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FGC 211 User Manual

1. 4 3 Display 4 4 Push Buttons 4 5 Menus 4 5 1 Using the Menus 4 6 Pump Control 4 4 4 4 4 4 5 5 6 8 9 9 9 9 9 10 10 10 10 11 11 12 12 12 12 13 13 13 13 13 13 13 13 14 14 14 14 14 14 14 15 16 17 17 17 17 17 17 18 18 4 7 Reset Function 4 8 Display Language 5 Configuration 5 1 Introduction 5 2 Startup 5 3 Configuring Level Switches 5 3 1 Using a Stop Level Switch 5 3 2 Stopping a Pump After a Time 5 4 Configuring a Level Sensor 5 4 1 Start Stop and High Levels 5 5 Pump Configuration 5 5 1 Maximum Motor Current 5 6 Restoring Default Values 6 Additional Configuration 6 1 Introduction 6 2 Level Configuration 6
2. 3 3 5 Pressure Switch 3 3 6 Flush timer or similar start blocking relay 3 4 Connecting Thermal Contact 3 5 Connecting Alarm Output 3 6 Internal Buzzer 3 7 Installing Power Supply 3 7 1 Cabling 3 7 2 Power Supply 3 7 3 Earthing Grounding 3 7 4 Overvoltage Protection 3 7 6 FGC 24 VDC Supply 3 8 FGC 211 in a LPSS application 3 8 1 Background 3 8 2 Preventing over pressure in system 3 8 3 Avoiding simultaneous pump starts 3 8 4 Handling pressure increases during operation 3 8 5 Preventing over flow at high pressure 3 8 6 Resetting over current protection 3 8 7 Flushing sewage from the system 3 8 8 System overview 3 9 Wiring Diagram 3 10 Controller Specification 4 Operator Panel 4 1 Introduction 4 2 Front Panel
3. Any open menu is closed 4 4 Push Buttons Available push buttons are listed below 4 5 Menus You use the menus to configure the FGC and view relevant information such as runtime data and alarms The following information is generally shown in a menu Menu name for example Pump Control Menu indicator for example 5_ or 5_1 It is shown for 3 seconds only If the indicator ends with an underscore there are submenus Parameter value For a complete list of menus see also Menu Descriptions on page 31 FGC 211 Reset Esc OK 1 0 Push buttons to navigate menus Display Power LED High level LED Pump status LED Relay status LED Alarm status LED Reset push button Push button to change between automatic and manual pump control Push button to block pump operation Escape Left arrow Right arrow Up arrow Down arrow OK Reset Manual pump stop and block Automatic mode and manual pump start Esc OK Reset 0 1 4 Operator Panel 28 30 Issued Supersedes 18 4 12 4 5 1 Using the Menus 1 Display the desired menu Press the button to browse forwards one menu at a time Press the button to browse backwards one menu at a time Press the button to show the first menu in a group of submenus Press the button to exit a group of submenus 2 You can now view the parameter value in t
4. Safety instruction Personal safety Safety instruction Personal safety dangerous voltage Special attention value Apparatus or component damage Special information Special information about a function Special information Special information about alarms 1 1 Introduction Before starting to use the FGC 211 read this chapter carefully It contains general information on documentation safety and guarantee 1 2 Safety Regulations for Owner Operator All government regulations local health and safety codes shall be complied with All danger due to electricity must be avoided 1 3 Guarantee Modifications or changes to the unit installation should be carried out only after consulting Xylem Inc Original 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 any claims for warranty or compensation 1 4 Used Symbols Observe all precautions for handling electrostatic sensitive devices before opening the unit The FGC has a high degree of protection against moist and dirt but should always be installed so that it will not be unnecessarily exposed to water or the risk of external physical damage A FGC 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 with t
5. 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 Issued Supersedes 12 4 12 3 3 6 Flush timer or similar start blocking relay A flush timer allows the sewage level to rise in the well above the normal start level The increased sewage volume is then used for purging the sewage system If used connect to terminals 14 and 15 Switch open blocking closed not blocking For more information refer to the installation instruction of the flush timer 3 4 Connecting Thermal Contact If the thermal contact for the pump is used connect the wires from the thermal contact to terminal 12 and 13 in the FGC not used make sure a jumper lead is placed between terminal 12 and 13 in the FGC The thermal contact in the pump is normally closed 3 5 Connecting Alarm Output The common alarm output is a potential free alternating relay with a maximum rating of 250 VAC 5 A The output can be used to activate an audible or visual alarm device for example a lamp or a siren The common alarm output does not supply power for the external device It must be must be supplied from another source Connect the external device to terminals 9 and 10 When the common alarm output is passive the relay closes between terminals 9 and 11 activated or the power supply is off the relay closes between terminals 9 and 10 3 6 Internal Buzzer When an alarm is generated t
6. Analogue level 4 20 mA3 3 The supply from the FGC can carry max 12 VDC Terminals Signal 1 5 mm2 Power 6 mm2 Earth Terminal 6 mm Type of level sensors to be used Pneumatic sensor LTU 301 4 20 mA with 0 2 5 m sensor range External level sensor 4 20 mA ENM 10 external level regulator Options and Accessories Level control accessories Level regulators ENM 10 Different level switches start stop and high level that provide digital input signals Open bell system and pneumatic sensor LTU 301 The open bell system includes a cast bell and a tube that can be connected to a pneumatic sensor It transforms the generated pressure to an analogue signal 4 20 mA Pressure sensor It transforms the measured pressure to an analogue signal 4 20 mA High water module It is used to detect a high level in the pump sump 3 10 Controller Specification Issued Supersedes 17 4 12 4 1 Introduction FGC 211 is a pump controller designed for single pump installations and household usage 4 2 Front Panel The figure below shows the front panel of FGC 211 The panel contains Display to show the different menus Push buttons to navigate menus and change values A set of LED indications see also LED Descriptions on page 29 4 3 Display The display shows the current menu When the display has been idle for 10 minutes Light is switched off
7. which is installed below the high level switch When there is no stop level switch in an installation the pump instead can be stopped after a specified time This time starts to run once the level in the pump sump drops below the start level switch That is the start level switch first have to revert to its normal position 5 3 1 Using a Stop Level Switch To use a stop level switch 1 Select Digital in the Control mode menu 7_1 2 Select Stoplevel switch in the Stop condition menu 7_2 When ready continue with Maximum Motor Current on page 22 5 3 2 Stopping a Pump After a Time To specify after how long time a pump should be stopped 1 Select Digital in the Control mode menu 7_1 2 Select Run on time in the Stop condition menu 7_2 3 Enter the time in the Run time menu 7_3 When ready continue with Maximum Motor Current on page 22 5 4 Configuring a Level Sensor To configure a level sensor 1 Select Analogue in the Control mode menu 7_1 2 Enter the sensor range in the Sensor range menu 2_4 For information on the range refer to the documentation delivered with the sensor 3 In the pump sump raise the sensor from the water 4 Return to the FGC and read the current level in the Level menu 2_ Since the sensor is raised from the water the level should read 0 00 or some other acceptable value for example 0 01 Since values are rounded it is no
8. be found after following the instructions above contact a FLYGT service agent 8 2 4 Blocked Pump Problem Relay status LED is continuously lit red Checklist 1 If the pump fails to start a Check if Auto is selected in the P1 State menu 5_1 b If not select Auto in the P1 State menu 5_1 The LED should stop being lit red c If the LED still is lit red check if On is selected in the Ex mode menu 7_5 d If selected the FGC is set to Ex mode see also EX classified Environment on page 23 The pump will be blocked as long as there is no liquid in the pump sump When there again is liquid in the pump sump the LED should stop being lit red 5 If the pump starts with the LED continuously lit red contact a FLYGT service agent 8 3 Diagnostic Programs Diagnostic programs are used to test the hardware All other functions are disabled when a diagnostic program is run that is normal pump control and operation are prevented After 10 minutes of idle time the FGC will automatically revert to normal operation To run a diagnostic program 1 Display the Diagnos Program menu 7_9 2 Select one of the diagnostic programs Available programs are listed below The rest of the programs are for future use To manually stop a diagnostic program select Off in the Diagnosis Program menu Reset Program Description Results 10 Digital inputs Shows the digital input
9. has to be fulfilled during this time for an alarm to be generated For example if the level in the pump sump drops below the configured high level alarm limit before the delay time has elapsed no alarm will be generated There are two delay types General alarm delay that affects all alarms except power fault alarms This delay is 3 seconds Alarm delay for power failure alarms To specify the alarm delay for power failures enter the delay time in the Al delay Powfail menu 6_1 6 4 2 Audible or Visual Alarm Indication The common alarm output can be connected to an audible or visual device for example a lamp or siren The output turns on the device when an alarm is generated To configure the output 1 Display the Common alarm menu 7_4 2 Select either Continuous for a steady indication Intermittent for a flashing indication No alarm condition present Alarm condition present Time Condition active shorter time than the alarm delay Alarm delay Alarm generated 20 22 22 29 Issued Supersedes 24 4 12 7 1 Introduction This chapter describes basic operation For information on configuration refer to previous chapters 7 2 Viewing Runtime Data The following runtime data can be shown in the FGC Level in the pump sump When a level sensor is used you can view the current level in the Level menu 2_ When level switches are used t
10. level sensor a start level switch or both start and stop level switches As backup a high level switch can be used together with the start and stop level switches as well as with a level sensor 3 3 1 Cabling Cables carrying different types of signals must be run separately For example make sure cables to an analogue level sensor are run separately from cables to digital level switches 3 3 2 Pneumatic Sensor LTU 301 The pneumatic sensor LTU 301 is used together with an open bell system The system includes a cast bell and a pneumatic tube There are two versions of LTU 301 One is for ATEX installations To install LTU 301 1 Install the open bell system in the pump sump see also example in figure below For more information refer to the Installation and operation manual for the open bell system 2 Check that the open bell is free from solid matter 3 Make sure that no solid matter collects at the bottom of the sump below the open bell 4 Mount LTU 301 in the FGC 5 Connect the pneumatic tube from the open bell system to LTU 301 6 Connect LTU 301 as follows see also figure below Connect the black wire to terminal 18 Connect the white wire to terminal 19 Connect the red wire to terminal 20 3 3 3 4 20 mA Level Sensor To install a 4 20 mA level sensor 1 Install the level sensor in the pump sump For more information refer to the Installation and opera
11. pump cycle is complete the FGC returns to Auto mode To return immediately press the button 7 4 3 Blocked Pump Blocked Mode In Auto mode you can manually block the pump This changes the mode to Blocked mode Block the Pump Manually Press the button The display will briefly show Blocked How Long Will the Pump Remain Blocked The pump will now remain blocked until the button is pressed Return to Auto Mode Press the button The display will briefly show Auto 7 4 4 View Control Status View control status in the P1 state menu 5_1 OK OK The exception is EX mode see also EX classified Environment on page 23 In Ex mode the pump will not start if there is no liquid detected in the pump sump 1 Alarm log Manual mode 0 0 1 1 7 Basic Operation 22 Issued Supersedes 25 4 12 7 5 Pump Failure Block The pump can also be blocked due to a pump failure For example the motor temperature is too high or the pump has run longer that the configured maximum time When the problem is corrected press the button to remove the automatic block 7 6 Handling Alarms An alarm alerts the receiver that something needs attention The FGC can generate alarms for example when the temperature in a pump motor is too high or the pump has run longer that the configured maximum time For a complete list of alarms see also Alarm Descriptions on page 30 Wi
12. starts It runs until the sump level drops below a specified stop level Start and stop level switches When the level in the pump sump exceeds the start level switch the pump starts It runs until the sump level drops below the stop level switch Only start level switch When the level in the pump sump exceeds the start level switch the pump starts It runs a specified time and then stops For each configuration there is a set of default values FGC 211 Reset Esc OK 1 0 Push buttons to navigate menus Display Power LED High level LED Pump status LED Relay status LED Alarm status LED Reset push button Push button to change between automatic and manual pump control Push button to block pump operation Language lt Not selected gt OK If the following is installed Use the following default values 4 20 mA level sensor Compit analogue Start and Stop level switches Level regulator Only Start level switch Level reg time FGC is used in PSS application PC Pump General 7_ OK Set default val No 7_8 LPSS 30 32 Issued Supersedes 7 4 12 To select defaults 1 Press the button to be able to change the value in the displayed Set default val menu 2 Press the button repeatedly to until the name of the defaults is displayed For example if the installation includes both start and stop level switches select Level regulator 3
13. states for example 1001100100000000 11 LED output Common alarm output Flashes at 1 second interval 20 Analogue input Shows the raw input values 0 16383 24 P1 current input Shows the raw input values 0 16383 This starts the pump 22 28 Troubleshooting c Check if the impeller is jammed or damaged d If used check if the level sensor is faulty e When the problem is corrected press the button The LED should no longer be continuously lit 6 If the error cannot be found after following the instructions above contact a FLYGT service agent 8 2 4 Blocked Pump Problem Relay status LED is continuously lit red Checklist 1 If the pump fails to start a Check if Auto is selected in the P1 State menu 5_1 b If not select Auto in the P1 State menu 5_1 The LED should stop being lit red c If the LED still is lit red check if On is selected in the Ex mode menu 7_5 d If selected the FGC is set to Ex mode see also EX classified Environment on page 23 The pump will be blocked as long as there is no liquid in the pump sump When there again is liquid in the pump sump the LED should stop being lit red 5 If the pump starts with the LED continuously lit red contact a FLYGT service agent 8 3 Diagnostic Programs Diagnostic programs are used to test the hardware All other functions are disabled when a diagnostic program is run that is no
14. 1 state 5_1 Stop delay range 5_2 Stop delay time 5_3 Hi lev run time 5_4 Max run time 5_5 Alarm setup 6_ Al delay Powfail 6_1 Resp err alarm 6_2 General 7_ Control mode 7_1 Stop condition 7_2 Run time 7_3 Common alarm 7_4 EX mode 7_5 Automatic reset 7_6 H lim retry del 7_7 Set default val 7_10 Diagnos Program 7_11 Language 8 Hold out run time 5_6 Blocking enable 5_7 L lim retry del 7_8 System version 7_9 A B Issued Supersedes 9 4 12 3 Installation 3 1 Introduction The installation descriptions and figures can refer to terminals on the main board For information on locations see also Wiring Diagram on page 16 The following symbols can also be used in the figures 3 2 Installing the FGC 3 2 1 Explosive or Flammable Environment 3 2 2 Equipment Cubicle The FGC can be installed in an equipment cubicle Ensure that its operating temperature is between 4 F to 113 F Heating will normally be required in winter if the cubicle is located outdoors or in a similarly cold environment Heating of the cubicle is also recommended to avoid condensation The cubicle temperature may become too high in summer if ventilation is inadequate Normally open Normally closed The FGC must not be installed in an explosive or flammable environment 15 Issued Supersedes 10 4 12 3 3 Installing Sensor or Switches Use either a
15. 2 1 Backup Pump Control 6 2 2 Stop Delay 6 3 Pump Control 6 3 1 Fixed Pump Delays 6 3 2 Automatic Maintenance Run 6 3 3 High Temperature 6 3 4 EX classified Environment 6 3 5 Maximum Run Time for a Pump 6 3 6 Pump Response 6 4 Alarm Configuration 6 4 1 Alarm Delay 6 4 2 Audible or Visual Alarm Indication 7 Basic Operation 7 1 Introduction 7 2 Viewing Runtime Data 7 3 Resetting Runtime Data 7 4 Controlling the Pump 7 4 1 Automatic Control Auto Mode 7 4 2 Manual Control Manual Mode 7 4 3 Blocked Pump Blocked Mode 7 4 4 View Control Status 7 5 Pump Failure Block 7 6 Handling Alarms 7 6 1 Acknowledge an Alarm 7 6 2 Viewing Alarms 7 6 3 Clear the Alarm Log
16. 3 Start run and stop The following describe the possible LPSS scenarios 10 3 1 Scenario A Normal pressure 1 Sewage level in the well rises above the start level 2 Pressure at the pump outlet is below the pressure sensor s threshold value 3 FGC starts the pump 4 Pumping lowers the sewage level in the well below the start level 5 FGC stops the pump 10 3 2 Scenario B High pressure at start 1 Sewage level in the well rises above the start level 2 Pressure at the pump outlet is above the pressure sensor s threshold value 3 FGC blocks the pump from starting 4 Count down to next start attempt begins 5 The pressure at the pump outlet is checked Pressure is above sensor s threshold Continued blocking 3 Pressure is below sensor s threshold Blocking no longer in effect 6 6 FGC starts the pump 7 Pumping lowers the sewage level in the well below the start level 8 FGC stops the pump 10 3 3 Scenario C High level 1 Pressure at the pump outlet is above the pressure sensor s threshold value 2 FGC blocks the pump 3 Sewage level in the well rises above the High level 4 FGC ignores the high pressure blocking 5 FGC starts the pump 6 Pumping lowers the sewage level in the well below the start level 7 FGC stops the pump 10 3 4 Scenario D1 Over current at start 1 FGC starts the pump 2 FGC immediately registers over curre
17. 8 Troubleshooting 8 1 Introduction 8 2 Basic Problems 8 2 1 Power Supply 8 2 3 Pump Failure 8 2 4 Blocked Pump 8 3 Diagnostic Programs 18 18 19 19 20 20 20 20 20 21 21 21 21 22 22 22 22 22 22 22 22 22 22 23 23 23 23 23 24 24 24 24 24 24 24 24 24 25 25 25 25 25 26 26 26 26 26 27 27 Issued Supersedes 3 4 12 9 Appendix A FGC Descriptions 9 1 LED Descriptions 9 2 Alarm Descriptions 9 3 Menu Descriptions 10 Appendix B LPSS Scenarios 10 1 Operation variants 10 2 Permanent blocking 10 3 Start run and stop 10 3 1 Scenario A Normal pressure 10 3 2 Scenario B High pressure at start 10 3 3 Scenario C High level 10 3 4 Scenario D1 Over current at start 10 3 5 Scenario D2 Current rising 28 28 29 30 33 33 33 33 33 33 33 33 33 Contents Issued Supersedes 4 4 12
18. Auto Program controlled automatic or blocked state for Pump 1 5_2 1 Stop delay range m Writable Interval 0 00 To 2 50 0 00 0 22 0 00 0 00 0 00 Specifies an additional height below the Stop level to be pumped down The RTU calculates the stop delay time required to lower this height 0 Inhibits the function 5_3 Stop delay time min s Writable Interval 00 00 To 59 59 00 00 00 45 01 00 00 00 00 01 Delays the stop of the pump with the set time NOTE If the calculated stop delay function is activated this set point defines the maximum allowed calculated stop delay time Appendix A FGC Descriptions Issued Supersedes 31 4 12 5_4 Hi lev run time min s Writable Interval 00 00 To 59 59 01 00 00 20 01 00 02 00 01 00 Backup control activated when there is a level sensor failure The high level switch activates the start of the pump which will then run for the period set in this menu 5_5 Max run time min s Writable Interval 00 00 To 59 59 30 00 30 00 30 00 30 00 30 00 The maximum time the pump is allowed to run continuously 0 disables the function 5_6 Hold out run time min s Writable Interval 00 00 To 59 59 00 00 00 00 00 00 00 00 00 00 The pump will continue running for the duration of the interval 0 disables the function 5_7 Blocking enable Writable Alternative No Yes No No No No No Yes enables blocking by an external blocking relay such as a purge tim
19. C2 Connection for display unit LED L2 Power on indicator L1 Power Fault Indicator Location Description Terminal 24 VDC Issued Supersedes 16 4 12 Denomination Model Part no Pumps LCD Display FGC 211 2000001 40 501830 1 Yes 1Consists of Qty 1 Circuit Board Qty 1 Display Card Qty 1 Ribbon Cable Qty 1 Overlay Power Supply Rated voltage 24 VDC 20 28 VDC Current consumption internal 100 mA at 24 VDC Rated pump current 1 phase Max 9 9 A Min 0 5 A Basic fuses Internal fuse 100 mA non replaceable Approvals and Standards EMC emission standard EN61000 6 3 EMC immunity standard EN61000 6 2 LVD electrical safety EN IEC 61010 1 CE Marking Environment Operational temperature2 4 F to 113 F Storage Temperature 4 F to 158 F Humidity non condensing 90 RH Operator Panel Class 1 IP 54 CAT II Altitude Max 6562 ft Pollution degree 2 2 The LCD display will update slower below 32 F Material Operator Panel ABS V0 Data Processing Power Processor PIC18F4620 Executed word length 8 bits Clock frequency 32 MHz Text memory 64 kB Watchdog Yes User Interface Display LCD 2x16 characters Push buttons 9 pcs Alarm indications 4 LEDs FGC status indications 3 LEDs Digital Inputs Start switch Stop switch High level switch Thermal contact Relay Outputs Common alarm Voltage free Max load 230 VAC 5 A Analogue input
20. Diagnos Program Writable Alternative Off 1 39 Diagnostic program for test of the RTU 8 Language Writable Alternative English Deutsch Nederlands Fran ais Dansk Svenska Norsk Espa ol Magyar Suomi Italiano PycckNN Polski Select display language No Menu Name Menu Options Factory Settings Compit Analogue Level Regulator Level Reg Time PC Pump Description 1 Menu shown only when Control mode menu 7_1 is set to Analogue 4 20 mA level sensor 2 Menu shown only when Control mode menu 7_1 is set to Digital Level switches Appendix A FGC Descriptions Issued Supersedes 33 4 12 10 1 Operation variants The scenarios presented below each describing a complete cycle assume that the equipment is set up as described in chapter 3 8 FGC 211 in a LPSS application In these examples pumping stops when the sewage level gets below the stop level Alternatively or in addition to this FGC 211 can be configured to stop the pump after a certain run time This may cause pumping to stop while the sewage level is still above the stop level In case the sewage is also above the start level this will result in a new count down to pump start 10 2 Permanent blocking Should the maximum number of allowed pump start attempts be exceeded the FGC will block the pump permanently Otherwise blocking is just temporary 10
21. Issued Supersedes 1 4 12 FGC 211 Installation and user manual This manual is applicable to the following versions Hardware FGC 211 Display board AFH1901 Rev 1 01 Main board AHH1901 Rev 1 01 System Software 2 42 or later Issued Supersedes 2 4 12 Contents 1 Read This First 1 1 Introduction 1 2 Safety Regulations for Owner Operator 1 3 Guarantee 1 4 Used Symbols 1 5 Safety Instruction 2 Short Guides 2 1 Installation Checklist 2 2 Getting Started 2 3 Menu Reference Chart 3 Installation 3 1 Introduction 3 2 Installing the FGC 3 2 1 Explosive or Flammable Environment 3 2 2 Equipment Cubicle 3 3 Installing Sensor or Switches 3 3 1 Cabling 3 3 2 Pneumatic Sensor LTU 301 3 3 3 4 20 mA Level Sensor 3 3 4 ENM 10 Level Regulators
22. On Off On Off Off Off When EX mode is on the pumps are not allowed to start unless water can be detected in the sump The function is used primarily in explosive environment 7_6 Automatic reset Writable Interval 0 To 200 1 0 1 1 1 Automatic reset of the pump following an Over current failure 0 Inactivated function The RTU blocks the pump on first Over current 1 200 Activated function The RTU will attempt to start the pump 1 200 times before blocking No Menu Name Menu Options Factory Settings Compit Analogue Level Regulator Level Reg Time PC Pump Description Appendix A FGC Descriptions 31 Issued Supersedes 32 4 12 33 Appendix A FGC Descriptions 7_7 H lim retry del min s Writable Interval 00 00 To 59 59 00 00 00 00 00 00 00 00 30 00 The value entered is the highest possible value for the randomized start retry delay 7_8 L lim retry del min s Writable Interval 00 00 To 59 59 00 00 00 00 00 00 00 00 10 00 The value entered is the lowest possible value for the randomized start retry delay 7_9 System version Read only The RTU system version Please have this number ready when calling Flygt support 7_10 Set default val Writable Alternative No Compit analogue Level regulator Level reg time Restores all parameter values to the selected set of default values Operating data and the language setting are not affected 7_11
23. Press the button to save the changes The FGC is restarted and initialised with the selected set of default values Specify Maximal Motor Current If the motor current for the pump exceeds this limit the pump is stopped and blocked An alarm is also generated To specify the maximal current 1 Press the button repeatedly until the display shows the P1 current menu The shown current can differ from 0 0 A 2 Press the button to access the submenu The display will show the High current P1 menu 3 Press the button to be able to change the value in the displayed menu A flashing cursor will appear 4 Press the button repeatedly to specify the first digit For example if the maximal current for the pump is 6 0 A enter the digit 6 5 Press the button to move the cursor a step to the right 6 Press the button repeatedly to specify the last digit For example if the maximal current for the pump is 6 0 A enter the digit 0 7 Press the button to save the changes The display will show Value stored and then the new parameter value 8 Press the button to exit the submenu The display will again show the P1 current menu The shown current can differ from 0 0 A Checking the Installation When the above configuration is complete the unit is in automatic mode and should be ready for operation The LEDs on the front panel indicate unit status including potential problems If there is a prob
24. able menus No Menu Name Menu Options Factory Settings Compit Analogue Level Regulator Level Reg Time PC Pump Description 1 Alarm log Writable Number of recorded alarms 2_ 1 Level m Read only NA 00 00 m NA NA NA Level in pump sump 2_1 1 Start Level 1 m Writable Interval 99 99 To 99 99 NA 00 15 m NA NA 00 50 m Start level for the pump 2_2 1 Stop Level 1 m Writable Interval 99 99 To 99 99 NA 00 10 m NA NA 00 20 m Stop level for the pump 2_3 1 High Level m Writable Interval 99 99 To 99 99 NA 00 25 m NA NA 00 70 m High level alarm limit 2_4 1 Sensor range m Writable Interval 0 00 To 20 00 NA 02 50 m NA NA 02 50 m Sensor range 2_5 1 Sensor calib m Writable Interval 99 99 To 99 99 NA 00 00 m NA NA 00 00 m Sensor calibration offset 3_ P1 current A Read only Interval 0 0 To 99 9 Measured current for the pump 3_1 High current P1 A Writable Interval 0 0 To 9 9 5 3 A 5 3 A 5 3 A 5 3 A 5 3 A High current alarm limit for the pump 4_ Operating data Read only Menu group for operating data 4_1 P1 start counter Writable 0 0 0 0 0 Number of start for the pump 4_2 P1 run hour h min Writable 0 00 0 00 0 00 0 00 0 00 Run hour for the pump 5_ Pump control Read only Menu group for pump control 5_1 P1 state Writable Alternative Auto Blocked Manual mode Auto Auto Auto Auto
25. ay initiate the flush when necessary 3 8 8 System overview This is a schematic view of the standard and optional components of the LPSS application Standard components are the Tank T Pump P FGC 211 and Open Bell level system OB with LTU 301 sensor Optionally a High level float H Pressure Switch PS and Flush Timer FT may be fitted P PS FT FGC211 H T OB system 22 Issued Supersedes 15 4 12 3 9 Wiring Diagram Main board AHH 1901 is used to control 1 pump The layout and contents are specified below Power P1 Power supply 1 4 P2 Earth terminal 4 pcs 6 mm2 5 8 P3 Fuse F2 T100mA L for internal use P4 Current transformer for the pump I O I1 Common alarm output potential free contact Max 250 VAC 5 A 9 11 I2 Thermal contact input for the pump 12 13 If not used make sure a jumper lead is placed on the input I3 Stop level switch input 14 15 Terminal 14 is a common terminal for all level switches stop start and high level I4 Start level switch input 14 16 Terminal 14 is a common terminal for all level switches stop start and high level I5 High level switch input 14 17 Terminal 14 is a common terminal for all level switches stop start and high level I6 Analogue level sensor input 4 20 mA 18 20 Connector C1 Jumper pins for internal buzzer Main board version 1 00 has no internal buzzer and no pins
26. cked Pump Blocked Mode on page 24 The FGC is set to Ex mode and there is no liquid in the pump sump see also EX classified Environment on page 22 Pump failure Possible causes Pump start is delayed see also Fixed Pump Delays on page 22 Pump status Green on Red on The pump is running The pump is stopped and blocked from restarting Possible causes Pump current exceeds its configured maximum see also Maximum Motor Current on page 21 Temperature in the pump is too high see also High Temperature on page 22 Pump has run longer than the configured maximum time see also Maximum Run Time for a Pump on page 23 High level Red on The level in the pump sump is high Possible causes Level exceeds a high level switch The pump is started automatically see also Backup Pump Control on page 22 Level exceeds the configured high level limit see also Start Stop and High Levels on page 21 This is only relevant if a level sensor is used 17 Issued Supersedes 29 4 12 9 2 Alarm Descriptions The FGC can generate the alarms listed in the table below The columns describe the following The alarm text shown in the Alarm log menu 1 The event or error that caused the alarm Whether the pump is stopped and blocked from restarting due to the event or error Whether any LED except the Alarm status LED i
27. configuration The right most rectangles contain footnotes Analogue level sensor Digital level switches Stop after a time Stop level switch If necessary enter an offset for the sensor in the Sensor calib menu 2_5 Enter when the pump should start in the Start level 1 menu 2_1 Enter when the pump should stop in in the Stop level 1 menu 2_2 Enter when a high level alarm is generated in the High level menu 2_3 Enter the range for the sensor in the Sensor range menu 2_4 How to stop the pump How to measure the level in the pump sump Enter the maximum pump current in the High current menu 3_1 5 Configuration 6 20 20 20 20 21 21 22 24 30 32 Issued Supersedes 20 4 12 5 2 Startup To measure the level in the pump sump you can use either Digital level switches Continue with Configuring Level Switches on page 21 Analogue level sensor Continue with Configuring a Level Sensor on page 21 5 3 Configuring Level Switches When the level in the pump sump Exceeds the start level switch the pump is started Drops below the stop level switch the pump is stopped In some installations there is no stop level switch as described below Exceeds the high level switch a High level alarm is generated Since a pump is used to drain a pump sump the stop level switch is installed below any start level switch
28. deleted e Press the button to delete the inactive alarms The message Log cleared is displayed Reset Reset OK Esc OK OK OK 29 Issued Supersedes 26 4 12 8 1 Introduction This chapter describes troubleshooting 8 2 Basic Problems 8 2 1 Power Supply Problem Power LED is not lit Checklist 1 The main power supply is off Check the external main switch and main fuse 2 If the error cannot be found after following the instructions above contact a FLYGT service agent Make sure mains power supply is disconnected before any maintenance work on the FGC or pump 8 2 3 Pump Failure Problem Pump status LED is continuously lit red Checklist 1 Check if the Alarm log menu 1 contains the alarm P1 high temp 2 If the log contains the alarm the thermal contact in the motor winding has opened due to high temperature The contact is normally closed a Check that the thermal contact is wired as shown in the wiring diagram see also Connecting Thermal Contact on page 13 b Check if the pump is damaged for example bearing or winding failure c Check if pump impeller is jammed d When the problem is corrected press the button If the pump has cooled down the LED should no longer be continuously lit Otherwise wait a while for the pump to cool down and then press the button again 5 Check if the Alarm log menu 1 contains the alarm P1 Hig
29. e the block If the pump has cooled down it will be allowed to start Otherwise try again a little later 6 3 4 EX classified Environment When a pump is used in an EX classified environment you can set the FGC to EX mode If no liquid is detected in the pump sump the FGC will prevent the pump from starting The starting method will not matter that is any manual start attempt or maintenance run will be blocked To configure Ex mode 1 Display the Ex mode menu 7_5 2 Select either On to set the FGC to EX mode Off to disable EX mode If the pump is installed in an EX classified environment check the pump approvals before pumping below the stop level Make sure to disconnect mains power supply before any maintenance work since the pump will start automatically every 96 hours as long as mains power supply is on 6 Additional Configuration 19 Issued Supersedes 23 4 12 6 3 5 Maximum Run Time for a Pump This is the maximum time a pump can run continuously When this time has elapsed the pump is stopped and blocked from restarting An alarm is also generated This limit is useful for example to stop a clogged pump from running too long The alarm indicates that something is wrong for example that the pump impeller is damaged and delivers insufficient flow or that a level sensor is faulty The specified limit must exceed one pumping cycle Consider that the following setti
30. er 6_ Alarm setup Read only Menu group for alarms 6_1 Al delay Powfail min Writable Interval 0 To 960 1 min 1 min 1 min 1 min 1 min The delay of a Power failure alarm before it is recorded 6_2 Resp err alarm Writable Alternative No Yes Yes Yes Yes Yes Yes When the pump current is below 0 5 A the RTU will register a pump response error alarm To disable the pump response error alarm function select No 7_ General Read only Menu group for general set points 7_1 Control mode Writable Alternative Digital Analogue Digital Anal Digital Digital Anal Selects if an analogue sensor or level switches are used for starting and stopping the pumps Also referred to as analogue and digital mode 7_2 2 Stop condition Writable Alternative Run on time Stoplevel switch Stop level switch NA Stop level switch Run on time NA Selects if a stop level switch is present or the pump is stopped after a time Applies to digital mode only 7_3 2 Run time min s Writable Interval 00 00 To 59 59 00 00 00 00 00 00 00 20 00 00 The pump running time when configured to Run on time i e no stop level switch is used Applicable to digital mode only 7_4 Common alarm Writable Alternative Continuous Intermittent Cont Inter Cont Inter Cont Type of common alarm output Continuous or pulsating 7_5 EX mode Writable Alternative Off
31. h cur Reset 6 If the log contains the alarm the pump current has exceeded its configured maximum a Check that the High current P1 menu 3_1 is set to the correct maximum current see also Maximum Motor Current on page 22 b Check if the pump is damaged for example bearing failure or winding fault c Check if the pump impeller is jammed d When the problem is corrected press the button The LED should no longer be continuously lit 5 Check if the Alarm log menu 1 contains the alarm P1 Max run 6 If the log contains the alarm the pump has run longer than the configured maximum time a Check that the Max run time menu 5_5 is set to the correct maximum current see also Maximum Run Time for a Pump on page 24 b Check if the pump is clogged Reset 8 Troubleshooting 12 21 23 3 4 c Check if the impeller is jammed or damaged d If used check if the level sensor is faulty e When the problem is corrected press the button The LED should no longer be continuously lit 7 If the error cannot be found after following the instructions above contact a FLYGT service agent Reset Issued Supersedes 27 4 12 28 Troubleshooting c Check if the impeller is jammed or damaged d If used check if the level sensor is faulty e When the problem is corrected press the button The LED should no longer be continuously lit 6 If the error cannot
32. he installed unit Use cables that minimize interference from electrical and magnetic fields Run the cables in a way that further minimize interference The many potential sources of such interference include relay coils solenoid valves switches thyristor units earth ground currents and static discharges Susceptibility to interference also varies with the electrical environment i e to factors such as cable lengths screening and the use or otherwise of interference suppression Many problems can be prevented by good planning 1 5 Safety Instruction Electrical wiring must be carried out only by a qualified electrician All electrical installation work must be carried out with the equipment disconnected from the power supply without any possibility of being made live and in accordance with local regulations 1 Read This First Issued Supersedes 5 4 12 2 Short Guides 2 1 Installation Checklist This is a short installation checklist It is included for convenience only and is in no way a replacement for the Installation manual Check Installation step More information mark Plan the installation of the FGC to Avoid all danger due to electricity Comply with the safety regulations Comply with the guarantee regulations Observe precautions for electrostatic sensitive devices Avoid unnecessary exposure of the FGC Minimize interference from electrical magnetic fields Make su
33. he internal buzzer sounds automatically To deactivate the buzzer functionality remove the jumper to the buzzer see also below Suitable for LPSS application In the standard LPSS application a flush timer essentially a type of stop relay can be used When a pump is installed in an explosive environment the thermal contact for the pump must be connected to the FGC 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 4 20mA 12 13 14 5 1 1 1 0 1 9 0 2 9 1 8 1 7 1 6 1 8 7 6 Wire with supply 9 10 11 9 10 11 Passive output Active output J16 On Fail Power Jumper pins for buzzer Issued Supersedes 13 4 12 3 7 Installing Power Supply 3 7 1 Cabling Make sure to run power and signal cables separately 3 7 2 Power Supply A separate fuse must protect the FGC power supply Flygt recommends the use of automatic switch acting on all poles If a Flygt pump is connected in accordance with the instructions for its electrical connection its direction of rotation will always be correct 3 7 3 Earthing Grounding An equipment earthing grounding conductor must be connected to one of the earth terminals in the FGC terminal 5 8 The earthing conductor should be connected to the be
34. he menu and change it if necessary To change the value press the button A flashing cursor will appear If a value cannot be changed the message Read only will be displayed instead 3 Enter or select the new value Press the button to increase the value Press the button to decrease the value Press the button to move the cursor a step to the right Only valid when you enter a text or a numerical value Press the button to move the cursor a step to the left Only valid when you enter a text or a numerical value 4 Either Press the button to save the changes Press the button to exit the menu without saving the value 5 When a parameter value is saved a message will show the result Value stored The value has been saved High value The value is too high Enter a lower value Low value The value is too low Enter a higher value For information on allowed values see also Menu Descriptions on page 31 4 6 Pump Control Use the and buttons to change between automatic and manual pump control see also Controlling the Pump on page 25 4 7 Reset Function With the button you can acknowledge a new alarm or remove a pump fault block see also Pump Failure Block on page 26 Acknowledge an Alarm on page 26 4 8 Display Language The display language is changed in the Language menu 8_ Lo
35. his menu is hidden Pump current View the present current in the P1 current menu 3_ Number of pump starts View how many times the pump has started in the P1 start counter menu 4_1 Run time for a pump View how long time the pump has run in the P1 run hour menu 4_2 7 3 Resetting Runtime Data You can reset the following runtime data Number of pump starts shown in the P1 start counter menu 4_1 Run time for a pump shown in the P1 run hour menu 4_2 To reset runtime data 1 Display the relevant menu for example the P1 start counter menu 2 Reset the value that is a Press the button to be able to reset the value The message Reset value is displayed b Press the button to select Yes c Press the button to reset the value 7 4 Controlling the Pump 7 4 1 Automatic Control Auto Mode Normally the FGC starts and stops the pump automatically This is called Auto mode 7 4 2 Manual Control Manual Mode In Auto mode you can manually start the pump This changes the mode to Manual mode Start the Pump Manually Press the button for 5 10 seconds until the display briefly shows Manual mode Example How Long Will the Pump Run The pump will now run until the level in the pump sump drops below the stop level If the level in the pump sump already is below the stop level the pump will run for 5 minutes Return to Auto Mode When the
36. lem check that everything is installed and configured correctly For information on how to interpret the LEDs and troubleshoot refer to LED Descriptions on page 29 Alarm Descriptions on page 30 Troubleshooting on page 27 What s Next When ready FGC is now initialized with default values for the specific installation Pump is now ready to run Trimming the FGC If necessary use the FGC menus to trim the installation see also Menu Reference Chart on page 9 Configuration on page 20 Additional Configuration on page 23 OK Set default val Level regulator OK P1 current 00 0 A 3_ OK High current P1 5 3 A 3_1 OK High current P1 5 3 A High current P1 6 3 A OK High current P1 6 0 A Esc P1 current 00 0 A 3_ 28 29 26 8 19 22 Issued Supersedes 8 4 12 2 3 Menu Reference Chart This chart shows the menu structure in the FGC Only shown when the Control mode menu 7_1 is set to Analogue 4 20 mA level sensor Only shown when the Control mode menu 7_1 is set to Digital Level switches A A A A A B B A A Alarm log 1 Level 2_ Start level 1 2_1 Stop level 1 2_2 High level 2_3 Sensor range 2_4 Sensor calib 2_5 P1 current 3_ High current P1 3_1 Operating data 4_ P1 start counter 4_1 P1 run hour 4_2 Pump control 5_ P
37. ngs can add time to a pumping cycle If the pump is set to run on time see also Stopping a Pump After a Time on page 21 High level run time see also Backup Pump Control on page 23 If a stop delay is used see also Stop Delay on page 23 To specify the maximum run time 1 Display the Max run time menu 5_5 2 Enter either Maximum run time 00 00 to disable the function There will be no limit for how long a pump can run 6 3 6 Pump Response When the FGC has set the pump to start and the pump current exceeds 0 5 A the pump is considered to have started When the FGC has set the pump to start but the pump current remains below 0 5 A the pump is considered not to have started An alarm can be generated To disable pump response alarms select 0 in the Automatic reset menu 7_6 Otherwise enter a number from 1 to 200 in this menu 6 4 Alarm Configuration An alarm alerts the receiver that something needs attention The FGC can generate alarms for example if the temperature in a pump motor is too high For a complete list of possible alarms see also Alarm Descriptions on page 30 6 4 1 Alarm Delay When the condition for an alarm is fulfilled for example if the level in the pump sump exceeds the configured high level alarm limit the alarm is generated However alarm generation can be delayed for a specified time The alarm condition then
38. nt and the over current protection trips the pump 3 FGC blocks the pump 4 The number of consecutive blocks counter is updated by 1 in the FGC Total number of allowed start attempts is exceeded Permanent blocking 5 Total number of allowed start attempts is not exceeded Count down to start 6 5 FGC blocks the pump permanently Alarm end 6 Count down to next start attempt begins Motor protection trips the pump Blocking 3 Current is below motor protection threshold Blocking no longer in effect 7 7 FGC starts the pump 8 The number of consecutive blocks counter in the FGC is reset to 0 9 Pumping lowers the sewage level in the well below the start level 10 FGC stops the pump 10 3 5 Scenario D2 Current rising 1 During pumping resistance in the system increases 2 FGC registers over current and the over current protection trips the pump 3 FGC blocks the pump Updating of consecutive blocks counter Scenario D1 4 etc Appendix B LPSS Scenarios 10 Appendix B LPSS Scenarios
39. ok for the symbol It is shown in the top left corner of the Language menu OK Esc OK OK Esc 1 0 Reset Language English 8 30 24 25 25 Issued Supersedes 19 4 12 5 1 Introduction This chapter describes how to configure basic parameters and set points in the FGC For simpler configuration refer to Getting Started on page 7 To configure the FGC follow the flow chart below For a complete list of menus refer to Menu Descriptions on page 31 33 For more information refer to A Configuring Level Switches on page 21 E Start Stop and High Levels on page 22 B Using a Stop Level Switch on page 21 F Maximum Motor Current on page 22 C Stopping a Pump After a Time on page 21 G Additional Configuration on page 23 D Configuring a Level Sensor on page 21 H Basic Operation on page 25 D A B C D A C A B A C D E E E F G H The basic configuration is now finished and the pump is ready to run Refer to the rest of the manual for information on operation as well as additional configuration options Select Stoplevel switch in the Stop condition menu 7_2 Select Run on time in the Stop condition menu 7_2 Enter pump run time in the Run time menu 7_3 Select Digital in the Control mode menu 7_1 Select Analogue in the Control mode menu 7_1 Start the
40. p that empties the sewage tank into the system A few problems that need to be addressed are presented here in order to demonstrate how certain functions and component accessories are employed in the application Make sure to comply with the Safety Instruction on page 5 When connecting a pump of a different brand the direction of rotation must always be checked even if the Phase fault LED does not light up Power Supply 24 VDC 4 Below describes how to connect the power supply to the FGC Issued Supersedes 14 4 12 15 3 8 2 Preventing over pressure in system Problem The individual pump controls must prevent dangerous pressure levels by regulating the number of pumps allowed to operate simultaneously Solution High pressure in the system is detected by a pressure switch connected to the pumping outlet When pressure is too high the FGC is prevented from starting the pump As a result some units may have to wait for other units to finish pumping High pressure is also detected indirectly by the FGC while monitoring the pump current Should the work load on the pump be too high the current protection i e motor protection trips the pump This not only protects the pump from damage but also protects the whole system from high pressure Note Using over current protection in this manner is viable for PC pumps For centrifugal pumps on the other hand over current is more likely caused by solids o
41. r debris clogging the pump necessitating a service stop 3 8 3 Avoiding simultaneous pump starts Problem The work load on the system is highly variable Many households will be pumping sewage during approximately the same morning and evening hours Should a power down occur the situation will be further aggravated When power is re established many pumps may attempt to start pumping simultaneously causing sudden pressure increases in the system Solution This problem is already handled in the FGC by the power on delay see Fixed Pump Delays on page 23 which randomizes the start of individual pumps within a 120 s time frame 3 8 4 Handling pressure increases during operation Problem When the pump starts pressure in the outflow increases and may exceed the sensor s limit Solution The pressure switch may only block the pump start i e when the pump is already running only over current protection can stop the pump prematurely 3 8 5 Preventing over flow at high pressure Problem A high sewage level suggests that the tank may be in danger of over flowing This must be avoided Solution When the high sewage level is reached the pressure switch signal is no longer allowed to block the pump start and the FGC can start the pump normally Note Over current will still block the pump from running In order for the pump control to operate appropriately the blocking function is modified by the settings for numbe
42. r of restart attempts described under the next heading 3 8 6 Resetting over current protection Problem In the LPSS application it is likely that over current protection will occasionally stop a pump Previously FGC 211 could only handle a single restart attempt If this failed due to the over current state still remaining restarting would be permanently blocked and a service technician would be required before the pump could be started again Solution It is now possible to enter a value for the number of allowed restarts from 1 to 200 As soon as the FGC successfully restarts the pump the internal counter of the number of consecutively blocked start attempts is nullified 3 8 7 Flushing sewage from the system Problem In normal operation sewage in the tank seldom rises above the start level This may cause residue to build up around the tank wall Additionally the limited volumes pumped out of the tank with each pumping cycle may not create sufficient flush to clear out the sand that may be settling in the pipes Solution A flush timer is used for blocking pump start for a given time period Xylem Inc does not advocate any particular settings for time delay or interval as these are determined by the actual situation In this way the sewage is occasionally allowed to rise above the start level The increased sewage volume aids in flushing the To prevent over flow the high level switch over rides the flush timer and m
43. re the main power supply for the FGC is off Mount the FGC Ensure that the temperature in any equipment cubicle will be neither too high nor too low Install desired level sensor or switches in the pump sump and connect them to the FGC If used connect the thermal contact for the pump to the FGC If not used make sure to place a jumper lead on the thermal contact input in the FGC If used connect an external alarm device to the common alarm output Make sure a separate fuse is used for the main power supply Connect an earthing grounding conductor to the FGC Recommended Provide the main power supply with overvoltage protection Connect the FGC both to the main power supply and to the pump Check that all connections are correctly installed Turn on the main power supply Configure the FGC Chapter Read This First on page 4 especially Chapter Safety Instruction on page 4 Chapter Installing the FGC on page 9 Chapter Installing Sensor or Switches on page 10 Chapter Connecting Thermal Contact on page 12 Chapter Connecting Alarm Output on page 12 Chapter Power Supply on page 13 Chapter Earthing Grounding on page 13 Chapter Overvoltage Protection on page 13 Chapter Installing Power Supply on page 13 Chapter Getting Started on page 6 Issued Supersedes 6 4 12 2 2 Getting Started This is a short description on how to get started wi
44. rmal pump control and operation are prevented After 10 minutes of idle time the FGC will automatically revert to normal operation To run a diagnostic program 1 Display the Diagnos Program menu 7_9 2 Select one of the diagnostic programs Available programs are listed below The rest of the programs are for future use To manually stop a diagnostic program select Off in the Diagnosis Program menu Reset Program Description Results 10 Digital inputs Shows the digital input states for example 1001100100000000 11 LED output Common alarm output Flashes at 1 second interval 20 Analogue input Shows the raw input values 0 16383 24 P1 current input Shows the raw input values 0 16383 This starts the pump Issued Supersedes 28 4 12 9 Appendix A FGC Descriptions 9 1 LED Descriptions The front panel of an FGC includes a set of LEDs see also Front Panel on page 18 The LEDs are described in the table below LED Indication Cause Power Green on Off The power supply is on The power supply is off or a fuse is blown Alarm status Red flashing Red on A new alarm has occurred The new alarm has been acknowledged but is still active Relay status Green on Red on Red flashing The pump relay is activated The pump is stopped and blocked from restarting Possible causes Pump is blocked manually see also Blo
45. s lit due to the event or error Text in Alarm Log s i p m u P e s u a C m r a l A Blocked LED Indication High level High level in pump sump Alarm from the level sensor No High level Mains error The main power has been disrupted Yes Relay status for phase failures Hi lev float The level in the sump reaches the high level switch The pump will be started No High level P1 Tripped High current pump 1 Alarm from the analogue current measurement The pump is blocked by this alarm Yes Pump status P1 No resp There is no response signal from pump 1 The pump has probably not started despite activation of the power relay No s u t a ts p m u P s e Y 1 p m u p ni e r u t a r e p m e t h gi H p m e t h gih 1 P Inval setp The level setpoints are incorrect The specified setpoints for Start Stop or High level is either outside the calibration range or they are mutually not corresponding i e the high level setpoint is lower than the start level setpoint No P1 Max run The pump 1 has exceeded the maximum allowed run time The pump is blocked by this alarm See also the Max run time set point Yes Pump status Sensor Fault An error in the analogue sensor has been detected The measured level is outside the sensor range No Appendix A FGC Descriptions Issued Supersedes 30 4 12 9 3 Menu Descriptions The table below describes avail
46. st 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 by connecting them to one of the earth terminals in the FGC 3 7 4 Overvoltage Protection Flygt recommends that the mains power supply unit be provided with overvoltage protection with lightning protection Since this will make the FGC less sensitive to overvoltage the FGC can be used in more severe environments 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 6 10 mm conductor should be used to connect the overvoltage protection to earth 3 7 6 FGC 24 VDC Power Supply 3 phase 400 VAC With Neutral Input Below it is described how to connect the power supply to the FGC 3 8 FGC 211 in a LPSS application 3 8 1 Background In response to demands for a simple efficient and reliable solution for a LPSS system Xylem Inc proposes an application where FGC 211 is used in combination with a Flygt PC pump i e a Progressive Cavity pump The application presented here is typically intended for situations where a number of family houses e g villas each with its individual sewage tank are connected to a common pressurised sewage system The FGC controls the pum
47. stop level switch To restore default values 1 Select the relevant set in the Set default value menu 7_10 2 Wait while the FGC restarts High level Start level Stop level 22 24 Issued Supersedes 22 4 12 6 1 Introduction Besides the basic parameters and set points described in Configuration on page 20 you may want to change the ones described in this chapter 6 2 Level Configuration 6 2 1 Backup Pump Control As backup an installation can include a high level switch It can be used together with start and stop level switches as well as with a level sensor If the start switches or the level sensor malfunctions the pump is started when the level in the pump sump exceeds the high level switch A High level alarm is also generated When the level in the pump sump drops below the high level switch the pump will continue to run for some additional time Specify this additional run time in the Hi lev run time menu 5_4 6 2 2 Stop Delay If a level sensor or level switch cannot be installed low enough in a pump sump a stop delay allows the pump to empty the sump completely A pump stop can be delayed until The specified time has elapsed The pump has lowered the level in the pump sump a specified height Only available for an analogue level sensor To delay the pump stop a specific time 1 If you use an analogue level sensor enter 0 0 in the S
48. t necessary to have 0 00 5 Optionally you can calibrate the sensor a Make a note of the displayed level value for example 00 20 m b Calculate the offset needed to display the level 0 00 m For example if the displayed level is 00 20 m the offset needed is 00 20 m c Enter the offset in the Sensor calib menu 2_5 d Read the current level in the Level menu 2 and make sure the displayed level is acceptable 5 In the pump sump lower the sensor in the water When ready continue with Start Stop and High Levels on page 22 High level switch Start level switch Stop level switch 20 20 21 21 21 Issued Supersedes 21 4 12 5 4 1 Start Stop and High Levels When the level in the pump equals specified Start level the pump is started Stop level the pump is stopped High level a High level alarm is generated Since the pumps are used to empty or drain a pump sump stop level lt start level lt high level To specify the levels 1 Enter the start level in the Start level 1 menu 2_1 2 Enter the stop level in the Stop level 1 menu 2_2 3 Enter when the high level alarm is generated in the High level menu 2_3 When ready continue below 5 5 Pump Configuration 5 5 1 Maximum Motor Current This is the maximum allowed current for a pump motor and is normally the same as the nominal current of the pump The FGC au
49. th alarms you can Acknowledge that you have received an alarm View recorded alarms in the alarm log Clear the alarm log from inactive alarms 7 6 1 Acknowledge an Alarm The FGC can be connected to both a buzzer and another audible or visual device for example a lamp or siren The devices will be turned on when an alarm is generated Press the button to acknowledge that you have received the alarm This will also silence any connected buzzer or other device 7 6 2 Viewing Alarms The last 50 alarms are recorded in the alarm log It shows both inactive and active alarms To view the alarm log 1 Display the Alarm log menu 1 It shows the number of recorded alarms 2 View the log that is a Press the button to show the log The first alarm shown is the oldest alarm b Either press the button to display the latest alarm or press the button repeatedly to browse the log c Press the button to exit the log 7 6 3 Clear the Alarm Log To remove one or more inactive alarms from the log 1 Display the Alarm log menu 1 It shows the number of recorded alarms 2 Clear the log of the alarms that is a Press the button to show the log b If necessary press the button repeatedly until desired alarm is displayed c Press the button d Press the button to select either Current Only the displayed alarm will be deleted All All inactive alarms will be
50. th the FGC 211 The description is included for convenience only and is in no way a replacement for the Installation manual The figure below shows the front panel of FGC 211 Selecting Language When the FGC is started for the first time the display will show the following To proceed 1 Press the button repeatedly until the display shows the desired language for example English 2 Press the button to save selected language The display will show Value stored and then change its text to the specified language Set Default Values Browsing to the Menu At delivery the FGC is set to factory defaults They are listed in Menu Descriptions on page 31 33 To use a different set of default values 1 Press the button repeatedly until the display shows the following 2 The underscore after the menu indicator 7_ indicates that there are submenus Press the button to access them 3 Press the button repeatedly until the display shows the following The following information is shown in the menu Menu name Set default val Menu indicator 7_8 This indicator is shown for 3 seconds only Parameter value No Set Default Values Changing Values One of the following sensor configurations is installed in the pump sump An analogue level sensor 4 20 mA The sensor measures the level in the pump sump When the sump level exceeds a specified start level the pump
51. tion manual for the sensor 2 Connect the sensor shield to the earth ground terminal of the FGC that is connect the shield cable to one of terminals 5 8 FGC 211 in LPSS application The components recommended for employing FGC 211 in a LPSS application are highlighted in the following texts by this light bulb symbol Suitable for LPSS application In the standard LPSS application the digital terminals 15 and 16 normally reserved for Start level and Stop level regulators are occupied by a pressure switch and a stop relay Instead an analog sensor is used LTU 301 is ideally suited for this application If the ATEX version is used the open bell and only the open bell can be installed in an explosive or flammable environment 200 mm 500 mm Open bell 4 20mA 12 13 14 15 16 17 18 19 20 Black wire White wire Red wire Issued Supersedes 11 4 12 3 The analogue input in the FGC terminals 18 20 has its own power supply and can carry a maximum total load of 12 V Connect the sensor as follows see also figure below Connect the black wire to terminal 19 Connect the red wire to terminal 20 3 3 4 ENM 10 Level Regulators Level Switches To install one or more ENM 10 level regulators 1 Install the level regulators in the pump sump For more information refer to the Installation and operation manual for the regulators 2 Connect the ENM 10 level regulators
52. to FGC as follows If used connect the Stop level switch to terminals 14 and 15 If used connect the Start level switch to terminals 14 and 16 If used connect the High level float to terminals 14 and 17 3 3 5 Pressure Switch An optional pressure switch can be connected to the pumping outlet preventing the FGC from starting the pump while the pressure in the sewage system is high If used connect to terminals 14 and 16 Switch open high pressure closed low For more information refer to the installation instruction of the pressure switch For normal operation use the blue and the black wires The switches will be normally open Terminal 14 is the common power supply terminal for all level switches 4 20mA 12 13 14 5 1 1 1 0 1 9 0 2 9 1 8 1 7 1 6 1 8 7 6 Black wire Red wire Shield wire High level float Start level switch Stop level switch Suitable for LPSS application In the standard LPSS application the High level switch is used Suitable for LPSS application In the standard LPSS application a pressure switch can be used 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 Blue wire Black wire 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 Blue wire Black wire 4 20mA 12 13 14 0 2 9 1 8 1 7 1 6 1 5 1 1 1 0 1 9 Blue wire Black wire 4 20mA
53. tomatically adds a 5 margin to the specified value If the motor current exceeds this limit after a calculated delay the pump is stopped and blocked from restarting An alarm is also generated However if the FGC is set to Automatic reset the FGC will attempt to restart the pump up to the specified number of times This is specified in the Automatic reset menu 7_6 Should all attempts fail the pump will remain blocked If restart is successful but the motor protection is tripped again during the following pump cycle the pump is again stopped and possibly also blocked from restarting as explained above To specify the maximum motor current 1 Enter the maximum current in the High current P1 menu 3_1 2 To use automatic reset enter 1 in the Automatic reset menu 7_6 Otherwise enter 0 in this menu to disable automatic reset When ready the basic configuration is complete If desired you can continue with Additional Configuration on page 23 Basic Operation on page 25 5 6 Restoring Default Values If needed you can restore the FGC to a set of default values Available are Compit analogue a set of default values for an analogue level sensor installed in a Compit pump sump Level regulator a set of default values when using both start and stop level switches Level reg time a set of default values when using a start level switch but no
54. top delay range menu 5_2 This will disable the stop delay based on a specific height 2 Enter the time in the Stop delay time menu 5_3 To set the pump to lower the level in the pump sump a specific height 1 Enter the desired height in the Stop delay range menu 5_2 2 The FGC calculates the pump run time necessary to lower the level the required height To prevent the pumps from running dry enter a maximum run time in the Stop delay time menu 5_3 6 3 Pump Control 6 3 1 Fixed Pump Delays Fixed delays are used to smoothen pump operation They cannot be re configured Minimum Stop Time When a pump is stopped it cannot be restarted until after at least 5 seconds Power on Delay This delay prevents pumps in different sumps from restarting simultaneously after a power failure When power is turned on after the power fault pump start is delayed 0 120 seconds During the delay the Relay status LED displays a flashing red light 6 3 2 Automatic Maintenance Run If a pump has not been started within 96 hours the FGC will start the pump for a maintenance run that lasts 1 second This is useful to keep the mechanical seals in the pump in shape 6 3 3 High Temperature The thermocontact in the pump can be connected to the FGC When the temperature in the pump is too high the pump is stopped and blocked from restarting Wait a while for the pump to cool down and then press the Reset button to remov

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