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