Xylem FLYGT Concertor FPG 411 User manual

Installation, Operation, and
Maintenance Manual
886072_5.0
FPG 411, FPG 412
Concertor™

Table of Contents
1 Introduction and Safety............................................................................................ 3
1.1 Introduction........................................................................................................3
1.2 Safety terminology and symbols..................................................................... 3
1.3 User safety.......................................................................................................... 4
1.4 End of life product disposal............................................................................. 5
1.5 Spare parts......................................................................................................... 6
1.6 Warranty..............................................................................................................6
1.7 Support............................................................................................................... 6
2 Product Description.................................................................................................. 7
2.1 Product design...................................................................................................7
2.2 System overview................................................................................................ 7
2.2.1 Concertor™EA........................................................................................... 8
2.2.2 Concertor™DP........................................................................................... 9
2.3 Approvals......................................................................................................... 10
2.4 Parts...................................................................................................................11
2.5 The data plate.................................................................................................. 11
3 Mechanical Installation...........................................................................................12
3.1 Do not install in an explosive zone................................................................12
3.2 Install the gateway...........................................................................................12
4 Electrical Installation...............................................................................................13
4.1 Connect the cables, FPG 411........................................................................ 14
4.2 Connect the cables, FPG 412........................................................................ 16
4.3 Connect multiple units....................................................................................18
4.4 Set the switches............................................................................................... 19
5 Operation.................................................................................................................20
5.1 Start-up and operation................................................................................... 20
5.2 LED indicators..................................................................................................20
6 Maintenance............................................................................................................ 21
6.1 Preventive maintenance................................................................................. 21
7 Troubleshooting......................................................................................................22
7.1 The unit does not work................................................................................... 22
8 Technical Reference................................................................................................23
8.1 Dimensions.......................................................................................................23
8.2 Environmental requirements......................................................................... 23
8.3 IP-rating.............................................................................................................23
Table of Contents
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 1

8.4 Electrical data...................................................................................................23
8.5 Terminals.......................................................................................................... 24
Table of Contents
2 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide necessary information for installation,
operation, and maintenance of the unit.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the
location of the unit.
CAUTION:
Read this manual carefully before installing and using the
product. Improper use of the product can cause personal injury
and damage to property, and may void the warranty.
The equipment, and its functioning, may be impaired if used in a manner not
specified by the manufacturer.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is
not covered in this manual could cause death, serious personal
injury, or damage to the equipment and the surroundings. This
includes any modification to the equipment or use of parts not
provided by Xylem. If there is a question regarding the
intended use of the equipment, please contact a Xylem
representative before proceeding.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety
messages and regulations carefully before handling the product. They are
published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
1 Introduction and Safety
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 3

Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not
personal injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical
Hazard:
CAUTION:
1.3 User safety
Introduction
All government regulations, local health and safety directives must be observed.
Prevent danger due to electricity
All danger due to electricity must be avoided. Electrical connections must
always be carried out in compliance with the following:
• The standard connections shown in the product documentation that is
delivered together with the product
• All international, national, state, and local regulations. (For details, consult
the regulations of your local electricity supplier.)
For more information about requirements, see sections dealing specifically with
electrical connections.
1 Introduction and Safety
4 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

Power lock-out
DANGER: Electrical Hazard
Before starting work on the unit, make sure that the unit and the
control panel are isolated from the power supply and cannot be
energized. This applies to the control circuit as well.
Equipment
locked out by
Name .......................
DANGER
Qualification of personnel
WARNING: Electrical Hazard
Risk of electrical shock or burn. A certified electrician must
supervise all electrical work. Comply with all local codes and
regulations.
All work on the product must be carried out by certified electricians or Xylem
authorized mechanics.
Xylem disclaims all responsibility for work done by untrained, unauthorized
personnel.
1.4 End of life product disposal
Handle and dispose of all waste in compliance with local laws and regulations.
EU only: Correct disposal of this product — WEEE Directive on waste electrical and electronic
equipment
WS009973A
This marking on the product, accessories or literature indicates that the product
should not be disposed of with other waste at the end of its working life.
1 Introduction and Safety
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 5

To prevent possible harm to the environment or human health from
uncontrolled waste disposal, please separate these items from other types of
waste and recycle them responsibly to promote the sustainable reuse of
material resources.
Waste from electrical and electronic equipment can be returned to the
producer or distributor.
EU only: Correct disposal of batteries in this product
WS009974A
This marking on the battery, manual or packaging indicates that the batteries in
this product should not be disposed of with other waste at the end of its
working life. Where marked, the chemical symbols Hg, Cd or Pb indicate that
the battery contains mercury, cadmium or lead above the reference levels in EC
Directive 2006/66. If batteries are not properly disposed of, these substances
can cause harm to human health or the environment.
To protect natural resources and to promote material re-use, please separate
batteries from other types of waste and recycle them through your local, free
battery return system.
1.5 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any
worn or faulty components. The use of unsuitable spare parts
may cause malfunctions, damage, and injuries as well as void
the warranty.
1.6 Warranty
For information about warranty, see the sales contract.
1.7 Support
Xylem only supports products that have been tested and approved. Xylem does
not support unapproved equipment.
1 Introduction and Safety
6 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

2 Product Description
2.1 Product design
The products are part of the Concertor™system. The gateways are connected to
Flygt pumps 6020.180 or 6020.090. The gateway starts and stops the pump
based on the input signal from the external control system. All the alarms are
sent back to the external control system. Data is logged by and stored in the
gateway.
Product name Part number Description
FPG 411 8012100 Gateway for Concertor™EA.
The pump performance is easily adjustable when the
pump is stopped.
FPG 412 8012000 Gateway for Concertor™DP.
Dynamic pump performance change, through 4–20 mA
or Modbus.
2.2 System overview
Concertor™is a wastewater pumping system with integrated intelligent
technology.
2 Product Description
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 7

2.2.1 Concertor™EA
WS009753B
34
1
2
5
Parts
Number Part Description
1 Pump A pump in the Concertor™N system series.
2 Components outside of
the Concertor™system
• Contactors, fuses, relays
• Controller / RTU / PLC
• Level sensors
• Cloud services
• Pump sum-alarm I/O
3 Gateway, FPG 411 • The gateway starts and stops the pump based on the
input signal from the external control system.
– Digital input signal
– Modbus
• All the alarms are sent back to the external control
system.
• The operator changes the pump settings through the
gateway.
• Data is logged by and stored in the gateway.
4 HMI, FOP 312 The HMI is handheld, or mounted inside the cabinet or in
the cabinet door.
The HMI is optional.
2 Product Description
8 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

Number Part Description
5 Embedded web server The embedded web server is an alternative interface with
access to the same menu system as the HMI.
Functions
• Pump clog detection
• Pump cleaning
• Soft-start
• Soft-stop
• Constant power
• Always correct rotation
• Set-up wizard from HMI or webserver
• Set pump performance (pump stopped)
• Pump alarms with priority A or B, through I/O
• Pump and motor control alarms, HMI or Modbus
• Alarm handling
• Status and alarm history
2.2.2 Concertor™DP
WS009754B
34
1
2
5
2 Product Description
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 9

Parts
Number Part Description
1 Pump A pump in the Concertor™N system series.
2 Components outside of
the Concertor™system
• Contactors, fuses, relays
• Controller / RTU / PLC
• Level sensors or flow meters
• Cloud services
• Pump sum-alarm I/O
3 Gateway, FPG 412 • The gateway starts and stops the pump based on the
input signal from the external control system.
– Digital input signal
– Analog input signal
– Modbus
• All the alarms are sent back to the external control
system.
• The operator changes the pump settings through the
gateway.
• Data is logged by and stored in the gateway.
4 HMI, FOP 312 The HMI is handheld, or mounted inside the cabinet or in
the cabinet door.
The HMI is optional.
5 Embedded web server The embedded web server is an alternative interface with
access to the same menu system as the HMI.
Functions
• External process control for dynamic pump performance, 4–20 mA or
Modbus
• Pump clog detection
• Pump cleaning
• Soft-start
• Soft-stop
• Constant power
• Always correct rotation
• Set-up wizard from HMI or webserver
• Pump alarms with priority A or B, through I/O
• Pump and motor control alarms, HMI or Modbus
• Alarm handling
• Status and alarm history
2.3 Approvals
• CE
• UL
• CSA
• RCM
2 Product Description
10 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

2.4 Parts
PWR
RS485
DI
1234GND A
AI AO HMI
12345
BGND
24VDC
+_
+_+_
DI1
DI2
DI3
DI4
DO1
DO2
DO3
DO4
ALARM A
ALARM B
PUMP RUN/CLEAN
PUMP COMMS
RS485
USB
NODE
ADDRESS
ON
OFF
MASTER
SLAVE
TERM
PUMP
DO1
NO COM NO COM
T4 T3 GND
DO2
DO3
NO COM NO COM
DO4
ETHERNET
Concertor™ FPG 411
WS009747B
4
7
8
3
9
0
6
1
2
5
4
3
2
1
1. Front connections
2. Status LEDs
3. Top connections
4. Bottom connections
2.5 The data plate
WS009750D
42 3 61
89
5
7
1. Brand
2. MAC address
3. Country of origin. Manufacturer.
4. Product
5. Rated supply
6. Approvals
7. Waste disposal symbol
8. Serial number
9. Part number
2 Product Description
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 11

3 Mechanical Installation
3.1 Do not install in an explosive zone
NOTICE:
Do not use this unit in environments that may contain
flammable/explosive or chemically aggressive gases or
powders.
3.2 Install the gateway
Snap the unit onto the DIN rail.
WS009751B
3 Mechanical Installation
12 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

4 Electrical Installation
Precautions
Before starting work, make sure that the safety instructions in the chapter
Introduction and Safety on page 3 have been read and understood.
DANGER: Electrical Hazard
Before starting work on the unit, make sure that the unit and the
control panel are isolated from the power supply and cannot be
energized. This applies to the control circuit as well.
Equipment
locked out by
Name .......................
DANGER
DANGER: Electrical Hazard
All electrical equipment must be grounded (earthed). Test the
ground (earth) lead to verify that it is connected correctly and
that the path to ground is continuous.
WARNING: Electrical Hazard
Risk of electrical shock or burn. A certified electrician must
supervise all electrical work. Comply with all local codes and
regulations.
WARNING: Electrical Hazard
There is a risk of electrical shock or explosion if the electrical
connections are not correctly carried out, or if there is fault or
damage on the product. Visually inspect equipment for
damaged cables, cracked casings or other signs of damage.
Make sure that electrical connections have been correctly
made.
4 Electrical Installation
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 13

CAUTION: Electrical Hazard
Prevent cables from becoming sharply bent or damaged.
Requirements
These requirements apply for electrical installation:
• All fuses and circuit breakers must have the proper rating, and comply with
local regulations.
• The cables must be in accordance with the local rules and regulations.
Cables
These requirements apply for cable installation:
• The cables must be in good condition, not have any sharp bends, and not be
pinched.
• The sheathing must not be damaged and must not have indentations or be
embossed (with markings, etc.) at the cable entry.
• The minimum bending radius must not be below the accepted value.
• Use cables with appropriate temperature rating.
4.1 Connect the cables, FPG 411
For more information about the connection terminals, see Terminals on page
24.
PWR
RS485
DI
1234GND A
AI AO HMI
12345
BGND
24VDC
+_
+_+_
DI1
DI2
DI3
DI4
DO1
DO2
DO3
DO4
ALARM A
ALARM B
PUMP RUN/CLEAN
PUMP COMMS
RS485
USB
NODE
ADDRESS
ON
OFF
MASTER
SLAVE
TERM
PUMP
DO1
NO COM NO COM
T4 T3 GND
DO2
DO3
NO COM NO COM
DO4
ETHERNET
Concertor™ FPG 411
WS010235A
4
7
8
3
9
0
6
1
2
5
6
2
1
7
3
4
5
1. Analog output
2. Digital inputs
3. + 24 VDC
4. Modbus slave
5. HMI
6. Digital outputs
7. T3, T4
1. Connect T3 and T4 from the pump.
2. Connect the DeviceNet cable between the gateway and the HMI.
Description HMI terminal Cable color FPG terminal
Ground GND Black 1
CAN low L Blue 2
Shield — Transparent 3
4 Electrical Installation
14 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

Description HMI terminal Cable color FPG terminal
CAN high H White 4
Power +24 V Red 5
3. Connect the external control system.
For more information about connections with Modbus, see separate
documentation.
a) Connect the digital input cables.
1 - 4
GND
1 2
WS010234A
GND
1 - 4
1. Open
2. Closed
Signal Terminal
Call to run DI1
DI1 is closed (active): The pump is active.
DI1 is open (inactive): The pump is inactive
Alarm reset DI2
DI2 is closed (active): Alarm reset. All active
alarms that require manual reset, are reset by
this signal.
DI2 is open (inactive): No alarm reset.
High-level float switch DI3
DI3 is closed (active): The gateway receives a
high level indication from the high-level float
switch.
DI3 is open (inactive): No signal received.
External off switch DI4
The following behavior is valid when the DI4
input is configured to Auto, and an external 0–
Auto switch is connected.
The external switch is in the auto position: DI4
is closed. The Call to run signal runs the pump.
The external switch is in the 0, or Off, position:
DI4 is open. The switch overrides the Call to
run signal and stops the pump.
b) Connect the digital output cables.
The digital outputs are potential free relay outputs. Connect a power
supply unit maximum 250 VAC or 30 VDC.
4 Electrical Installation
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 15

NO
COM
WS009968A
PSU
Signal Terminal
Pump run feedback DO1
Sum alarm A DO2
Sum alarm B DO3
Cleaning active / Contactor enable DO4
c) Connect the analog output cables.
Signal Terminal
Actual power / Actual speed AO
Minimum value: 4 mA
Maximum value: 20 mA
4. Connect the power cables.
The power supply unit must fulfill isolation class II.
4.2 Connect the cables, FPG 412
For more information about the connection terminals, see Terminals on page
24.
PWR
RS485
DI
1234GND A
AI AO HMI
12345
BGND
24VDC
+_
+_+_
DI1
DI2
DI3
DI4
DO1
DO2
DO3
DO4
ALARM A
ALARM B
PUMP RUN/CLEAN
PUMP COMMS
RS485
USB
NODE
ADDRESS
ON
OFF
MASTER
SLAVE
TERM
PUMP
DO1
NO COM NO COM
T4 T3 GND
DO2
DO3
NO COM NO COM
DO4
ETHERNET
Concertor™ FPG 411
WS010235A
4
7
8
3
9
0
6
1
2
5
6
2
1
7
3
4
5
1. Analog input and output
2. Digital inputs
3. + 24 VDC
4. Modbus slave
5. HMI
6. Digital outputs
7. T3, T4
1. Connect T3 and T4 from the pump.
2. Connect the DeviceNet cable between the gateway and the HMI.
4 Electrical Installation
16 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual

Description HMI terminal Cable color FPG terminal
Ground GND Black 1
CAN low L Blue 2
Shield — Transparent 3
CAN high H White 4
Power +24 V Red 5
3. Connect the external control system.
For more information about connections with Modbus, see separate
documentation.
a) Connect the analog input signal cables.
Signal Terminal
Reference power / Reference speed AI 4–20 mA
4 mA = Minimum power / Minimum speed
20 mA = Set power / Set speed
b) Connect the digital input cables.
1 - 4
GND
1 2
WS010234A
GND
1 - 4
1. Open
2. Closed
Signal Terminal
Call to run DI1
DI1 is closed: The pump is active.
DI1 is open: The pump is inactive
Alarm reset DI2
DI2 is closed: Alarm reset. All active alarms
that require manual reset, are reset by this
signal.
DI2 is open: No alarm reset.
High-level float switch DI3
DI3 is closed: The gateway receives a high
level indication from the high-level float
switch.
DI3 is open: No signal received.
4 Electrical Installation
FPG 411, FPG 412 Installation, Operation, and Maintenance Manual 17

Signal Terminal
External off switch DI4
The following behavior is valid when the DI4
input is configured to Auto, and an external 0–
Auto switch is connected.
The external switch is in the auto position: DI4
is closed. The Call to run signal runs the pump.
The external switch is in the 0, or Off, position:
DI4 is open. The switch overrides the Call to
run signal and stops the pump.
c) Connect the digital output cables.
The digital outputs are potential free relay outputs. Connect a power
supply unit maximum 250 VAC or 30 VDC.
NO
COM
WS009968A
PSU
Signal Terminal
Pump run feedback DO1
Sum alarm A DO2
Sum alarm B DO3
Cleaning active / Contactor enable DO4
d) Connect the analog output cables.
Signal Terminal
Actual power / Actual speed AO
Minimum value: 4 mA
Maximum value: 20 mA
4. Connect the power cables.
The power supply unit must fulfill isolation class II.
4.3 Connect multiple units
When multiple units are installed in the same application, cables are connected
in parallel or separately.
4 Electrical Installation
18 FPG 411, FPG 412 Installation, Operation, and Maintenance Manual