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6 Mechanical Installation

Precautions

Before starting work, make sure that the safety instructions in the chapter

Introduction and Safety

(page 4) have been read and understood.

6.1 Do not install in an explosive zone

NOTICE:

Do not use this unit in environments that may contain
flammable/explosive or chemically aggressive gases or
powders.

6.2 Install the controller

1. Fasten the DIN-rail in the cabinet.
2. Fasten the units to the DIN-rail.

a) Fasten the controller.
b) Install the HMI.

For more information, see the Installation, Operation, and Maintenance
manual for the HMI.

6 Mechanical Installation

Flygt FGC 400 Installation, Operation, and Maintenance

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Summary of Contents for Flygt FGC 400

Page 1: ...Installation Operation and Maintenance Flygt FGC 400...

Page 2: ......

Page 3: ...0 3 1 3 Parts 10 3 1 4 The data plate 10 4 System Description 11 4 1 Overview 11 5 Function Description 12 5 1 Overview 12 5 2 Level monitoring 12 5 2 1 Pressure sensor 13 5 2 2 Open Bell 13 5 2 3 Flo...

Page 4: ...oning 29 8 3 Run the setup wizard 29 8 4 Common procedures 30 8 4 1 Modify the start and stop levels 30 8 4 2 Configure the general purpose digital input 31 8 4 3 Change the profile 31 8 4 4 Set the d...

Page 5: ...utputs 50 11 9 Setup Wizard 53 11 10 About 54 12 Technical Reference 55 12 1 Dimensions 55 12 2 Environmental requirements 55 12 3 IP rating 55 12 4 Electrical data 55 12 5 Terminals 56 12 6 Source co...

Page 6: ...ating installing or maintaining the unit in any way that is not covered in this manual could cause death serious personal injury or damage to the equipment and the surroundings This includes any modif...

Page 7: ...Magnetic fields hazard Electrical Hazard CAUTION 1 3 User safety Introduction All government regulations local health and safety directives must be observed Prevent danger due to electricity All dang...

Page 8: ...sonnel 1 4 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations EU only Correct disposal of this product WEEE Directive on waste electrical and el...

Page 9: ...the environment To protect natural resources and to promote material re use please separate batteries from other types of waste and recycle them through your local free battery return system 1 5 Spar...

Page 10: ...n accordance with local regulations 2 Inspect the product to determine if any parts are damaged or missing 3 If applicable unfasten the product by removing any screws bolts or straps For your personal...

Page 11: ...through an HMI with a wizard that guides through the steps The configuration is duplicated upgraded and maintained through the use of a USB drive External interfaces USB RS 232 RS 485 Expansion modul...

Page 12: ...nals 4 Status LEDs For more information about the terminals see Technical Reference page 55 3 1 4 The data plate 2 3 4 5 6 7 8 1 WS009136A 1 Brand 2 Product 3 Batch number Edition number 4 Country of...

Page 13: ...he DeviceNet CAN Controller Area Network protocol 2 HMI The HMI is handheld or mounted inside the cabinet or in the cabinet door Power supply for the HMI is included in the controller 3 Level device A...

Page 14: ...level This float switch is optional 3 Start level standby pump This float switch is used in a two pump station 4 Start level duty pump This float switch is always used when the controller is configur...

Page 15: ...Bell The Open Bell level sensor connects to a pneumatic sensor in the controller The range is 0 m to 5 1 m 16 7 ft The lowest water level must sink below the Open Bell level sensor in each pump cycle...

Page 16: ...regardless of any configured delay Inter Pump Delay This function prevents the pumps from starts and stops in quick successions which can damage the wastewater piping system and activate the overcurre...

Page 17: ...uded in the profiles are also available in the other levels of the menu system When these parameters change for example the stop level the profile that is active also takes on the same changes The par...

Page 18: ...nced When an alarm is silenced only the HMI alarm LED still flashes and the alarm is still shows on the screen in the Alarms menu 5 6 Running data and history data Running data and history are stored...

Page 19: ...not use this unit in environments that may contain flammable explosive or chemically aggressive gases or powders 6 2 Install the controller 1 Fasten the DIN rail in the cabinet 2 Fasten the units to...

Page 20: ...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 con...

Page 21: ...not be damaged and must not have indentations or be embossed with markings etc at the cable entry The minimum bending radius must not be below the accepted value Use cables with appropriate temperatu...

Page 22: ...L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM NC 24V OUT T1 T2 P1 SENSOR T1 T2 DI 1 MUTE H P2 H O A O RS485 IN AI 1 STOP FLOAT SWITCHES STBY ALARM 24V H P1 H O A O HIGH 1 2 3 4 HMI 5 DO 2 RS232 N USB...

Page 23: ...s passive Voltage is supplied by the control unit Connect to the and IN terminals The sensor is active Voltage is supplied by the sensor Connect to the IN and terminals 7 5 Connect a pump sensor circu...

Page 24: ...1 2 1 Pump 1 2 Pump 2 Connect the windings of the current transformer to the terminals Rated current maximum 5 A 7 7 Connect a 24 V alarm lamp P2 SENSOR L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM N...

Page 25: ...ivation The alarm is silenced Activation 10 s The alarm is reset 7 9 Connect an external hand off auto switch P2 SENSOR L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM NC 24V OUT T1 T2 P1 SENSOR T1 T2 D...

Page 26: ...N low 3 Shield 4 CAN H white CAN high 5 24 V red power 7 11 Connect a communication device P2 SENSOR L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM NC 24V OUT T1 T2 P1 SENSOR T1 T2 DI 1 MUTE H P2 H O A...

Page 27: ...DO3 NO Normally opened DO3 COM Common DO3 NC Normally closed 7 13 Connect to the general purpose digital input P2 SENSOR L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM NC 24V OUT T1 T2 P1 SENSOR T1 T2...

Page 28: ...escription L1 Phase 1 L2 Phase 2 L3 Phase 3 N Neutral optional Protective earth 7 15 Connect to a single phase power supply P2 SENSOR L1 AC L2 L3 PE DO 1 NO COM NO COM DO 3 NO COM NC 24V OUT T1 T2 P1...

Page 29: ...Terminal Description Protective earth 7 Electrical Installation Flygt FGC 400 Installation Operation and Maintenance 27...

Page 30: ...the menus Rotate it to navigate Press it to select 5 Home button The home button is used to return to the Home menu 6 Back button The back button is used to return to the previous menu 7 Status LEDs...

Page 31: ...ugh the wizard Use the jog wheel to select and confirm Menu Action Language Select the language Unit of Measurement Select metric or imperial system This option appears only when the English language...

Page 32: ...ettings will be overwritten Confirm the settings Please wait Unit is rebooting with new configuration Wait for the controller to restart The controller is ready to operate 8 4 Common procedures This s...

Page 33: ...Input Usage 2 Select the device that is connected to the general purpose digital input 3 Go to Settings Alarms 4 Configure the alarm for the device that is connected to the general purpose digital in...

Page 34: ...parameter The setting is in meters or feet for an analog sensor and in seconds for a float switch 8 4 7 Modify the alarm settings 1 Go to Settings Alarms 2 Select the alarm 3 Select and configure the...

Page 35: ...Voltage phases are not wired in the correct sequence Station Inhibit The station is remotely inhibited Personnel Alarm Personnel on site has not acknowledged their presence Test Call Used to test the...

Page 36: ...mperature Pump 1 Sensor Short Circuit Thermal contact in pump instead of FLS Pump 2 Sensor Short Circuit Controller alarms Alarm Probable cause Comms Fail Comms lost to controller Startup Failure Corr...

Page 37: ...stant light Remove the USB drive The upgrade is completed No light 1 Remove the USB drive 2 Power off the controller 3 Power on the controller when the LED is not lit 4 Repeat the procedure 9 3 Upgrad...

Page 38: ...ore the configuration settings The settings are erased at a firmware upgrade If saved they can be restored after the upgrade 1 Insert the USB 2 Go to Settings Backup Restore Restore from USB Proceed w...

Page 39: ...the controller No configuration found on USB drive 1 Remove the USB drive 2 Check the USB drive Controller alarms Alarm Probable cause Remedy Comms Fail Comms lost to controller See Check the HMI for...

Page 40: ...present near the cable or the unit 2 Make sure that the cable is correctly connected and has no faults 3 Restart the controller 4 Upgrade the HMI firmware 5 For more information contact the sales and...

Page 41: ...tion WS009288A The Home menu shows the two pumps and the well The following information is shown for the pumps Part Description Status The pump status Running Fault Stopped Current The load current th...

Page 42: ...erflows Number of overflows Visible for the configuration Parameter GP Input Value Station Overflow Total Overflow Duration The accumulated duration of all overflows Visible for the configuration Para...

Page 43: ...PRESENT The condition that triggered the alarm is still present Status RESET REQUIRED The condition that triggered the alarm has ceased A manual confirmation is required to clear the alarm Text messag...

Page 44: ...mp Control The settings for the pump control Motor Protection The settings for motor protection Alarms The settings for the alarms Communication The settings for communication between the controller a...

Page 45: ...time The setting in seconds for the high level runtime Applicable to the high level float switch If the analog sensor is broken this setting is used for extra protection Low Level Block Time The setti...

Page 46: ...Level The alarm deactivation level High level Low Level Activation Level The alarm activation level Low level Low Level Deactivation Level The alarm deactivation level Low level Analog Level The sens...

Page 47: ...ge The setting for the nominal input voltage to the system Pump 1 The settings for the pump current and the sensor type Full Load Current Overcurrent Threshold Sensor Type Pump 2 The settings for the...

Page 48: ...is above the configured level for the overflow float switch for a defined time Maximum Run Time After a defined duration the pump stops for a defined stop time This alarm starts when the duration is...

Page 49: ...ndition only Table 2 Parameters for all the alarms All the alarms are configurable except the Station Inhibit alarm The following parameters are included for all the alarms Part Description Activation...

Page 50: ...gs parameter or the Pump 1 or Pump 2 parameters give access to the parameters that are included for all the alarms Analog High Level Analog Low Level Enabled Activation Level Deactivation Level Genera...

Page 51: ...ity First Char Timeout Inter Char Timeout Radio On Time Radio Off Time RTS Control Channel Configuration The settings for communication over PSTN Baud Parity Write Timeout Connect Timeout Retry Delay...

Page 52: ...eters with information about all incoming or outgoing signals Part Description Digital Inputs The status of the digital inputs Analog Inputs The status of the analog inputs Voltage Inputs The voltage...

Page 53: ...he leakage sensor resistance Pump 1 Pump 2 FLS The leakage sensor resistance Pump 2 Bell Pressure The Open Bell pressure Bell Temperature The temperature in the pressure sensor UPS 24 V The voltage on...

Page 54: ...The digital output signal to run the pump in reverse mode Pump 1 ON OFF Pump 2 Reverse The digital output signal to run the pump in reverse mode Pump 2 ON OFF GP Output The general purpose digital out...

Page 55: ...e The sensor range Duty Start Level The start level for the duty pump Standby Start Level The start level for the standby pump Pump Stop Level The stop level for the pump GP Input Usage The usage of t...

Page 56: ...tions of the HMI and the controller Controller HMI HMI Bootloader Reset Statistics This option leads to statistics and alarm history reset Reset Controller This option leads to a complete reboot of th...

Page 57: ...20 C 85 C 4 F 185 F Operating humidity Relative humidity non condensing 90 Sunlight exposure UV resistant Maximum altitude With UL approval 2000 m 6562 ft Without UL approval 4000 m 13 123 ft 12 3 IP...

Page 58: ...B A B GND DUTY L1 L2 L3 P1 RUN L1 L2 L3 P2 RUN WS009649A 24 25 1 2 3 9 8 7 6 5 4 19 16 18 17 20 20 23 22 21 15 14 12 15 13 10 11 Section Terminal Description FGC 421 FGC 411 FGC 401 1 L1 Power supply...

Page 59: ...rmer Pump 2 x 10 Analog input 4 20 mA for level sensor x x x IN 11 STOP Digital input for external sensors 24 VDC Float switches x x x DUTY STBY HIGH 12 Output for modem power 24 VDC Maximum 500 mA x...

Page 60: ...ocols are also supported x x x 22 USB Standard A USB plug x x x 23 A RS 485 Not used x x x B GND 24 L1 Pump connection Maximum 460 VAC Maximum 12 A Up to 2 5 mm2 Pump 1 x x L2 L3 25 L1 Pump connection...

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Page 64: ...dings factories and farms In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combination of leading product brands and applications exper...

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