APP 521 Installation Manual
Contents
1. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 5455 5657 58 59 St Qt ht Qt Vt Mtge aot dt Nt Vt Ot N Vt Dt F 5 S a S Sa AS d e OF d L Af Z sor o xe oy so o g x x X KY KY EI S wre C E V K Z V K O O e ZZ e ess d Ei ez TA NS Ai amp we S ge af Ka g d g g bi gt Bi as Z 2 Ai Zi So ai E se SZ a SF FS S a SF OS Z B ae RE S s nS S Es gt O O e E E g E FS SF SE ei d amp x E E gt L Ba Ba Es EN a A E ai eS FS Ba ay a Ba A Ss d ZA So amp ce gt lt S 2 og oe DN SL Se RS a x N S S Foe A ve S al e al ei S E d amp ei b Es D i i a e e i 1 2 3 4 5 6 7 8 9 10 ll 22 13 14 15 16 17 18 19 20 21 22 23 24 2 HK CET me ai _ la z IZ Di 00600 em 00 N B Terminals 6 8 and 10 are connected together internally N B Terminals 29 31 33 N B and J are closed during normal operation 59 are connected together internally FLYGT Fault tracing 6 Fault tracing Power on LED does not light up Alarm status LED red Is power supply off Contact FLYGT service agent Blocked displays steady ligh Pump status indicator red LED Pump fails to start Contact FLYGT service agent Yes Check the external Alarm status LED Red Check Alarm log menu mains switch and mains fuse or miniature circuit breake2. 1 power supply Flygt recommends the use of a miniature circuit breaker that opens on all poles The I O module is designed to operate 24VDC power supply The I O module also supplies power to the operator panel The unit can also operate on 24 V DC as backup power supply and can charge the backup battery when the mains power supply is on N B Max current availabe to the modem 24 V DC 180 mA 4 5 Watt 4 1 1 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 4 1 2 Overvoltage protection Flygt recommends that the mains power supply unit be provided with overvoltage protection with lightning protection Since this will make the APP 521 less sensitive to overvoltage it will enable it to 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 earthing wire should be used to connect the overvoltage protection to earth 4 2 Emergency operation When the control unit is in the normal running mode a relay 1
3. 4 1 1 Earthing grounding 8 4 1 2 Overvoltage protection 8 4 2 Emergency operation 8 4 3 CONNECTIONS EE 9 4 3 1 Digital inputs s e 9 4 3 2 Inversion of inputs 9 4 3 3 Analogue input 9 4 3 4 Digital outputs 9 4 4 COMMUNICATION E 9 4 4 1 Connection to a modem or radio 9 4 4 2 Connection to a PC using a fixed a EAEE A ATEN 9 5 Wiring diagram 24V DC 10 6 Fault tracing 00 11 7 Specification ccsceeeee 12 FLYGT Read this first 1 Read this first Before starting installation of the APP 521 read this 1 4 1 Symbols used chapter carefully It contains general information on documentation safety and guarantee Safety instruction 1 1 Product documentation Personal risk Documentation delivered with the APP 521 Check that this manual version is applicable to the delivered Safety instruction APP 521 version see cover inlet Personal risk dangerous voltage 1 2 Safety rules for the owner S operator Special attention value e All government regulations local health and safety Risk of apparat r component damage directives must be observed oe ee eS Or L OMPRPENTH ge e All danger due to electricty must be avoided 1 4 2 Abbreviations 1 3 Guarantee CS Central system e Modifications or changes to the unit installation should be don
4. FLYGT 3 3 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 Use the paper template to mark off the opening to be made in the cubicle door Tape the template to the cubicle door Mark with a centre punch the positions of holes 5 and 8 in the template First drill a small pilot hole at every punch mark Then open up the screw holes marked 5 in the template to 5 mm Drill 8 mm dia holes marked 8 in the template for the corners of the opening in the cabunet door Then tape with masking tape between the outsides of the holes 8 See the drawing en D E e LN Lal L Use a jigsaw or some other suitable tool to make the opening for the operator panel in the cubicle door Place the operator panel in the opening Fit the washers and nuts and tighten them firmly 3 3 1 l O module The I O module has clamps at the rear e Place the unit in a suitable location on a DIN rail e Connect the cables supplied between the operator panel and the I 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 1 8 max length 3m FLYGT Electrical
5. Rated voltage Relay output Operating temperature Storage temperature Humidity non condensing Degree of protection EMC emission standard EMC immunity standard LVD electrical safety Display Push buttons Alarm indications Dimensions control pane I x w x h Dimensions O module x w x h Weight of operator panel Weight of I O module Mounting Terminals Cable from I O unit to operator panel Level sensor types Total of 16 Pump fault circuit tripped start feedback start stop amp high level switches thermal overload switch external Manual O Auto switch external alarm general purpose Total of 6 Start pump reset circuit common alarm emergency operation Total of 3 Analogue level 4 20 mA analogue current CT 0 1 A AC 16 bits Motorola HCS12 3 V Lithium Battery will normally last for 8 years lt 50 mA 100 240 V AC T3 15 A 24 V DC 1 1 A 24 V DC 18 36 V DC Max load 240 V AC 2 A Operating temperature 20 C to 50 C The LCD display will respond more slowly at temperatures below 0 C 10 C to 70 C 90 RH IP 65 Front IP 20 EN 61000 6 3 EN 61000 6 2 EN 61010 1 LCD 2 x20 character 8 7 LEDs 220 x 150x25 mm 210 x 149 x 47 mm 1 kg 0 9 kg Cabinet 2 2 Signal 1 5 mm Power 2 5 mm Ethernet cable is a crossover UTP RJ 45 cat 5e The cable length is 1 8 max length 3 m External level sensor 4 20 mA External level regulator ENM 10 eoljou J
6. e only after consulting ITT Flygt e Genuine spare parts and accessiories authorized by the manufacturer are essential for COR Gt with the terms of the guarantee The use c E arts may invalidate the guarantee 1 4 This manual In order to avoid repetition of information this manual describes how information regarding one pump P1 should be read or entered If a second pump P2 is included in the installation the corresponding steps must be repeated on it Introduction FLYGT 2 Introduction The APP 521 is a pump controller It consists of two parts i e a DIN rail mounted I O module and a operator panel The APP 521 can use a modem GSM or radio to communicate with a SCADA system e g the AquaView A special communication module is available for this purpose Observe all precautions for handling electrostatically sensitive devices before opening the unit The front surface of the APP 521 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 521 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 FLYGT Mechanical installation 3 Mechanical installation 3 1 Installation in explosive areas The unit must nev
7. er be installed in an explosive or flammable environment For instructions concerning installation of the level sensors in such an environment see section 3 2 Level sensor installation If the pump is installed in an explosive environment its thermal overload switch must be connected 3 1 1 Installation in an equipment cubicle Ensure that the operating temperature of the cubicle is between 0 and 50 C Heating will normally be required in winter if the cubicle is located outdoors or in a 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 3 2 Level sensor installation N B See separate operation and installation manual for details of installation in the pump sump 3 2 1 4 20 mA level sensor The sensor shield must be connected to the earth ground terminal of the APP 521 as shown in the diagram under Analogue input on page 9 The sensor may be installed in an explosive or flammable environment provided that an external Ex barrier is used 3 2 2 ENM 10 level regulator High level switch Start level switch 2 Start level switch 1 Stop level switch Installation of the ENM 10 level regulator in the pump sump ENM 10 level regulators may be installed in an explosive or flammable environment provided that an intrinsically safe Ex barrier is used Mechanical installation
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9. installation 4 Electrical installation 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 live and in accordance with local regulations An ON OFF isolating switch must be provided adjacent to the installation to enable the APP 521 to be isolated from the power supply This isolating switch must be located close to the APP 521 and must be easily accessible to the user The isolating switch should be marked to show that it belongs to the APP 521 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 4 1 Power supply A separate fuse must protect the APP 52
10. r Alarm High temperature P1 or P2 SR Go to next Alarm Yes Thermal overload switch must be wired as shown in wiring diagram If not used jumper the input hermal overload switchin motor winding has tripped due to high temperature Contact FLYGT service agent Alarm Tripped P1 or P2 Pump is damaged e g bearing failure winding fault pump impeller is jammed No Check that Manual Go to next Alarm 0 Auto selector is set to Auto If not Manual 0 Auto is used jumper the auto input Yes Check external motor Check that Auto is External motor selected in P1 protection has tripped protector Status or P2 Status Pump is running on two menu as appropriate phases Alter if necessary Pump is damaged e g bearing failure winding fault pump impeller is jammed Contact FLYGT service agent Alarm Max run P1 or P2 Check start and stop levels in Start level 1 Stop level 1 Start level 2 and Stop level 2 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 Yes Contact FLYGT service agent 11 Specification FLYGT 7 Specification Digital inputs Relay outputs Analogue inputs Processor Battery back up for the real time clock Current consumption Fuses
11. ret a xylem brand Installation manual APP 521 d D V UN UN A o OOOOH 6 O Automatic Pump Pilot 892780_app521_inst_eng_rev1_01 FLYGT This manualis applicable to the following APP 521 versions Hardware Operator panel AFH1801 Rev 1 02 1 0 module AHH1801 Rev 1 02 Com module TMX1801 Rev 1 00 System Software 2 20 Application 1 00 Copyright 2004 Flygt AB All rights reserved No part of this manual may be reproduced or copied without the written permission of Flygt AB Flygt AB PO Box 2058 SE 291 02 Kristianstad Sweden Tel 46 44 20 59 00 September 2004 This document may be changed without any prior notice Contents FLYGT 1 Read this first 4 1 1 Product documentation 4 1 2 Safety rules for the owner Operator cidiri REENEN A 1 3 Guarantee ee eeeceeeeeeeeeeeeeeeeeees 4 1 4 This manual seenen 4 1 4 1 Symbols used 4 1 4 2 Abbreviations 4 2 Introduction 5 3 Mechanical installation 6 3 1 Installation in explosive areas 6 3 1 1 Installation in an equipment elt TEE 6 3 2 Level sensor installation 6 3 2 1 4 20 mA level sensor 6 3 2 2 ENM 10 level regulator 6 3 3 Mounting instructions asas 7 3 3 1 VO module ssssss 7 4 Electrical installation 8 4 1 Power supply sessen 8
12. uration see the User manual Wiring diagram 24 V DC FLYGT Wiring diagram 24 A Ground 3 P Analogue inputs see section 4 3 3 Level sensor input 4 20 mA 4 5 6 Current transformer for pump 1 0 1 A AC 7 8 Lo Current transformer for pump 2 0 1 A AC 9 10 Digital outputs see section 4 3 4 Start pump 1 11 12 Reset circuit 1 13 14 Start pump 2 15 16 Reset circuit 2 17 18 Common alarm output 19 20 Emergency operation 21 22 Operator panel see section 3 3 1 Operator panel 24V DC 23 24 Communication to operator panel 25 Power supply see section 4 1 Power supply 24 V DC input or Battery backup 24 V DC Option 26 27 Digital inputs see section 4 3 1 Thermal contact 1 28 29 If not used jumper the AD input Motor protector to pump 1 30 31 ye E Onm N e lt C HA AA AB AC VDC Start feedback from pump 1 32 33 Automatic mode for pump 1 34 35 Thermal contact 2 36 37 If not used jumper the input Motor protector to pump 2 38 39 Start feedback from pump 2 40 41 Automatic mode for pump 2 42 43 Stop level switch 44 45 Start level switch 1 46 47 Start level switch 2 48 49 High level switch 50 51 General purpose input 1 52 53 General purpose input 2 54 55 General purpose input 3 56 57 General purpose input 4 58 59 M MODO OOO YOO
13. ut for current transformer with 0 1 A AC output Input for current transformer with 0 1 A AC output 4 3 4 Digital outputs The digital outputs are connected to terminals 11 22 see the Wiring diagram The outputs are potential free relays with a max rating of 2 A at 230 V AC or 30 V DC 4 4 Communication To install the communication module in the operator panel follow the instructions below N B Make sure that the power supplay is isolated 1 Release the four screws 1 holding the rear cover to the front of the unit 2 Lift off the rear cover 2 Unpack the communication module 3 3 Place module 3 in the position 4 see above 4 Make sure it is securely in position 5 Refit the rear cover 4 4 1 Connection to a modem or radio Connect the enclosed dedicated modem cable from the modem radio to the RS232 connector on the COM1 Connect the modem radio to its own power supply 4 4 2 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 Acommon 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 different connected internally to the contact pins Be sure to use the right cable for each purpose N B For config
14. will be activated If the control unit should fail due to software hardware or power supply fault the relay will be deactivated 0 This relay can be connected between a high level switch a timer 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 e Emergency operation is delayed by 5 seconds after the supply has been switched on s External Manual 0 Auto switch is located close to the operator panel Electrical installation FLYGT 4 3 Connections The terminal blocks on the APP 521 are described below and are shown in the Wiring diagram 24VDC on page 10 4 3 1 Digital inputs The digital inputs are connected to terminals 28 59 see the Wiring diagram 24VDC on page 10 Each input has its own power supply 4 3 2 Inversion of inputs 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 4 3 3 Analogue input The analogue input 4 20 mA is connected to terminala 4 5 see the Wiring diagram and has its own power supply The input can carry a maximum total voltage of 16 V 4 1 2 3 45678910 EE i Analogue terminals for 3 Shield 4 Red 5 Black 7 8 Inp
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