Sulzer EC 531 User manual

www.sulzer.com
Pump controller EC 531
EN Installation guide
81307137B (10/2018)
Ethernet RS 485 Digital outputs (V+)
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 49 50 51 52
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
232SR-medoM)CDV43-9(stupnilatigiDrewoP
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
12345678910 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26
Pt100/Leak

2
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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1 INSTALL ATION
1.1 Mount the controller
Mount the controller on a 35 mm DIN rail. The physical dimensions of the controller is: 86 x 160 x
60mm (3.39 x 6.30 x 2.36inch) (H x W x D). If it doesn’t easily snap onto the rail, you can pull the
small tab at the bottom side of the unit, using a small screwdriver.
1.2 Make all connections
There are a total of 48 terminals that may be connected to power, sensors, switches, relays and a mo-
dem; these terminals are numbered from 1 to 52 according to the following gure:
WARNING! Ensure that all power is off, and that all output devices to be connected to the controller also is
turned off before you connect anything!
Table 1 shows all connections to terminals 1–26 at the bottom side of the controller. The usage of the
congurable Digital in (terminals 3–16) and Analog in 7 and 8 (terminals 17–20) for Leakage or Pt100
(these are not 4–20mA inputs) shown in the table is the default conguration. A modem should be
connected according to gure 11. For communications, see section 3.
Table 2 shows all connections to terminals 27–52 at the top side of the controller. The usage of the
congurable DO 1 to DO 8, AO 1 to AO 2 and AI 1 to AI 6 shown in the table is the default congu-
ration. “DO” stands for “Digital Outputs”, which are voltage outputs. “AI 1–8” stands for “Analog Input
1– 8”. AI 1–AI 4 are 4–20mA inputs, it is recommended to use AI 1 as input for the level sensor due to
higher resolution on AI 1 port. AI 5 and AI 6 are congurable Pt100 or PTC / Bi-metallic switch inputs
(these are not 4–20mA inputs). AI 7 and AI 8 are congurable Pt100 or Leakage inputs (nor these are
not 4–20mA inputs). For communications, see section 3.
The power must be between 9 and 34 volts DC. Figure 2 shows how to connect a power-fail switch to
Digital In 9 (terminal 11) and how to connect a battery pack for uninterrupted operation.
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Table 1:
Terminals at the bottom side of the pump controller
Factory settings Logic mode
(NO/NC)
Name Term.
Voltage supply, 9–34 VDC
V+ 1
V- 2
Overow level NO Digital ini1 3
High level oat NO Digital ini 2 4
Power fail NO Digital ini3 5
Local mode NO Digital ini4 6
Motor protector pump 1 NO Digital ini5 7
Pump 1 set auto NC Digital ini6 8
OFF NO Digital ini 7 9
Motor protector pump 2 NO Digital ini8 10
Pump 2 set auto NC Digital ini 9 11
OFF NO Digital ini10 12
Low level oat NO Digital ini11 13
OFF NO Digital ini 12 14
OFF NO Digital ini13 15
OFF NO Digital ini14 16
Leakage / (Pt100)
Leakage
pump 1
Analog in 7 17
V- 18
Leakage
pump 2
Analog in 8 19
V- 20
Modem port RS 232
V- 22
In RXD 23
Out TXD 24
Out RTS 25
In CTS 26
i. “Digital In” means a signal that is either on or off (high or low), where high is anything
between 5 and 32 volts DC and low is anything below 2 volts. All digital inputs are congurable in the
menu Settings > Digital inputs, but the conguration shown here is the default one.
Figure 1
The Digital in terminals may be connected to either passive devices, such as switches, or
active devices that are powered and deliver signals. Connect devices according to the gure.
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Table 2:
Terminals at the top side of the pump controller
Term. Name Factory settings Logic mode
(NO/NC)
27 V-
28 Digital outi1 Alarm alert NC
29 Digital outi 2 Pump ctrl pump 1 NO
30 Digital outi3 Pump ctrl pump 2 NO
31 Digital outi4 OFF NO
32 Digital outi5 OFF NO
33 Digital outi6 Personnel alarm NO
34 Digital outi 7 Mixer ctrl NO
35 Digital outi8 High level NO
36 Analog outii 1 Pit level
37 Analog outii 2 Pit outow
38 V+
39 Analog in 1 Level sensor
4–20 mA
Inputs
40 Analog in 2 OFF
41 Analog in 3 OFF
42 Analog in 4 OFF
43 V-
44 Analog in 5 Pump 1, PTC Pt100 / PTC
temperature
45 Analog in 6 Pump 2, PTC
47 Ethernet
49 RS 485 +
50 RS 485 -
51 RS 485 shield
52 RS 485 Bias and termination Jumpers see section 3.5.2 and gure 12
i. Digital output is a voltage output. See the menu Settings > Digital outputs for conguration.
ii. Analog output, See Settings > Analog outputs for conguration.
Figure 2 The power must be DC between 9 and 34 volts, but if it also charges 24V
batteries, it should be 27.2 V. Connect a power-fail switch to Digital in 9 (terminal 11) accord-
ing to the gure. For uninterrupted operation in case of power failure, connect a battery pack
according to the gure.
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4-20 mA Analog input connection. Recommended to use Analog Input 1 as Level sensor because
highest resolution.
Figure 3 Analog input connection level sensor
Analog input 5-8 for connection of Pt100 sensors (temperature sensor).
Figure 4 Connection of Pt100 use corresponding V-
Use Analog In 5–6 for temperature sensor PTC and/or Bi-metallic switches. If several PTC or Bi-me-
tallic switch sensors: connect the sensors in serial.
Figure 5 Analog input connection PTC and/or Bi-metallic switch (temperature sensors)
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Analog
In 1-4
Analog
In 5-8
Analog
In 5-6

7
Analog In 7–8 for leakage sensor. If several leakage sensors: connect the sensors in parallel.
Figure 6 Analog input connection leakage sensors
Digital output connections. Recommendation is to use external relays together with a yback diode to
each relay according to gure.
Figure 7 Digital output connection (external relay)
Analog output connections. Several loads must be in serial.
Figure 8 Analog Output connection
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Analog
In 7-8
With analog input
reference to V-

8
2 CHECK YOUR INSTALLATION
After the installation, there are possibilities to check the status of the digital and analog in- and
outputs in the menus of EC 531. This could be used for validations of the installation and for fault
tracking.
To check the Digital in- and outputs: Go into menus by pressing [Down Arrow]:
Main Menu – Quick Status – DI / DO Status – Enter:
Figure 9 Status of Digital in- and outputs
NOTE! Toggle between Terminal I/O status and Logical I/O status by pressing Enter and up / down arrow.
NO = Normally Open, NC = Normally closed
The difference between Terminal I/O status and Logical I/O status in DI / DO is how the EC 531
perceives the inputs as active or not in normal state depending if the inputs are set as Normally open
or Normally closed (NO / NC).
Example: Digital In 11 is the Low level oat, and it is normally always active (Normally
closed) but the software interprets it as non-active until it gets released. This is
exemplies in gure 9 above.
To check the Analog in- and outputs: Go into the menus by pressing [Down Arrow]:
Main Menu – Quick Status – AI / AO Status – Enter:
Figure 10 Status of the Analog inputs- and outputs
NOTE! Use the down arrow to step down to see all the analog signals.
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3 COMMUNICATION PORTS
EC 531 has several communication ports, listed below.
3.1 USB Port (Mini-B)
This service port is primary for temporary connections to download conguration and updating rm-
ware by using AquaProg.
Select Modbus RTU or TCP and Modbus ID in settings. Cross reference table is available.
First time a PC connects to EC 531, a wizard appears at the screen. Just follow the instructions on
your PC.
3.2 RS 232 port (9-pols D-Sub on the front)
This service port is primary for temporary connections to download conguration and updating rm-
ware by using AquaProg.
Select Modbus RTU or TCP and Modbus ID in settings. Cross reference table is available.
Communication parameters are congurable.
3.3 Modem Port RS 232 (screw terminals 22 – 26)
This port is designed for modem communication and has protocol Modbus RTU or Modbus TCP.
Other protocol can be used by using modem, which converts the signal.
Default this port has:
Protocol: Modbus RTU, Baud rate: 115200, Parity: None,
Handshake: Off, Protocol ID: 1. Message Time Out: 2 s
On this port there are possibilities to change the properties of baud rate (300–115200), protocol ID
(1–255), station ID (1–65535), parity (none, odd, even) and handshake (on / off) as well. For more set-
tings, see user manual or menus.
Necessary for AquaWeb concept is that the station ID is set according to subscription and that the
protocol ID is correct!
Figure 11 Modem connections, modem cable P/N: 43320588
3.4 Ethernet port (Terminal 47)
Ethernet port in a RJ45-jack. In the settings, select between static or dynamic IP-address. Default
Modbus TCP port is 502.
3.5 RS 485 bus (Terminals 49 – 51)
A RS 485 network is of multi drop type, which means that all units are connected in parallel on the
same cable. In a RS 485 network, every unit must have a unique Modbus ID-number.
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3.5.1 Communication parameters RS 485
The EC 531 can act as a slave or master in the RS 485 network. If EC 531 is set as master, all the
surrounding units must be set as slaves.
All the units in the RS 485 network must be using the same communication parameters; baud rate,
parity and stop bits. Compare the setting in the menu of EC531 and consult the manuals for sur-
rounding units.
3.5.2 RS 485 cable and the termination
The RS485 cable between EC531 and surrounding units must be a shielded twisted pair cable. The
RS 485 interface on EC531 is galvanically isolated from the rest of the circuits. Therefore, the shield
of the RS485 communication cable between EC531 and adjacent devices must be connected in
both ends.
A rule of thumb is that the speed in bit/s multiplied by the length in meters should not exceed 108.
Thus, a 50 meter cable should not signal faster than 2 Mbit/s. In strong electrical disturbing environ-
ments, it is recommended to keep the baud rate in lower speed. Never split the RS485 communica-
tion line into several lines. The communication must go from one unit to next in a clear dened line.
EC 531 include biasing resistors to ensure stable data state even when communication is in idle.
Consult the manuals for surrounding units if biasing is needed.
The RS485 bus shall be terminated with 120ohms resistor at both cable ends. The cable type must
be a shielded twisted pair and all the shields in the RS485 network shall be connected to ground in
one point only.
NOTE! The RS 485 bus must be terminated in both ends, but not in between.
Figure 12 RS 485-bus drawing
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4 MINIMUMREQUIREDVFDSETUPFOREC531CONTROL
This section describes only the requirements to enable communication with device. All other param-
eters for the application and safety demands must be set according to actual vendor documentation.
Baud and parity must be the same for all units on the same data-bus. Slave ID must be unique on
every attached Modbus slave.
Modbus time out must be lower on the Modbus slaves than setting on EC531 (default two seconds).
RS485 must have termination resistors at both cable ends (with jumper in terminal position 52 on
EC531 side). Missing termination at VFD end may cause communication to fail in presence of external
electrical interference e.g. when motor is on.
4 .1 ABB
ACQ 810 Variable speed drive
10.01 Ext 1 start func FBA
21.01 Speed ref 1 sel EFB ref 1 (P.02.38)
21.04 Neg speed ena CONST C.TRUE to enable pump reverse
50.04 FBA ref 1 modesel Speed
50.15 FBA cw used P.02.36 EFB main cw
58.01 Protocol ena sel Modbus RTU
58.03 Node address Unique slave ID corresponding to EC 531 setting
58.04 Baud rate Same as EC 531
58.05 Parity Same as EC 531
58.06 Control prole ABB enhanced (default)
58.10 Refresh settings Refresh
16.07 Param. save Save
ACS 580 Variable speed drive
58.01 Protocol enable Modbus RTU
58.03 Node address Unique slave ID corresponding to EC 531 setting
58.04 Baud rate Same as EC 531
58.05 Parity Same as EC 531
58.33 Addressing mode Mode 2 (32 bit)
58.06 Communication control Refresh setting
20.01 Ext. 1 commands Embedded eldbus
28.11 Ext. 1 frequency ref 1 EFB ref 1
96.07 Parameter save manually Save
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ACS 550 Variable speed drive
9902 Applic. macro 1 = ABB standard
9802 Comm prot sel 1 = Std modbus
1001 Ext1 commands 10 = Comm
1103 Ref1 select 8 = Comm
1604 Fault reset sel 8 = Comm
If remote drive reset is enabled in EC 531
5302 EFB station ID (Node address) Unique slave ID corresponding to EC 531 setting
5303 EFB baud rate Same as EC 531
5304 EFB parity Same as EC 531
5305 EFB ctrl. prole 0 = ABB Drv Lim
4.2 Danfoss - Vacon
FC 200 Variable speed drive
4–10 Motor speed direction [2] Both directions
8-01 Control site [2] Ctrl. word only
8-02 Control source [1] FC port
8-30 Protocol [2] Modbus RTU
8-31 Address Unique slave ID corresponding to EC 531 setting
8-32 Baud rate Same as EC 531
8-33 Parity / Stop bits Same as EC 531
8-43 PCD Read
• [02] Conguration [1612] Motor voltage
• [03] Conguration [1613] Frequency
• [04] Conguration [1616] Torque [Nm]
• [05] Conguration [1617] Speed [RPM]
• [06] Conguration [1622] Torque %
• [07] Conguration [1610] Power [kW]
• [08] Conguration [1614] Motor current
MCD 200 - With optional RS 485 expansion.
Add a cable jumper between terminal A1–N2.
MCD 500 - With optional RS 485 expansion.
Add cable jumpers between terminal 17–18 and 18–25. Use max 19200 Baud.
MCD 200, MCD 500 Soft starter
Protocol Modbus RTU
Slave ID Unique slave ID corresponding to EC 531 setting
Baud rate Same as EC 531. Max 19200 baud.
Parity Same as EC 531
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Vacon 100 Variable speed drive
P5.8.1.1 RS 485 Protocol 1= Modbus RTU
P5.8.3.1.1. Slave address Unique slave ID corresponding to EC 531 setting
P5.8.3.1.2 Baud rate Same as EC 531
P5.8.3.1.4 Stop bits 1=1 stop bit
P5.8.3.1.3 Parity type Same parity as EC 5311
P3.2.1 Rem control place Select eldbus CTRL for EC 531 operation
P3.3.1.10 Fieldbus ref sel Select eldbus for EC 531 speed control
1Note! Mark parity in EC 531 is the same as 2 stop bit. No parity in Vacon drive.
Vacon 20 Variable speed drive
P2.1 Remote control place selection 1= Fieldbus
P3.3 Remote freq. reference 3 = Fieldbus
S System parameters
S-P2.2 Fieldbus protocol 1 = Modbus used
S-P2.3 Slave address Unique slave ID corresponding to EC 531 setting
S-P2.4 Baud rate Same as EC 531
S-P2.6 Parity type Same parity as EC 5311
1Note! Mark parity in EC 531 is the same as 2 stop bit. No parity in Vacon drive.
4.3 Yaskawa
P 1000 Variable speed drive
H5-01 Drive node address Same as EC 531
H5-02 Communication speed Same as EC 531
H5-03 Communication parity Same as EC 531
b1-01 Frequency reference [2] for Modbus control
b1-02 Run command [2] for Modbus control
Select “P 1000 > 11kW” if current (0.01A) and power (0.01kW) is scaled to 0.1A and 0.1kW.
4.4 CG (Emotron)
Emotron use two stop bits as standard, this is the same as “MARK” parity in EC531. Optional RS485
expansion board is required.
TSA Soft starter
260 Serial com.
• 261 Com type Select RS 485
• 262 Modbus RTU
◦ 2621 Baud rate Same as EC 531
◦ 2622 Address Unique slave ID corresponding to EC 531 setting
• 264 Com fault Select preferred behaviour
210 Operation
• 215 Action ctrl
◦ 2151 Run / Stp ctrl Select “Com” for eldbus control
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FDU 2 Variable speed drive
260 Serial com
• 261 Com type Select RS 232 / 485
• 262 RS 232 / 485
◦ 2621 Baud rate Same as EC 531
◦ 2622 Address Unique slave ID corresponding to EC 531 setting
• 264 Com fault Select preferred behaviour
210 Operation
• 214 Ref ctrl Select “Com” for eldbus control
• 215 Run/Stp ctrl Select “Com” for eldbus control
4.5 Invertek
Control and inhibit terminals must have some jumpers to enable Modbus control.
Place a cable between terminal one to two, to enable start command, 1–12 and 9–13 for inhibit and
safety control.
Optidrive Variable speed drive
P5-01 Drive eldbus address Unique slave ID corresponding to EC 531 setting
P5-03 Modbus / BACnet baud rate Same as EC 531
P5-04 Modbus / BACnet format Same parity as in EC 531
P1-12 Command source select 4:Fieldbus control
4.6 NFO Drives
Sinus G2 Sinewave variable speed drive
Par group:
Serial
• Bustype Mbus RTU
• Address Unique slave ID corresponding to EC 531 setting
• Si Baud Same baud rate as EC 531
• Si Prot Same parity as EC 5311
Control
• Auto Start OFF
1 Note! Mark parity in EC 531 is the same as 2 stop bit. No parity in NFO drive.
Enable “Run input” with a cable jumper between terminal 1 and 5 to allow Modbus control.
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4.7 Schneider
ATS 48 Soft starter
COP menu:
• Add Unique slave ID corresponding to EC 531 setting
• tbr Same baud rate as EC 531
• FOr Same parity as EC 531
• tLP 1.8 if using default EC 531 setting
• PCt ON to enable new settings with a power reset
Enable with a power reset (OFF / ON).
Place a jumper between terminal +24V and STOP to allow Modbus control.
ATV 12 1->3 phase variable speed drive
COnF menu:
• FULL
◦ COM-
▪ Add Unique slave ID corresponding to EC 531 setting
▪ Tbr Same baud rate as EC 531
▪ Tfo Same parity as EC 531
◦ Ctl-
▪ Fr 1 = Mdb Select modbus for control over RS 485 eldbus
Enable with a power reset (OFF / ON).
ATV 61 Variable speed drive
1.9 COMMUNICATION
• MODBUS NETWORK
◦ Modbus address Unique slave ID corresponding to EC 531 setting
◦ Modbus baud rate Same baud rate as EC 531
◦ Modbus format Same parity as EC 531
1.6 COMMAND
• Ref.1 channel = Modbus Select modbus for control over RS 485 eldbus
Enable with a power reset (OFF / ON).
ATV 600 series Variable speed drive
6.1 Comm parameters
• Modbus SL
◦ Modbus fieldbus
▪ Modbus address Unique slave ID corresponding to EC 531 setting
▪ Modbus baud rate Same baud rate as EC 531
▪ Modbus format Same parity as EC 531
5.4 Command and refere.
• RefFreq 1 cong
◦ = Ref. freq modbus Select modbus for control over RS 485 eldbus
Enable with a power reset (OFF / ON).
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4.8 Supported function table
Brand:
Model:
ACQ 810 ACS 580 ACS 550 FC 200 MCD 200 MCD 500 TSA FDU 2 Optidrive Sinus 100 FLOW 20 P 1000 ATS 48 ATV 12 ATV 61 ATV 600 PM 5100 PM 710 Acuvim II ND10
Type of unit:
VFD / VSD X X X X X X X X X X X X X
Soft starter X X X X
Energy meter X X X X
Control:
On / Off ctrl X X X X X X X X X X X X X X X X X
Reverse control X X X X X X X X X X X X X
Speed control X X X X X X X X X X X X X
Monitor:
Run XXXXXXXXXXXXX XXX
Fault X X X X X X X X X X X X X X X X
Frequency Hz X X X X X X X X X X X X X X X X X
Speed RPM X X X X X X X X X X X
Torque % X X X X X X X X X X X
Torque Nm X X
Motor voltage X X X X X X X X X X X X
Motor current X X X X X X X X X X X X X X X X
Motor power X X X X X X X X X X X X X X X
Power factor X X X X X X X
Input power X X X X X
L1 Volt X X X X
L2 Volt X X X X
L3 Volt X X X X
LN Average volt X X X X X
L1–L2 Volt X X X X X
L2–L3 Volt X X X X X
L3–L1 Volt X X X X X
L-L Average volt X X X X X
L1 Current A X X X X X X
L2 Current A X X X X X X
L3 Current A X X X X X X
Average current A X X X X
ABB
Danfoss
CG (Emotron)
Invertek
NFO
Vacon
Schneider
Accuenergy
Yaskawa
Lumel
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5 TECHNICALDATAEC531
Electrical
Installation category CAT II
Power consumption < 5.0 W (without output load)
Power supply 9–34 VDC SELV or Class 2
Environmental
Ambient operation temperature -20 to +50 °C (-4 to +122 °F)
Ambient storage temperature -30 to +80 °C (-22 to +176 °F)
Humidity 0–95% RH non condensing
Max altitude 2000 m
Pollution degree 2
Physical
Dimension HxWxD: 86 x 160 x 60 mm (3.39 x 6.30 x 2.36 inch)
Mounting DIN Rail 35 mm (1.378” W)
Degree of protection IP 20, NEMA: Type 1
Flame rated UL 94 V-0
Housing material PPO and PC
Ports
Analog inputs (AI) Number of: 4
mA Range: 4–20 mA (DC)
Input resistance: 136 ohm. PTC protected
Resolution: AI1: 15 bits, AI2–4: 10 bits
Analog inputs (AI) Number of: 4, less if alternative functions are used
Pt100 Range: -20 to +200 °C (-4 to +392 °F)
Connection setup: 2 wire
Resolution: 0.1 degree
Alternative functions: Leakage or PTC / Bi-metallic switch surveillance see below
Leakage Number of: 2 (Alternative function to Pt100)
Trig level: <100 kohm
PTC / Bi-metallic
switch
Number of: 2 (Alternative function to Pt100)
Trig level: >3.3 kohm
Analog outputs (AO) Number of: 2
Range: 4–20 mA, Sourcing from power supply
Max load: 500 ohm@12 VDC, 1100 ohm@24 VDC
Resolution: 15 bits 0.5 uA
Digital inputs (DI) Number of: 14
Congurable logic
Input resistance: 10 kohm
Input voltage: 0–34 VDC, Trig level ~ 4 VDC.
Max pulse rate: 1 kHz (pulse channels)
Digital outputs (DO) Number of: 8
Congurable logic. < 34 VDC (sourcing from power supply)
Max load: 1A / output. Max total current for all 8 outputs together is 4 A.
Only sourcing, no drain
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Ports
Communication 1 USB Service port (USB mini-b)
1 RS 232 Service port (9p D-SUB)
1 RS 232 port for telemetry interface
(modem)
(screw term.)
1 RS 485 2-wire
(Galvanic Isolated)
(screw term.)
1 Ethernet (RJ45)
User interface 2,2” TFT Color display,
Animated front screen and menus for settings and status 6 menu
maneuver buttons, 4 pump maneuver buttons
Alarm, Power On and Pump mode indication LEDs
Approvals CSA pending
5.1 Cleaning
How to clean the unit
Power off the unit. Only outside / front shall be cleaned by using a dry, soft cloth.
A good choice would be the microber type of cloth. Gently wipe the EC 531 front in order not to
scratch the overlay. If the dry cloth did not completely remove the dirt, do not press harder in an
attempt to scrub it off. If necessary, moisten the cloth by adding a small amount of water with thin
solution of mild detergent and try again. Never use detergent with polish or solvent which can have an
impact of the plastic surface.
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Sulzer Pump Solutions Ireland Ltd., Clonard Road, Wexford, Ireland
Tel. [phone], Fax [phone], www.sulzer.com
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