Xylem FLYGT Concertor APP 411 User manual

Installation, Operation, and
Maintenance manual
887957_6.0
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
4
7
8
3
9
0
6
1
2
5
Concertor™
APP 411
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
1.3.1 Power lock-out........................................................................................... 5
1.3.2 Qualification of personnel........................................................................ 5
1.4 End-of-life product disposal.............................................................................5
1.5 Spare parts......................................................................................................... 6
1.6 Warranty..............................................................................................................6
1.7 Support............................................................................................................... 6
2 System Description................................................................................................... 7
2.1 System overview................................................................................................ 7
2.2 Concertor™XPC.................................................................................................7
3 Product Description.................................................................................................. 9
3.1 Product design...................................................................................................9
3.2 Approvals............................................................................................................9
3.3 Parts.....................................................................................................................9
3.4 The data plate.................................................................................................. 10
4 Mechanical Installation...........................................................................................11
4.1 Do not install in an explosive zone................................................................11
4.2 Concertor™XPC, single unit...........................................................................11
4.2.1 Install the unit...........................................................................................11
4.3 Concertor™XPC, multiple units.....................................................................11
4.3.1 Install the units......................................................................................... 11
5 Electrical Installation...............................................................................................13
5.1 Precautions.......................................................................................................13
5.2 Concertor™XPC, single unit...........................................................................14
5.2.1 Connect a single unit.............................................................................. 14
5.2.2 Set the switches....................................................................................... 16
5.3 Concertor™XPC, multiple units.....................................................................17
5.3.1 Connect the units.................................................................................... 17
5.3.2 Set the switches....................................................................................... 18
6 Operation.................................................................................................................19
6.1 Startup and operation.....................................................................................19
6.2 LED indicators..................................................................................................19
Table of Contents
APP 411 Installation, Operation, and Maintenance manual 1

7 Maintenance............................................................................................................ 22
7.1 Preventive maintenance................................................................................. 22
7.2 Change the battery......................................................................................... 22
8 Troubleshooting......................................................................................................24
8.1 The unit does not work................................................................................... 24
9 Technical Reference................................................................................................25
9.1 Dimensions.......................................................................................................25
9.2 Environmental requirements......................................................................... 25
9.3 IP rating.............................................................................................................25
9.4 Electrical data...................................................................................................26
9.5 RTC battery.......................................................................................................26
9.6 Terminals.......................................................................................................... 26
Table of Contents
2 APP 411 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
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
1 Introduction and Safety
APP 411 Installation, Operation, and Maintenance manual 3

Hazard level Indication
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 APP 411 Installation, Operation, and Maintenance manual

1.3.1 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.
1.3.2 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 and UK only: Correct disposal of this product — waste electrical and electronic
equipment
• EU: Directive 2012/19/EU on waste electrical and electronic equipment
(WEEE)
• UK: SI 2013 No. 3113
WS009973A
This marking on the product, accessories, or literature shows that the product
should not be disposed of with other waste at the end of its working life.
1 Introduction and Safety
APP 411 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 and UK only: Correct disposal of batteries in this product
WS009974A
This marking on the battery, manual, or packaging shows 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
2006/66/EC or UK SI 2008 No. 2164. 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 reuse, 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 APP 411 Installation, Operation, and Maintenance manual

2 System Description
2.1 System overview
Concertor™is a wastewater pumping system with integrated intelligent
technology.
Specifically designed for sewage pumping stations in collection systems, the
XPC system consists of one to four pumps, with one XPC control unit and one
FPG 414 gateway for each additional pump. Perfect for users who require the
full functionality of the Concertor™system, including maximum energy savings
and clean wet wells.
2.2 Concertor™XPC
Parts
1
2
6
7
5
4
3
WS011095B
8
9
10
No. Part Product name Description
1 Pump 6020 A Concertor™pump.
2 System Description
APP 411 Installation, Operation, and Maintenance manual 7

No. Part Product name Description
2 Controller APP 411 • The controller starts and stops the pump based on
input signals from, for example, level sensors and
high-level switches.
• The operator changes the pump settings through the
local HMI or through a SCADA system over Modbus.
• Data is logged by and stored in the controller.
• All the alarms are available on the local HMI and
Modbus.
• System communication through the backplane.
3 Gateway FPG 414 A gateway that is controlled by the APP 411.
• System communication through the backplane.
• All the alarms and data are sent to the controller.
4 HMI FOP 402 HMI - Alternative 1
• A touchscreen HMI that is used for navigation and
selection in the menus.
• The touchscreen HMI is connected to a web server
that is embedded in the controller.
5 HMI FOP 315 HMI - Alternative 2
• A basic HMI with a jog wheel that is used for
navigation and selection in the menus.
6 Computer – HMI - Alternative 3
• The computer gives access to the same menu system
as the touchscreen HMI.
• The computer is connected to a web server that is
embedded in the controller.
7 Level sensors – • Analog sensor
• Digital switch
8 Cloud connection – Cloud services
9 Connection to
power
– Contactors, fuses, relays
10 Extended I/O
module
FPG 414 A gateway that is used as an extended I/O module
2 System Description
8 APP 411 Installation, Operation, and Maintenance manual

3 Product Description
3.1 Product design
APP 411 is a controller that is part of the Concertor™system. The controller is
connected to Flygt pumps 6020.180/090 or 6020.181/091. The controller starts
and stops the pump based on input signals from, for example, level sensors and
high-level switches.
Product name Part number Description
APP 411 8011900 Controller for Concertor™XPC
3.2 Approvals
• CE
• UL
• CSA
• RCM
3.3 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
WS009747C
4
7
8
3
9
0
6
1
2
5
4
3
2
1
Concertor™
5
1. Front connections
2. Status LEDs
3. Top connections
4. Bottom connections
5. Backplane connector
3 Product Description
APP 411 Installation, Operation, and Maintenance manual 9

3.4 The data plate
WS009750E
42 3 61
89
5
7
8xxxxxx
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
3 Product Description
10 APP 411 Installation, Operation, and Maintenance manual

4 Mechanical Installation
4.1 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.
4.2 Concertor™XPC, single unit
4.2.1 Install the unit
Snap the unit onto the DIN rail.
WS009751B
4.3 Concertor™XPC, multiple units
In a Concertor™XPC system, the controller is installed with FPG 414 gateways.
For more information, see System Description on page 7.
4.3.1 Install the units
1. Connect the backplane connectors.
4 Mechanical Installation
APP 411 Installation, Operation, and Maintenance manual 11

WS011301A
2. Install the backplane connectors on the DIN rail.
WS011302A
3. Snap the unit or units onto the DIN rail.
WS011148B
4 Mechanical Installation
12 APP 411 Installation, Operation, and Maintenance manual

5 Electrical Installation
5.1 Precautions
Before starting work, make sure that the safety instructions 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.
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.
CAUTION: Electrical Hazard
Prevent cables from becoming sharply bent or damaged.
5 Electrical Installation
APP 411 Installation, Operation, and Maintenance manual 13

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.
5.2 Concertor™XPC, single unit
Some of the connection terminals are configurable. For more information, see
the System Installation and Operation Manual.
5.2.1 Connect a single unit
This instruction describes all connection possibilities. Some of them are
optional. Connect only one HMI.
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
4
7
8
3
9
0
6
1
2
5
WS011125A
34 5 8
67
1
2
Concertor™
1. Analog input and output
2. Digital inputs
3. HMI, FOP 315
4. RS-485, Modbus RTU
5. + 24 VDC
6. Digital outputs
7. T3, T4
8. Ethernet
Pump
1. Connect the T3 and T4 cables from the pump to the T3, T4 terminal.
Create as much separation as possible between the power cores and the
control cables. Keep the T3 and T4 cables twisted and shielded as close to
the terminals as possible.
Ethernet
2. Connect the Ethernet cable to the Ethernet terminal.
It is possible to use the Ethernet terminal for multiple communication
options:
– Communication with FOP 402
– Communication with SCADA systems through Modbus TCP
If the Ethernet terminal is used for multiple communication options, then use
an Ethernet switch.
– The Ethernet cable must fulfill category 5.
– For more information about the Modbus interface, see separate
documentation.
FOP 315 HMI
5 Electrical Installation
14 APP 411 Installation, Operation, and Maintenance manual

3. Connect the FOP 315 cable to the HMI terminal.
The maximum cable length is 100 m (328 ft).
Description HMI cable Cable color HMI terminal on the
controller
Ground GND Black 1
CAN low L Blue 2
Shield — Transparent 3
CAN high H White 4
Power +24 V Red 5
Modbus RTU
4. Connect the Modbus RTU cable to the RS-485 terminal.
Analog input
5. Connect the analog input cables to the analog input terminal.
The analog input is passive. The external circuit needs an external power
source.
+
WS011511A
-PSU
AI
Signal Description
4 mA Minimum input
20 mA Maximum input
Digital inputs
6. Connect the digital input cables to the digital input terminal.
1 - 4
GND
1 2
WS010234A
GND
1 - 4
1. Open
2. Closed
Digital outputs
7. Connect the digital output cables to the digital output terminals.
The digital outputs are potential free relay outputs. Connect a power supply
unit maximum 250 VAC, or 30 VDC, 5 A.
5 Electrical Installation
APP 411 Installation, Operation, and Maintenance manual 15

The digital outputs are configurable to be normally open or normally closed.
NO/NC
COM
WS009968B
PSU
Analog output
8. Connect the analog output cables to the analog output terminal.
The analog output is active. The external circuit does not need an external
power source.
+
WS011512A
-
AO
Signal Description
4 mA Minimum level
20 mA Maximum level
Power
9. Connect the power cables to the + 24 VDC terminal.
The power supply unit must fulfill isolation class II.
5.2.2 Set the switches
Set the switches.
Switch Correct setting
NODE ADDRESS, 0–9 All the node addresses in the system must be unique and not 0.
MASTER/SLAVE MASTER
TERM, ON/OFF ON
The groove is perpendicular to the arrow in the node address setting. This
image shows node address 1.
5 Electrical Installation
16 APP 411 Installation, Operation, and Maintenance manual

RS485DI
1 2 3 4 GND A
AI AO HMI
1 2 3 4 5
B GND
24VDC
+_
+_+_
PWR
DI1
DI2
DI3
DI4
DO1
DO2
DO3
DO4
ALARM A
ALARM B
RUN/CLEAN
COMMS
RS485
USB
NODE
ADDRESS
ON
OFF
MASTER
SLAVE
TERM
DO1
NO COM NO COM
T4 T3 GND
DO2
DO3
NO COM NO COM
DO4
ETHERNET
1
2
3
4
5
6
7
8
9
0
WS012553A
DO3
DO4
NODE
ADDRESS
ON
OFF
TERM
1
2
3
4
5
6
7
8
9
0
5.3 Concertor™XPC, multiple units
Some of the connection terminals are configurable. For more information, see
the System Installation and Operation Manual.
5.3.1 Connect the units
When multiple units are installed in the same application, cables are connected
in parallel or separately.
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
4
7
8
3
9
0
6
1
2
5
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
4
7
8
3
9
0
6
1
2
5
WS011149B
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
4
7
8
3
9
0
6
1
2
5
Concertor™ Concertor™ Concertor™
1
2
1. Gateways, controller
2. Backplanes
1. Make sure that the backplanes are connected.
2. Connect the cables for the applicable equipment to all units.
3. Connect the power cables to the + 24 VDC terminal of each gateway or
controller.
5 Electrical Installation
APP 411 Installation, Operation, and Maintenance manual 17

5.3.2 Set the switches
Set the switches.
Switch Correct setting
NODE ADDRESS, 0–9 All the node addresses in the system must be unique and not 0.
MASTER/SLAVE – APP 411: MASTER
– FPG 414: SLAVE
TERM, ON/OFF – Set the termination switch of the first and the last unit in the chain to
ON.
– Set the termination switches of the other units in the system to OFF.
The groove is perpendicular to the arrow in the node address setting. This
image shows node address 1.
RS485DI
1 2 3 4 GND A
AI AO HMI
1 2 3 4 5
B GND
24VDC
+_
+_+_
PWR
DI1
DI2
DI3
DI4
DO1
DO2
DO3
DO4
ALARM A
ALARM B
RUN/CLEAN
COMMS
RS485
USB
NODE
ADDRESS
ON
OFF
MASTER
SLAVE
TERM
DO1
NO COM NO COM
T4 T3 GND
DO2
DO3
NO COM NO COM
DO4
ETHERNET
1
2
3
4
5
6
7
8
9
0
WS012553A
DO3
DO4
NODE
ADDRESS
ON
OFF
TERM
1
2
3
4
5
6
7
8
9
0
5 Electrical Installation
18 APP 411 Installation, Operation, and Maintenance manual