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Modular Controls for wastewater pumping stations
GRUNDFOS WASTEWATER
Multi-purpose, modular pump control system
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 day-to-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.
Grundfos Modular Controls
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> Infinite number of variantsThe 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.
> Interaction and controlThe 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 applicationsThe Grundfos Modular Controls system is a control platform suitable for many applications. The first edition is designed for wastewater pumping instal-lations where advanced control and data communi-cation are required. The system is equally suitable for new or existing installations – regardless of type or make of the pumps.
Installation options
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Total control – any time, any whereThe 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.
If you already use a SCADA system for monitoring and control of pumps and pumping systems, the Grundfos Modular Controls can easily be incorpo-rated in this system.
Pump data on a silver platterWith 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.
Pump condition monitoringThe 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.
Meeting future demandsThe 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 friendli- ness 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.
Control System
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Up to six pumps per controllerThe 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.
A system solution approachThe 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.
Quick and easy installationThe 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.
Pump data at a glanceThe Grundfos Modular Controls is designed with the day-to-day user in mind. All relevant pump information and data are avail-able 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.
Easy to operateThe 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.
Technical data > 5
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.
Open communicationThe 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.
Preventive maintenanceThe 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.
Efficient alarm managementThe Modular Controls also offers an advanced alarm manage-ment 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.
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.
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 con-trolling 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 time-consuming 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.
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Main components
The following is a short presentation of the main components of the Grundfos Modular Controls system:
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 modemThe 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 >
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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
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)
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
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/m3
9 Functions overview >
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
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
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
Interlocking function
• Interlocking between several pumping stations
• Each station in the network can send and receive interlocking commands, even without supervising/SCADA system
Applications
The Grundfos Modular Controls can easily be incor-porated 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, main- tenance 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.
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Control panel configurationGrundfos 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 systemExample of dry-installed pump system with
a Modular Controls control panel.
SCADA system
11 Applications >
The overview on pages 12-13 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.
Mini SCADA on-siteThe Grundfos Modular Controls provides the main-tenance personnel with a number of information on the pumps individually as well as on the pumping system as a whole. The measurement and calcula-tion 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 illu- stration of the main measurements thus supplying the user with vital information on how the measure-ments have developed. Together with the compre-hensive warning systems, this allows for long-term planning and order of priority of future service actions.
Warnings and alarms via SMSThe 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.
Configuration: Basic 1-2 pump control
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-4 pump control
Component: CU 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-6 pump control
Component: CU 401 IO 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079929 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-2 pump control with GSM com.
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 G 401 Antenna Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96095256 96095288 96377410
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 Battery G 401 Antenna Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079938 96079948 96095256 96095288 96377410
Configuration: Basic 1-2 pump control with Analogue modem com.
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Analogue modem Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079939 96377410
Configuration: Basic 1-2 pump control with GSM com. and motor protection
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 G 401 Antenna MP 204 MP 204 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96095256 96095288 96079927 96079927 96377410
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 Battery G 401 Antenna MP 204 MP 204 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079938 96079948 96095256 96095288 96079927 96079927 96377410
Configuration examples and product numbers
12 >
Configuration: Basic 1-2 pump control
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-4 pump control
Component: CU 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-6 pump control
Component: CU 401 IO 401 IO 401 IO 401 OD 401 PU 101 Program Card WW1 Level sensor
Product number: 96079928 96079929 96079929 96079929 96079935 96079937 See column at right 96377410
Configuration: Basic 1-2 pump control with GSM com.
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 G 401 Antenna Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96095256 96095288 96377410
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 Battery G 401 Antenna Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079938 96079948 96095256 96095288 96377410
Configuration: Basic 1-2 pump control with Analogue modem com.
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 Analogue modem Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079939 96377410
Configuration: Basic 1-2 pump control with GSM com. and motor protection
Component: CU 401 IO 401 OD 401 PU 101 Program Card WW1 G 401 Antenna MP 204 MP 204 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96095256 96095288 96079927 96079927 96377410
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 Battery G 401 Antenna MP 204 MP 204 Level sensor
Product number: 96079928 96079929 96079935 96079937 See column at right 96079938 96079948 96095256 96095288 96079927 96079927 96377410
Program Card WW1
13 language versions available. Product number, see below
96079940 (English)
96095235 (Danish)
96095236 (Dutch)
96095237 (Finnish)
96095238 (Portuguese)
96095291 (Italian)
96377412 (German)
96377419 (Greek)
96377424 (Swedish)
96377429 (Polish)
96377432 (Russian)
96377437 (Hungarian)
96377444 (Spanish)
More versions will be made available later
Configuration examples and product numbers
13 Technical data >
DimensionsCU401 / IO 401 PU 102 / G401 PU 101
OD 401 FB 101 MP 204
IO111
Technical data Electrical dataAmbient temperature Digital inputs
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
Output voltage, open contact: 24 V
Relative air humidity Relay outputs
From 5% to 95% 400 VAC, 2 A, AC 1524 VDC, 2 A, DC 13
Materials Supply voltage
Enclosure class: IP 20OD401 when mounted plate/door IP55Plastic type: Black PC/ABS
24 VDC ±7% from the PU 101 or from the CU 401 module bus24 VDC from the PU 102 (UPS)
Standards conformity Power consumption
Electromagnetic compatibility (89/336/CEE): EN 61 000-6-2 and EN 61 000-6-3
Electrical equipment designed for use within certain voltage limits (73/23/EEC): EN 60 335-1 and EN 50 178
Max. 11 W per module
110
136
16286
136
59
+ + - -
PU 101
24Vdc/2.5A
N L
50
125
10397
44
215
201
30
60
116
66 116
151140 164
127 63
Reset
90
116
66.5
PET1 T2 G1 A1 G2 A2 K1 K2 R1 R2
D1 D2 D3 D4 D5 D6 D7 D8
P1 P2 P3 P4 P5
A Y B
I1 I2 I3
ON DIP
1 2 3 4 5 6 7 8 9 10
Technical data
14 Technical data >
15
The Grundfos wastewater range
The range >
S range 5 – 29 kWBrochure 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 15 – 155 kWBrochure 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 kWBrochure 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 1.65 – 5.0 kWThe 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 3.0 – 24 kWBrochure covers the Grundfos range of SRP submersible recirculation pumps for waste-
water treatment plants and flood control.Available in 50 Hz and 60 Hz versions.
SEN range 1.0 – 21 kWBrochure covers the Grundfos range of
heavy-duty stainless steel pumps (SEN) for aggressive and corrosive environments.
Multlift M, MD, MDV, and MD1 rangesBrochure covers Grundfos lifting stations for individual as well as multi-user applications.
LC/LCD Ranges – level controllersBrochure covers the Grundfos range of con-trols for the wastewater pumping systems.
AMD, AMG, and AFG rangesBrochure 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 ranges0.6 – 2.6 kWBrochure 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.
Prefabricated pumping stationsBrochure covers the Grundfos range of pre-fabricated pumping stations for collecting and removing drainwater, surface water, domestic and industrial wastewater and sewage.
SE1 and SEV ranges 1.1 – 11 kWThis 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.
S pump range 72Brochure 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 stationsBrochure covers the Grundfos range of large, prefabricated pumping stations designed to meet many different customer needs.
Being responsible is our foundationThinking ahead makes it possible
Innovation is the essence
www.grundfos.com
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.
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