Sulzer PC 441 User guide

Brand: Sulzer

Model: PC 441

Category: Measuring, testing & control

Type: User guide

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1.30 m

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352.5 A 353.8 A 354.1 A

1.55 m 1827 l/s

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2013.08.21 05:56:19 Low level

 980.3 l/s

P3 P4

P1 P2

07:25:58 07:28:10 07:30:26

0.15 kWh/m3

CA 511

CA 441

CA 442

CA 443 CA 781

CAN

CA 622

RX/TX

ON-OFF

485-term.

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CAN Bus

www.sulzer.com

Pump controller type ABS PC 441

EN User guide SW 1.70

81307063K (08/2022)

81307063K

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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III

CONTENTS

ABOUT THIS GUIDE, AUDIENCE AND CONCEPTS 1

1 OVERVIEW OF FUNCTIONS AND USAGE 3

1.1 Field bus status indicator ................................................. 4

1.2 CA 511 operator panel ................................................... 4

1.2.1 Status view ............................................................ 6

1.2.2 How to access the status view ............................................. 6

1.2.3 Pump alarms under status view ............................................ 7

1.2.4 Trend curve ............................................................ 7

2 CONFIGURE THE PC 441 9

2.1 Setgeneralconguration,system,IDandcommunicationsettings . . . . . . . . . . . . . . . . . 9

2.2 Congurethedigitalinputs,digitaloutputs,analoginputsandanalogoutputs ....... 11

2.3 Conguretheeldbusunitmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4 Congurethepumppitparameters ........................................ 14

2.5 Settings for pump 1 to pump 4 and their alarms ............................... 16

2.6 Common P1 – P4 ...................................................... 18

2.7 Set log settings and events ............................................... 19

2.8 IfusingCA622;setupcommunicationstosurroundingunitsVFD,softstartersand

energymeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.9 Setupcleaner,mixerordrain(ifused) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 DETAILED DESCRIPTION OF THE FUNCTIONS 21

3.1 Pump controller and/or monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Pumpcapacityandin/outowofthepit ..................................... 22

3.2.1 Auto-setlimitlowpumpcapacityalarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.2 Pit shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.2.3 Pump curve ........................................................... 33

3.2.4 Systemcurve ......................................................... 34

3.2.5 Energyeciency:kWh/volumeunit ........................................ 35

3.3 Overowowcalculation ................................................ 36

3.3.1 Howtocalculateoverowsbyusingconstantsandexponents ................... 37

3.4 Pump alternation ....................................................... 37

3.4.1 Maxnumberofpumpsrunning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.5 Pump reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.5.1 Othersettingsregardingpumpreversing:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.6 Speedcontrolledpumps(VFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.6.1 CongurePC441forVFDpump(s) ........................................ 41

3.6.2 PIDsettings ........................................................... 42

3.6.3 Variablefrequencydriveautoreset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 FURTHER EXPLANATIONS ABOUT SOME DIGITAL/ANALOG OUTPUT/INPUT

TYPES 43

4.1 Digitaloutput:LogicIO .................................................. 43

4.2 Digitaloutputtype:datareg.setpoint ...................................... 44

4.3 Digitaloutputtype:externalresetalert ..................................... 45

4.4 Digitalinputtype:blockremotedate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.5 Digitalinputtype:mixeranddrainpumpblocking ............................. 45

4.6 Analogoutputtype:dataregister .......................................... 45

4.7 Analogueinput:Secondarypitlevelsensor .................................. 46

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5 COMMUNICATION AND AQUAPROG 47

5.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1.1 Com port (screw terminals 48 – 52) ........................................ 47

5.1.2 Serviceport(9-polsD-Subinthefront) ..................................... 47

5.1.3 USBport(USBtypeBinthefront) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1.4 Modem .............................................................. 47

5.1.5 Com Echo PC 441 ..................................................... 48

5.1.6 Alarms ............................................................... 48

5.2 AquaProg ............................................................ 49

5.2.1 HowtosetupAquaProg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.3 Cross reference table ................................................... 50

6 SETTINGS 51

6.1 Select language ....................................................... 51

6.2 Overview of settings .................................................... 51

6.3 Systemsettings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.4 Pump pit settings ...................................................... 54

6.5 Pump 1 to 4 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.6 Commonsettingsforpump1,2,3and4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.7 SettingsforPIDcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.8 Settingsformixer ...................................................... 65

6.9 Drainpump ........................................................... 65

6.10 Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.11 Analoglogging ........................................................ 66

6.12 Settings for digital inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.13 Settings for digital outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.14 Settings for analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.15 Settings for analog outputs ............................................... 69

6.16 Settings for pulse channels ............................................... 71

6.17 Settings for trend curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.18 Communication settings ................................................. 72

6.19 Settingsforeldbusmodules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.20 Common settings ...................................................... 77

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ABOUTTHISGUIDE,AUDIENCEANDCONCEPTS

ThisguidedescribesthepumpcontrollerPC441andtheoperatorpanelCA511.Thepumpcontrollerscanei-

therbeusedstand-aloneorcommunicateall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Sulzerweb).

Audience ThisguideisintendedforsystemadministratorsandoperatorsofPC441pumpcontrollerwithoperatorpanel

CA511orPCprogramAquaProg.

Prerequisites Thisguideassumesthatyoualreadyareacquaintedwiththosepumpsyouaresettocontrolandhavethesen-

sorsandoperatorpanelCA511connectedtoPC441.

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ad-

ditional alarm input.

• Ananaloglevel-sensorhasseveraladvantagesoveroatswitches:itismorerobust(cannotget

stuckorbemechanicallyjammed);itismoreaccurate;itismoreexible(youcaneasilychange

thestartandstoplevels);youcangetreadingsofthewaterlevelinthepit,theinow,overow

andthepumpcapacity;youcanoptimisethepumpperformanceinvariousways,includingexer-

cising,alternativestoplevels,taricontroletc.

• Itisalsopossibletoemployanalternativestoplevel,usuallyalowerlevelthannormal,thatis

eective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two

pumpsormore,youneedtodecideifthepumpsshouldalternate.

3. Iftheelectricityhasdailyvaryingtaris,youmustknowthetimesofhigh/lowtaris.

4. Youmustknowhowoverowwillbemeasured:ifitwillbemeasuredusingbothanoverowdetector(tode-

tect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accuratelymeasuredbya

calculation in PC 441.

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documentsInstallation guidesforrespectiveproduct,PC441,CA511,

CA44x,CA622andCA781,whichcanbefoundonSulzerhomepage.Beforeyoumakeanysettings,oruse

thecontrolpanel,readchapter 1 Overview of functions and usage—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 6 Settings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inthedisplayofCA511oradescriptionhowyoundyourwaythroughthe

menusbykeystrokes.Textsinbold,ishowyouhavetodoachangeofthesettingsintheCA511menu.

Most settings in chapter 6onlyapplytothesystemadministrator,butthefollowingalsoapplytothosewhoonly

operatethecontroller:languageselection,dateandtimesettings,units,backlighttime-out,buzzer,operator

passcode,start/stoplevels.

Glossary and conventions

Todesignateamenuiteminahierarchy,ananglebracketisusedtoseparatethelevels.Example: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

eects.

Cos j: Cosine of the phase angle j between the motor current and the voltage.

Alarm class:ThealarmclasscanbeeitherA-alarmorB-alarm.A-alarmsarethosethatrequireimmediateac-

tion,sooperationalstaintheeldshouldbealertedregardlessofthetimeofday.B-alarmsarelessimpor-

tant,butshouldbetakencareofduringnormalworkhours.

Digital in means a signal that is either on or o (high or low),wherehighisanythingbetween5and24volts

DC,andlowisanythingbelow2volts.

Digital outputAnoutputsignalthatiseitheron or o.

Atonconditionoutputcurrentissourcedfromthepowersupplyandtheoutputishigh(~V+).Ato condition

the output is low (no output current).

Aretypicallyconnectedtorelays.

Analog outputs Anoutputsignalintherange4-20mAor0-20mA.

Sourcedfrompowersupply.

Analog inputsareforsensors,andtheseinputssensecurrentintherange4-20mAor0-20mA.

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1 OVERVIEWOFFUNCTIONSANDUSAGE

PC441isdesignedtocontrol1-4pumps.Itcanoperateapumpstationstandaloneand/orasapumpmonitor.

ForcongurationandoperatorinteractionthegraphicoperatorpanelCA511maybeused.WiththeAquaProg

software(evaluationversionavailable)aPCcanbeusedforcongurationandbackupofsettings.Byadding

amodem,afullremotealarmandmonitoringsolutioncanbeachievedwithjustanAquaWebrentalcontract

orbymostSCADAsystems.Optionalmonitoringmodulesforleakage,temperatureandelectricalparameters

givesahighlyscalablesolutionforoptimalcostandperformance.

ThePC441canworkstandaloneortogetherwithextensionmodules,buttheextensionmodulescannotwork

without the PC 441.

As a pump monitoring devicethePC441oersthemarketacombinedstandardsolutionforsubmersible

pumpandpumpstationsurveillance.Canbesetupforfull-scalemonitoringofoneoruptofoursubmersible

pumps plus ancillaries.

As a pump controllerthePC441controlsthestart/stopofthepumps,oeringastandardizedsolutionfor

sewagepumpstationswithuptofourpumps.Avarietyofsolutionsfromstandardon/ocontroluptoad-

vancedVFDsupportincludingpumpcapacitycalculation.

As a combined control and monitoring devicethePC441canbeoeredasasolutionsupportingboththe

areas above in a single unit.

Modules:

1.CA511-Graphicaloperatorinterface

Max 1 of this unit per system

2.CA622-RS485Communicationinterfacemodule

Max 1 of this unit per system

3.PC441-Pumpmonitoringand/orcontroller

4.CA781-Analoganddigitaloutexpansionmodule

Max 1 of this unit per system

5.CA441-Moisturemonitoringmodule

Max 4 of this unit per system

6. CA442-Temperaturemonitoringmodule

Max 6 of this unit per system

7.CA443-Motorandsupplypowermonitoringmodule

Max 5 of this unit per system

PC 441 is the heart

ofthesystem!Other

modules are optional.

2. 3. 4.

5. 6. 7.

81307063K

8.Sulzerwirelessmodem

Max 1 unit per system

Thebaseunit,PC441,communicateswiththeextensionmodulesviaCANcommunication.

Seetheinstallationguidehowtoconnecttheextensionmodules.Afullyextendedsystemcanlooklikethis:

Modem

Figure 1-1

RS-232 port for a computer

(service port or com echo see 3.8.5)

Power indicator

Field bus indicator

Alarm indicator

USB (service port)

Agreenlampattheveryleftindicatesthattheunitispowered(eitherbatteryormains).

Theredalarmindicatorwillblinkwheneverthereisanunacknowledgedalarm.

1.1 Field bus status indicator

Pumpcontroller,operatorpanelandmonitoringmodulescommunicatesviaaCANbus.

Fixedgreenlight=connectedOK

Flashinggreenlight=searchingformodules

Flashingredlight=InvalidIDsetonmodule

1.2 CA 511 operator panel

Younavigatethemenusbythearrowbuttons.PresseithertheUp or Down arrow button to switch to the menu

view.YouconrmanoperationwiththeEnterbutton,oracknowledgeanalarm.PressingtheEscape button

will cancel the current operation.

Figure 1-2

0 A

1.30 m

0.50 m



1.50 m

0.55 m



1.70 m

0.60 m



1.90 m

0.65 m





352.5 A 353.8 A 354.1 A

1.55 m

1827 l/s

3.8 bar

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2019.01.23 05:56:19 Low level

 980.3 l/s

P3 P4

P1 P2

07:25:58 07:28:10 07:30:26

0.15 kWh/m3

Height of water in pit

Overflow detector

Inward flow to pit

Trend curve

Shows operation

(animated)

Height of water

(animated)

High-level float sensor

Low-level float sensor

Outward flow from pit

Back-pressure

Current consumption for pump

Total pump efficiency

Start / Stop levels

Thedisplayanditsinformationeldsinthedefaulttop-levelview.

Upto4pumpsvia16Din,16Dout,5Ain,4Aout

3 moisture and 5 temperature inputs per pump

Temp L2 & L3

-> CA 511

Station P1 P2 P3 P4 P1 P3

P2 P4

81307063K

Thedefault(top-level)viewofthedisplaydynamicallyshowstheoperatingstatusofthepumpsandconditions

inthepit.Figure1-2showsthesymbolsandexplainstheirmeanings.Theunitwillalwaysreverttothisview

after10minutesofinactivityinanyotherview(suchasshowingmenus).

WhenPC441issettouselessthan4pumps,theviewadaptstoshowactualnumberofpumps.

Power and alarm ThetwoleftmostsymbolsontheCA511panelareforpowerandalarmindication:

indicator

• Buttons at bottom gives direct access to the most common

menus.

• Bottomrightmost“Ackn.”.Buttonwillacknowledgethemostcur-

rentalarmdisplayedonstatusrowattopofdisplay.

• Right buttons will start or stop the pump. (Toggle actual state.)

Bykeepingbuttonpressed,forcedpumprunbelowstoplevelis

possible.

Right-hand buttons Thebuttonstothelowerrightofthedisplayhavethefollowingfunctions:

• To leave the overview image of the pump pit and go into the

menus,presseithertheUp or Down arrow button.

• Yougo“into”amenuitembypressingeithertheRight/Forward

button or the Enter button.

• Youconrm(orperform/execute)anoperationwiththeEnter

button (  ).

• Toexitthecurrentoperation,orleavethemenusandgobackto

overviewimageofthepumppit,presstheEscape button.

Main menu Figure1-3showstheMainmenu,whichyoureachfromtheoverviewimagebypressingeithertheUp or Down

 arroworshortcutkeyMainbelowdisplay:

Main Menu Manual Control

Manual Control Pump 1

Alarm List Pump 2

Show Status Pump 3

Settings Pump 4

Select Language Mixer

Drain Pump

Cleaner

Remote Blocking

Esc  

Figure 1-3 Thetop-levelmenuofthePC441graphicaldisplay.

Howtoselectlanguageandmakeallsettings(menuitemsSelect language and Settings) are described in

chapter 6 Settings.

How to enter values Press Enter to enable editing of a value.

and strings

0 A

1.30 m

0.50 m



1.50 m

0.55 m



1.70 m

0.60 m



1.90 m

0.65 m





352.5 A 353.8 A 354.1 A

1.55 m 1827 l/s

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2013.08.21 05:56:19 Low level

 980.3 l/s

P3 P4

P1 P2

07:25:58 07:28:10 07:30:26

0.15 kWh/m3

Esc

tuv

pqrs

wxyz

jkl

ghi

mno

abc

def

Use the Left/Right buttons to choose the insertion point.

Use the Up/Down buttons to increase/decrease a value or letter.

Valuesandstringscanalsobealteredthroughthealphanumeric

keyboard.

Anasterisk(*)gives=adot(.).

Finishtheeditingbypressingenter.

Esc

tuv

pqrs

wxyz

jkl

ghi

mno

abc

def

• GreenlightisthepowerLED.

• Theredalarmindicatorasheswheneverthereisanunacknowledgedalarm,andthedisplaytells

youthetypeofthealarm.Whenthealarmisacknowledged,thelightturnssteadyred,andremains

lituntiltherearenoactivealarms,thisfunctionsthesameasthePC441alarmindicatorLED.

Direct functions,   Thebuttonsatthebottomandtotherightofthedisplayhavethefollowingfunctions:

bottom and right

displays

81307063K

Passcodes  Therearethreesecuritylevels:

1. Dailyoperations,suchasacknowledginganalarmorstoppingapump,donotrequireanypasscodeor

authorization.

2. Operationalsettings,suchassettingthestartorstoplevelsforthepump,requireapasscodeatthelevelof

Operator;

3. Congurationsettingsthataectthebasicfunctionalityoraccess,suchasthetypeoflevelsensor,require

a passcode at the level of System.

Thefactorydefaultpasscodesare1and2respectively,butthecodescanbechangedunderthemenuitem

Settings > System.WheneverapasscodeforOperatorisrequested,youmaysupplyeitherthepasscodefor

OperatororSystem.

Personal alarm,

and how to reset it  Whenthepumpstationismanned,apersonalalarmcanbeissuedifthemaintenancepersonhasn’tshown

activitywithinacertainperiodoftime.Fordetailsaboutsettingsrelatedtothis,seesection6.3Systemset-

tings (assigning Alarm type, Alarm delay and Max time to reset),section 6.12 Settings for digital inputs (as-

signing Sta in stationtoaDigitalin),andsection 6.13 Settings for digital outputs (assigning Personal alarm

alert to a digital output).

AfterthespeciedMax time to reset,theassignedoutputisactivatedsoavisualoraudiosignalcanalert

themaintenancepersonthatthealarmtimermustbereset.IfthealarmtimerisnotresetwithinAlarm delay,a

personal alarm is sent out.

Toresetthetimer,justpushanybuttononthecontrolpanel.

1.2.1 Status view

One of the useful functions in PC 441 is Status view.InthestatusviewshowsPump running time, Number of

starts, Capacity and Energy consumption.InthosecasesthereCA441,CA442andCA443areinthesystem,

youwillbeabletoseeTemperaturesinthedierentbearings,monitoringtheVibrations,Power absorbed and

Motor current.YouwillalsoseethepowersupplyvoltageL1 – L3iftheisaCA443inthesystem.Allthepump

alarms will show up here in the graphic.

Pump Running Time

Number of Pump Starts

Pump Capacity

Energy Consumption

Temp. Upper Bearing

Temp. Stator

Temp. Lower Bearing

Vibrations

Power absorbed

Motor Current

L1-2 406 V L2-3 406 V

588 h

2940

609 l/s

115248 kWh

68 ˚C

79 ˚C

70 ˚C

2.7 mm/s

196 kW

353.2 A

L3-1 401 V

Total

P 1

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2011.06.23 05:56:19 NO UNACK ALARMS

Figure 1-4 Status view

1.2.2 How to access the status view

Statusviewiseasytobeaccessedbypushingthe“Status”belowthedisplay,andthen“Pump 1”–“Pump 4”

ontherightsideofthedisplay.Seepicturebelow.

Pump Running Time

Number of Pump Starts

Pump Capacity

Energy Consumption

Temp. Upper Bearing

Temp. Stator

Temp. Lower Bearing

Vibrations

Power absorbed

Motor Current

L1-2 406 V L2-3 406 V

588 h

2940

609 l/s

115248 kWh

68 ˚C

79 ˚C

70 ˚C

2.7 mm/s

196 kW

353.2 A

L3-1 401 V

Total

P 1

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2011.06.23 05:56:19 NO UNACK ALARMS

Figure 1-5 How to access Status view

81307063K

It’spossibletousetheleftandrightarrowkeysatthenumeralkey

board to step to the other pumps.

Use up and down arrowstostepbetweendays.

Upto7daysbackcanbedisplayed.

LeavetheStatusviewbyESC.

1.2.3 Pump alarms under status view

IftheField bus modules CA 441 and CA 442areattachedtothePC441andpumpalarmsappears,when

under Status viewyouwillbeabletoseeanindicationwherethefaultisphysicallylocatedinthepump.

Motor protector Pump

or other general Pump

failures from PC 441

DI 2 Electric Area

DI 3 Motor Housing

T3 Hi Temp Lo. Bearing

T1 Hi Temp Stator /

T4 Hi Temp Stator

(T1 & T4 share the same

alarm numbers)

Stator temperature L2 - L3 with

additional CA 442

T2 Hi Temp Up. Bearing

DI 1 Oil Chamber /

or Leakage Pump

from PC 441

Figure 1-6 Pump sensor indications in Status view

Esc

tuv

pqrs

wxyz

jkl

ghi

mno

abc

def

How to access Trend cur ve

1.2.4 Trend cur ve

AnotherusefulfunctioninPC441isTrend cur ve.Hereyoucangetanoverviewofpitlevel,inowandoutow

oranyotherparameteryouchooseovertime.Fourdierenttrendcurvescanbedisplayedatthesametime.

Thereisalsoapossibilitytoadjusttheintervalsamplingforthecurves.Defaultsettingis1samplepersecond.

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

P3 P4

P1 P2

l/s

300

400

12:42:24 12:44:24 12:46:24

Figure 1-7 Trend curve

81307063K

To get a presentation of the curve titles in the menu Trend curve,thenpushEnterthenyouhavetheTrend

curvepictureonthedisplay,thepicturewillappearwiththedescriptionasbelow:

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

P3 P4

P1 P2

l/s

300

400

12:42:24 12:44:24 12:46:24

[Pit Level]

[Pit Inflow]

[Outflow]

[Closed]

Figure 1-8 DescriptionofthecurvesinTrend curve

The presentation will disappear after a few seconds.

One screen of Trend curves covers 300 samplings and that corresponds to 5 minutes in default settings of 1

second.

81307063K

2 CONFIGURETHEPC441

Overview of settings

Eachstationhasanuniquecongurationsetup,buttheprocedureissimilartosetupthese.Thischapterwill

guideyouthroughthebasicsettingsinPC441.Note:Thisdoesnotcoverallcongurations,youmustconsider

yourprerequisites.

The menu item Settingshas21submenuswithmanysettingsthatneedtobeenteredbythesystemadmin-

istrator(althoughtheyallhavesensibledefaultvalues).Thefollowing9notesbelowarearecommended

procedure to setup PC 441.

2.1. Setgeneralconguration,system-andcommunicationsettings

2.2. ConguredesignatedIOfunctionsatDI,DO,AIandAOaccordingtotheelectricalwiringdrawing

2.3. CongureI/Omodules,CA441,CA442,CA443,CA622,CA511andCA781

2.4. Pump pit parameters and alarms

2.5. Setpump1-4settingsandtheiralarms

2.6. CommonP1-P4

2.7. Set log settings and events

2.8. Setupcommunicationstosurroundingunits(VFD,softstartersand/orenergymeters(ifused)

2.9. Setupcleaner,mixerordrain(ifused)

Each of the 21 submenus under settings are described in separate tables in section 6.

To enter the settings area:

Press down arrowonceandyouareinthemenus,continuetopressdownarrowtoSettings,pressEnter.

ThemajorityofsettingsrequireapasscodeforSystemexceptsomesettingsunderthesub-menuSystem and

the start/stop levels under submenus Pump 1-4whichonlyrequireapasscodeforOperator.

AllthesettingscanbedonelocallyformthemenusorbyAquaProg.TheadvantageofAquaProgisyoucan

savethecongurationatyourPCandeasilyrestorethecontrollerifneeded.

2.1 Setgeneralconguration,system,IDandcommunicationsettings

SetupthebasicsystemparametersandcommunicationparametersbyusingthemenusinCA511:

Basic system parameters

• Fromthebasescreen,pressthekeyforSettingunderthedisplay,pressEntertwiceandgivethe

password (default 2).Scrollontheleftpartofthescreentoyourlanguagebyusingtheup/down

arrowkeys,pressEnteratyourchoice.

• UsethedownarrowkeytoStation application and press Enter. Select Pump controller or Pump

monitor byusingtheup/down arrow in the left part of the screen, pressEnteratyourchoice.Use

thedownarrowkeytoMain graphics and choose the base screen (Pump pit statusoranypump)

• UsethedownarrowkeytoSelect units,metricorUSunits,pressEnteratyourchoice.

• UsethedownarrowkeytoDate format,pressEnter.Chooseyourdateformat.

• UsethedownarrowkeytoSet date,Set time,andallothersettingsunderthisparameter.

• Set System alarmsaccordingtoyourpreferences.

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Communication parameters

• Fromthebasescreen,pressthekeyforSettingunderthedisplay,scrolldownbyusingthedownar-

rowkeytoCommunication and press Enter. Press enter again and select Protocol (Modbus/Comli/

ModbusTCP)andpressEnteratyourchoice.Pressleftarrowkeytogobacktotheleftpartofthe

screen. Use the down arrow to Com port and press Enter. Select Station ID,PressEnter.Typein

yourStation IDbyusingnumeralkeysorup/downarrowkeys,requiredforAquaWeboranyother

surveillancesystem.SelectBaudrate,Parity and Handshake.Usetheleftarrowkeytogobackto

the left part of the screen and select Service port,pressEnter.SelectBaudrate for the service port.

• Selectmodemtype

Nowit’spossibletoconnecttoAquaProgthroughserviceportorUSB.

In AquaProg:

Figure 2-2 Communication

Figure 2-1 Systemsettings

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2.2 Congurethedigitalinputs,digitaloutputs,analoginputsandanalog

outputs

SetdesignatedIO-functionsaccordingtotheelectricalwiringdrawing.Seeyourdrawingsofthestation.

Under Settings, Digital inputs;chooseforeachinputaccordingtotable2-1andDigital outputstotable2-2.

Digital outputs

OFF

Pump control

Reset motor protector

Pump fail

Too many pumps blocked

One pump fail

Master reset motor protector

Mixer control

Reset motor protector Mixer

Drain pump control

Reset motor protector Drain

Cleaner control

Modem control

Remote control

Personnel alarm

High level

Alarm alert

Not ackn. A-alarm

Not ackn. A/B-alarm

Active A-alarm

Active A/B-alarm

Pump reversing

Active B-alarm

Logic IO

Data register set point

Extern reset alert

Under Settings, Analog inputs,chooseforeachinputaccordingtotable2-3.Analoginput1isxedtoleveland

cannot be changed.

Table 2-3: Table 2-4:

Analog input 2-5

OFF

Motor current P1-P4

Back-pressure

Vibrations

Free choice

Vibrations P1-P4

Xylem MiniCas Sim P1-P4

Outow meter

Note

 Analog1ispredenedtolevelsensor

and cannot be changed.

Analog outputs

OFF

Pit level

Pit inow

Pit outow

Pit overow

Pulse channel 1

Pulse channel 2

Pulse channel 3

Pulse channel 4

PID controller

Data register

Table 2-1: Table 2-2:

Digital inputs

OFF

Pump run indication

Manual pump start

Pump not in auto

Start oat

Pump failure

Motor protector

High temperature

Leakage

Stop oat P1-P4

Low level oat

Overow sensor

High level oat

Drain pump oat

Run indicator Drain pump

Motor protector Drain pump

Run indicator Mixer

Motor protector Mixer

Staff in station

Alarm reset

Power fail

DI pulse channel 1-4

Block PID controller

Alarm input

Mixer block + Alarm input

Drain pump block + Alarm input

Block remote data

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In AquaProg:

Figure 2-3 Analoganddigitalinputs/outputs

2.3 Conguretheeldbusunitmodules

AlltheextensionmodulestoPC441areoptional.ThecommunicationisdonebytheCAN-bus.SeeInstal-

lation guide CA 441, CA 442, CA 443(P/N:81307058)onSulzerhomepageformoredetailinformationto

setup Leakage, Temperature and Power monitors.InstallationguidestoCA511(P/N81307061),CA622

(P/N81307133)andCA781(P/N81307132)canalsobefoundatSulzerhomepage.

CA 441 Leakage module

AsystemwithPC441cancontainuptofourCA441modules.

OneCA441modulecanmonitorleakageinoneorfourpumps

dependingonthesettingoftheaddressknobonthefrontof

themodule,seeInstallation guide CA 441, CA 442, CA 443

(P/N:81307058)formoreinformation.Ifusingonemoduletofour

pumps,thereisoneinputforeachpump.IfusingoneCA441

moduleforeachpump,therearefourinputstoeachpump.

Inthesettings,youmustspecifythatthemodule(s)areconnected

andwhichtypeofsensortypeyourpumpshave.DefaultisABS

standard and can be changed to Xylem (ITT Flygt).

CA 442 Temperature module

PC441supportsuptosixunitsofCA442.OneCA442module

can monitor temperatures in one or four pumps depending on the

settingoftheaddressknobonthefrontofthemodule,seeInstal-

lation guide CA 441, CA 442, CA 443(P/N:81307058)formore

information.Ifusingonemoduletofourpumps,thereisoneinput

foreachpump.IfusingoneCA442moduleforeachpump,there

arefourinputstoeachpump.Inthesettings,youmustspecify

sensortypes(Klixon/Pt100/PTC).

EachmodulefromCA442-1(“-1”referstotheaddressonthe

knob)toCA442-4hasa4-20mAVibrationinput,oneforeach

pump.ThevibrationinputsaredisabledinunitsCA442-5and

CA442-6.

CA 441

CA 442

CA 443

CA 441

CA 442

CA 443

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CA 443 Power monitor module

PC441supportsuptoveCA443modules,onemoduleforeach

pumpandoneforwholesystem.CA443modulescannotbe

usedtogetherwithVFD.TheCA443modulesmustbeconnected

beforepumpcontactorsotheinputsL1-L3nevergetpowerless.

Iftheinputsgetpowerless,thephasealarmgoon,andthepump

willnotstart,seeInstallation guide CA 441, CA 442, CA 443

(P/N:81307058)formoreinformation.

CA 511 Graphical operator interface panel

PC441supportsoneCA511.ItisnotpossibletouseoneCA511

toseveralPC441s.CA511isconnectedtoPC441viaCAN-bus

andhasaCAN-busterminationontheback.Thermwarever-

sioninCA511mustconformtotheversioninPC441.Alwaysuse

thelatestrmwaretoensurefullfunctionality.

CA 781 Output expansion module

CA781isamodulewhichgivesyoueightextradigitaloutputs

andtwoextraanalogoutputs.CA781modulemustbepowered

from the same source as PC 441 and cannot be powered from

theCAN-busbecauseofitshigherpowerconsumption.PC441

supportsoneCA781module.SeeInstallation and user guide

(P/N81307123)onSulzerhomepageformoreinformation.

CA 622 RS 485 communication module

PC441cancommunicatedirectlytoVFDs,energymetersand

softstartersviaCA622module.CA622actsasModbusmaster,

communicating with attached Modbus slave devices. See the In-

stallation and user guide(P/N81307133)onSulzerhomepagefor

moreinformationandwhichVFD,energymetersandsoftstarters

PC441andCA622support.Ifmissingyourmodel-contactCon-

trol&MonitoringatSulzerandwemightbeabletoaddthenew

model.PC441supportoneCA622inthesystem.

WhenusingCA622inthesystem,thevaluesfrommany

parameterscanbereadoutbytheRS485busdirectfromVFD/

softstartersorenergymetersandstoredinthecontroller.These

valuescanalsobelogged.PC441togetherwithCA622canalso

controltheon/o,speedandreversingofthepumps.Consult

theInstallationanduserguideCA622(P/N81307133)onSulzer

homepageformoreinformationaboutwhichVFD/softstarters/

energymetersPC441andCA622supports.

CA 441

CA 442

CA 443

Esc

tuv

pqrs

wxyz

jkl

ghi

mno

abc

def

0 A

1.30 m

0.50 m



1.50 m

0.55 m



1.70 m

0.60 m



1.90 m

0.65 m





352.5 A 353.8 A 354.1 A

1.55 m 1827 l/s

MAIN STATUS SETTING TREND ALARM ACKN.

PUMP 4

PUMP 3

PUMP 2

PUMP 1

2013.08.21 05:56:19 Low level

 980.3 l/s

P3 P4

P1 P2

07:25:58 07:28:10 07:30:26

0.15 kWh/m3

CA 511

CA 781

CAN

CA 622

RX/TX

ON-OFF

485-term.

0V -485 +485

678

A B

V+ H Shld L V-

1235 4

CAN Bus

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2.4 Congurethepumppitparameters

Table 2-5:

Pit settings

Level sensor type

Max number of pump running

Min time between relay change

Alternation

Alternative stop level

Start/stop on fast change

Station ow*

Calculation of pump capacity*

Overow

Backup running

Pit alarms

Pump blocking

Level sensor check

Tariff control

Level above sea

* MUST for accurate pump capacity calculation

Level sensor type (required parameter, default level sensor)

Analogsensororstart/stopoats.Analogsensorisrecommendedifyouwanttotrackthecapacityofthe

pumps and pumping volume.

Max number of pumps running (optional parameter)

Ifyourpipesystemcannothandletoohighows/pressureoryourpowergridhaslimitations,reducenumberof

pumps running at the same time. See section 3.4.1

Alternation (optional parameter)

Normalorasymmetrical

Normal:Thepumpsstartinsequencefrom1-4.Thereisalwaysonepumpstartattherst(lowest)startlevel.

Asymmetrical:Thepumpsaredividedintwogroupsthereonegroupisworkingmorefrequentlythantheother

group. See also section 3.4

Alternative stop level (optional parameter)

Thisfunctionistoaidreductionofsedimentsinthepitandavoidingoatingcrust

Start/stop on fast change (optional parameter)

Forexample:Ifthepumpstationispumpingclearwaterandaheavyrainllsthepitveryfast,thepumpcan

start before the level reach the start level.

Station ow (recommended parameters)

Under Meas. parameters set the Inow calculation=ONandyourpitshape,alsothefunctionEmptying or

Filling the pit must be set. System curve at duty pointisusedifthereisn’tanyOutlet pressure sensor.

Recommended is to setup the Pit area under Station ow.That’sbecausethepumpcalculationsshallpreform

as accurate as possible. This are bound to Energy calculation,Pump capacity and Outlet calculations. Best

accuracyofpumpcapacitycalculationsandpumpedvolumeiswhenanOutlet pressure sensor is used.

See section 3.2 for more information.

Calculation of pump capacity (recommended parameter)

Recommended to set Calculation=ON.Thelevelmustbeinthespanofminimumandmaximumduringthe

calculations.Makesurethatthealltimestogetherinstart delay/calculation time/stop delay in total must be in

oneandthesamepumpsequence.Seesection 3.2 and forward.

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Overow (optional parameter)

Overowcanbedetectedbyanoverowdetector(MD137)orbythecertainlevel.Seemoreinformationabout

overowin section 3.3.

Backup running (optional parameter)

BackuprunningstartwhenaHigh-level oatgetsactivated.Youcanspecifywhichpumpsshallparticipatein

backuprun,andhowlongthepumpshallrun.

Pit alarms (some parameters are recommended)

There are several alarms which can be set under Pit alarms.EachalarmiscongurabletobeA-orB-alarms.

Consultyourdrawingsandverifywhichareimportantforyourinstallation.

Pump blocking (optional parameter)

Thepumpcanbeblockedonremote.Thereisatimeoutwhichreleasestheblockingafteracertaintime.

BlockingonLow level oat and/or High pressure can be set here.

Level sensor check (optional parameter)

Level sensor checkItispossibletocheckthelevelsensorreadingcomparedtotheinstalledoats.Seethe

settings under Level sensorchecksetthisup.

Tari control (optional parameter)

Thisfunctionistoreduceenergyconsumptioninhoursofhighcostofenergy.Youcansetthisupforseparate

daysintheweek.

Level above sea (optional parameter)

Ifyoutypeinavaluehere,thisvaluewillbeaddedinthepitlevelbutnotaectthestart/stoplevels.

In AquaProg:

Figure 2-4 Pump pit settings

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2.5 Settings for pump 1 to pump 4 and their alarms

Hereyoucangivethepumpatagname(max20characters).InstalledpumpsmusthaveRelay control

pump=YES,otherwisethepumpwillnotshowupinCA511graphics.Alternately;ifpump3andpump4are

notinstalled;Relay control pump=NO that pump disappears from the graphics.

Importantparametertosetupforeachpump:

Typeofpump(xedorVFD)

Runningindication(digitalinput,motorcurrentoreldbusmoduleCA622)

Start/stop level

Pump alarms

Pump curve

Optionalparameters:

Time settings

Pumpblocking

Pumpblockingonalarms

Dryrundetection

Type of pump:

• Fixedpumps

A digital output starts the pump

• Speedcontrolledpump(PID/VFD)

Start a VFD which has predened frequency

Pump parameters:

• Set the nominal current for the pump

• Set the power factor for the pump

Usefulparameterstodetectdryrunandheavyload

Select run indication:

• Digitalinput

• Motor current

Require current transformers connected to an analog input

• ModbusCA622

RS 485 communication to/from VFD or soft starter

Start/stop levels for each pump

Recommendedtohavedierentstartlevelsforallthepumps.Samestoplevelforallthepumpsisne.

Time settings (optimal parameter)

Setthemaximumruntimeforthepumps

QH curve (pump curve)

Togetaccuratevaluesforpumpcapacityandpumpedvolume,thisparameterisimportant.Seechapter5for

more information about pump curve.

Mixer prestart

IfMixerfunctionisselectedandthePC441isactingasa[Pump controller],theMixerwillbestartedbefore

therstpumpisstarted.Thisallowsthemixertimetospeedupbeforeanypumpisstarted.

ThisistrueiftheMixerispumpstartcountcontrolled.

IftheMixeristimecontrolled,itwillstartindependentofpumpstart.

Inbothcasesminandmaxlevelformixstartmustbeperformed.

Congurethepumpstartdelayinmenu:

Settings / Pump x / Time settings/ Threshold on delay.

Youmustsetthisdelayonthepumpwiththeloweststartlevel.

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Sulzer PC 441 User guide

Brand: Sulzer

Model: PC 441

Category: Measuring, testing & control

Type: User guide

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Sulzer PC 441 User guide

Sulzer PC 441 User guide

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