Sulzer EC 531 User manual

www.sulzer.com
Equipment controller EC 531
EN User guide
81307150B (08/2018)
Ethernet RS 485 Digital outputs (V+)
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V- DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8 AO1 AO2 V+ AI1 AI2 AI3 AI4 V- AI5 AI6 RJ45 + - Shld
out (4-20 mA) in Pt100/PTC
Bias +
Term.
Bias -
EC 531
AUTO
0
AUTO
0
1 2
Esc.
RS 232
USB
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V+ V- DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14 AI7 V- AI8 V- V- RXD TXD RTS CTS
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Pt100/Leak

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Copyright © 2018 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 5
1 Overview of the display symbols 7
1.1 EC 531 panel......................................................................................................................7
1.2 Symbols on the graphic display .........................................................................................8
1.2.1 Time and date ....................................................................................................................8
1.2.2 Level and the dynamic eld ................................................................................................8
1.2.3 Outlet value on the display .................................................................................................8
1.2.4 Pump information window..................................................................................................9
1.3 Floats and overow sensor on the display..........................................................................9
1.4 Pump, mixer, pipe and start / stop symbols.....................................................................10
1.5 Power and alarm indicator ..............................................................................................10
1.6 Menus and submenus, passcodes and personal alarm...................................................10
1.6.1 Status view....................................................................................................................... 11
1.7 Entering the main menu and set the language ................................................................. 12
1.7.1 Manual control ................................................................................................................. 12
1.8 Quick status ..................................................................................................................... 13
2 Setup the EC 531 15
2.1 Set general conguration, system, ID and communication settings ................................. 15
2.2 Setup the digital inputs, digital outputs, analog inputs and analog outputs ..................... 17
2.3 Setup the pump pit parameters .......................................................................................18
2.4 Set pump 1 and pump 2 settings and their alarms ..........................................................18
2.5 Common P1–P2...............................................................................................................20
2.6 Set log settings and events ..............................................................................................20
2.7 Set up communications to surrounding units VFD, soft starters and energy meter .........21
2.8 Set up cleaner, mixer or drain pump (if used) ...................................................................21
3 Detailed description of the functions 23
3.1 Pump capacity calculation...............................................................................................23
3.2 Overow ow calculation..................................................................................................34
3.3 Pump alternation..............................................................................................................35
3.4 Pump reversing ................................................................................................................37
3.5 Speed controlled pumps (VFD) ........................................................................................38
3.6 Best efciency point pump control ..................................................................................40
3.7 Crash log.......................................................................................................................... 41
3.8 Communication................................................................................................................ 41
3.9 Cross reference table .......................................................................................................43
4 Further explanations of some functions of analog- and digital in- and output signals 45
4.1 Digital in: personnel alarm and local mode.......................................................................45
4.2 Digital in: block operation.................................................................................................45
4.3 Digital out: data register set point.....................................................................................45
4.4 Digital out: logic IO ...........................................................................................................46
4.5 Digital out: external reset alert..........................................................................................47
4.6 Analog in: outlet pressure.................................................................................................47
4.7 Analog out: data register and data register 2’s complement............................................ 47
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5 APpendix: tables of guide line to the menus in EC 531 49
5.1 Quick status: system menu ..............................................................................................50
5.2 Quick status: pump pit.....................................................................................................50
5.3 Quick status: pump 1 and pump 2................................................................................... 51
5.4 Quick status: digital in and digital out...............................................................................53
5.5 Quick status: analog in and analog out ............................................................................53
5.6 Detailed status: system ....................................................................................................54
5.7 Detailed status: pump pit .................................................................................................55
5.8 Detailed status: pump 1 and pump 2 ...............................................................................57
5.9 Detailed status: PID regulator...........................................................................................58
5.10 Detailed status: analog inputs ..........................................................................................59
5.11 Detailed status: analog outputs........................................................................................60
5.12 Detailed status: digital inputs ...........................................................................................60
5.13 Detailed status: digital outputs .........................................................................................61
5.14 Detailed status: communication .......................................................................................61
5.15 Detailed status: eld bus modules (RS 485).....................................................................63
5.16 Settings: alarm legend .....................................................................................................64
5.17 Settings: system...............................................................................................................65
5.18 Settings: pump pit............................................................................................................65
5.19 Settings: pump 1 and pump 2 .........................................................................................67
5.20 Settings: common P1 – P2 ..............................................................................................70
5.21 Settings: PID regulator .....................................................................................................72
5.22 Settings: pulse channels ..................................................................................................72
5.23 Settings: analog logging...................................................................................................73
5.24 Settings: analog inputs..................................................................................................... 74
5.25 Settings: analog outputs ..................................................................................................77
5.26 Settings: digital inputs......................................................................................................78
5.27 Settings: digital outputs....................................................................................................79
5.28 Settings: communication .................................................................................................80
5.29 Settings: eld bus modules (RS 485) ...............................................................................82
5.30 Settings: select language.................................................................................................83
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ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS
This guide describes the equipment controller EC 531. The equipment controller can either be used
stand-alone or communicate 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 www.sulzer.com).
Audience This guide is intended for system administrators and operators of EC 531 equipment controller.
Prerequisites This guide assumes that you already are acquainted with those pumps you are set to control and
have the sensors connected to EC 531.
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
additional alarm input.
• An analog level-sensor has several advantages over oat switches: it is more robust
(cannot get stuck or be mechanically jammed); it is more accurate; it is more exible (the
start and stop levels can easily changed); you can get readings of the water level in the
pit, the inow, overow and the pump capacity; you can optimize the pump performance
in various ways, including exercising, alternative stop levels, tariff control etc.
• 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.
2. You need to know if the pump(s) should be exercised in case of long idle periods. If the installation
has one or two pumps, you need to decide if the pumps should alternate.
3. If the electricity has daily varying tariffs, you must know the times of high / low tariffs.
4. You must know how overow will be measured: if it will be measured using both an overow detector
(to detect 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 accu-
rately calculated by the EC 531.
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 document Installation guide, which covers EC 531. Before you
make any settings, or use the control panel, read chapter 1 Oiverview of the display symbols —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 2 Setup the EC 531 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 on the display or a description how you nd your way through
the menus by key strokes. Text in bold, is how you have to do a change of the settings in the EC 531
menu.
Most settings in chapter 2 only apply to the system administrator, but the following also apply to those
who operate the controller: language selection, date and time settings, units, backlight time-out,
buzzer, operator passcode, start / stop levels.
Glossary and conventions
To designate a menu item in a hierarchy, an angle bracket is used to separate the levels. Ex-
ample: 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 effects.
Alarm class: The alarm class can be either A-alarm or B-alarm. A-alarms are those that require
immediate action, so operational staff in the eld should be alerted regardless of the time of day.
B-alarms are less important, but should be taken care of during normal work hours.
Digital in: A signal that is either ON or OFF (high or low), where high is anything between 5 and
35 volts DC, and low is anything below 2 volts.
Digital output: A signal that is either ON or OFF. At ON condition output current is sourced
from the power supply and the output is high (~V+). At OFF condition the output is low but it
cannot serve as a drain function (no output current). Are typically connections to relays.
Analog output: Signal in the range 4-20 mA. Sourced from power supply.
Analog input: Eight analog inputs used for connecting sensors. Ain:1 to Ain:4 are 4-20mA in-
puts. Ain:5-Ain:6 are congurable for Pt100 and PTC. Ain:7-Ain:8 are congurable for or Pt100
and Leakage.
Pump reversing: The controller can reverse the pump if the necessary external equipment is
installed in the station. The controller can reverse the pumps on number of occasions, e.g. low
capacity, pump fail, fallen motor protector, over currents and after number of starts
RS 485 modules: Refer to surrounding units connected to the RS 485 bus, e.g. soft starters,
VFDs, and an energy meter.
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1 OVERVIEW OF THE DISPLAY SYMBOLS
EC 531 is designed to control 1-2 pumps. It can operate a pump station stand alone and / or within
a surveillance system together with some communication equipment. For conguration and opera-
tor interaction, use the menus which can be selected using the arrow, Enter and Esc keys. With the
AquaProg software, conguration and back up of settings can be stored on a PC.
Add the 3G modem CA523 to create a full remote alarm and monitoring solution, together with an
AquaWeb rental contact or by any SCADA system.
This section will guide you through all the symbols on the display of EC 531.
1.1 EC 531 panel
1.2 Symbols on the graphic display
1.2.1 Time and date
1.2.2 Level and the dynamic eld
1.2.3 Outlet value on the display
1.2.4 Pump information window
1.3 Floats and overow sensor on the display
1.4 Pump, mixer pipe and start / stop symbols
1.5 Power and alarm indicator
1.6 Menus and submenus, passcodes and personal alarm
1.6.1 Status view
1.7 Entering the main menu and set the language
1.7.1 Manual control
1.8 Quick status
1.1 EC 531 panel
The default screen (top-level view) of the display on the EC 531 dynamically shows the operating sta-
tus of the pumps and conditions in the pit, displaying just about everything you need to know about
the current situation. Figure 1-1 shows symbols and explains their meanings. The unit will always re-
vert to this view after 10 minutes of inactivity in any other view (such as showing menus or submenus).
In the submenus you can always return to the default screen by pressing ESC.
Figure 1-1 EC 531 panel
Pumps in auto (green) or
Manual (yellow) mode
Alarm indicator, ashing when
unacknowledged alarms
Start / Stop the pumps
in manual mode
Service ports, RS 232 and USB
Keypad to enter the menus
and alter settings
Power indicator
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1.2 Symbols on the graphic display
There are several symbols in the EC 531 display which are described below.
Figure 1-2 Symbols on the display
The top screen appears differently depending if there is a level sensor in the system or not. There is
no level value presented if the pit is without a level sensor. If no analog (Ain1-4, preferred Ain1) input is
dedicated for Level sensor, the controller assumes there are Start / Stop oats. The start / stop oats
are animated and must have a dedicated input if they are to appear on the display.
1.2.1 Time and date
When an alarm occurs, this eld turns red for A-alarm or yellow for B-alarms and the alarm text is also
shown here. The time and date is no longer visible.
Graphic display with level sensor Graphic display with start / stop oats
Figure 1-3 Examples of the rst line
Alarm line
When no active or unacknowledged alarm, System time and date will be shown instead.
(This is the clock used for time stamped events such as logging)
(())
Unacknowledged alarm (red line = A-alarm, yellow line = B-alarm)
Symbol and alarm text will be shown.
Acknowledged active alarm
Symbol and alarm text will be shown.
1.2.2 Level and the dynamic eld
If level sensor is installed on one of the analog inputs, the height of the level in the pit is present-
ed, shown with two decimal places, and by means of a visual water level indicator on the graphics
display. Level can be referenced from sea level (if set). If there is a high-level alarm setup and it gets
activated, the dynamic eld turn into red. If the system runs on oats, no level or visual water level
indicator will be shown on the display.
1.2.3 Outlet value on the display
Outow: After the controller has calculated the pump capacity, a value appears on the display when
the pump or pumps run. See the se c t i o n 3.1 Pump capacity calculation for information on how the
calculation is done and which parameters are necessary to set.
Outlet pressure: If there is an outlet pressure sensor installed, the value appears on the display. See
the section 3.1 Pump capacity calculation for information on how the calculation is done and which
parameters are necessary to set.
First line in normal mode First line when A-alarm
Pit water level
Overow sensor
Start / Stop levels
Inlet info
First line
Clock / Alarm
Mixer
Outlet info
Pump info. windows
High level oat
Visual water level
indicator
Low level oat
High level oat
Low level oat
Pump Pump
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1.2.4 Pump information window
The pump information window contains several symbols and not all of them are visible if there isn’t
an alarm. Without any alarms or fault conditions, only Current and grey shaded Temperature and
Leakage symbols are shown.
Figure 1-4 Pump information window without alarms or fault conditions
Summary of the symbols in pump information window:
High temperature, combination of set up sensors.
Orange when pending. Turns red when there is an active alarm associ-
ated. Grey when inactive.
Leakage, combination of set up sensors.
Orange when pending. Turns red when there is an active alarm associ-
ated. Grey when inactive.
Vibration fault, only shown when active.
Orange when pending alarm and red when active alarm.
Electric fault, only shown when active. Combination of electric faults
(Fallen motor protector, High / low motor current, Phase missing). Or-
ange when pending alarm and red when active alarm.
Current indicator bar, top turns red when reaching high current limit.
Motor
Current
Will be shown:
• with one decimal in range 0 to 9.9, otherwise without decimals
• will show kilo ampere as integers if above 999 A
Active alarms are prioritized, if more than two alarms are active they are prioritized as follows
1) Temperature, 2) Leakage, 3) Vibration, 4) Electric faults
1.3 Floats and overow sensor on the display
High- and low level oats are green in normal mode. They switch position (animated) and are ashing
red when activated.
Start / stop oats are gray in non-active mode, and blue when activated.
Overow sensor is green in normal mode, turn to ashing red when activated.
Motor current
Temperature Leakage
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1.4 Pump, mixer, pipe and start / stop symbols
The symbols are as follows:
Pipe with pump reference
• Animated ow when pump running in forward direction
Pump symbol, will rotate when pump running
Triangle can be:
• Green – Non blocked
• Yellow – Externally blocked or in reverse
• Red – Blocked by pump fault
• When blocked, symbol will be crossed
• If manual reset is needed a ashing ’!’ will appear.
Mixer symbol
• Same colour coding as pump symbol
Start and stop symbols are just relative to each other and no value is shown on the top screen.
1.5 Power and alarm indicator
The two leftmost symbols on the panel are for power and alarm indication:
• A green light indicates that the unit is powered.
• The red alarm indicator ashes whenever there is an unacknowledged alarm, and the dis-
play tells the type of the alarm. When the alarm is acknowledged, the light turns steady
red, and remains so until the active alarm is remedied.
1.6 Menus and submenus, passcodes and personal alarm
The arrow keys on the key pad have different functions depending where in the menus you are. From
the top screen, the functions are following:
Key pad shortcuts
Left arrow Will open ”Quick status” menu for pump 1
Right arrow Will open ”Quick status” menu for pump 2
Enter Will acknowledge present alarm in alarm list
 Up / down arrows Will open the menus
Key pad
Press either the up or down arrow button to switch to the menu view. When entering the menus and
submenus, you can navigate through them all by using the arrow buttons and Enter. If there are visible
triangles on the last line on the screen, these symbolize which choices could be made. Step through
the lines by pressing up / down arrow and press Enter to enter a submenu or change value. Esc
button will cancel the current operation and goes back to top screen (or default screen). A right arrow
indicates that a submenu is available.
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