control accessory type abs ca 441, ca 442, ca 443

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Control accessory type ABS CA 441, CA 442, CA 443

EN Installation guide

8130

7058

L (0

3/20

19)

0 1 2 3 4

5 6 7 8 9 A B

C D

E F

I I I I I I I I I I I I I

I I I

CA 441

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I I

CA 442

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I I

CA 443

813

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II

Copyright © 2019 Sulzer. All rights reserved.

This manual, as well as the software described in it, is furnished under license and may be used or copied only in accordance with the terms of such license. The content of this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Sulzer. Sulzer assumes no responsibility or liability for any errors or inaccuracies that may appear in this book.

Except as permitted by such license, no part of this publication may be reproduced, stored in a retrieval sys-tem, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Sulzer.

Sulzer reserves the right to alter specifications due to technical developments.

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1 INSTALLATION

CA 441, CA 442 and CA 443 are extension modules to PC 441 and do not work stand alone.

1.1 Mount the controllerMount the unit on a 35 mm DIN rail. The physical dimensions of the device is: 86 x 70 x 58 mm (3.39 x 2.76 x 2.28 inch) (H x W x D). If it doesn’t easily snap onto the rail, you can pull the small tab at the bottom side of the unit, using a small screwdriver.

1.2 Make all connectionsThe terminals should be connected to power and sensors. See table for each device:

Figure 1 Outer terminals for the CA 44X series.

WARNING! Ensure that all power is off, and that all output devices to be connected to the controller also are turned off before you connect anything!

The power must be DC between 9 and 34 volts. Figure 3 shows how to connect power and how to connect a battery pack for uninterrupted operation.

For cables longer than 30 m extra surge protection should be mounted where needed.

1.3 Common for CA 44XThis part of the guide is common for all three units, CA 441, CA 442 and CA 443. Later chapters will explain the differences between the units. The expression CA 44x is used when referring to an unspecified unit of the devices specified above.

Power LED When unit is powered up and running the green power LED will be lit.

CAN LED See chapter about CAN.

Alarm LED’s These four LED’s are controlled from the supervising controller e.g. PC 441 and can indicate differ-ent type of errors or malfunction.

0 1 2 3 4

5 6 7 8 9 A B

C D

E F

I I I I I I I I I I I I

I I

I I

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 441 CA 442 CA 443

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1.4 CAN

1.4.1 CAN ID A CAN network is of multi drop type which means that all units are connected in parallel on the same cable. In a CAN network every unit must have a unique address or ID-number.

On the CA 44x series one part of the address is set default depending on type of device, the other part of the address is set by a hexadecimal switch, marked “ID”. Choose address by pump number as in table below. If the device has a unique address and contact with the network master, the CAN LED is still fixed green. For error codes of the CAN LED see PC 441 User guide.

Use the following addresses to achieve correct functions.

Table 1. CA 441 Leakage monitor

CAN SUB ID Monitoring function

0 Not used with PC 441

1 Pump 1 or pumps 1-4

2 Pump 2

3 Pump 3

4 Pump 4

5 - > F Not used with PC 441

Table 2. CA 442 Temperature monitorCAN SUB ID Monitoring function

0 Not used with PC 4411 Pump 1 or pumps 1-4

2 Pump 2

3 Pump 3

4 Pump 4

5 Pump 1 & Pump 2

6 Pump 3 & Pump 4


Table 3. CA 443 Power monitorCAN SUB ID Monitoring function

0 Main power monitor

1 Pump 1

2 Pump 2

3 Pump 3

4 Pump 4


0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

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1.4.2 CAN TERM The CAN bus shall be terminated at both cable ends. If used, PC 441 is bus master and has a built-in termination that is always active and should there-fore always be placed at one of the endpoints of the cable. For other devices you can activate the selectable termination with a switch, marked “CAN term”. Activate termination for the device placed on the other endpoint of the cable. All other devices between should have their termination switch in “OFF” position.

Figure 2 CAN network with connection

1.4.3 CAN connectionsThe CAN cable uses 5 wires. Two wires are used for commu-nication CAN_L and CAN_H. One wired is shield CAN_SHLD and two wires are used as bus power V+ and 0V. Bus power allow devices to get power directly from the bus.

The connections is prepared to be done by screw plug in con-nectors.

Table 4. Top side connections

# Usage

1 0V Voltage supply neg. terminal

2 ← → CAN_L low signal line

3 ← CAN_SHLD cable shield

4 ← → CAN_H high signal line

5 V+ Voltage supply pos. terminal

Figure 3 The power must be between 9 and 34 volts DC. For uninterrupted operation in case of power fail-ure, connect a battery pack according to the figure.

CAN TERMON

CAN TERMOFF

CAN TERMOFF

CAN TERMOFF

CA 511 CA 44xCA 44x CA 44x PC 441

AlwaysON

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 44x

VoltageSupply

CA 44x

Backup battery pack

+

+

Fuse

AC

DC

Batterycharger

27.2 V

V+

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1.5 The units

1.5.1 CA 441The product is for measuring leakage of water into non water areas of pumps.

If pump is operated from a motor drive or frequency converter, special precautions are required.

The high electric noise level can distort electrical readings and in extension jeopardize functionality. To avoid conducted electrical noise, follow best practices and manufacturer EMC compliance recommendations when installing frequency converters. Use shielded cables and 50 cm separation between power and signal cables. Ensure that the cables are also separated from each other in cabinets.

Table 5. CA 441 ratings

Input Range

ABS mode 0 - 220 kohm

Xylem mode 0 - 10 kohm

If one module of CA 441 is used for all pumps, Sensor 1 = Pump 1, Sensor 2 = Pump 2 etc. In case of one CA 441 module for each pump, follow the table 6 below.

Table 6. Configuration of the analogue input on CA 441 ID 1-4

# Dir. Signal Description6 ← Sensor 1

Leakage sensor 1: Oil chamber

7 ← Ref 1*8 ← GND9 ← Sensor 2

Leakage sensor 2: Connect chamber

10 ← Ref 2*11 ← GND12 ← Sensor 3

Leakage sensor 3: Motor housing

13 ← Ref 3*14 ← GND15 ← Sensor 4

Leakage sensor 4: Not used16 ← Ref 4*

17 ← GND

* Ref is the negative reference point - it shall be connected to ground directly, or at pump if problems with 50 Hz / 60 Hz interference signal.

Figure 4 Connection of leakage sensor

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 441

+6

-7 8

+6

-7 8

CA 441

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1.5.2 CA 442The product is for indicating temperature and prevent overheating of pumps.

If pump is operated from a motor drive or frequency converter, special precautions are required.

The high electric noise level can distort electrical readings and in extension jeopardize functionality. To avoid conducted electrical noise, follow best practices and manufacturer EMC compliance recommendations when installing frequency converters. Use shielded cables and 50 cm separation between power and signal cables. Ensure that the cables are also separated from each other in cabinets.


Input Range Comment

Opt mA in 4.0 - 20.0 mA ± 0.5 mA

Pt100 -20 - +180ºC (-4 - +356ºF) ± 2ºC / ± 4ºF

PTC 0 - 10 kohm

If one module of CA 442 is used for all pumps, Sensor 1 = Pump 1, Sensor 2 = Pump 2 etc. In case of one CA 442 module for each pump, follow the table 8 below.

Table 8a. Configuration of the temperature input on CA 442 ID 1-4

# Dir. Signal Description6 ← Sensor 1 Temp. sensor 1:

T1 Stator*7 ← GND8 ← Sensor 2 Temp. sensor 2:

T2 Upper bearing9 ← GND10 ← Sensor 3 Temp. sensor 3:

T3 Lower bearing11 ← GND12 ← Sensor 4 Temp. sensor 4:

T4 Stator*13 ← GND

14 ← 0 V Reference vibration sensor15 ← Analogue mA in Analogue input (4 - 20 mA)

Vibration sensor

* The properties of the inputs of T1 and T4 are shared. T1 and T4 are using same alarm number (see Modbus register manual for more information) and T1 and T4 can have separate type of sensors (T1 can be connected to PTC and T4 Pt100 or vv.).

1.5.2.1 VibrationTerminal 14 and 15 are a 4-20 mA analogue input for vibration sensor. The input is only active in CA 442 ID 1-4.

If the sensor has own power supply:

15 mA In

14 0V

External SensorWith own power supply, 4-20 mA

+

-

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 442

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If the sensor is loop powered:

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 442

0V mAin

14 15

HV+

45 2 13

Shld L V-

+

-

Vibrationsensor

If additional temperature module, CA 442 ID 5 and CA 442 ID 6 are used.

Table 8b. Configuration of the temperature input on CA 442 ID 5


Temp. sensor 1: T1 Stator L2, Pump 17 ← GND8 ← Sensor 2



Temp. sensor 4: T2 Stator L3, Pump 213 ← GND

14 ← 0 VN/A in CA 442 ID 5

15 ← Analogue mA in

Table 8c. Configuration of the temperature input on CA 442 ID 6





Temp. sensor 4: T2 Stator L3, Pump 413 ← GND

14 ← 0 VN/A in CA 442 ID 6

15 ← Analogue mA in

Vibration Sensor

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1.5.3 CA 443The product is for measuring current consumption, phase deviation and voltage input for a pump or a complete station.

If pump is operated from a frequency converter, special precautions are required.

The high electric noise level can distort electrical readings, especially phase timing readings are sensitive to switch transients from frequency converter. Turn off all phase related alarms and dry run detection in PC 441 and ensure PC 441 firmware ver-sion is V.1.42 or later Normal current transformers operate from 45-60 Hz and must be placed on mains line input to frequency converter. Use only mains phase (voltage) missing alarm for pump protection (blocking). To avoid conducted electrical noise in cabinet, follow best practices and manufacturer EMC compli-ance recommendation when installing frequency converters. Use shielded cables. Ensure mains and motor cables are separated from signal cables in cabinet.

General precautions: If CA 443 for P1 also is used for mains monitoring, L1, L2 and L3 voltage inputs must be connected before pump circuit breaker.


Input Range Comment

Voltage 30 - 300 V ac ± 5.0 V ac At higher voltages use voltage transformer

Current 0 - 5 A ± 0.1 A ac phase shift 0 - 90 deg ± 1.5 deg

Always use current trans-former

Table 10. Bottom side connections

# Dir. Signal Description6 ← Sensor 1 AC voltage input L17 ← Sensor 2 AC voltage input L28 ← Sensor 3 AC voltage input L3

9 ← GND Voltage reference input

10 ← a Sensor 4Current transformer input 1

11 ← b GND12 ← a Sensor 5

Current transformer input 213 ← b GND14 ← a Sensor 6

Current transformer input 315 ← b GND

Table 11. CA 443 LED indicators from PC 441 firmware 1.42

LED Indication Mains monitor (0 or 1) Pump monitor (1-4)1 Phase 1 Voltage missing Voltage missing2 Phase 2 Voltage missing Voltage missing3 Phase 3 Voltage missing Voltage missing4 Warning Alarm wrong phase order

Alarm phase missing Pending high voltage Pending low voltage Pending unbalanced voltage Pending high freq. Pending low freq.

Alarm phase current missing

0 1 2 3 4

5 6 7 8 9 A B

C D

E F


I I

I I

CA 443

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Figure 5 Simple connection of CA 443

a10

Ib

11L38

GND9

L16

L27

CA 443

V

~L1~L2~L3

PE /

max

5A current

transformer

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2 TECHNICAL DATA

2.1 Technical data CA 44x Device CA 441 CA 442 CA 443

Ambient operation temperature -20 to +50°C (-4 to +122°F)

Ambient storage temperature -30 to +80°C (-22 to +176°F)

Degree of protection IP 20, NEMA: Type 1

Housing material PPO and PC

Mounting DIN Rail 35 mm

Installation category CAT II

Pollution degree 2

Flame rate V0 (E45329)

Power rating current Transformers CA443

1.0 - 5.0 VA Class 1

Dimension HxWxD 86 x 70 x 58 mm (3.39 x 2.76 x 2.28 inch) Plug in connectors will add 2x 9.5 mm (0.375 inch) to ‘H’

Humidity 0-95 % RH non condensing

Power supply 9-34 VDC SELV or Class 2

Power consumption < 2.0 W

Inputs 4 channels 4 leakage

5 channels 4 temp, 1 low dc current

6 channels 3 voltage, 3 ac current

Modes ABS mode

Xylem mode

PTC mode

Pt100 mode

0/4-20 mA Int. res 136

Ω. PTC protected

Voltage Current

Approx range

0-220 kΩ 0-10 kΩ

0-10 kΩ

-20 - +180ºC (-4ºF - + 356 ºF)

0-20 mA 30-300 VAC 0-5A AC

Note

Input mode can be set

individually for each channel.

Input mode can be set individually for each channel.

All current measuring

is done through current trans-

formers

Outputs None

Communication ports Field Bus 1 CAN port 1 galvanic

isolated CAN port

Max altitude 2000 m

Approval

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2.2 CleaningHow to clean the unit

Power off the unit and on CA 443 disconnect the connector for the phases. Only outside/front shall be cleaned by using a dry, soft cloth. A good choice would be the microfiber type of cloth and gently wipe the CA 44x unit on front in order not to scratch the overlay. If the dry cloth did not completely remove the dirt, do not press harder in an attempt to scrub it off. If necessary, moisten the cloth by adding a small amount of water with thin solution of mild detergent and try again. Never use detergent with polish or solvent which can have an impact of the plastic surface.

Declaration of ConformityAs defined by: EMC Directive 2014/30/EU, RoHS II Directive 2011/65/EU, Low Voltage Directive 2014/35/EU

EN EC Declaration of Conformity SV EG-försäkran om överensstämmelseDE EG-Konformitätserklärung NO EUs SamsvarserklæringFR Déclaration de Conformité CE DA EC-OverensstemmelseserklæringNL EC-Overeenkomstigheidsverklaring FI EU-VaatimustenmukaisuusvakuutusES Declaración de confirmidad CE ET EÜ Vastavuse deklaratsioonPT Declaracão de conformidade CE PL Deklaracja zgodnosci WE IT Dichiarazione di conformità CE CS Prohlášení o shodšĕ ESEL Δήλωση εναρμόνισης EK SK EC Vyhlásenie o zhodeTR AT Uygunluk Beyanı HU EK Megfelelőségi nyilatkozat

Sulzer Pumps Sweden AB, Rökerigatan 20, SE-121 62 Johanneshov, Sweden

EN: Name and address of the person authorised to compile the technical file to the authorities on request: DE: Name und Adresse der Person, die berechtigt ist, das technische Datenblatt den Behörden auf Anfrage zusammenzustellen:FR: Nom et adresse de la personne autorisée pour générer le fichier technique auprès des autorités sur demande :NL: Naam en adres van de persoon die geautoriseerd is voor het op verzoek samenstellen van het technisch bestand:

ES: Nombre y dirección de la persona autorizada para compilar a pedido el archivo técnico destinado a las autoridades:PT: Nome e endereço da pessoa autorizada a compilar o ficheiro técnico para as autoridades, caso solicitado:IT: Il nome e l’indirizzo della persona autorizzata a compilare la documentazione tecnica per le autorità dietro richiesta::EL: Όνομα και διεύθυνση του ατόμου που είναι εξουσιοδοτημένο για τη σύνταξη του τεχνικού φακέλου προς τις αρχές επί τη απαιτήσει:TR: Yetkili makamlara istek üzerine teknik dosyayı hazırlamaya yetkili olan kişinin adı ve adresi:SV: Namn och adress på den person som är auktoriserad att utarbeta den tekniska dokumentsamlingen till myndigheterna:NO: Navn og adresse på den personen som har tillatelse til å sette sammen den tekniske filen til myndighetene ved forespørsel:DA: Navn og adresse på den person, der har tilladelse til at samle den tekniske dokumentation til myndighederne ved anmodning om dette:FI: Viranomaisten vaatiessa teknisten tietojen lomaketta lomakkeen valtuutetun laatijan nimi ja osoite:ET: Isiku nimi ja aadress, kelle pädevuses on koostada nõudmise korral ametiasutustele tehnilist dokumentatsiooni:PL: Nazwisko i adres osoby upoważnionej do przygotowania dokumentacji technicznej w przypadku, gdy jest ona wymagana przez władze:CS: Jméno a adresa osoby oprávnĕné na vyžádání ze strany úřadů vytvořit soubor technické dokumentace:SK: Meno a adresa osoby oprávnenej na zostavenie technického súboru pre úrady na požiadanie:HU: Asmens, įgalioto valdžios institucijoms pareikalavus sudaryti techninę bylą, vardas, pavardė ir adresas:

Frank Ennenbach, Director Product Safety and Regulations, Sulzer Management AG , Neuwiesenstrasse 15, 8401 Winterthur, Switzerland

EN: Declare under our sole responsibility that the products: SV: Försäkrar under eget ansvar att produkterna:DE: Erklärt eigenverantwortlich dass die Produkte: NO: Erklærer på eget ansvar, at følgende produkterFR: Déclarons sous notre seule responsabilité que les produits: DA: Erklærer på eget ansvar, at følgende produkter:NL: Verklaren geheel onder eigen verantwoordelijkheid dat de produkten: FI: Vakuutamme yksinomaan omalla vastuullamme, että seuraavat tuotteetES: Declaramos bajo nuestra exclusiva responsabilidad que los productos: ET: Deklareerime ainuvastutajana, et tooted:PT: Declaramos sob nossa unicia responsabilidade que los produtos: PL: Deklaruje z pelna odpowiedzialnoscia, ze urzadzenia typu:IT: Dichiariamo sotto la nostra esclusiva responsabilità che i prodotti: CS: Prohlašuje na vlastní odpovědnost, že výrobky:EL: Δηλώνουμε με αποκλειστική μας ευθύνη ότι τα προϊόντα: SK: Vyhlasujeme na našu zodpovednost’, že výrobky:TR: Sorumluluk tamamen bize ait olarak beyan ederiz ki aşağıdaki ürünler: HU: Felelösségünk teljes tudatában kijelentjük, hogy a termékek:

Moisture monitoring module type ABS CA 441, Temperature monitoring module type ABS CA 442, Motor and supply power monitoring module type ABS CA 443

EN: to which this declaration relates are in conformity with the following standards or other normative documents:DE: auf die sich diese Erklärung bezieht, den folgenden und/oder anderen normativen Dokumenten entsprechen:FR: auxquels se réfère cette déclaration sont conformes aux normes ou à d’autres documents normatifs:NL: waarop deze verklaring betrekking heeft, in overeenstemming zijn met de volgende normen of andere normatieve documenten:ES: objeto de esta declaración, están conformes con las siguientes normas u otros documentos normativos:PT: aque se refere esta declaracáo está em conformidade com as Normas our outros documentos normativos:IT: ai quali questa dichiarazione si riferisce sono conformi alla seguente norma o ad altri documenti normativi:EL: τα οποία αφορά η παρούσα δήλωση είναι σύμφωνα με τα ακόλουθα πρότυπα ή άλλα κανονιστικά έγγραφα:TR: bu beyanın konusunu oluşturmakta olup aşağıdaki standart ve diğer norm belgelerine uygundur:SV: som omfattas av denna försäkran är i överensstämmelse med följande standarder eller andra regelgivande dokument:NO: som dekkes av denne erklæringen, er i samsvar med følgende standarder eller andre normative dokumenter:DA: som er omfattet af denne erklæring, er i overensstemmelse med følgende standarder eller andre normative dokumenter:FI: joihin tämä vakuutus liitty, ovat seuraavien standardien sekä muiden sääntöämääräävien asiakirjojen mukaisia:ET: mida käespöev deklaratsioon puudutab, on vastavuses järgmiste standardite ja muude normatiivdokumentidega:PL: do których odnosi sie niniejsza deklaracja sa zgodne z nastepujacymi normami lub innymi dokumentami normatywnymi:CS: na které se toto prohlášeni vztahuje, jsou v souladu s následujícími normami nebo jinými normativními dokumenty:SK: na ktoré sa vz ahuje toto vyhlásenie, zodpovedajú nasledujúcim štandardom a iným záväzným dokumentom:HU: amelyekre ez a nyilatkozat vonatkozik, megfelelnek a következőszabványokban és egyéb szabályozó dokumentumokban leírtaknak:

Safety: EN 61010-1:2010 EMC: EN 61326-1:2013

Stockholm 2017-06-28

Per Askenström Sulzer Pumps Sweden AB

control accessory type abs ca 441, ca 442, ca 443

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