Installation manual
Contents
1. 0000 00 OO Figure 9 N B Terminals 6 8 and 10 are connected together internally N B Terminals 29 31 33 59 are connected together internally N B and J are activated at normal operation APP 541 Installation manual 13 Troubleshooting Troubleshooting Troubleshooting Power on LED does not light up Alarm status LED red Check the external mains switch and mains fuse or miniature circuit breaker Is power supply off Contact FLYGT service agent Blocked displays steady light Pump status indicator red LED Check that Manual 0 Auto selector is set to Auto If not Manual 0 Auto is used jumper the auto input Pump fails to start Check that Auto is selected in from P1 Status to P4 Status menu as appropriate Alter if necessary Contact FLYGT service agent Figure 10 14 Alarm status LED Red Check Alarm log menu Alarm High temperature P1 P4 motor winding has tripped due to high temperature Contact FLYGT service agent Alarm Tripped P1 P4 External motor protection has tripped Contact FLYGT service agent Alarm Max run P1 P4 Contact FLYGT service agent Thermal overload switchin Go to next Alarm Check configuration of general purpose inputs and wi2. 1 The tissue in plants that brings water upward from the roots 2 A leading global water technology company We re 12 000 people 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 xylem Let s Solve Water Xylem Water So utions AB Visit our Web site for the latest version of this document and Geass II Ze 33 more information esallvagen 1 74 87 Sund byberg The original instruction is in English All non English S d instructions are translations of the original instruction weaen Tel 46 8 475 60 00 2011 Xylem Inc Fax 46 8 475 69 00 http tpi xyleminc com 896810_2 2_en US_2012 10_IOM_ APP541
3. see the Wiring diagram page 11 DKG 4 1 2 3 4567 8 910 OO PREPPED 24 VDC Figure 5 Digital outputs The digital outputs are connected to terminals 11 22 see the Wiring diagram page 11 The outputs are potential free relays with a max rating of 2 A at 230 V AC or 30 V DC Communication To install the communication module in the operator panel follow the instructions below N B Make sure that the power supply is disconnected APP 541 Installation manual Electrical installation 1 Release the four screws 1 holding the rear cover to the front of the unit 2 Lift off the rear cover 2 Figure 6 3 Unpack the communication module 3 4 Place module 3 in the position 4 Figure 7 5 Make sure it is securely in position 6 Refit the rear cover Connection to communication equipment Connect the enclosed dedicated modem cable from the modem radio to the RS232 connector on the COM1 Connect the modem radio to a power supply Connection to a PC using a fixed line Connect a dedicated null modem cable from the PC to the RS232 connector on the COM1 N B A common misunderstanding is to confuse the use of a modem cable and a null modem cable Normally a modem cable has a male contact in one end and female contact in the opposite end The null modem cable has normally female contacts in both ends Note that they are
4. 1 Mark the positions of holes A and B on the cubicle door Figure 1 2 Drill small pilot holes and then open up e Holes marked A to 3 16 in 5 mm in diameter e Holes marked B to 5 16 in 8 mm in diameter 4 APP 541 Installation manual Mechanical installation 3 Tape with masking tape between the outsides of holes marked B a pay HE B B B Ba iE mt LN Figure 2 4 Use a jigsaw or some other suitable tool to make the opening for the operator panel in the cubicle door 5 Place the operator panel in the opening Fit the washers and nuts and tighten them firmly Notice about mounting front seal according to IP 65 1 O module WARNING Be careful not to get any grease in your eyes and avoid prolonged skin contact Wash your hands afterwards To assure a front seal according to IP 65 the front unit has to be mounted on to a rigid and smooth surface If otherwise mounted on to a textured surface and or flexible steel plate cabinet it is normally necessary to apply a thick layer of grease on the sealing surfaces to obtain sealing according to IP 65 Suitable grease is Gleitmo 1810v After application wipe gently all overflowing grease away NOTICE Do never use grease containing silicone since this might seriously damage sensitive electric contact surfaces inside the cabinet The I O module has clamps at the rear 1 Place the unit in a
5. AHH1801 Rev 1 02 or later e Com module TMX1801 Rev 1 00 or later System Software 2 73 or later Application 1 44 or later Product Overview APP 541 is a pump controller It consists of two parts a DIN rail mounted O module and an operator panel APP 541 can use a PSTN GSM GPRS or radio modem to communicate with a SCADA system for example AquaView A special communication module is available for this purpose Safety rules for the owner operator e All government regulations local health and safety directives must be observed es All danger due to electricity must be avoided Guarantee e Modifications or changes to the unit installation should be done only after consulting Xylem e Genuine spare parts and accessories authorized by the manufacturer are essential for compliance with the terms of the guarantee The use of other parts may invalidate the guarantee This manual In order to avoid repetition of information this manual describes how one pump P1 should be read or entered If a second pump or more pumps are included in the installation the corresponding steps must be repeated on those too Symbols used WARNING Safety instruction Risk of personal damage Electrical Hazard Safety instruction Risk of personal damage dangerous voltage 2 APP 541 Installation manual Read this first NOTICE Special attention value Risk of apparatus or component damage Safety Instruction NOTICE Observe all
6. different connected internally to the contact pins Be sure to use the right cable for each purpose N B For configuration see the User manual 10 APP 541 Installation manual Wiring diagram Wiring diagram 100 240 V AC Table 2 Power supply See a so Power supply Power supply See a so Power supply page 7 page 7 Power supply phase neutral and Battery backup 24 V DC Option 26 ground 100 240V AC 50 60 Hz 1 2 27 3 Analogue inputs See also Connections Digital inputs See a so Connections page Ell page 8 Level sensor input 4 20 mA 4 5 6 Motor protector to pump 1 28 29 Current transformer for pump 1 3 0 1 Start feedback from pump 1 30 31 AAC 7 8 Current transformer for pump 2 4 0 1 Motor protector to pump 2 32 33 AAC 9 10 Digital outputs See also Connections Start feedback from pump 2 34 35 page 8 Start pump 1 11 12 Motor protector to pump 3 36 37 Start pump 2 13 14 Start feedback from pump 3 38 39 Start pump 3 15 16 Motor protector to pump 4 40 41 Start pump 4 17 18 Start feedback from pump 4 42 43 Common alarm output 19 20 General purpose input 1 44 45 Emergency operation 21 22 General purpose input 2 46 47 Operator panel See also Installing the General purpose input 3 48 49 Unit page 4 Operator panel 24 V DC 23 24 General purpose input 4 50 51 Communica
7. precautions for handling electrostatically sensitive devices before opening the unit The front surface of the APP 541 has a high degree of protection against moisture and dirt but should always be installed so that it will not be unnecessarily exposed to water or the risk of external physical damage The APP 541 may be used only in the manner specified by the manufacturer The manufacturer does not allow any internal modifications to be made in the unit Always keep this manual in the vicinity of the installed unit APP 541 Installation manual 3 Mechanical installation Mechanical installation Installing the Unit WARNING e The unit must never be installed in an explosive or flammable environment es Ifthe pump is installed in an explosive environment its thermal overload switch must be connected Equipment cubicle Ensure that the operating temperature of the cubicle is between 4 F and 122 F Heating will normally be required in winter if the cubicle is located outdoors orina similarly cold environment The cubicle temperature may become too high in summer if ventilation is inadequate Heating of the cubicle is also recommended to avoid condensation Mounting instructions The enclosure is designed for mounting into a rectangular hole in a larger cabinet door A rubber gasket will seal against the front surface of the cabinet door Studs welded to the rear of the front plate must enter into holes in the cabinet door
8. suitable location on a DIN rail 2 Connect the cables supplied between the operator panel and the O module Secure the cable so that they will not be nipped Note The Ethernet cable is a crossover UTP RJ 45 cat 5e The cable length is 6 ft max length 10 ft Level sensor installation N B For details on installation in the pump sump refer to the level sensor documentation APP 541 Installation manual 5 Mechanical installation 4 20 mA level sensor WARNING The sensor may be installed in an explosive or flammable environment provided that an external Ex barrier is used The sensor shield must be connected to the earth ground terminal of the APP 541 as shown in the diagram under Connections page 8 ENM 10 level regulator WARNING ENM 10 level regulators may be installed in an explosive or flammable environment provided that an intrinsically safe Ex barrier is used The figure shows installation of ENM 10 level regulators in the pump sump High level switch Low level switch Figure 3 APP 541 Installation manual Electrical installation Electrical installation Safety instruction Electrical Hazard Do not open machine with the grounding wire disconnected More than one live circuit The electric wiring should be done only by an authorized electrician All electrical installation work must be carried out with the equipment disconnected from the power supply without any possibility of being made l
9. unit and operator panel Crossover UTP RJ 45 cat 5e 6 ft max length 10 ft Contact your local Xylem supplier for valid modems in your area Options and Accessories Table 4 Power supply and Battery backup unit Ope pe 40 501483 Power supply with batteries 2 2Ah 40 501517 Power supply with batteries 7 2Ah 40 501216 Power supply DR 75 24 gt 230 or 115VAC 24 VDC 3 2A 18 APP 541 Installation manual Technical Specification Is ee Sg 40 501190 APP battery backup unit 2Ah to be used with 40 501216 Table 5 Level sensor 4 20 mA pressure transmitter O pe pee E o 40 501200 LTU501 Range 0 5 0 m 15 m cable 40 501201 LTU501 Range 0 10 0 m 15 m cable 40 501202 LTU501 Range 0 2 0 m 10 m cable 40 501203 LTU501 Range 0 5 0 m 10 m cable 40 501204 LTU501 Range 0 5 0 m 20 m cable 40 501205 LTU501 Range 0 5 0 m 30 m cable 40 501206 LTU501 Range 0 10 0 m 10 m cable 40 501207 LTU501 Range 0 10 0 m 20 m cable 40 501208 LTU501 Range 0 10 0 m 30 m cable 843061 LS100 Range 0 3 5 m 20 m cable 843058 LS100 Range 0 5 0 m 15 m cable 843062 LS100 Range 0 5 0 m 25 m cable 843059 LS100 Range 0 10 m 15 m cable Table 6 Ultrasonic level sensors 4 20mA Opo e 839422 LSU100 Range 0 5 m 15 m cable 839424 LSU100 Range 0 10 m 10 m ca
10. Installation manual Autamatic Pump Pibt APP 541 APP 541 FLYGT a xylem brand Table of Contents Table of Contents Read eet gek Seeerei A 2 rte tege E Oh cet el E 2 PRODUCE OV Ieren ere Dee desist eaten Geer 2 Safety rules for the OWNEL OPELAtON ee eceescessseseseseeesesesescetesesesessueeseseseseeecseseaesecseseaeeeeeeserenseeeetseees 2 GU Ara EE 2 h nt ae EE E 2 oes eek 2 Safety St UCE OM case sci ceae tas Osan ee ceatas ee Ee 3 Mechanical mstallatton rtt 4 aee a ERSA E E Ee 4 lev l Sensor installati Essen T E E NE 5 Electeal EEO a E E E E E 7 SHEET H NEE H Erer entev Gp talerpt beer Seege EENEG Deen 8 une 8 COMMU CEO 352652252 sate etches ech ao Sh bulbs eek Secret lees Dee ee 9 Wiring ET EE 11 Wiring diagram 100 240 NA 11 Wiring diagnani24 VDE vst ssescest ot alta atest eg oh ected alee tet das a Se ated Sia tes Sec N 12 TrOUBISSHOOLING erte oe oh aa arenes ade nas te nai de os 14 TROUBISS MOORING EE 14 Technical S EreeeCatleft eenegen Stegen dees E E a dh aie hase een eae le det 15 Techmicalspecificatioi irissen Medan Eet eebe Ee aati he ee 15 Options and RE 18 APP 541 Installation manual 1 Read this first Introduction Before starting installation of the APP 541 read this chapter carefully It contains general information on documentation safety and guarantee This manual is applicable to the following APP 541 versions Hardware e Operator panel AFH1801 Rev 1 02 or later e O module
11. and a power supply relay controlling the pump This function will provide an emergency function that will run the station on the high level switch even if the control unit is out of operation Connections Digital inputs Inversion of inputs Analogue input The terminal blocks on the APP 541 are described below and are shown in the Wiring diagram 100 240 VAC page 11 The digital inputs are connected to terminals 28 59 see the Wiring diagram 100 240 VAC page 11 Each input has power supply but the terminals for all inputs are connected internally The digital input signals can be inverted to change the operating mode from closing to opening or vice versa 0 indicates no inversion This is the default state See the User manual Analogue terminals Table 1 Shield 24 VDC input 0V Input for current transformer with 0 1 A AC output Input for current transformer with 0 1 A AC output Passive sensor APP 541 Installation manual Electrical installation A passive sensor 4 20 mA is connected to terminals 4 5 see the Wiring diagram page 11 and is powered by the MIO 501 board The input can carry a maximum total voltage of 16V L x EI 4 i 2 3 45678910 OOO IQ0OQQQQ Ge Figure 4 Active sensor An active sensor 4 20 mA has its own power supply and is connected to terminals 5 6
12. ble Table 7 Overflow sensor O pe peoo 843053 S003 Overflow sensor 15 m cable 843054 S003 Overflow sensor 25 m cable Table 8 Level regulator Can only be used for High Low level Ope e 582 88 02 ENM 10 Blue 1 2 kg 0 95 1 10 6m 582 88 03 ENM 10 Blue 1 7 kg 0 95 1 10 13m APP 541 Installation manual 19 Technical Specification Opo p a 582 88 04 ENM 10 Blue 2 2 kg 0 95 1 10 20m Table 9 Over voltage protection Zener barrier a ae 0 843052 Single channel safety barrier for transmitters 4 20 mA Active 0O 840107 Two channel safety barrier for ENM 10 Digital Switch Table 10 Current transformer O pe Jee 40 501210 Current transformer 50 1A 40 501481 Current transformer 100 1A Table 11 Communication equipment O pe pe 40 501152 Communication module including modem cable 40 501529 Modem TDW 33 12 36 VDC V90 Europe 40 501530 Modem TDW 33 12 36 VDC V23 Europe 40 501300 Modem GDW 11 GSM modem 24 VDC 40 501465 Modem EDW 100 serial ethernet adapter 24 VDC 40 501275 Antenna Low Profile Roof Mounted GSM antenna 40 500956 Power supply PS 12 12 V 10W for TDW 33 GDW 11 EDW 100 Installations tee E ETETE ET ET O date B A E A E E 20 APP 541 Installation manual Xylem zilam
13. ive and in accordance with local regulations An ON OFF isolating switch must be provided adjacent to the installation to enable the APP 541 to be isolated from the power supply This isolating switch must be located close to the APP 541 and must be easily accessible to the user The isolating switch should be marked to show that it belongs to the APP 541 When installing electronic measuring and control systems it is important that the cabling be specified and run so as to minimize interference by electric and magnetic fields The many potential sources of such interference include relay coils solenoid valves switches thyristor units earth ground currents and static electrical discharges Susceptibility to interference also varies with the electrical environment i e due to factors such as cable lengths screening and whether or not interference suppression is provided Many problems can be prevented by good design Cables carrying signals of different types for example analogue and digital signals must be run separately Power and signal cables must never be run in close proximity to one another Power supply A separate fuse must protect the APP 541 power supply Xylem recommends the use of a miniature circuit breaker that opens on all poles e One I O module is designed to operate on 100 to 240 V AC power supply The unit can also operate on 24 V DC as backup power supply and can charge the backup battery when the mains po
14. leakage 2 e Pump 3 fault thermal leakage 2 E Pump 4 fault thermal leakage Rain meter General input 5 6 7 and 8 4 e Auto mode pump 1 input 5 only e Auto mode pump 2 input 6 only e Auto mode pump 3 input 7 only e Auto mode pump 4 input 8 only e Blocking of pumps e External alarm e High level switch e Low level switch e Overflow sensor e Personnel alarm e Power failure e Rain meter 2 Counter input 3 Input when using thermal contact or supervision relay 4 Monitoring up to eight external circuits the general inputs can be assigned in all combinations that make logical sense 5 Mandatory in ATEX mode Analogue Inputs Level sensor input Analogue level 4 20 mA Inaccuracy 0 5 FS Resolution 10 bits APP 541 Installation manual 17 Technical Specification Current transformer inputs Analogue current CTS 0 1 AAC Inaccuracy Resolution Pump 1 and 3 Pump 2 and 47 2 FS 10 bits CT external current transformer with 0 1 A on secondary side 7 Pump currents are measured in pairs Digital Outputs Start pump Common alarm Emergency operation Rated load Type of Sensors to be Used e 4 20 mA level sensor e ENM 10 level regulator Terminals Signal Power Ethernet Cable Connects Cable type Cable length Communication Protocol e AquaCom e Comii e Modbus e SMS text Approved Modems Pump 1 Pump 2 Pump 3 Pump 4 2 A by 240 V AC or 30 V DC 16 AWG 13 AWG I O
15. low 32 F Material I O Unit Weight Enclosure Side gable Upper side Mounting Dimensions LxWxH APP 541 Installation manual 2 0 Ib Aluminum Painted steel Polycarbonate Cabinet 8 27 x 5 87 x 1 85 in Technical Specification Operator Panel Weight Enclosure Gasket Overlay Mounting Dimensions LxWxH Data Processing Power User Interface Digital Inputs Processor Executed word length Clock frequency Application Memory Flash System Memory Flash Parameter Memory EEPROM Battery backup Watchdog Display Push buttons LED indications 2 2 b Galvanized steel EPDM Polyester Cabinet 8 66 x 5 91 x 0 98 in Freescale HCS12 16 bits 29 5 MHz 256 kB 256 kB 8kB Yes Real time clock Yes LCD 2x20 character 8 pcs 12 pcs Note APP 541 only supports analog level sensor and not digital start and stop level switches APP 541 Installation manual Technical Specification Motor protector thermal 3 e Pump 1 Pump 2 Pump 3 Pump 4 Start relay feedback e Pump 1 Pump 2 Pump 3 Pump 4 General input 1 2 3 and 4 4 Blocking of pumps External alarm High level switch Low level switch Manual mode pump 1 input 1 only Manual mode pump 4 input 4 only Overflow sensor input 2 only input 3 only Manual mode pump 2 Manual mode pump 3 ys ys ys ys Personnel alarm Power failure e Pump 1 fault thermal leakage 2 e Pump 2 fault thermal
16. r to pump 3 36 37 Start pump 3 15 16 Start feedback from pump 3 38 39 Start pump 4 17 18 Motor protector to pump 4 40 41 Common alarm output 19 20 Start feedback from pump 4 42 43 Emergency operation 21 22 General purpose input 1 44 45 Operator panel See also Installing the Unit page 4 General purpose input 2 46 47 Operator panel 24 V DC 23 24 General purpose input 3 48 49 APP 541 Installation manual Wiring diagram Communication to operator panel 25 General purpose input 4 50 51 General purpose input 5 52 53 General purpose input 6 54 55 General purpose input 7 56 57 General purpose input 8 58 59 St Sto t vet pt etn tot Staotote t bto tate t 8 lt D k d ty tye ty s te tA ts se A amp SF SF a A ES SS ES a CE SS ZA S KF SF S E amp ff amp amp E E amp E re d d a Z Z S LLE S a E ef sg a S F S ae ae as s ae s 4s x A A x d d d amp oo SS E FF SF oS SF APP Sit rer MIO 501 eps y S EE e a SS lt fa e E ae 5 FEO E E e D e ai C a SF S DS So Soe S S s S D SS SESE a By w Ki amp S fo Ke vii a F eo a So 4 4 i T 3 ene SO PH psp ei pe ape a Patz j
17. ring for thermal overload switch Pump is damaged e g bearing failure winding fault pump impeller is jammed Go to next Alarm Check external motor protector Pump is running on two phases Pump is damaged e g bearing failure winding fault pump impeller is jammed Check start and stop levels from Start level 1 Stop level 1 to Start level 4 and Stop level 4 menus as appropriate Check time setting in Max run time menu and adjust if necessary Pump impeller is damaged and delivering insufficient flow Level sensor is faulty High level switch or start stop switch is faulty APP 541 Installation manual Technical Specification Technical Specification Technical specification Approved Standards EMC emission Standard EMC immunity standard LVD electrical safety CSA UL Power Supply AC version Rated Voltage Rated Power Current Consumption Fuse DC version Rated Voltage Rated Power Current Consumption Fuse Environment Operational temperature Storage Temperature Humidity non condensing Enclosure Operator panel front side Enclosure I O unit Operator panel back side EN61000 6 3 EN61000 6 2 EN61010 1 C22 2 No 14 95 UL61010 1 100 240 V AC 50 60 Hz 25 W lt 200 mA at 230 V AC 3 15A 24 V DC 18 36 V DC 20 W lt 1Aat24VDC 1 1A 4 F to 122 F 14 F to 158 F 90 RH IP65 IP 20 1 LCD display will respond more slowly at temperatures be
18. tion to operator panel 25 General purpose input 5 52 53 General purpose input 6 54 55 General purpose input 7 56 57 General purpose input 8 58 59 APP 541 Installation manual 11 Wiring diagram 0 OOOO OOO OOOO MMA Gomm o oo oO GO o Figure 8 N B Terminals 6 8 and 10 are connected together internally N B Terminals 29 31 33 59 are connected together internally N B and J are activated at normal operation Wiring diagram 24 V DC Table 3 Ground 3 Power supply See a so Power supply page A Analogue inputs See a so Connections M page 8 Power supply 24 V DC input or Battery backup 24 V DC Option 26 27 Level sensor input 4 20 mA 4 5 6 Digital inputs See a so Connections page 8 Current transformer for pump 1 3 0 1 AAC 7 8 Motor protector to pump 1 28 29 Current transformer for pump 2 4 0 1 AAC 9 10 Start feedback from pump 1 30 31 Digital outputs See a so Connections page 8 Start pump 1 11 12 Motor protector to pump 2 32 33 Start feedback from pump 2 34 35 Start pump 2 13 14 Motor protecto
19. wer supply is on e One model designed to operate at 24 v DC The I O module also supplies power to the operator panel N B Max current available to the modem 24 VDC 180 mA 4 5 Watt Earthing grounding An equipment earthing grounding conductor must be connected to terminal 3 see Wiring diagram The earthing conductor should be connected to the best possible earth such as an earthed mounting plate or an earth rod Remember that the earthing conductor must be as short as possible The shields of all shielded cables must be earthed Overvoltage protection Xylem recommends that the mains power supply unit be provided with overvoltage protection with lightning protection Since this will make the APP 541 less sensitive to overvoltage it will enable it to be used in more severe environments APP 541 Installation manual 7 Electrical installation The protection should be connected in series with the power supply preferably to a separate earth ground such as an earth rod although connection to the earth busbar in the distribution box may sometimes suffice A 10 7 AWG earthing wire should be used to connect the overvoltage protection to earth Emergency operation When the control unit is in the normal running mode a relay will be activated If the control unit should fail due to software hardware or power supply fault the relay will be deactivated This relay can be connected between a high level switch a timer
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