Xylem FLYGT Concertor APP 411 Installation, Operation And Maintenance Manual Download | Manualshive

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Installation, Operation, and

Maintenance manual

887957_6.0

PWR

RS485

DI

1

2

3

4

GND

A

AI

AO

HMI

1

2

3

4

5

B

GND

24VDC

+

_

+

_

+

_

DI1

DI2

DI3

DI4

DO1

DO2

DO3

DO4

ALARM A

ALARM B

PUMP RUN/CLEAN

PUMP COMMS

RS485

USB

NODE
ADDRESS

ON

OFF

MASTER

SLA

VE

TERM

PUMP

DO1

NO

COM

NO

COM

T4

T3

GND

DO2

DO3

NO

COM

NO

COM

DO4

ETHERNET

4

7

8

3

9 0

6

1

2

5

Concertor™

APP 411

Concertor

™

1
2
3
...
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Summary of Contents for FLYGT Concertor APP 411

Page 1: ...ND A AI AO HMI 1 2 3 4 5 B GND 24VDC _ _ _ DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 ALARM A ALARM B PUMP RUN C LEAN PUMP COMMS RS485 USB NODE ADDRESS ON OFF MASTER SLAVE TERM PUMP DO1 NO COM NO COM T4 T3 GND DO2 DO3 NO COM NO COM DO4 ETHERNET 4 7 8 3 9 0 6 1 2 5 Concertor APP 411 Concertor ...

Page 2: ......

Page 3: ... Parts 9 3 4 The data plate 10 4 Mechanical Installation 11 4 1 Do not install in an explosive zone 11 4 2 Concertor XPC single unit 11 4 2 1 Install the unit 11 4 3 Concertor XPC multiple units 11 4 3 1 Install the units 11 5 Electrical Installation 13 5 1 Precautions 13 5 2 Concertor XPC single unit 14 5 2 1 Connect a single unit 14 5 2 2 Set the switches 16 5 3 Concertor XPC multiple units 17 5...

Page 4: ... Troubleshooting 24 8 1 The unit does not work 24 9 Technical Reference 25 9 1 Dimensions 25 9 2 Environmental requirements 25 9 3 IP rating 25 9 4 Electrical data 26 9 5 RTC battery 26 9 6 Terminals 26 Table of Contents 2 APP 411 Installation Operation and Maintenance manual ...

Page 5: ... covered in this manual could cause death serious personal injury or damage to the equipment and the surroundings This includes any modification to the equipment or use of parts not provided by Xylem If there is a question regarding the intended use of the equipment please contact a Xylem representative before proceeding 1 2 Safety terminology and symbols About safety messages It is extremely impo...

Page 6: ... 3 User safety Introduction All government regulations local health and safety directives must be observed Prevent danger due to electricity All danger due to electricity must be avoided Electrical connections must always be carried out in compliance with the following The standard connections shown in the product documentation that is delivered together with the product All international national...

Page 7: ...ertified electricians or Xylem authorized mechanics Xylem disclaims all responsibility for work done by untrained unauthorized personnel 1 4 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations EU and UK only Correct disposal of this product waste electrical and electronic equipment EU Directive 2012 19 EU on waste electrical and electronic equ...

Page 8: ...cadmium or lead above the reference levels in 2006 66 EC or UK SI 2008 No 2164 If batteries are not properly disposed of these substances can cause harm to human health or the environment To protect natural resources and to promote material reuse please separate batteries from other types of waste and recycle them through your local free battery return system 1 5 Spare parts CAUTION Only use the m...

Page 9: ...of one to four pumps with one XPC control unit and one FPG 414 gateway for each additional pump Perfect for users who require the full functionality of the Concertor system including maximum energy savings and clean wet wells 2 2 Concertor XPC Parts 1 2 6 7 5 4 3 WS011095B 8 9 10 No Part Product name Description 1 Pump 6020 A Concertor pump 2 System Description APP 411 Installation Operation and M...

Page 10: ...oller 4 HMI FOP 402 HMI Alternative 1 A touchscreen HMI that is used for navigation and selection in the menus The touchscreen HMI is connected to a web server that is embedded in the controller 5 HMI FOP 315 HMI Alternative 2 A basic HMI with a jog wheel that is used for navigation and selection in the menus 6 Computer HMI Alternative 3 The computer gives access to the same menu system as the tou...

Page 11: ... for Concertor XPC 3 2 Approvals CE UL CSA RCM 3 3 Parts PW R RS4 85 DI 1 2 3 4 GND A AI AO HMI 1 2 3 4 5 B GND 24 VD C _ _ _ DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 AL AR M A AL AR M B PU MP RUN C LE AN PU MP COMMS RS4 85 USB NODE AD DRES S ON OFF MAS TE R SL AV E TERM PU MP DO1 NO COM NO COM T4 T3 GND DO2 DO3 NO COM NO COM DO4 ET HER NET WS009747C 4 7 8 3 9 0 6 1 2 5 4 3 2 1 Conce rtor 5 1 Front connect...

Page 12: ...8 9 5 7 8xxxxxx 1 Brand 2 MAC address 3 Country of origin Manufacturer 4 Product 5 Rated supply 6 Approvals 7 Waste disposal symbol 8 Serial number 9 Part number 3 Product Description 10 APP 411 Installation Operation and Maintenance manual ...

Page 13: ...Concertor XPC single unit 4 2 1 Install the unit Snap the unit onto the DIN rail WS009751B 4 3 Concertor XPC multiple units In a Concertor XPC system the controller is installed with FPG 414 gateways For more information see System Description on page 7 4 3 1 Install the units 1 Connect the backplane connectors 4 Mechanical Installation APP 411 Installation Operation and Maintenance manual 11 ...

Page 14: ...011301A 2 Install the backplane connectors on the DIN rail WS011302A 3 Snap the unit or units onto the DIN rail WS011148B 4 Mechanical Installation 12 APP 411 Installation Operation and Maintenance manual ...

Page 15: ...at the path to ground is continuous WARNING Electrical Hazard Risk of electrical shock or burn A certified electrician must supervise all electrical work Comply with all local codes and regulations WARNING Electrical Hazard There is a risk of electrical shock or explosion if the electrical connections are not correctly carried out or if there is fault or damage on the product Visually inspect equi...

Page 16: ...NO CO M NO CO M DO 4 ET HE RN ET 4 7 8 3 9 0 6 1 2 5 WS011125A 3 4 5 8 6 7 1 2 Con ce rto r 1 Analog input and output 2 Digital inputs 3 HMI FOP 315 4 RS 485 Modbus RTU 5 24 VDC 6 Digital outputs 7 T3 T4 8 Ethernet Pump 1 Connect the T3 and T4 cables from the pump to the T3 T4 terminal Create as much separation as possible between the power cores and the control cables Keep the T3 and T4 cables tw...

Page 17: ... input terminal The analog input is passive The external circuit needs an external power source WS011511A PSU AI Signal Description 4 mA Minimum input 20 mA Maximum input Digital inputs 6 Connect the digital input cables to the digital input terminal 1 4 GND 1 2 WS010234A GND 1 4 1 Open 2 Closed Digital outputs 7 Connect the digital output cables to the digital output terminals The digital outputs...

Page 18: ... Minimum level 20 mA Maximum level Power 9 Connect the power cables to the 24 VDC terminal The power supply unit must fulfill isolation class II 5 2 2 Set the switches Set the switches Switch Correct setting NODE ADDRESS 0 9 All the node addresses in the system must be unique and not 0 MASTER SLAVE MASTER TERM ON OFF ON The groove is perpendicular to the arrow in the node address setting This imag...

Page 19: ... DO 2 DO 3 NO CO M NO CO M DO 4 ET HE RN ET 4 7 8 3 9 0 6 1 2 5 PW R RS 48 5 DI 1 2 3 4 GN D A AI AO HM I 1 2 3 4 5 B GN D 24 VD C _ _ _ DI 1 DI 2 DI 3 DI 4 DO 1 DO 2 DO 3 DO 4 AL AR M A AL AR M B PU MP RU N CL EA N PU MP CO MMS RS 48 5 US B NO DE AD DR ES S ON OF F MAS TE R SL AV E TERM PU MP DO 1 NO CO M NO CO M T4 T3 GN D DO 2 DO 3 NO CO M NO CO M DO 4 ET HE RN ET 4 7 8 3 9 0 6 1 2 5 WS011149B ...

Page 20: ... the system to OFF The groove is perpendicular to the arrow in the node address setting This image shows node address 1 RS485 DI 1 2 3 4 GND A AI AO HMI 1 2 3 4 5 B GND 24VDC _ _ _ PWR DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 ALARM A ALARM B RUN CLEAN COMMS RS485 USB NODE ADDRESS ON OFF MASTER SLAVE TERM DO1 NO COM NO COM T4 T3 GND DO2 DO3 NO COM NO COM DO4 ETHERNET 1 2 3 4 5 6 7 8 9 0 WS012553A DO3 DO4 NO...

Page 21: ...SLAVE TERM PUMP DO1 NO COM NO COM T4 T3 GND DO2 DO3 NO COM NO COM DO4 ETHE RNET 4 7 8 3 9 0 6 1 2 5 Con certo r Table 1 Normal operation LED Description Color Indication PWR Power Green The power is on 21 6 26 4 V The power is off Orange 20 0 21 6 V 26 4 29 4 V Red 20 0 V 29 4 V DI1 DI4 Digital inputs Green The digital input receives a signal The digital input does not receive a signal DO1 DO4 Dig...

Page 22: ... pump is operating Pump cleaning Orange The cleaning process is running PUMP COMMS Pump communication Green The pump communication is established No pump communication is established RS 485 Modbus RTU communication Green Modbus RTU communication No Modbus RTU communication Table 2 Fault indications ALARM A ALARM B PUMP RUN CLEAN PUMP COMMS RS 485 Indication Flashing red Flashing green The unit is ...

Page 23: ... RS 485 Indication Flashing red Flashing red The communication between the controller and the gateways in an XPC system is lost The gateways are operating in redundancy mode 6 Operation APP 411 Installation Operation and Maintenance manual 21 ...

Page 24: ...move the unit from the backplane 3 Remove the battery lid PW R RS4 85 DI 1 2 3 4 GND A AI AO HMI 1 2 3 4 5 B GND 24 VD C _ _ _ DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 AL AR M A AL AR M B PU MP RUN C LE AN PU MP COMMS RS4 85 USB NODE AD DRES S ON OFF MAS TE R SL AV E TERM PU MP DO1 NO COM NO COM T4 T3 GND DO2 DO3 NO COM NO COM DO4 ET HER NET WS014090A 4 7 8 3 9 0 6 1 2 5 Conce rtor 4 Change the battery For...

Page 25: ...7 Turn on the power to the system 8 Make sure that the real time clock RTC shows the correct time 7 Maintenance APP 411 Installation Operation and Maintenance manual 23 ...

Page 26: ...unit receives voltage Restart the unit The unit does not communicate with the pump Make sure that the pump receives voltage Restart the pump and the unit If the problem persists then contact a sales or authorized service representative Always state the product number and the serial number of the product 8 Troubleshooting 24 APP 411 Installation Operation and Maintenance manual ...

Page 27: ...uirements Parameter Value Operating temperature 20 C 65 C 4 F 149 F Storage temperature 20 C 70 C 4 F 158 F Operating humidity Relative humidity maximum 90 Sunlight exposure UV resistant Maximum altitude With UL approval Maximum 2000 m 6562 ft Without UL approval 4000 m 13 123 ft Pollution degree 2 Installation location Indoors Not intended for use in wet locations Overvoltage category II 9 3 IP r...

Page 28: ...ock RTC Parameter Value Battery type BR1632 CR1632 Nominal battery voltage 3 V Battery capacity 120 mAh 9 6 Terminals PW R RS 48 5 DI 1 2 3 4 GND A AI AO HM I 1 2 3 4 5 B GND 24 VD C _ _ _ DI 1 DI 2 DI 3 DI 4 DO 1 DO 2 DO 3 DO 4 AL AR M A AL AR M B PU MP RU N CL EA N PU MP CO MMS RS 48 5 US B NO DE AD DR ES S ON OFF MAS TE R SL AV E TERM PU MP DO 1 NO CO M NO CO M T4 T3 GND DO 2 DO 3 NO CO M NO CO...

Page 29: ...Common ground earth 7 HMI Flygt FOP 315 1 Ground 2 CAN low 3 Shield 4 CAN high 5 24 VDC output 8 RS 485 A Modbus RTU B GND 9 24 VDC 24 VDC Tolerance 21 5 28 5 VDC The power supply unit must fulfill isolation class II 700 mA Typical 150 mA Fuse 1 A 10 DO3 NO Digital outputs Potential free relay output Maximum 250 VAC or 30 VDC 5 A External fuse required 5 A COM DO4 NO COM 11 DO1 NO COM DO2 NO COM 1...

Page 30: ... Description 13 Ethernet Modbus TCP Web server 14 Backplane The Flygt controller communicates with the Flygt gateways through the backplane 9 Technical Reference 28 APP 411 Installation Operation and Maintenance manual ...

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Page 32: ...ing network technologies and advanced analytics solutions for water electric and gas utilities 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 with a strong focus on developing comprehensive sustainable solutions For more information on how Xylem can help you go to www...

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