Press ESC to
go back to the main view.
To adjust the contrast To adjust the contrast of the display, press the ESC button and rotate the knob.
To enter values Rotate the knob to the desired value. (A value is either a number or an item in a
list of alternatives.)
Battery backup CP 112 ⁄ 212 includes a charger for a lead-acid battery backup. The battery itself
is optional, and can be installed inside the cabinet. During battery operation (no
230 V power), the pump relays are always off. The power indicator will remain
on, and the alarm indicator will be on. The alarm relay will function according to
the setting in Table 2-2 (Func Alarm Relay).
Chapter 1 Overview of Functions and Usage

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2 MENUS: STATUS AND SETTINGS
This chapter describes all settings that need to be properly set before the pump
controller is used. How to use the menu selection knob to enter and save values
is described in Chapter 1 Overview of functions and usage. The default settings
are listed in the Installation Guide.
2 .1 Select language
1. Rotate the menu selection knob anticlockwise one step (or until you see the
menu item Select Language).
2. Press the knob.
3. Scroll to the desired language by rotating the knob.
4. Press the knob to save the choice.
2.2 Menus: status information and all settings
The rst clockwise items are only intended to show the current status.
Table 2-1 shows these items. The other menu items are settings you can make.
Table 2-2 shows all those items.
The menu system adapts dynamically to show only those items that currently are
“usable”; for instance, if Sensor Type is set to Start/Stop oat rather than Analogue, you
will not see the menu items for setting start and stop levels. Likewise, the menu
on CP 112 will not show items related to pump 2.
Table 2- 1. Menu items that show current status, sorted clockwise
Menu item Value
Pit status The main view, which shows the pit status (the level in the pit or the status of start oats)
and alarm status.
Current P1
The electric current and its phase angle.
Cosine φ P1
Current P2
Cosine φ P2
Run. Time P1 The accumulated running time of the pump.
(This value can be edited.)
Run. Time P2
No. Starts P1 The accumulated number of times the pump has started.
(This value can be edited.)
No. Starts P2
Back-Pressure The current value of the back-pressure (if such a sensor is used).
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Table 2- 2. Settings, sorted clockwise (Sheet 1 of 2)
Menu item Value Comment
Sensor Type
{Analogue,
Air Pressure,
Start/stop oat}
Choose method of level control: an analogue level-sensor or
start/stop oats.
Scaling 100%= Value in m/ft/bar
If Sensor Type is Analogue or Air Pressure.
For Unit , select the unit you will use for scaling. (For ft, you get
foot with decimals, not foot/inch.)
Scaling 0%= Value in m/ft/bar
Unit {m, ft, bar}
Filter Seconds
High-Level Alarm Chosen unit
Low-Level Alarm Chosen unit
Start Level P1 Chosen unit
Stop Level P1 Chosen unit
Start Level P2 Chosen unit
Stop Level P2 Chosen unit
Start Criteria {2 start oats,
1 oat + time}
If CP212, and Sensor Type is Start/stop oat.
Unless Start Criteria is 2 start oats, the second pump will start
Time to Start seconds after the (single) oat is triggered.
Time to Start P2 Seconds
Stop Criteria
{Stop oat,
Time,
Delta cos φ
Cos φ or Time}
If Sensor Type is Start/stop oat.
If Stop Criteria is Time , a single pump will stop Time to Stop seconds
after the start oat releases, whereas two running pumps will
stop after half that time.
If Stop Criteria is Delta cos φ , the pump(s) will stop when cosine of the
phase angle φ has changed Delta cos φ . See noteifor details.
f Stop Criteria is Cos φ or Time , both criteria described above are
used, whichever is achieved rst.
Stop Float NO/NC {Normally open,
Normally closed}
Time to Stop Seconds
Delta cos φ Value 0 –1
Func. Back-Press.
{Off, Block Pump,
Only Alarm,
Alarm + Block.}
If a back-pressure sensor is connected (mA input 2).
Scaling 100%= Value in m/ft/bar
Scaling 0%= Value in m/ft/bar
Hi Pressure Lim Value in m/ft/bar
Alternation {Off, Both stopped,
Each pump stop
Unless
Off , it will switch to the other pump, either after each
pump stop, or after both pumps have stopped.
Max Run. Pumps {Max 1 pump,
2 pumps}
If 2 pumps would consume more power than available fuse, set
it to run maximum 1 pump.
Pmp 2 Connected? {Yes, No} CP 212: If set to
No , menus will be simplied.
Start Delay Seconds To suppress spikes and noise, triggered thresholds from sen-
sors can be required to persist for a certain time before a state
change is accepted.
Stop Delay Seconds
Alternative Stop Level {On, Off}
If alternative stop level is employed.
The Alternative Stop Level , usually a lower level than normal, is effec-
tive once every Starts to Alt . number of pump starts.
By setting an Alt Stop Delay , the actual level at which the pump
stops will be even lower. (Any low-level alarm or low-level oat
is blocked, but a dry-run detect will still block the pump.)
Starts to Alt. Integer
Alt. Stop Level Chosen unit
Alt. Stop Delay Seconds
Chapter 2 Menus: Status and Settings

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Table 2- 2. Settings, sorted clockwise (Sheet 2 of 2)
Menu item Value Comment
Nominal Curr. P1 Amperes
CP 112 ⁄ 212 has a current transformer for each pump.
Note: It is important to set
Nominal Curr . to the reading you get in
normal conditions! If left at zero, it disables all pump blockings
and alarms related to current or phase loss.
The setting in
Dry Run Detect , determines if the Low Current or Delta cos
φ
is shown. Set a value that indicates that the pump is running
dry.
If
Low Current is selected, the pump will be blocked when the
current is < Low Current . If Delta cos φ is selected, the pump will be
blocked when cos φ changes more than Delta cos φ .
If D
ry Run Reset is > 0, the dry-run alarm will be reset (and the
pump deblocked) after that time.
Dry Run Det. P1 {Off, Low current,
Delta cos φ}
Low Current P1 Amperes
Delta cos φ P1 Value 0 –1
Nominal Curr. P2 Amperes
Dry Run Det. P2 {Off, Low current,
Delta cos φ}
Low Current P2 Amperes
Delta cos φ P2 Value 0 –1
Dry Run Reset Minutes
Curr Alarm-Delay Seconds
P1 Backup Start {On, Off}
If set to
On , and the high-level oat turns on, the pump(s) will run
for a period of Backup Run Time after the oat has turned off.
P2 Backup Start {On, Off}
Backup Run Time Seconds
Exercise P1 {On, Off} Can “exercise” the pumps if they have been standing still for
Max
Still Time . If the current level is below the stop level/stop oat, the
pump(s) will run for Exercise Time , otherwise, the pump(s) will run
until stop level/stop oat is reached.
Exercise P2 {On, Off}
Exercise Time Seconds
Max Still Time Hours
Leakage Mon. P1 {Off, Normal,
Block pump} Leakage monitor. With
Normal , an alarm will be issued when the
leakage monitor conducts, but the pump will not be blocked.
Leakage Mon. P2 {Off, Normal,
Block pump}
Temp. Monitor P1 {Off, Man reset,
Auto reset}
Temperature monitor, usually a PTC element. When the
temperature exceeds the element’s threshold, the pump will
be blocked. With
Auto reset , the alarm (and blocked state) will be
reset when the temperature goes down again. With Man reset , it
must be manually reset.
Temp. Monitor P2 {Off, Man reset,
Auto reset}
Panel Buzzer {On, Off} If
On , a buzzer will sound according to Alert On-Time and Alert Pause
Time , described below under Func Alarm Relay set to Alarm alert .
Backlight Time Minutes A value of zero means that the backlight will always be on.
Func Alarm Relay
{Alarm alert,
High level,
Active alarm}
If set to
Alarm alert , the relay will switch as follows:
It switches to active alarm if one or more alarms occur, and
remains active for
Alert On-Time , turns off for Alert Pause Time and
then repeats. It turns off (inactive) if you press the menu selec-
tion knob or the alarm disappears. If Alert On-Time is zero, there is
no pause.
If set to
High level , it will be active as long as the level is too high
(either high-level oat or analogue sensor).
If set to
Active alarm , it will be active as long as there is an active
alarm.
Alert On-Time Minutes
Alert Pause Time Minutes
Password {On, Off} If the setting is changed, you must enter the current password.
The default password is 2.
If you have forgotten the password, contact the distributor to
unlock the controller.
Change Password Integer
Station Id Integer
CP 112 ⁄ 212 Ver Version
Select Language Select a language
i. Cos φ is measured about 5 seconds after the pump has started. If either Stop Criteria or Dry Run Detect is set to
Delta cos φ, then the measured value, subtracted by the chosen Delta cos φ, is the threshold that will stop the
pump. If both functions are active, please set Delta cos φ for the Stop Criteria lower than Delta cos φ for the Dry Run
Detect — the pump will then stop without Dry Run Detect issuing an alarm.
{
{
P1
P2
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Chapter 2 Menus: Status and Settings

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Control panel type ABS CP 112/212, User Guide
3 TECHNICAL DATA AND EMC COMPATIBILITY
3.1 Technical data
Ambient operating temperature: –20 to +50 °C
Ambient storage temperature: –30 to +80 °C
Cabinet and mounting: DIN rail, IP65. Mounting holes: see gure
Dimensions: H x W x D: 370 x 250 x 123 mm
Weight: < 5 kg, CP 212 with battery
Humidity: 0–95 % RH non-condensing
Power supply: 230/400 V AC, maximum 16 A fused
Power consumption: < 16 VA
Contactor, max load: ABB B7-30-10, 5.5 kW, 12 A, coil 24 V AC
Fuses (only CP 212): 3 x10 A 3-pole type D circuit breakers
Fuse for external air pump: 500 mA slow blow
Max load on alarm relays: 250 V AC, 4 A, 100 VA resistive load
Max current from 12 V DC out: 50 mA
Input voltage at Digital In and Block Pump: 5–24 V DC
Resistance at Digital In and Block Pump: 5 kohm
Analogue sensor: 4–20 mA
Analogue input resistance: 110 ohm
Temperature sensor: PTC, limit: 3 kohm
Leakage sensor: Limit: 50 kohm
Maximum length of I/O cables: 30 meters
Charge for lead-acid battery: Max 80 mA, 13.7 V DC
3.2 Maximum load
CP 112 Since it does not have fuses, it is only limited by the contactor. Maximum load is
5.5 kW, 12 A at 400 V AC.
CP 212 This version has two fuses. Maximum load is 3.5 kW, 7.5 A at 400 V AC if both
pumps can run simultaneously. If set so that only one pump may run (menu item
Max Run. Pumps set to 1), a higher load is permitted: maximum load is limited by
the fuses, which means about 4.3 kW, 9.5 A.
3.3 Electromagnetic compatibility
Description Standard Class Level Remarks Criteria i
Electrostatic discharge
immunity (ESD) EN 61000-4-2 415 kV Air discharge B
48 kV Contact discharge B
Fast transient/burst
immunity EN 61000-4-4 4 4 kV A
Surge immunity 1.2 ⁄ 50 µs.
See note ii EN 61000-4-5 4 4 kV CMV A
4 2 kV NMV A
Immunity to conducted
disturbances, induced by
RF elds
EN 61000-4-6 310 V 150 kHz – 80 MHz A
Immunity to radiated RF
elds EN 61000-4-3 310 V/m 80 MHz – 1 GHz A
Immunity to short interrup-
tions and voltage variations EN 61000-4-11 A
i. Performance criteria A = Normal performance within the specication limits.
Performance criteria B = Temporary degradation or loss of function or performance that is self-
recoverable.
ii. Maximum length of I/O cables is 30 meters.
180mm
5.5x9mm
295mm

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