Xylem FLYGT MiniCAS II User manual

Installation, Operation,
and Maintenance Manual
MiniCAS II

Table of Contents
1 Introduction and Safety..............................................................................................................2
1.1 Introduction.......................................................................................................................... 2
1.2 Safety terminology and symbols........................................................................................2
1.3 User safety.............................................................................................................................3
1.4 Product warranty.................................................................................................................. 3
1.4.1 Support...........................................................................................................................4
2 Transportation and Storage...................................................................................................... 5
2.1 Inspect the delivery..............................................................................................................5
3 Product Description....................................................................................................................6
3.1 Product design..................................................................................................................... 6
3.2 Parts....................................................................................................................................... 6
3.3 Approvals..............................................................................................................................6
4 Installation....................................................................................................................................7
4.1 Do not install in an explosive zone.................................................................................... 7
4.2 Connect the MiniCAS II....................................................................................................... 7
4.3 Prevent interference from a variable frequency drive.....................................................9
4.4 Check the sensor output current....................................................................................... 9
5 Operation.................................................................................................................................. 10
5.1 The current levels for alarm lights................................................................................... 10
5.2 LED indications.................................................................................................................. 10
5.3 Reset the alarms after a fault indication.......................................................................... 10
6 Troubleshooting....................................................................................................................... 11
6.1 Check for an earth fault in the sensor circuit..................................................................11
6.2 Check which sensor tripped the leakage alarm............................................................ 11
6.3 Test the function of the relay............................................................................................12
7 Technical Reference.................................................................................................................13
7.1 Dimensions......................................................................................................................... 13
7.2 Environmental requirements............................................................................................13
7.3 Electrical data..................................................................................................................... 13
7.4 Terminals.............................................................................................................................13
7.5 Circuit functions................................................................................................................. 14
7.6 Sensor combinations.........................................................................................................14
7.7 Filter connection diagrams...............................................................................................15
7.8 Filter kits..............................................................................................................................16
Table of Contents
MiniCAS II Installation, Operation, and Maintenance Manual 1

1 Introduction and Safety
1.1 Introduction
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.
• In addition to these instructions, also pay attention to universal safety and accident
prevention regulations.
• Save this manual for future reference, and keep it readily available at the location of
the system controller.
Purpose of this manual
The purpose of this manual is to provide the necessary information for:
• Installation
• Operation
• Maintenance
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
• Product malfunction
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:
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Electrical hazards
Electrical hazards are indicated by the following specific symbol. This symbol warns for
presence of a dangerous voltage.
1 Introduction and Safety
2 MiniCAS II Installation, Operation, and Maintenance Manual

Electrical Hazard:
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.
1.4 Product warranty
Coverage
Xylem undertakes to remedy faults in products from Xylem under these conditions:
• The fault is due to defects in design, materials, or workmanship.
• The fault is reported to a Xylem representative within the warranty period.
• The product is used only under the conditions described in this manual.
• All service and repair work is done by qualified and authorized personnel. All
modifications must be done by qualified technicians.
• Genuine Xylem parts are used.
Limitations
The warranty does not cover faults caused by these situations:
•Deficient maintenance
• Improper installation
•Modifications or changes to the product and installation made without consulting
Xylem
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injury
• Material damage
• Economic loss
Warranty claim
Xylem products are high quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your Xylem
representative.
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.
1 Introduction and Safety
MiniCAS II Installation, Operation, and Maintenance Manual 3

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.
1.4.1 Support
Xylem only supports products that have been tested and approved. Xylem does not
support unapproved equipment.
1 Introduction and Safety
4 MiniCAS II Installation, Operation, and Maintenance Manual

2 Transportation and Storage
2.1 Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the product
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts are damaged or missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
2 Transportation and Storage
MiniCAS II Installation, Operation, and Maintenance Manual 5

3 Product Description
3.1 Product design
The MiniCAS II overall purpose is to protect pumps and mixers. It is a monitoring relay for
temperature and leakage sensors and is made to plug into a standard 11-pin socket.
The relay monitors the following sensors:
Type Description
Thermal contact Temperature sensor for detection of high temperature in the stator winding
FLS Float switch for leakage detection in pumps and mixers
FLS10 Float switch for leakage detection in the inspection chamber
CLS Water-in-oil sensor for detection of excessive water in the oil chamber
3.2 Parts
WS009766A
1
2
3
4
1. LEAKAGE LED
2. TEMPERATURE LED
3. SUPPLY LED
4. 11–pin contact
3.3 Approvals
MiniCAS II Version Part No. Approval
24 V AC/DC 83 58 57 CE, UR, CSA
120 V AC 40–50 10 98 CE, UR, CSA
230 V AC 40–50 15 60 CE
3 Product Description
6 MiniCAS II Installation, Operation, and Maintenance Manual

4 Installation
Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety (page 2) 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.
External switch
This product cannot be used as an emergency stop device.
An external switch or circuit breaker must be provided near the installation to enable the
pump to be isolated from the power supply.
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 Connect the MiniCAS II
An 11–pin socket must be installed in the pump control panel.
The MiniCAS II is used in one of two ways:
• Both overtemperature and leakage alarms stop the pump
• Overtemperature alarm stops the pump and leakage alarm is only indicated.
1. Connect the wires to the 11–pin socket terminals according to the applicable diagram.
See Terminals (page 13).
4 Installation
MiniCAS II Installation, Operation, and Maintenance Manual 7

– Overtemperature and leakage stop the pump
T1 +
–
T2
1
2
3
4
9
8
11
6
7
5
10
~(+) ~(–)
10 s
12 VDC
WS009339A
M
3~
3
1
2
4
5
6
7
89
~(+) ~(–)
10
11
– Overtemperature stops the pump and leakage is only indicated
T1 +
–
T2
1
2
3
4
9
8
11
6
7
5
10
~(+) ~(–)
10 s
12 VDC
WS009340A
M
3~
3
1
2
4
5
6
7
89
~(+) ~(–)
10
11
Position Description
1 Alarm reset
2 Sensor circuit
3 Start and stop by a pump controller
4 Power supply
5 High temperature relay
6 Leakage detection relay
7 High stator temperature alarm lamp
8 Leakage alarm lamp
4 Installation
8 MiniCAS II Installation, Operation, and Maintenance Manual

Position Description
9 Auxiliary relay
10 Pump contactor
11 Pump main supply
2. Insert the MiniCAS II into the 11–pin socket.
4.3 Prevent interference from a variable frequency drive
Interference from a variable frequency drive (VFD) can cause nuisance tripping of the CLS
sensor.
1. Connect a filter between the sensor and the terminal block in the junction box, see
Filter kits (page 16) and Filter connection diagrams (page 15).
Usually with VFD and CLS, this filter is preinstalled.
FLS
CLS
WS009341A
M
3~
7
5
3
1
2
4
5
6
7
8
3
T1 T2
T1T2
1. Pump with junction box
2. Filter
3. Terminal block
4. Screened SUBCAB®cable
5. Control panel
6. MiniCAS II
7. VFD
8. EMC filter
2. Connect the cable to the control panel.
Do not exceed 40 m (130 ft) due to the occurrence of harmonic distortion.
3. Connect an EMC filter between the VFD output and the control panel.
4.4 Check the sensor output current
1. Connect a multimeter in series with the sensor circuit.
T1 +
−
T2
WS009344A
A
+
–
FLS CLS TC x 3
7
5
2. Make sure that the measured values correspond to the applicable sensor combination
values.
3. See Sensor combinations (page 14) for the no fault values.
4 Installation
MiniCAS II Installation, Operation, and Maintenance Manual 9

5 Operation
5.1 The current levels for alarm lights
When the current level is between 3–22 mA, it is only the SUPPLY LED that is light.
Current level (mA) Type of alarm
> 22 Leakage alarm
< 3 Overtemperature alarm
5.2 LED indications
Symptom Cause Remedy
The leakage indicator LED is lit. There is a leakage in the pump. Service the pump. For information,
see Check which sensor tripped the
leakage alarm (page 11).
There is an earth fault in the sensor
circuit wiring.
See Check for an earth fault in the
sensor circuit (page 11) .
The temperature indicator LED is lit. A thermal contact is open. Service the pump.
The CLS is connected with the wrong
polarity in series with the
temperature switches.
Change polarity on the sensor output
of the relay.
The sensor output voltage is low. There is an earth fault in the sensor
circuit wiring.
See Check for an earth fault in the
sensor circuit (page 11).
The relay has a fault. Replace the relay.
The leakage indicator is nuisance
tripping.
The drive unit has CLS and VFD, and is
not protected by a filter.
Install a filter in the drive units
junction box, see Filter kits (page
16)
The drive unit has a CLS and no VFD,
but the fault is due to interference
from other drive units.
Install a filter on the sensor output of
the relay.
5.3 Reset the alarms after a fault indication
After a leakage fault, the relay resets automatically.
After an overtemperature fault, the relay requires a manual reset.
Select one of the following steps to reset the relay:
– Push the external push-button that is connected to pin 6 and pin 7.
When using the 24 V relay, pin 6 and pin 2 also resets.
– Interrupt the power supply for a short while.
5 Operation
10 MiniCAS II Installation, Operation, and Maintenance Manual

6 Troubleshooting
Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety (page 2) have been read and understood.
DANGER: Electrical Hazard
Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical
troubleshooting must be done by a qualified electrician.
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.
6.1 Check for an earth fault in the sensor circuit
1. Measure between the T1 wire and ground (earth).
T1 +
−
T2
WS009342A
Ω
2. Measure between the T2 wire and ground (earth).
T1 +
−
T2
WS009343A
Ω
3. When the value is lower than one megaohm, inspect the circuit wiring in the pump.
A lower value indicates an earth fault.
6.2 Check which sensor tripped the leakage alarm
The sensor circuit has a CLS and FLS connected.
1. Select one of the following steps to disconnect the power to the relay:
Condition Action
No pump runs. Switch off the power to the control panel and switch it back on.
The second pump in a dual pumping station
runs.
Pull out the relay from the socket and insert it back.
2. Measure the time for the leakage alarm to trip from the moment the relay is powered.
Delay time Sensor tripping the alarm
10 s FLS
15 s CLS
6 Troubleshooting
MiniCAS II Installation, Operation, and Maintenance Manual 11

6.3 Test the function of the relay
1. Simulate a normal condition.
a) Connect a 1 kilohm resistor in series with an ammeter to the sensor output.
b) Connect terminal 6 and 7 to reset the relay.
WS009345A
A
+
–
6
7
5
~(+) ~(–)
10 s
12 VDC
1 k
1
3
4
9
8
11
Only the supply LED lights up and the meter shows 12 mA if the condition is
normal.
2. Simulate the temperature alarm.
a) Disconnect the resistor.
The temperature LED is lit.
b) Reconnect the resistor.
The temperature LED is still lit.
c) Connect terminal 6 and 7 for a short while to reset the relay.
The temperature LED is turned off.
3. Simulate the leakage alarm.
a) Connect a lead between terminal 5 and 7.
WS009346A
+
–
6
7
5
~(+) ~(–)
10 s
12 VDC
1
3
4
9
8
11
This short circuit does not damage the unit.
b) Keep the short circuit closed for 10 s.
The leakage LED is lit.
c) Remove the lead between terminal 5 and 7.
The leakage LED is turned of.
6 Troubleshooting
12 MiniCAS II Installation, Operation, and Maintenance Manual

7 Technical Reference
7.1 Dimensions
Parameter Value mm (in)
(W×H×D) 33×79×75 (1.29×3.11×2.95)
7.2 Environmental requirements
Parameter Value
Temperature -25˚ C – +60˚ C
Operating humidity Relative humidity, non-condensing: 90%
7.3 Electrical data
Version 24 VDC 24 VAC 120 VAC 230 VAC
Supply voltage 24 24 120 230
Supply voltage tolerance -2%–25% -17%–25%, ±15%
Frequency - 50–60 Hz
Relay resistive contact rating 24 VDC, 250 VAC, 5 A
Relay inductive contact rating 24 VDC, 250 VAC, 2 A
Sensor output voltage 12 VDC, ±5%
Required power supply 5 W
7.4 Terminals
4359
2161110
87
WS009765A
1. Temperature relay input
2. Power supply +
3. Temperature relay normal output
4. Temperature relay alarm output
5. Sensor input T1
6. Reset input
7. Sensor input T2
8. Leakage relay alarm output
9. Leakage relay normal output
10.Power supply -
11.Leakage relay input
7 Technical Reference
MiniCAS II Installation, Operation, and Maintenance Manual 13

7.5 Circuit functions
T1 +
–
T2
1
2
3
4
9
8
11
6
7
5
10
~(+) ~(–)
10 s
12 VDC
WS009338A
Relay connections Description
1–3 Normal temperature
1–4 Overtemperature
2–10 Power supply: 24 V AC/DC, 120 VAC, or 230 VAC
5–7 Sensor input from drive unit sensors: 12 V
6–7 Alarm reset
11–8 No leakage
11–9 Leakage
7.6 Sensor combinations
The T1 and T2 wires are connected to the sensor input of the relay. Overtemperature
always results in 0 mA sensor output current. The value of the current can vary within 10%.
Combination Configuration No fault
(mA)
Leakage
(mA)
FLS
Thermal contacts
T1 +
−
3301.2 k T2
FLS TC x 3
WS009333A
7.8 36
FLS10
Thermal contacts
T1 +
−
430770 T2
FLS10
WS009334A
TC x 3
10 28
CLS
Thermal contacts
T1 +
−
T2
CLS
WS009335A
TC x 3
CLS must be connected with the correct polarity: brown = + and
black = –.
5.5 29
7 Technical Reference
14 MiniCAS II Installation, Operation, and Maintenance Manual

Combination Configuration No fault
(mA)
Leakage
(mA)
FLS
CLS
Thermal contacts
T1 +
−
3301.2 k T2
FLS
CLS
WS009336A
TC x 3
CLS must be connected with the correct polarity: brown = + and
black = –.
13.3 36–42
Thermal contacts
1 kilohm resistor
T1 +
−
1 k
T2
WS009337A
TC x 3
12 -
7.7 Filter connection diagrams
1. Junction box
2. Filter
3. MiniCAS II
4. Sensor circuit
5. Connection terminals to be removed when using a filter
Filter part number Connection diagram
604 68 00
T1
T2 CLS
WS009347A
+ –
12 VDC
T1
T2
3
1
25
4TC x 3
604 68 01
T1
T2 CLS
WS009394A
+
–
12 VDC 3
124TC x 3
7 Technical Reference
MiniCAS II Installation, Operation, and Maintenance Manual 15

Filter part number Connection diagram
604 68 02
604 68 04
661 60 00
661 60 01
WS009395A
T1
T2 CLS
+
–
12 VDC
T1
T2
3
1
2
4TC x 3
7.8 Filter kits
Drive unit Part.no
3102, 3127, 4430 6046800
3085, 4410 6046801
3140, 3152, 3170, 3201, 3300 6046802
3231, 3306, 3312, 3351, 3356, 3400, 3501, 3602, 3800, 7045, 7061, 7081, 7101, 7115,
7121, 7125
6046804
4630, 4640, 4650, 4660 6616000
4670, 4680 6616001
7 Technical Reference
16 MiniCAS II Installation, Operation, and Maintenance Manual

Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company
We’re a global team unified in a common purpose: creating innovative solutions
to meet our world's water needs. Developing new technologies that will improve
the way water is used, conserved, and re-used in the future is central to our work.
We move, treat, analyze, and return water to the environment, and we help
people use water efficiently, in their homes, buildings, factories and farms. In
more than 150 countries, we have strong, long-standing relationships with
customers who know us for our powerful combination of leading product brands
and applications expertise, backed by a legacy of innovation.
For more information on how Xylem can help you, go to xyleminc.com
Refer to www.xylemwatersolutions.com/contacts/ for contact details of your local sales and service
representative.
Xylem Water Solutions Global
Services AB
361 80 Emmaboda
Sweden
Tel: [phone]
Fax: [phone]
http://tpi.xyleminc.com
Visit our Web site for the latest version of this document
and more information
The original instruction is in English. All non-English
instructions are translations of the original instruction.
©2016 Xylem Inc
892472_13.0_en-US_2016-04_IOM.MiniCASII