GRUNDFOS WASTEWATER. Modular Controls for wastewater pumping stations

Transcription

1 GRUNDFOS WASTEWATER Modular Controls for wastewater pumping stations

2 Grundfos Modular Controls Multi-purpose, modular pump control system > Infinite number of variants The Grundfos Modular Controls system is based on a number of individual modules and programs, which like building blocks can be put together in a large number of variants specifically adapted for the size and complexity of the pump system at hand that needs to be controlled. The Grundfos Modular Controls system is the first fully integrated multi-purpose pump control system. It is a user-friendly solution that combines superior technology with an extremely flexible modular approach. The Grundfos Modular Controls will set a completely new standard for pumping station efficiency. In combination with Grundfos pumps, the Modular Controls allow for substantial savings in installation, maintenance and service costs as well as in the dayto-day operation of the pumps. Decades of experience are built into the outstanding modular platform of the Grundfos Modular Controls and the system opens a window to all the pump data you will ever need to have. > Interaction and control The modular design ensures a high level of interaction and control. If the needs or operating circumstances change, upgrading is simple as additional hardware can be clicked into place in a matter of seconds. The relevant software is quick and easy to install. > Suitable for many applications The Grundfos Modular Controls system is a control platform suitable for many applications. The first edition is designed for wastewater pumping installations where advanced control and data communication are required. The system is equally suitable for new or existing installations regardless of type or make of the pumps. 2 >

3 Installation options Total control any time, any where The Grundfos Modular Controls system enables a total overview of every single detail in a pumping station. The control can be operated and monitored at the site by means of an extremely user-friendly control panel with a large graphical display, or remotely on-line via a PC. Pump condition monitoring The Modular Controls provides the users with vital pump and system information to help maintenance organisation to change from service on-demand to preventive and predictive service. If you already use a SCADA system for monitoring and control of pumps and pumping systems, the Grundfos Modular Controls can easily be incorporated in this system. Pump data on a silver platter With the Modular Controls, Grundfos innovation takes technology to a level far above any existing control systems. The Modular Controls hand you all the key performance indicators of your pumping system on a silver platter such as: Actual water level and flow measurement Pumped-volume and pump efficiency Overflow measurement Number of starts and operating hours Running time Power consumption and mains supply monitoring Temperature measurement Moisture detection Water-in-oil measurement Load monitoring and power factor Phase sequence and phase missing Current imbalance Trend curves for analogue values Alarms, including unique snapshot function Insulation resistance and much more. When and where you require it for efficient pump condition monitoring. Meeting future demands The Grundfos Modular Controls is designed to meet future demands for more reliable and cost-efficient pumping operation. In order to enable preventive maintenance and optimum facility management, modern pumping systems feature increasingly advanced sensors. This calls for control systems capable of even better data handling and more efficient communication to remote monitoring systems. The Grundfos Modular Controls is able to meet these demands with a high level of user friendliness and ease of operation. This means total control of your pumps and pumping network, improved long-term cost efficiency and, perhaps most importantly, total peace of mind. 3 >

4 Control System A system solution approach The Grundfos Modular Controls is designed with a system solution approach. The control system consists of a range of components and control programmes, which can be put together in a large variety of combinations, so that the control system matches the size and complexity of the pump system that needs to be monitored and controlled. Easy to operate The Grundfos Modular Controls is extremely easy to operate. The large graphical display provides the user will a full overview of the entire pumping system. The menu-based interface is similar to that found on modern computers. It is easy to become familiar with, even without manuals. The push buttons feature a light guidance system that assists the operator in navigating the menus. The display is available in most local languages. Pump data at a glance The Grundfos Modular Controls is designed with the day-to-day user in mind. All relevant pump information and data are available at a glance at the location or remotely. The system provides a comprehensive range of pump and system data, such as user selectable trend curves for each individual pump as well as the entire pump system. All organised in a logical and easy-readable page setup. Quick and easy installation The Modular Controls system consists of a number of modules with terminal blocks that are extremely easy to install. All cable connections are fitted with clearly marked screw terminals for safe and quick mounting. Each module features LEDs for quick status check of the external controls. Comprehensive factory settings enable quick and easy commissioning. Up to six pumps per controller The Modular Controls system is designed for the control and monitoring of one or several Grundfos wastewater pumps, or pumps of any other make, in individual pumping stations or networks. 4 >

5 The user does not have to invest in an oversize controller in order to provide for possible future upgrades. With the Grundfos Modular Controls, new modules can simply be added to the system as the need arises. New software upgrades are easily adopted by updating the software card, which is accessible without dismantling the control modules. Efficient alarm management The Modular Controls also offers an advanced alarm management system. This includes an alarm log with data on the latest 100 alarms phenomena. The system also features a unique snapshot function that provides a detailed overview of the operating conditions at the time of the alarm. This enables the operator quickly to pinpoint the cause of the alarm and to take appropriate preventative action. Open communication The Modular Controls is designed for a variety of communication methods from on-site interface communication, and simple alarm relaying via mobile telephone text messages, to full-scale SCADA communication. The Grundfos approach to SCADA communication is open for all system integrators to adapt the Modular Controls into their system as a front-end outstation. PC Tool The Grundfos PC Tool Modular Controls is a management and service tool for Modular Controls applications. The tool can be used for on-site service as well as for off-site preparation, verification and management. The PC Tool can be used for setup, commissioning and backup of Modular Controls settings and parameters. The PC Tool offers the possibility of on-line monitoring of pump condition, adjust settings, start/stops pumps, acquisitions of datalogs, create operation and service reports etc. Everything can be done locally or remotely via modems. Preventive maintenance The trend curves and other detailed operation information, which the Modular Controls is able to provide, enable the operator to take relevant preventative maintenance action before a fault develops. This helps to reduce operating costs and to keep downtime at a minimum. 5 Technical data >

6 Main components The following is a short presentation of the main components of the Grundfos Modular Controls system: CU 401 The CU 401 is a Control Unit designed to monitor system level and operation data. The CU 401 is the brain and backbone of the Modular Controls system. It controls the operation of the other system modules and, consequently, the entire pumping system. IO 401 The IO 401 is an Input and Output module. When connected with the CU 401 Control Unit, the combination operates as a pump controller capable of controlling and monitoring one or two wastewater pumps. The IO 401 module consists of two galvanically isolated parts, which each handles one pump. In order to ensure optimum pump operation, Grundfos pumps are recommended. However, the IO 401 module is suitable for pumps of any make or model. OD 401 The OD 401 is an Operator Display module, which serves as an interface between the operator and the Modular Controls. It features a large graphical display that gives the operator an instant overview of the entire pumping system. The OD 401 also provides a mini-scada like approach to all system and pump data, including history trend curves and alarm history logs with detailed snap-shot information. The OD 401 is extremely easy to operate with only a few and clearly marked push buttons with a light-guidance system. The OD 401 provides an easy approach to the pumping system without the need for manuals or timeconsuming learning. The OD 401 is available in most local languages. PU 101 The PU 101 is a Power Unit module, which supplies the low-voltage power for the Modular Controls. It is a switch-mode power supply with galvanic isolation. The module is suitable for all commonly used mains voltage ranges. Program card The program card contains the application software for the Modular Controls system. It also stores all settings and measurements of the system in order to enable easy application update and data back-up. 6 >

7 PU 102 The PU 102 is a Power Unit for uninterruptible power supply (UPS) to the Modular Controls system. In case of a mains failure, the PU 102 powers the controller via a back-up battery for up to 31 hours. FB 101 The FB 101 is an interface module between the mains supply and the Modular Controls system. The FB 101 enables phase-sequence detection and provides information of phase failure or wrong phase order. G 401 The G 401 is a communication module incorporating a GSM/GPRS modem. The G 401 enables wireless communication to and from the pumping system by means of GSM data, SMS (text messages), or GPRS technology. Analogue modem The analogue modem enables wired communication to and from the pumping system via a public services telephone network (PSTN). MP 204 The MP 204 is an electronic motor protection and data-collecting unit. Motor protection is achieved by measuring all three phases of the motor power supply by means of true RMS values. A secondary protection of the pumps is achieved via various temperature measurements and moisture sensor information. In addition to protecting the pump, the MP 204 provides a substantial flow of information and measurements for the Modular Controls, such as warnings, alarms, power consumption data, load information, power factor and motor temperature. The MP 204 is equally suitable for single-phase and three-phase motors, and for stand-alone installations as well as in combination with the Modular Controls system. IO 111 The IO 111 unit serves as an interface between a wastewater pump equipped with analogue and digital sensors and the Modular Controls system. The module protects the pump against abnormal conditions, such as over-temperature in the motor or bearings, high water content in the seal oil, low stator insulation resistance, or moisture in the motor. The most vital sensor data are indicated on the front panel. The IO 111 unit handles one pump and forms a galvanic isolation between the pump and the controller. The unit is equally suitable for stand-alone installations and in combination with the Modular Controls system. 7 Technical data >

8 Functions overview The Grundfos Modular Controls wastewater program offers a wide range of control and monitoring functions. The following is an overview of the standard functions available on the program card: Analogue sensors (operating up to six pumps) Actual water level Pump control according to set water levels Alarms: dry running, alarm level and high-water level Flow measurement Pumped volume measurement Pump performance measurement (efficiency) Overflow measurement Float switches (operation of one or two pumps) Pump control according to one of several pre-defined configurations Alarms: dry running and alarm level Analogue sensor combined with safety float switch(es) Alarm for conflicting levels in addition to the above Warnings/ alarms User-configurable alarms and warnings List of active alarms Alarm- and warning-level adjustment Acknowledging method automatic/manual Forwarding to a SCADA system and/or mobile telephone text message Alarm history log for 100 alarms phenomena with date/time Alarm snapshot for each alarm with detailed overview of the operating conditions when the alarm occurred Advanced pump control Pump groups User-configurable start and stop delays User-selectable pump alterations Anti seizing Daily emptying Foam drain Maximum number of pumps running in parallel Mixer control Pump operation measurements Cumulative number of starts Number of starts per hour Cumulative operating hours Running time since latest start Parallel running time (two or more pumps running at the same time) Pump flow (efficiency) Station condition monitoring UPS battery back-up module with battery condition monitoring Actual water level in the pit Readiness for external flowmeter Energy consumption measurement Mains supply monitoring, phase failure detection Safety float switches to secure operation even if the analogue sensor fails External alarm indicators (horn, alarm light, etc.) User-defined outputs, e.g. mixer control, external reset function System efficiency measurement, specific energy, kwh/m 3 8 >

9 Pump condition monitoring Temperature detection and measurement Klixon/PTC sensor/ thermal switch Pt 100/Pt 1000 sensors Moisture sensor detection Water-in-oil measurement (WIO) Overload/underload Overvoltage/undervoltage Phase sequence Phase missing Power factor (cos ϕ) Power consumption Current imbalance Operating hours and number of starts On/Off/Auto switch feedback Contactor relay feed-back Trend curves at site Station level trend curves Pump level trend curves 24 hours/7 days/30 days curve view Optional interface settings and security SI or US units Local language or English Access-code protection, three levels Modems and communication Compact flash type analogue modem (PSTN) GSM/GPRS module Mobile telephone text message service (SMS) SCADA interface and protocols Well documented functional profile open for any system integrator Large numbers of system and pump data logged on hourly basis, memory for latest seven days ModBus COMLI OPC server interface Graphical display and control buttons Self-guiding wizard, light guidance to buttons Logical use Large display, all relevant data visible at once Graphical illustration of the pumping system Interlocking function Interlocking between several pumping stations Each station in the network can send and receive interlocking commands, even without supervising/scada system 9 Functions overview >

10 Applications SCADA system The Grundfos Modular Controls can easily be incorporated into an existing SCADA system where the Modular Controls can provide well-structured data and information about the pumps and pumping stations. Using these data in a modern SCADA system will generate substantial savings in operation, maintenance and service costs. Additionally, the data provided by the Modular Controls will enable efficient preventative maintenance and service of the pumps and pumping stations. The Modular Controls use either ModBus, Comli or OPC server protocols for SCADA communication. A well documented functional profile is available for system integrators how to integrate Modular Controls into their SCADA systems. Please refer to your local Grundfos representative for further information. Control panel configuration Grundfos offers examples of complete electrical wiring diagrams in different formats and for different applications. The switchgear must be dimensioned according to the size of the pumps. Switchgear is not a part of the Modular Controls modules supplied by Grundfos. (Please refer to your local Grundfos representative for further information). Pump system Example of dry-installed pump system with a Modular Controls control panel. 10 >

11 Mini SCADA on-site The Grundfos Modular Controls provides the maintenance personnel with a number of information on the pumps individually as well as on the pumping system as a whole. The measurement and calculation data, which normally are available only at the control centre of a SCADA system, are now easily accessible, right at the site of the pumping station, to support immediate service actions fault finding and repair. The user-log trend curves provide a graphical illustration of the main measurements thus supplying the user with vital information on how the measurements have developed. Together with the comprehensive warning systems, this allows for long-term planning and order of priority of future service actions. The overview on pages shows some typical configurations of a Grundfos Modular Controls system. The above example is from a system, which monitors pumps with the new analogue water-in-oil sensor. Warnings and alarms via SMS The Grundfos Modular Controls allows for warnings and alarm messages to be sent directly from the pumping station to the service technician s mobile telephone via SMS (text message). In addition to warnings and alarm messages, a heartbeat message can be sent at any chosen time of day, any day of the week. The heartbeat function, in combination with the SMS message system, offers small water facilities the possibility of maintaining highly cost-effective supervision of their pumping stations network. 11 Applications >

12 Configuration examples and product numbers Configuration: Basic 1-2 pump control Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-4 pump control Component: CU 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-6 pump control Component: CU 401 IO 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-2 pump control with GSM com. Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-2 pump control with GSM com. and UPS back-up Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 PU 102 Product number: See column at right Configuration: Basic 1-2 pump control with Analogue modem com. Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-2 pump control with GSM com. and motor protection Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Product number: See column at right Configuration: Basic 1-2 pump control with GSM com. UPS back-up and motor protection Component:t CU 401 IO 401 OD 401 PU 101 Program Card WW1 PU 102 Product number: See column at right >

13 Level sensor Program Card WW language versions available. Product number, see below Level sensor Level sensor G 401 Antenna Level sensor Battery G 401 Antenna Level sensor (English) (Danish) (Dutch) (Finnish) (Portuguese) (Italian) (German) (Greek) (Swedish) (Polish) (Russian) (Hungarian) (Spanish) More versions will be made available later Analogue modem Level sensor G 401 Antenna MP 204 MP 204 Level sensor Battery G 401 Antenna MP 204 MP 204 Level sensor Technical data >

14 ON DIP Technical data Ambient temperature Technical data During operation: 20 C ( 10 C OD401) to +60 C (must not be exposed to direct sunlight) UPS back-up batteries during charging: 20 C to +50 C (must not be exposed to direct sunlight) In stock: 25 C to +85 C During transportation: 25 C to +85 C Digital inputs Electrical data Output voltage, open contact: 24 V Relative air humidity Relay outputs From 5% to 95% 400 VAC, 2 A, AC VDC, 2 A, DC 13 Materials Enclosure class: IP 20 OD401 when mounted plate/door IP55 Plastic type: Black PC/ABS Standards conformity Electromagnetic compatibility (89/336/CEE): EN and EN Electrical equipment designed for use within certain voltage limits (73/23/EEC): EN and EN Supply voltage 24 VDC ±7% from the PU 101 or from the CU 401 module bus 24 VDC from the PU 102 (UPS) Power consumption Max. 11 W per module 110 Dimensions CU401 / IO 401 PU 102 / G401 PU Vdc/2.5A PU 101 N L OD 401 FB 101 MP IO T1 T2 G1 A1 G2 A2 K1 K2 R1 R2 PE D1 D2 D3 D4 D5 D6 D7 D8 A Y B Reset 116 P1 P2 P3 P4 P5 I1 I2 I3 14 Technical data >

15 The Grundfos wastewater range S range 5 29 kw Brochure covers the Grundfos range of submersible channel-impeller pumps from 5 kw up to 21 kw and Super-Vortex pumps up to 29 kw. All designed for handling unscreened raw sewage. Available in 50 Hz and 60 Hz versions. S range kw Brochure covers the Grundfos range of sewage pumps from 15 kw up to 155 kw for handling of raw sewage in heavy-duty applications. Available in 50 Hz and 60 Hz versions. S/SA ranges Up to 520 kw Brochure covers the Grundfos range of super-heavy-duty channel pumps, axial flow pumps, and propeller pumps from 7.5 kw up to 520 kw. S range pumps kw The brochure covers the Grundfos range of heavy-duty submersible SuperVortex and channel-impeller pumps from 1.65 to 5.0 kw. All suitable for unscreened sewage. SRP range kw Brochure covers the Grundfos range of SRP submersible recirculation pumps for wastewater treatment plants and flood control. Available in 50 Hz and 60 Hz versions. SEN range kw Brochure covers the Grundfos range of heavy-duty stainless steel pumps (SEN) for aggressive and corrosive environments. Multlift M, MD, MDV, and MD1 ranges Brochure covers Grundfos lifting stations for individual as well as multi-user applications. LC/LCD Ranges level controllers Brochure covers the Grundfos range of controls for the wastewater pumping systems. AMD, AMG, and AFG ranges Brochure covers the new range of mixers and flowmakers for optimal control of liquids and solids throughout the wastewater treatment process. Submersible sewage grinder pumps Brochure covers the Grundfos range of sewage grinder pumps (SEG) for pumping of wastewater with toilet discharge. DP, EF, SE1 and SEV ranges kw Brochure covers the Grundfos range of submersible channel-impeller and Super- Vortex-impeller pumps from 0.6 to 2.6 kw. Designed for handling drainage, effluent and sewage from private dwellings. SE1 and SEV ranges kw This brochure describes the innovative SEV/SE1 pump lines. Fitted with Super- Vortex or single-channel impellers, these pumps can meet approximately 80% of all wastewater pumping needs. Prefabricated pumping stations Brochure covers the Grundfos range of prefabricated pumping stations for collecting and removing drainwater, surface water, domestic and industrial wastewater and sewage. S pump range 72 Brochure covers the Grundfos range of heavy-duty submersible pumps from 90 to 225 kw for pumping of large quantities of wastewater and unscreened raw sewage. Large prefabricated pumping stations Brochure covers the Grundfos range of large, prefabricated pumping stations designed to meet many different customer needs. 15 The range >

16 Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence Business with an attitude Knowledge The sharing of knowledge, experience and expertise across our global network will always lead our business forward. Innovation Combining the best technology with fresh ways of thinking, we will continue to develop even better pumps, systems, services and standards. Solution With a complete product range, capable of providing every conceivable water solution, we are the most complete player on the market VENTURE I/S