Xylem CCD 401 - User Manual

Installation, Operation, and
Maintenance Manual
90018601_1.0
CCD 401

Summary

Introduction and Safety

Introduction

Purpose and reading guidelines for the manual.

Safety Terminology and Symbols

Defines hazard levels and symbols for safety warnings.

User Safety and Electrical Precautions

General safety, power lock-out procedure, and personnel qualifications.

End of Life Product Disposal

Guidelines for responsible disposal of the product.

Spare Parts and Warranty Information

Information on using original spare parts and product warranty coverage.

Support Policy

Xylem's support policy for tested and approved products.

Product Description

Product Design Overview

Overview of the wireless unit and its capabilities for data transmission.

Unit Components and Extra Parts

Identification of unit components and available extra parts.

Installation Procedures

Connection and Configuration

Steps for connecting, configuring, and installing the unit, including precautions and requirements.

Installing the Equipment

Instructions for physically installing the unit and its antenna.

Checking Mobile Connection

Steps to verify network signal strength and cloud service connection.

Troubleshooting Guide

Symptoms and Remedies

Common issues and their solutions, focusing on connection problems.

Technical Reference

Product Dimensions

Physical dimensions of the unit's components.

Environmental Requirements

Operating and storage conditions for temperature and humidity.

Material Specifications

Details on the materials used in the unit's construction.

Electrical Data

Information on supply voltage, current, and enclosure protection.

Radio Data and Bands

Supported radio bands for different regional versions of the unit.

Terminal Connections

Detailed list and description of all unit terminals and their functions.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The CCD 401 is a wireless unit designed for use in pumping stations, enabling remote monitoring and data collection from any location. It transmits data over the Long Term Evolution (LTE) network, with fallback to 2G or 3G depending on geographical location and supported radio standards.

Function Description

The primary function of the CCD 401 is to provide wireless connectivity for data transmission from pumping stations to Xylem Cloud Services. It is designed to operate exclusively with these services and not as a standalone modem. The unit facilitates remote monitoring and data collection, allowing for efficient management of water systems. Xylem reserves the right to remotely upgrade the software and configuration files, making continuous connectivity essential for updates.

Important Technical Specifications

Dimensions:

• Length: 101 mm (4.0 in)
• Width: 127 mm (5.0 in)
• Height: 46 mm (1.8 in)

Environmental Requirements:

• Operating temperature: -30°C to +55°C (-22°F to +131°F)
• Storage temperature: -50°C to +85°C (122°F to +185°F)
• Operating humidity: 95% relative humidity, non-condensing

Electrical Data:

• Supply voltage: 24 VDC
• Current: Maximum 200 mA at 24 VDC
• Degree of protection of enclosure: IP40

Radio Data: The unit features a radio modem supporting the following bands:

• CE (European version): LTE Cat 1 bands 3, 7, and 20; GPRS 900/1800 MHz Fallback
• NA (North America version): LTE Cat 1 bands 2, 4, and 12

Terminals: The CCD 401 offers various terminals for connectivity:

• Digital Inputs (DI1, DI2, DI3, DI4): Pull-up inputs for digital signals.
• Analog Inputs (AI1, AI2): 4-20 mA analog inputs.
• RS-232 Terminals (232 TX, 232 RX): For serial communication (Tx, Rx, RTU Rx, RTU Tx).
• RS-485 Terminals (485 A, 485 B): Includes 120 ohm termination resistors for A and B.
• Power Input (DC+, DC-): +24 VDC input power.
• Signal Ground (GND): Multiple ground terminals, including chassis ground.
• +24 VDC Supply (+24): Maximum 50 mA supply.
• Ethernet Terminal: For network connectivity.
• Unused Terminals: E01, E02, E06, E07, E09, E10, E21, E24, E26, E27.

Antenna:

• Connector type: SMA connector
• Cable length: Maximum 4 m (13.1 ft)
• Torque: 0.56 Nm (0.41 lb.ft)

Usage Features

Installation: The unit is designed for DIN rail installation. Before installation, it is crucial to record the serial number as it becomes inaccessible afterward. The unit should not be installed over 2 m (6.56 ft) height from the ground.

• Antenna Attachment: The antenna must be attached, with considerations for keeping it away from radio or EMC sources and other electronics. Antenna cables should be as short as possible, in good condition, and not sharply bent or pinched.
• Device Connection: The unit supports connections to various devices:
  • Modbus TCP to the RJ45.
  • RS-232 cable from the pump controller to the designated terminals (RTU Tx, RTU Rx).
  • RS-485 cable from the pump drive to the designated terminals (A, B).
  • Digital switches to the digital input terminals (DI1-DI4), where active is connected to GND and inactive is open.
  • 4-20 mA analog input devices to the AI1 and AI2 terminals.
• Power and Grounding: Power leads connect to the input terminals, and the signal ground (chassis ground) connects to the external chassis ground.
• Configuration: After power-up, connected devices need to be configured, with further information available on the xylem.com/avensor support site.

Mobile Connection Check: After installation, the mobile connection can be verified using the LED indicators:

• Network Signal Strength LED (three vertical bars):
  • Solid green: Excellent or good signal strength.
  • Solid red: Medium or fair signal strength.
  • Unlit: Poor or no signal.
  • For optimal performance, the LED should be solid green. If signal strength is low, the external antenna may need repositioning.
• Cloud Service Connection LED (cloud icon):
  • Blink or solid yellow: Connected to the cloud service.
  • Unlit: Not connected.
  • The connection procedure typically takes a maximum of 15 minutes. The unit must not be disconnected during this process.

LED Indicators:

• Antenna (1): Indicates antenna status.
• Network Signal Strength (2): Shows the strength of the mobile network signal.
• Cloud Service Connection (3): Yellow indicates connection to the cloud service.
• Power (4): Green indicates power is on.

Maintenance Features

Safety Precautions:

• Electrical Hazard: Always ensure the unit and control panel are isolated from power before any work. All electrical equipment must be properly grounded. Electrical work should only be carried out by certified electricians or Xylem authorized mechanics, complying with all local codes and regulations.
• Cable Integrity: Prevent cables from sharp bends or damage. Visually inspect equipment for damaged cables, cracked casings, or other signs of damage.
• Product Disposal: At the end of its life, the product and its batteries must be disposed of in compliance with local laws and regulations, following WEEE Directive guidelines for electrical and electronic equipment and Directive 2006/66/EC for batteries.

Troubleshooting:

• Slow Cloud Service Connection:
  • Ensure the equipment is not disconnected from the cloud service, as repeated disconnections can slow reconnection.
  • Check signal strength and consider installing or moving the external antenna to improve signal strength.

Spare Parts: Only original manufacturer's spare parts should be used to replace worn or faulty components. Using unsuitable parts can lead to malfunctions, damage, injuries, and void the warranty.

Warranty and Support: Warranty information is provided in the sales contract. Xylem only supports tested and approved products, not unapproved equipment.

Xylem CCD 401 Specifications