Sulzer ABS PC 441 User manual

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MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2013.08.21 05:56:19 Low level
 980.3 l/s
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CA 511
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CA 443 CA 781
CAN
CA 622
RX/TX
ON-OFF
485-term.
0V -485 +485
678
A B
V+ H Shld L V-
1235 4
CAN Bus
www.sulzer.com
Pump controller type ABS PC 441
EN User guide SW 1.70
81307063I (02/2019)

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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 specications due to technical developments.

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CONTENTS
ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS 1
1 OVERVIEW OF FUNCTIONS AND USAGE 3
1.1 Field bus status indicator ................................................. 4
1.2 CA 511 operator panel ................................................... 4
1.2.1 Status view ............................................................ 6
1.2.2 How to access the status view ............................................. 6
1.2.3 Pump alarms under status view ............................................ 7
1.2.4 Trend curve ............................................................ 7
2 CONFIGURE THE PC 441 9
2.1 Setgeneralconguration,system,IDandcommunicationsettings . . . . . . . . . . . . . . . . . 9
2.2 Congurethedigitalinputs,digitaloutputs,analoginputsandanalogoutputs ....... 11
2.3 Conguretheeldbusunitmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Congurethepumppitparameters ........................................ 14
2.5 Settings for pump 1 to pump 4 and their alarms ............................... 16
2.6 Common P1 – P4 ...................................................... 18
2.7 Set log settings and events............................................... 19
2.8 IfusingCA622;setupcommunicationstosurroundingunitsVFD,softstartersand
energymeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.9 Setupcleaner,mixerordrain(ifused) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 DETAILED DESCRIPTION OF THE FUNCTIONS 21
3.1 Pump controller and/or monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Pumpcapacityandin/outowofthepit ..................................... 22
3.2.1 Pit shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2.2 Pump curve........................................................... 32
3.2.3 Systemcurve ......................................................... 33
3.2.4 Energye󰀩ciency:kWh/volumeunit ........................................ 34
3.3 Overowowcalculation ................................................ 35
3.3.1 Howtocalculateoverowsbyusingconstantsandexponents ................... 36
3.4 Pump alternation....................................................... 36
3.4.1 Maxnumberofpumpsrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5 Pump reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5.1 Othersettingsregardingpumpreversing:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Speedcontrolledpumps(VFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6.1 CongurePC441forVFDpump(s) ........................................ 40
3.6.2 PIDsettings........................................................... 41
3.6.3 Variablefrequencydriveautoreset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 FURTHER EXPLANATIONS ABOUT SOME DIGITAL/ANALOG OUTPUT/INPUT
TYPES 43
4.1 Logic IO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Digitaloutputtype:datareg.setpoint ...................................... 44
4.3 Analogoutputtype:dataregister .......................................... 45
4.4 Mixerprestart ......................................................... 45
4.5 Mixeranddrainpumpblocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 Digitalout:externalresetalert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7.1 Com port (screw terminals 48 – 52) ........................................ 46
4.7.2 Serviceport(9-polsD-Subinthefront) ..................................... 46
4.7.3 USBport(USBtypeBinthefront) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7.4 Modem .............................................................. 46
4.7.5 Com Echo PC 441 ..................................................... 47

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4.7.6 Alarms............................................................... 48
4.8 AquaProg ............................................................ 48
4.8.1 How to set up AquaProg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.9 Cross reference table ................................................... 49
5 SETTINGS 51
5.1 Select language ....................................................... 51
5.2 Overview of settings .................................................... 51
5.3 Systemsettings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.4 Pump pit settings ...................................................... 54
5.5 Pump 1 to 4 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.6 Commonsettingsforpump1,2,3and4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.7 SettingsforPIDcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.8 Settingsformixer ...................................................... 65
5.9 Drainpump ........................................................... 65
5.10 Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.11 Analog logging ........................................................ 66
5.12 Settings for digital inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.13 Settings for digital outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.14 Settings for analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.15 Settings for analog outputs ............................................... 69
5.16 Settings for pulse channels............................................... 71
5.17 Settings for trend curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.18 Communication settings ................................................. 72
5.19 Settingsforeldbusmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.20 Common settings ...................................................... 77

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ABOUTTHISGUIDE,AUDIENCEANDCONCEPTS
This guide describes the pump controller PC 441 and the operator panel CA 511. The pump controllers can ei-
therbeusedstand-aloneorcommunicateallvaluesandconditionstoacentralScadasystemorawebbased
alarmandmonitoringsolutionlikeAquaWebfromSulzer.
Installation guide There is a separate document Installation guidethatdescribeshowtophysicallyinstallthepumpcontroller
(printeddocumentintheinstallationpackage,andalsoaPDFonSulzerweb).
Audience ThisguideisintendedforsystemadministratorsandoperatorsofPC441pumpcontrollerwithoperatorpanel
CA 511 or PC program AquaProg.
Prerequisites Thisguideassumesthatyoualreadyareacquaintedwiththosepumpsyouaresettocontrolandhavethesen-
sors and operator panel CA 511 connected to PC 441.
Thesystemadministratormustalsoknowanddecideonthefollowing:
1. Thepumpcontrollercaneitheruseananalog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.
• Floatswitchescanbeusedinadditiontoananaloglevel-sensor,asabackup,andasanad-
ditional alarm input.
• Ananaloglevel-sensorhasseveraladvantagesoveroatswitches:itismorerobust(cannotget
stuckorbemechanicallyjammed);itismoreaccurate;itismoreexible(youcaneasilychange
thestartandstoplevels);youcangetreadingsofthewaterlevelinthepit,theinow,overow
andthepumpcapacity;youcanoptimisethepumpperformanceinvariousways,includingexer-
cising,alternativestoplevels,tari󰀨controletc.
• Itisalsopossibletoemployanalternativestoplevel,usuallyalowerlevelthannormal,thatis
e󰀨ectiveonceafteranumberofpumpstarts.Thiscanbeusefulifitisdesirableto“completely”
emptythepitonceinawhile.
2. Youneedtoknowifthepump(s)shouldbeexercisedincaseoflongidleperiods.Iftheinstallationhastwo
pumpsormore,youneedtodecideifthepumpsshouldalternate.
3. Iftheelectricityhasdailyvaryingtari󰀨s,youmustknowthetimesofhigh/lowtari󰀨s.
4. Youmustknowhowoverowwillbemeasured:ifitwillbemeasuredusingbothanoverowdetector(tode-
tectthestartoftheoverow)andalevelsensor(tomeasuretheactualow),youmustknowtheparameters
(exponentsandconstants)tobeenteredassettingssothattheoverowcanbeaccuratelymeasuredbya
calculation in PC 441.
5. Youneedtoknowwhichalarmclass,A-alarmorB-alarm(seeGlossaryandconventions),toassigneach
alarm.
Reading guide Forinstallation,seetheseparatedocumentsInstallation guidesforrespectiveproduct,PC441,CA511,
CA44x,CA622andCA781,whichcanbefoundonSulzerhomepage.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.
Thesystemadministratormustensurethatallsettingsaccordingtochapter 5 Settingsaresuitableforyour
application.
NOTE! The default settings are listed in the Installation guide.

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Text appearing and declaration in this guide
TextinitalicisadescriptionoftextinthedisplayofCA511oradescriptionhowyoundyourwaythroughthe
menusbykeystrokes.Textsinbold,ishowyouhavetodoachangeofthesettingsintheCA511menu.
Most settings in chapter 5onlyapplytothesystemadministrator,butthefollowingalsoapplytothosewhoonly
operatethecontroller:languageselection,dateandtimesettings,units,backlighttime-out,buzzer,operator
passcode,start/stoplevels.
Glossary and conventions
Todesignateamenuiteminahierarchy,ananglebracketisusedtoseparatethelevels.Example:Settings
>SystemmeansthemenuitemyoureachbyrstchoosingthemenuitemSettings,whichhasanumberof
submenus,whereyouchoosethemenuitemSystem.
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
e󰀨ects.
Cos j:Cosine of the phase angle jbetween the motor current and the voltage.
Alarm class: The alarm class can be either A-alarm or B-alarm. A-alarms are those that require immediate ac-
tion,sooperationalsta󰀨intheeldshouldbealertedregardlessofthetimeofday.B-alarmsarelessimpor-
tant,butshouldbetakencareofduringnormalworkhours.
Digital in means a signal that is either on or o (high or low),wherehighisanythingbetween5and24volts
DC,andlowisanythingbelow2volts.
Digital output An output signal that is either on or o.
At onconditionoutputcurrentissourcedfromthepowersupplyandtheoutputishigh(~V+).Ato condition
the output is low (no output current).
Aretypicallyconnectedtorelays.
Analog outputs An output signal in the range 4-20 mA or 0-20 mA.
Sourcedfrompowersupply.
Analog inputsareforsensors,andtheseinputssensecurrentintherange4-20mAor0-20mA.

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1 OVERVIEWOFFUNCTIONSANDUSAGE
PC 441 is designed to control 1-4 pumps. It can operate a pump station stand alone and/ or as a pump monitor.
ForcongurationandoperatorinteractionthegraphicoperatorpanelCA511maybeused.WiththeAquaProg
software(evaluationversionavailable)aPCcanbeusedforcongurationandbackupofsettings.Byadding
amodem,afullremotealarmandmonitoringsolutioncanbeachievedwithjustanAquaWebrentalcontract
orbymostSCADAsystems.Optionalmonitoringmodulesforleakage,temperatureandelectricalparameters
givesahighlyscalablesolutionforoptimalcostandperformance.
ThePC441canworkstandaloneortogetherwithextensionmodules,buttheextensionmodulescannotwork
without the PC 441.
.
As a pump monitoring devicethePC441o󰀨ersthemarketacombinedstandardsolutionforsubmersible
pump and pump station surveillance. Can be set up for full-scale monitoring of one or up to four submersible
pumps plus ancillaries.
As a pump controllerthePC441controlsthestart/stopofthepumps,o󰀨eringastandardizedsolutionfor
sewagepumpstationswithuptofourpumps.Avarietyofsolutionsfromstandardon/o󰀨controluptoad-
vancedVFDsupportincludingpumpcapacitycalculation.
As a combined control and monitoring devicethePC441canbeo󰀨eredasasolutionsupportingboththe
areas above in a single unit.
Modules:
1. CA 511 - Graphical operator interface
Max 1 of this unit per system
2. CA 622 - RS 485 Communication interface module
Max 1 of this unit per system
3. PC 441 - Pump monitoring and/or controller
4.CA781-Analoganddigitaloutexpansionmodule
Max 1 of this unit per system
5. CA 441 - Moisture monitoring module
Max 4 of this unit per system
6. CA 442 - Temperature monitoring module
Max 6 of this unit per system
7.CA443-Motorandsupplypowermonitoringmodule
Max 5 of this unit per system
PC 441 is the heart
ofthesystem!Other
modules are optional.
1.
2. 3. 4.
5. 6. 7.

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8.Sulzerwirelessmodem
Max 1 unit per system
Thebaseunit,PC441,communicateswiththeextensionmodulesviaCANcommunication.
Seetheinstallationguidehowtoconnecttheextensionmodules.Afullyextendedsystemcanlooklikethis:
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)
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.
1.1 Field bus status indicator
Pumpcontroller,operatorpanelandmonitoringmodulescommunicatesviaaCANbus.
Fixedgreenlight=connectedOK
Flashinggreenlight=searchingformodules
Flashingredlight=InvalidIDsetonmodule
1.2 CA 511 operator panel
Younavigatethemenusbythearrowbuttons.PresseithertheUp or Down arrow button to switch to the menu
view.YouconrmanoperationwiththeEnterbutton,oracknowledgeanalarm.PressingtheEscape button
will cancel the current operation.
Figure 1-2
0 A
1.30 m
0.50 m

1.50 m 0.55 m

1.70 m 0.60 m

1.90 m 0.65 m


352.5 A 353.8 A 354.1 A
1.55 m
1827 l/s
3.8 bar
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2019.01.23 05:56:19 Low level
 980.3 l/s
m
P3 P4
P1 P2
3
0
07:25:58 07:28:10 07:30:26
0.15 kWh/m3
Height of water in pit
Overflow detector
Inward flow to pit
Trend curve
Shows operation
(animated)
Height of water
(animated)
High-level float sensor
Low-level float sensor
Outward flow from pit
Back-pressure
Current consumption for pump
Total pump efficiency
Start / Stop levels
Thedisplayanditsinformationeldsinthedefaulttop-levelview.
Upto4pumpsvia16Din,16Dout,5Ain,4Aout
3 moisture and 5 temperature inputs per pump
Temp L2 & L3
-> CA 511
Station P1 P2 P3 P4 P1 P3
P2 P4

81307063I
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Thedefault(top-level)viewofthedisplaydynamicallyshowstheoperatingstatusofthepumpsandconditions
in the pit. Figure 1-2showsthesymbolsandexplainstheirmeanings.Theunitwillalwaysreverttothisview
after10minutesofinactivityinanyotherview(suchasshowingmenus).
WhenPC441issettouselessthan4pumps,theviewadaptstoshowactualnumberofpumps.
Power and alarm ThetwoleftmostsymbolsontheCA511panelareforpowerandalarmindication:
indicator
• Buttons at bottom gives direct access to the most common
menus.
• Bottomrightmost“Ackn.”.Buttonwillacknowledgethemostcur-
rentalarmdisplayedonstatusrowattopofdisplay.
• Right buttons will start or stop the pump. (Toggle actual state.)
Bykeepingbuttonpressed,forcedpumprunbelowstoplevelis
possible.
Right-hand buttons Thebuttonstothelowerrightofthedisplayhavethefollowingfunctions:
• To leave the overview image of the pump pit and go into the
menus,presseithertheUp or Down arrow button.
• Yougo“into”amenuitembypressingeithertheRight/Forward
button or the Enter button.
• Youconrm(orperform/execute)anoperationwiththeEnter
button (  ).
• Toexitthecurrentoperation,orleavethemenusandgobackto
overviewimageofthepumppit,presstheEscape button.
Main menu Figure1-3showstheMainmenu,whichyoureachfromtheoverviewimagebypressingeithertheUp or Down
 arroworshortcutkeyMainbelowdisplay:
Main Menu Manual Control
Manual Control Pump 1
Alarm List Pump 2
Show Status Pump 3
Settings Pump 4
Select Language Mixer
Drain Pump
Cleaner
Remote Blocking
Esc  
Figure 1-3 Thetop-levelmenuofthePC441graphicaldisplay.
Howtoselectlanguageandmakeallsettings(menuitemsSelect language and Settings) are described in
chapter 5 Settings.
How to enter values Press Enter to enable editing of a value.
and strings
0 A
1.30 m
0.50 m

1.50 m 0.55 m

1.70 m 0.60 m

1.90 m 0.65 m


352.5 A 353.8 A 354.1 A
1.55 m 1827 l/s
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2013.08.21 05:56:19 Low level
 980.3 l/s
m
P3 P4
P1 P2
3
0
07:25:58 07:28:10 07:30:26
0.15 kWh/m3
Esc
8
tuv
7
pqrs
9
wxyz
0
*#
5
jkl
4
ghi
6
mno
2
abc
1
,.
3
def
Use the Left/Right buttons to choose the insertion point.
Use the Up/Down buttons to increase/decrease a value or letter.
Values and strings can also be altered through the alphanumeric
keyboard.
Anasterisk(*)gives=adot(.).
Finishtheeditingbypressingenter.
Esc
8
tuv
7
pqrs
9
wxyz
0
*#
5
jkl
4
ghi
6
mno
2
abc
1
,.
3
def
• GreenlightisthepowerLED.
• Theredalarmindicatorasheswheneverthereisanunacknowledgedalarm,andthedisplaytells
youthetypeofthealarm.Whenthealarmisacknowledged,thelightturnssteadyred,andremains
lituntiltherearenoactivealarms,thisfunctionsthesameasthePC441alarmindicatorLED.
Direct functions,   Thebuttonsatthebottomandtotherightofthedisplayhavethefollowingfunctions:
bottom and right
displays

81307063I
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Passcodes  Therearethreesecuritylevels:
1. Dailyoperations,suchasacknowledginganalarmorstoppingapump,donotrequireanypasscodeor
authorization.
2. Operationalsettings,suchassettingthestartorstoplevelsforthepump,requireapasscodeatthelevelof
Operator;
3. Congurationsettingsthata󰀨ectthebasicfunctionalityoraccess,suchasthetypeoflevelsensor,require
a passcode at the level of System.
Thefactorydefaultpasscodesare1and2respectively,butthecodescanbechangedunderthemenuitem
Settings > System.WheneverapasscodeforOperatorisrequested,youmaysupplyeitherthepasscodefor
OperatororSystem.
Personal alarm,
and how to reset it  Whenthepumpstationismanned,apersonalalarmcanbeissuedifthemaintenancepersonhasn’tshown
activitywithinacertainperiodoftime.Fordetailsaboutsettingsrelatedtothis,seesection5.3Systemset-
tings (assigning Alarm type, Alarm delay and Max time to reset),section 5.12 Settings for digital inputs (as-
signing Sta in stationtoaDigitalin),andsection 5.13 Settings for digital outputs (assigning Personal alarm
alert to a digital output).
AfterthespeciedMax time to reset,theassignedoutputisactivatedsoavisualoraudiosignalcanalert
the maintenance person that the alarm timer must be reset. If the alarm timer is not reset within Alarm delay,a
personal alarm is sent out.
Toresetthetimer,justpushanybuttononthecontrolpanel.
1.2 .1 Status view
One of the useful functions in PC 441 is Status view. In the status view shows Pump running time, Number of
starts, Capacity and Energy consumption.InthosecasesthereCA441,CA442andCA443areinthesystem,
youwillbeabletoseeTemperaturesinthedi󰀨erentbearings,monitoringtheVibrations,Power absorbed and
Motor current.YouwillalsoseethepowersupplyvoltageL1 – L3iftheisaCA443inthesystem.Allthepump
alarms will show up here in the graphic.
Pump Running Time
Number of Pump Starts
Pump Capacity
Energy Consumption
Temp. Upper Bearing
Temp. Stator
Temp. Lower Bearing
Vibrations
Power absorbed
Motor Current
L1-2 406 V L2-3 406 V
588 h
2940
609 l/s
115248 kWh
68 ˚C
79 ˚C
70 ˚C
2.7 mm/s
196 kW
353.2 A
L3-1 401 V
Total
P1
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2011.06.23 05:56:19 NO UNACK ALARMS
Figure 1-4 Status view
1.2.2 How to access the status view
Statusviewiseasytobeaccessedbypushingthe“Status”belowthedisplay,andthen“Pump 1”–“Pump 4”
ontherightsideofthedisplay.Seepicturebelow.
Pump Running Time
Number of Pump Starts
Pump Capacity
Energy Consumption
Temp. Upper Bearing
Temp. Stator
Temp. Lower Bearing
Vibrations
Power absorbed
Motor Current
L1-2 406 V L2-3 406 V
588 h
2940
609 l/s
115248 kWh
68 ˚C
79 ˚C
70 ˚C
2.7 mm/s
196 kW
353.2 A
L3-1 401 V
Total
P1
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2011.06.23 05:56:19 NO UNACK ALARMS
2
1
Figure 1-5 How to access Status view

81307063I
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It’spossibletousetheleftandrightarrowkeysatthenumeralkey
board to step to the other pumps.
Use up and down arrowstostepbetweendays.
Upto7daysbackcanbedisplayed.
LeavetheStatusviewbyESC.
1.2.3 Pump alarms under status view
If the Field bus modules CA 441 and CA 442areattachedtothePC441andpumpalarmsappears,when
under Status viewyouwillbeabletoseeanindicationwherethefaultisphysicallylocatedinthepump.
Motor protector Pump
or other general Pump
failures from PC 441
DI 2 Electric Area
DI 3 Motor Housing
T3 Hi Temp Lo. Bearing
T1 Hi Temp Stator /
T4 Hi Temp Stator
(T1 & T4 share the same
alarm numbers)
Stator temperature L2 - L3 with
additional CA 442
T2 Hi Temp Up. Bearing
DI 1 Oil Chamber /
or Leakage Pump
from PC 441
Figure 1-6 Pump sensor indications in Status view
Esc
8
tuv
7
pqrs
9
wxyz
0
*#
5
jkl
4
ghi
6
mno
2
abc
1
,.
3
def
How to access Trend curve
1.2.4 Trend curve
Another useful function in PC 441 is Trend curve.Hereyoucangetanoverviewofpitlevel,inowandoutow
oranyotherparameteryouchooseovertime.Fourdi󰀨erenttrendcurvescanbedisplayedatthesametime.
Thereisalsoapossibilitytoadjusttheintervalsamplingforthecurves.Defaultsettingis1samplepersecond.
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
P3 P4
P1 P2
m
l/s
l/s
2
300
400
10
0
0
0
0
12:42:24 12:44:24 12:46:24
Figure 1-7 Trend curve

81307063I
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To get a presentation of the curve titles in the menu Trend curve,thenpushEnterthenyouhavetheTrend
curvepictureonthedisplay,thepicturewillappearwiththedescriptionasbelow:
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
P3 P4
P1 P2
m
l/s
l/s
2
300
400
10
0
0
0
0
12:42:24 12:44:24 12:46:24
[Pit Level]
[Pit Inflow]
[Outflow]
[Closed]
Figure 1-8 DescriptionofthecurvesinTrend curve
The presentation will disappear after a few seconds.
One screen of Trend cur ves covers 300 samplings and that corresponds to 5 minutes in default settings of 1
second.

81307063I
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2 CONFIGURETHEPC441
Overview of settings
Eachstationhasanuniquecongurationsetup,buttheprocedureissimilartosetupthese.Thischapterwill
guideyouthroughthebasicsettingsinPC441.Note:Thisdoesnotcoverallcongurations,youmustconsider
yourprerequisites.
The menu item Settingshas21submenuswithmanysettingsthatneedtobeenteredbythesystemadmin-
istrator(althoughtheyallhavesensibledefaultvalues).Thefollowing9notesbelowarearecommended
procedure to setup PC 441.
2.1. Setgeneralconguration,system-andcommunicationsettings
2.2. ConguredesignatedIOfunctionsatDI,DO,AIandAOaccordingtotheelectricalwiringdrawing
2.3. CongureI/Omodules,CA441,CA442,CA443,CA622,CA511andCA781
2.4. Pump pit parameters and alarms
2.5. Set pump 1 - 4 settings and their alarms
2.6. Common P1-P4
2.7. Set log settings and events
2.8. Setupcommunicationstosurroundingunits(VFD,softstartersand/orenergymeters(ifused)
2.9. Setupcleaner,mixerordrain(ifused)
Each of the 21 submenus under settings are described in separate tables in section 5.
To enter the settings area:
Press down arrowonceandyouareinthemenus,continuetopressdownarrowtoSettings,pressEnter.
ThemajorityofsettingsrequireapasscodeforSystemexceptsomesettingsunderthesub-menuSystem and
the start/stop levels under submenus Pump 1-4whichonlyrequireapasscodeforOperator.
AllthesettingscanbedonelocallyformthemenusorbyAquaProg.TheadvantageofAquaProgisyoucan
savethecongurationatyourPCandeasilyrestorethecontrollerifneeded.
2.1 Setgeneralconguration,system,IDandcommunicationsettings
SetupthebasicsystemparametersandcommunicationparametersbyusingthemenusinCA511:
Basic system parameters
• Fromthebasescreen,pressthekeyforSettingunderthedisplay,pressEntertwiceandgivethe
password (default 2).Scrollontheleftpartofthescreentoyourlanguagebyusingtheup/down
arrowkeys,pressEnteratyourchoice.
• UsethedownarrowkeytoStation application and press Enter. Select Pump controller or Pump
monitor byusingtheup/down arrow in the left part of the screen, pressEnteratyourchoice.Use
thedownarrowkeytoMain graphics and choose the base screen (Pump pit statusoranypump)
• UsethedownarrowkeytoSelect units,metricorUSunits,pressEnteratyourchoice.
• UsethedownarrowkeytoDate format,pressEnter.Chooseyourdateformat.
• UsethedownarrowkeytoSet date,Set time,andallothersettingsunderthisparameter.
• Set System alarmsaccordingtoyourpreferences.

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Communication parameters
• Fromthebasescreen,pressthekeyforSettingunderthedisplay,scrolldownbyusingthedownar-
rowkeytoCommunication and press Enter. Press enter again and select Protocol (Modbus/Comli/
ModbusTCP)andpressEnteratyourchoice.Pressleftarrowkeytogobacktotheleftpartofthe
screen. Use the down arrow to Com port and press Enter. Select Station ID,PressEnter.Typein
yourStation IDbyusingnumeralkeysorup/downarrowkeys,requiredforAquaWeboranyother
surveillancesystem.SelectBaudrate,Parity and Handshake.Usetheleftarrowkeytogobackto
the left part of the screen and select Service port,pressEnter.SelectBaudrate for the service port.
• Selectmodemtype
Nowit’spossibletoconnecttoAquaProgthroughserviceportorUSB.
In AquaProg:
Figure 2-2 Communication
Figure 2-1 Systemsettings

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2.2 Congurethedigitalinputs,digitaloutputs,analoginputsandanalog
outputs
SetdesignatedIO-functionsaccordingtotheelectricalwiringdrawing.Seeyourdrawingsofthestation.
Under Settings, Digital inputs; choose for each input according to table 2-1 and Digital outputs to table 2-2.
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,chooseforeachinputaccordingtotable2-3.Analoginput1isxedtoleveland
cannot 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
Outow meter
Note
 Analog1ispredenedtolevelsensor
and cannot be changed.
Analog outputs
OFF
Pit level
Pit inow
Pit outow
Pit overow
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 oat
Pump failure
Motor protector
High temperature
Leakage
Stop oat P1-P4
Low level oat
Overow sensor
High level oat
Drain pump oat
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 Analog and digital inputs / outputs
2.3 Conguretheeldbusunitmodules
AlltheextensionmodulestoPC441areoptional.ThecommunicationisdonebytheCAN-bus.SeeInstal-
lation guide CA 441, CA 442, CA 443(P/N:81307058)onSulzerhomepageformoredetailinformationto
setup Leakage, Temperature and Power monitors.InstallationguidestoCA511(P/N81307061),CA622
(P/N81307133)andCA781(P/N81307132)canalsobefoundatSulzerhomepage.
CA 441 Leakage module
AsystemwithPC441cancontainuptofourCA441modules.
OneCA441modulecanmonitorleakageinoneorfourpumps
dependingonthesettingoftheaddressknobonthefrontof
themodule,seeInstallation guide CA 441, CA 442, CA 443
(P/N:81307058)formoreinformation.Ifusingonemoduletofour
pumps,thereisoneinputforeachpump.IfusingoneCA441
moduleforeachpump,therearefourinputstoeachpump.
Inthesettings,youmustspecifythatthemodule(s)areconnected
andwhichtypeofsensortypeyourpumpshave.DefaultisABS
standard and can be changed to Xylem (ITT Flygt).
CA 442 Temperature module
PC441supportsuptosixunitsofCA442.OneCA442module
can monitor temperatures in one or four pumps depending on the
settingoftheaddressknobonthefrontofthemodule,seeInstal-
lation guide CA 441, CA 442, CA 443(P/N:81307058)formore
information.Ifusingonemoduletofourpumps,thereisoneinput
foreachpump.IfusingoneCA442moduleforeachpump,there
arefourinputstoeachpump.Inthesettings,youmustspecify
sensortypes(Klixon/Pt100/PTC).
EachmodulefromCA442-1(“-1”referstotheaddressonthe
knob)toCA442-4hasa4-20mAVibrationinput,oneforeach
pump. The vibration inputs are disabled in units CA 442-5 and
CA 442-6.
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CA 443

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CA 443 Power monitor module
PC441supportsuptoveCA443modules,onemoduleforeach
pumpandoneforwholesystem.CA443modulescannotbe
usedtogetherwithVFD.TheCA443modulesmustbeconnected
before pump contactor so the inputs L1-L3 never get powerless.
Iftheinputsgetpowerless,thephasealarmgoon,andthepump
willnotstart,seeInstallation guide CA 441, CA 442, CA 443
(P/N:81307058)formoreinformation.
CA 511 Graphical operator interface panel
PC 441 supports one CA 511. It is not possible to use one CA 511
toseveralPC441s.CA511isconnectedtoPC441viaCAN-bus
andhasaCAN-busterminationontheback.Thermwarever-
sioninCA511mustconformtotheversioninPC441.Alwaysuse
thelatestrmwaretoensurefullfunctionality.
CA 781 Output expansion module
CA781isamodulewhichgivesyoueightextradigitaloutputs
andtwoextraanalogoutputs.CA781modulemustbepowered
from the same source as PC 441 and cannot be powered from
theCAN-busbecauseofitshigherpowerconsumption.PC441
supports one CA 781 module. See Installation and user guide
(P/N81307123)onSulzerhomepageformoreinformation.
CA 622 RS 485 communication module
PC441cancommunicatedirectlytoVFDs,energymetersand
softstartersviaCA622module.CA622actsasModbusmaster,
communicating with attached Modbus slave devices. See the In-
stallation and user guide(P/N81307133)onSulzerhomepagefor
moreinformationandwhichVFD,energymetersandsoftstarters
PC441andCA622support.Ifmissingyourmodel-contactCon-
trol&MonitoringatSulzerandwemightbeabletoaddthenew
model.PC441supportoneCA622inthesystem.
WhenusingCA622inthesystem,thevaluesfrommany
parameterscanbereadoutbytheRS485busdirectfromVFD/
softstartersorenergymetersandstoredinthecontroller.These
values can also be logged. PC 441 together with CA 622 can also
controltheon/o󰀨,speedandreversingofthepumps.Consult
theInstallationanduserguideCA622(P/N81307133)onSulzer
homepageformoreinformationaboutwhichVFD/softstarters/
energymetersPC441andCA622supports.
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CA 443
Esc
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0 A
1.30 m
0.50 m

1.50 m 0.55 m

1.70 m 0.60 m

1.90 m 0.65 m


352.5 A 353.8 A 354.1 A
1.55 m 1827 l/s
MAIN STATUS SETTING TREND ALARM ACKN.
PUMP 4
PUMP 3
PUMP 2
PUMP 1
2013.08.21 05:56:19 Low level
 980.3 l/s
m
P3 P4
P1 P2
3
0
07:25:58 07:28:10 07:30:26
0.15 kWh/m3
CA 511
CA 781
CAN
CA 622
RX/TX
ON-OFF
485-term.
0V -485 +485
678
A B
V+ H Shld L V-
1235 4
CAN Bus

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2.4 Congurethepumppitparameters
Table 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 ow*
Calculation of pump capacity*
Overow
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)
Analogsensororstart/stopoats.Analogsensorisrecommendedifyouwanttotrackthecapacityofthe
pumps and pumping volume.
Max number of pumps running (optional parameter)
Ifyourpipesystemcannothandletoohighows/pressureoryourpowergridhaslimitations,reducenumberof
pumps running at the same time. See section 3.4.1
Alternation (optional parameter)
Normalorasymmetrical
Normal:Thepumpsstartinsequencefrom1-4.Thereisalwaysonepumpstartattherst(lowest)startlevel.
Asymmetrical:Thepumpsaredividedintwogroupsthereonegroupisworkingmorefrequentlythantheother
group. See also section 3.4
Alternative stop level (optional parameter)
Thisfunctionistoaidreductionofsedimentsinthepitandavoidingoatingcrust
Start/stop on fast change (optional parameter)
Forexample:Ifthepumpstationispumpingclearwaterandaheavyrainllsthepitveryfast,thepumpcan
start before the level reach the start level.
Station ow (recommended parameters)
Under Meas. parameters set the Inow calculation=ONandyourpitshape,alsothefunctionEmptying or
Filling the pit must be set. System curve at duty pointisusedifthereisn’tanyOutlet pressure sensor.
Recommended is to setup the Pit area under Station ow.That’sbecausethepumpcalculationsshallpreform
as accurate as possible. This are bound to Energy calculation,Pump capacity and Outlet calculations. Best
accuracyofpumpcapacitycalculationsandpumpedvolumeiswhenanOutlet pressure sensor is used.
See section 3.2 for more information.
Calculation of pump capacity (recommended parameter)
Recommended to set Calculation=ON.Thelevelmustbeinthespanofminimumandmaximumduringthe
calculations.Makesurethatthealltimestogetherinstart delay/calculation time/stop delay in total must be in
one and the same pump sequence. See section 3.2 and forward.

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Overow (optional parameter)
Overowcanbedetectedbyanoverowdetector(MD137)orbythecertainlevel.Seemoreinformationabout
overowin section 3.3.
Backup running (optional parameter)
BackuprunningstartwhenaHigh-level oatgetsactivated.Youcanspecifywhichpumpsshallparticipatein
backuprun,andhowlongthepumpshallrun.
Pit alarms (some parameters are recommended)
There are several alarms which can be set under Pit alarms.EachalarmiscongurabletobeA-orB-alarms.
Consultyourdrawingsandverifywhichareimportantforyourinstallation.
Pump blocking (optional parameter)
Thepumpcanbeblockedonremote.Thereisatimeoutwhichreleasestheblockingafteracertaintime.
BlockingonLow level oat and/or High pressure can be set here.
Level sensor check (optional parameter)
Level sensor checkItispossibletocheckthelevelsensorreadingcomparedtotheinstalledoats.Seethe
settings under Level sensorchecksetthisup.
Tari󰀨 control (optional parameter)
Thisfunctionistoreduceenergyconsumptioninhoursofhighcostofenergy.Youcansetthisupforseparate
daysintheweek.
Level above sea (optional parameter)
Ifyoutypeinavaluehere,thisvaluewillbeaddedinthepitlevelbutnota󰀨ectthestart/stoplevels.
In AquaProg:
Figure 2-4 Pump pit settings

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2.5 Settings for pump 1 to pump 4 and their alarms
Hereyoucangivethepumpatagname(max20characters).InstalledpumpsmusthaveRelay control
pump=YES,otherwisethepumpwillnotshowupinCA511graphics.Alternately;ifpump3andpump4are
not installed; Relay control pump=NO that pump disappears from the graphics.
Importantparametertosetupforeachpump:
Typeofpump(xedorVFD)
Runningindication(digitalinput,motorcurrentoreldbusmoduleCA622)
Start/stop level
Pump alarms
Pump curve
Optionalparameters:
Time settings
Pumpblocking
Pumpblockingonalarms
Dryrundetection
Type of pump:
• Fixedpumps
A digital output starts the pump
• Speedcontrolledpump(PID/VFD)
Start a VFD which has predened frequency
Pump parameters:
• Set the nominal current for the pump
• Set the power factor for the pump
Usefulparameterstodetectdryrunandheavyload
Select run indication:
• Digitalinput
• Motor current
Require current transformers connected to an analog input
• Modbus CA 622
RS 485 communication to/from VFD or soft starter
Start/stop levels for each pump
Recommendedtohavedi󰀨erentstartlevelsforallthepumps.Samestoplevelforallthepumpsisne.
Time settings (optimal parameter)
Setthemaximumruntimeforthepumps
QH curve (pump curve)
Togetaccuratevaluesforpumpcapacityandpumpedvolume,thisparameterisimportant.Seechapter5for
more information about pump curve.