FLYGT FPC100 User manual

Single pump controller
Installation and user
manual for FPC100

Table of Contents
QUICK SET-UP OF FPC100...................................................................................................................2
Quick set-up of FPC100......................................................................................................................2
SAFETY.................................................................................................................................................... 3
Safety.....................................................................................................................................................3
UNPACKING, INSPECTION AND RECYCLING...................................................................................4
Unpacking, inspection and recycling................................................................................................4
INSTALLATION.......................................................................................................................................5
............................................................................................................................................................... 5
Connection terminals..........................................................................................................................5
Choice and adaptation of current transformer................................................................................6
Current transformer connection........................................................................................................7
Supply voltage connection................................................................................................................ 7
Alarm relay connection.......................................................................................................................7
Pump relay connection.......................................................................................................................7
Digital input connection (DIG IN)......................................................................................................8
Terminal 5 connection (e.g. temperature supervision).................................................................. 8
FRONT PANEL LAYOUT AND FUNCTION KEYS............................................................................... 9
Front panel layout and function keys................................................................................................9
DISPLAY, SYMBOLS AND UNITS....................................................................................................... 10
Display, symbols and units...............................................................................................................10
DETAILED SETTINGS...........................................................................................................................11
General...............................................................................................................................................11
Lock and unlock menu settings.......................................................................................................11
Returning to default settings........................................................................................................... 11
Complete set-up............................................................................................................................... 11
Adjustment of the stop level............................................................................................................14
Start conditions and pause time adjustment.................................................................................14
Window parameters......................................................................................................................... 15
PROTECTION AND ALARM................................................................................................................19
Protection and alarm........................................................................................................................ 19
TROUBLESHOOTING..........................................................................................................................21
Troubleshooting................................................................................................................................21
TECHNICAL SPECIFICATIONS...........................................................................................................22
Electronics..........................................................................................................................................22
EU specifications............................................................................................................................... 22
USA specifications.............................................................................................................................22
Canadian specifications................................................................................................................... 23
Part numbers......................................................................................................................................23
Table of Contents
Single pump controller Installation and user manual for FPC100 1

QUICK SET-UP OF FPC100
Quick set-up of FPC100
The purpose with the quick set-up is to initiate the stop function. FPC100 stops the pump
when the water level has dropped to such a low level that the pump begins to draw air
(snore). At air intake the pump motor power drops and below a manually set power-level
FPC100 stops the pump.
Pump power
Manually set power level
Full load power
Stop level
“Snore power”
Time
Stop at underpower
If FPC100 has been used previously, some parameters could have been changed and
locked. Then go to Complete set-up (page 11) that describes a complete set-up.
The prerequisite for quick set-up is that the pump is installed to a control panel including
FPC100. The control panel should preferably also include a Hand-0-Auto switch for the
pump.
In event of an alarm during the set-up, see PROTECTION AND ALARM (page 19).
Auto-set at normal pumping (pumping water without drawing air)
1. Check that the amount of water is enough for pumping about 30 seconds without
drawing air.
2. Turn on the supply voltage to FPC100 and set the Hand-0-Auto switch in the Auto-
position. The pump shall now be pumping water without drawing air. If the pump
doesn’t start, press START/RESET.
3. When the pump is working steadily, press AUTOSET until “SEt” is shown on the
display. The power level for stop is now set.
The stop function is now initiated and FPC100 controls the pump. Adjustments can be
made according to DETAILED SETTINGS (page 11).
Auto-set at snoring (pumping a mix of air and water)
1. Set the Hand-0-Auto switch in the 0-position and turn on the supply voltage to
FPC100.
2. Step with NEXT to window 13 and press “–“ so that the line is shown at the bottom of
the display ( _ ). Press ENTER to verify. FPC100 is now prepared for Auto-set at
snoring.
3. Set the Hand-0-Auto switch in the Auto-position to start the pump. If necessary, press
START/RESET.
4. Run the pump until it starts to snore.
5. Press AUTOSET until “SEt” is shown on the display. The power level for stop is now
set, hence stopping the pump due to the snoring.
The stop function is now initiated and FPC100 controls the pump. Adjustments can be
made according to DETAILED SETTINGS (page 11).
QUICK SET-UP OF FPC100
2 Single pump controller Installation and user manual for FPC100

SAFETY
Safety
WARNING:
Before doing any work, check that the automatic control cubicle is disconnected from the
power supply and cannot become live.
Always isolate the power supply before attempting to trace a fault. Otherwise the pump
can start without warning.
• Read TECHNICAL SPECIFICATIONS (page 22) before starting the installation.
• Authorised electrician shall perform the installation.
• The installation shall comply with general and local regulations.
• Disconnect all supply circuits before installation. Also disconnect all supply circuits
before connecting and disconnecting cables to FPC100.
FPC 100 conforms to international standards and is UL/ CSA and CE-marked.
WARNING:
Antes de empezar cualquier trabajo, comprobar que el armario de sistemas automáticos
esté desconectado de la red eléctrica, y que no pueda recibir tensión.
Prima di iniziare qualsiasi lavoro, controllare che la centralina degli automatismi sia
staccata dalla rete di alimentazione elettrica e che non sia sotto tensione.
Controleer, voordat u begint te werken, of de schakelkast gescheiden is van de elektrische
voeding en niet omder spanning kan komen te staan.
Antes de iniciar qualquer trabalho, verifique se o compartimento do sistema automático se
encontra desligado da rede eléctrica e assegure-se de que a corrente não poderá ser
activada.
Inden nogen form for arbejde påbegyndes, skal det kontrolleres, at automatikskabet er
koblet fra elnettet, og at det ikke kan blive spændingsførende.
Før arbeide påbegynnes, påse at automatikkskapet er frakoplet strømnettet og at det ikke
kan bli spenningsførende.
Ennen kuin mitään työtä aloitetaan, on varmistettava, että automatiikkakaappi on kytketty
irti sähköverkosta eikä voi tulla jännitteiseksi.
Áður en starfræksla hefst, gangið úr skugga um að sjálfvirkur gangsetningarbúnaður sé
óvirkur, þ.e.a.s. ekki tengdur við rafmagn.
Ðñéí áðü êÜèå åñãáóßá, åëÝãîôå áí ôï êéâþôéï ôïõ áõôüìáôïõ åëÝã÷ïõ Ý÷åé áðïóõíäåèåß
áðü ôï ñåýìá êáé äåí ìðïñåß íá ôåèåß õðü ôÜóç.
SAFETY
Single pump controller Installation and user manual for FPC100 3

UNPACKING, INSPECTION AND
RECYCLING
Unpacking, inspection and recycling
The delivery comprises:
• FPC100 control unit
• Current transformer
• Installation and user manual for FPC100
If anything is missing or damaged in the delivery, contact your local Xylem sales office.
Keep the packing. It can be needed for return of the delivery or in case of inspection at
damage.
The housing of the FPC100 is made of recyclable plastic, type PC/ABS. The circuit boards
contain minimal amounts of tin and lead.
When scrapping the FPC100, all parts must be handled and recycled according to local
regulations.
UNPACKING, INSPECTION AND RECYCLING
4 Single pump controller Installation and user manual for FPC100

INSTALLATION
The installation shall be performed by an authorised electrician according to local safety
regulations.
WARNING:
Before installing, make sure that no voltage is applied to the equipment.
Check that the rated voltage of FPC100 corresponds with the supplying line voltage. The
rated voltage can be found on the rating plate on the side of the control unit.
FPC 100 is mounted on a standard DIN-rail, 35 mm. Dimensions, temperature range and
other necessary data for the installation can be found in TECHNICAL SPECIFICATIONS
(page 22).
PE
L1
L2
L3
N
M
3
Max
240VAC
Hand
IDig
in
Temp Alarm Pump
1 3 45 7 8 6
9
L1
11
L2 L3
13
2
Supply
Auto 0
Alarm
Auto-set
Reset
High level
Thermistor (PTC)
or
Thermal contact
Alternative connection
K
FPC100
R
Connection terminals
No Label Function
1 I Current transformer input
2 I Current transformer input
3 DIG IN Digital input for closing contact
4 DIG IN/TEMP Signal ground for terminals 3 and 5
5 TEMP Input for thermistor (PTC), thermal
contact and/or any voltage-free
opening contact
6 ALARM Alarm relay output
7 ALARM/PUMP Common input for alarm- and pump
relay
INSTALLATION
Single pump controller Installation and user manual for FPC100 5

No Label Function
8 PUMP Pump relay output
9 L1 Supply voltage
10 (not used)
11 L2 Supply voltage
12 (not used)
13 L3 Supply voltage
Choice and adaptation of current transformer
The pump motor size decides whether one or two current transformers shall be used. For
motor currents up to 100 A, one current transformer shall be used. From 100 to 1000 A
two transformers are needed.
0-100A
The current through the transformer should be close to its primary current rating, but
should not exceed it.
Current transformers with a choice of four ratings are available, i.e. 10A, 25A, 50A and
100A.
The phase conductor of the motor can be run through the current transformer core an
additional number of turns to put the available transformer capacity to full use.
The formula below can be used to determine how many turns the phase conductor of the
motor should be run through the transformer core.
Number =rated primary current of current transformer
of turns rated motor current
(Round down to next lowest integer value).
Example 1:
Rated current of motor = 12 A
Primary current of current transformer = 25 A
Number of turns = 25 A/12 A
Answer = 2
Example 2:
Rated current of motor = 7.8 A
Primary current of current transformer = 10 A
Number of turns = 10 A/7.8 A
Answer = 1
100-1000A
If the rated motor current is in excess of the highest rated primary current of the available
transformers (100A), proceed as follows:
INSTALLATION
6 Single pump controller Installation and user manual for FPC100

1. Use a standard current transformer which has a primary current rating just in excess
of the rated motor current and which has a rated secondary current of 5 A.
2. Pass the lead, connecting to the secondary side of the standard current transformer,
twice through the 10 A current transformer (CT10).
Example:
Rated current of motor = 210 A
A standard current transformer with a current rating 250:5 A is chosen. The secondary side
of the standard transformer should be run twice through the 10 A current transformer core.
Note: The choice and adaptation of current transformer(s) should at pumping with full load
power result in a secondary current as close to 55 mA as possible, but should not exceed
it. This in order to put the available capacity of the current input range in FPC100 to full
use, hence resulting in a better functionality. The secondary current can be checked in
window 61 or with an external multimeter.
Current transformer connection
Choose appropriate current transformer (CT) according to Choice and adaptation of
current transformer (page 6).
Connect the CT secondary winding to terminals 1 and 2.
Note: The CT must be linked to the phase connected to terminal 9 (L1).
Supply voltage connection
Connect FPC100 directly to the pump motor supply cable via terminals 9 (L1), 11 (L2), and
13 (L3). Make this connection before the contactor to the pump motor in order to supply
FPC100 also when the contactor is open. See circuit diagram.
When motor fuses larger than 10 A are used, FPC100 must be fused separately.
Alarm relay connection
Terminals 6 and 7 are the alarm relay connections. Terminal 6 is the alarm relay output.
Terminal 7 is the common input for the alarm- and pump relays.
When FPC100 is powered off, the alarm relay is “nc” (normally closed). When powered on,
“nc” or “no” (normally open) can be selected in window 51. Default setting is “no”.
Pump relay connection
Terminals 7 and 8 are the pump relay connections. Terminal 8 is the pump relay output.
Terminal 7 is the common input for the pump- and alarm relays.
When FPC100 is powered off, the pump relay is “nc”. When powered on, “nc” or “no” can
be selected in window 52. Default setting is “nc”.
INSTALLATION
Single pump controller Installation and user manual for FPC100 7

Digital input connection (DIG IN)
Terminals 3 and 4 are intended for an external closing contact. The input is galvanically
isolated.
Terminal 4 is the common signal ground for terminal 3 and terminal 5.
The functions for the digital input that can be selected in window 53 are:
1. High level switch (to enable immediate start of the pump)
2. External Reset
3. External Auto-set
Terminal 5 connection (e.g. temperature supervision)
Terminals 4 and 5 can be used for temperature supervision: a thermal contact or a PTC
thermistor. As an alternative the terminals can be used with any device using a voltage-free
opening contact such as a motor protection unit.
Terminal 4 is the common signal ground for terminal 5 and terminal 3.
INSTALLATION
8 Single pump controller Installation and user manual for FPC100

FRONT PANEL LAYOUT AND
FUNCTION KEYS
Front panel layout and function keys
The operator’s panel comprises a display and a set of six keys.
The keys are described below and the display is described in
DISPLAY, SYMBOLS AND
UNITS (page 10).
Key Function
RESET/START Resets a latched alarm / Starts pump motor
AUTO SET Sets the stop level when pressed for 3 s
NEXT Proceeds to the next window
–Decreases the displayed value
For fast decrement, depress button 6 sec
+Increases the displayed value
For fast increment, depress button 6 sec
ENTER Confirms the adjustments made
FRONT PANEL LAYOUT AND FUNCTION KEYS
Single pump controller Installation and user manual for FPC100 9

DISPLAY, SYMBOLS AND UNITS
Display, symbols and units
The display contains three symbols, five units, three bigand two small digits.
The small digits show the window number in the menu structure. The big digits show a
value. If the value is greater than three digits the two small digits alternate between the
window number and the first two digits in the value.
Example: The total pumping time (window 07) is 13467 hours. Window number 07 is
displayed for 2 sec and then 13467 is displayed for 2 sec.
Symbol Meaning
Alarm
Time value
Parameter lock
Unit Meaning
V Volt
mA Milli-ampere
m Minutes
S Seconds
% Percent
Note 1: When FPC100 is turned on, a self test is performed during 3 seconds and all
characters and symbols on the display are shown.
Note 2: During alarm the entire display is flashing.
Note 3: If “oor” (out of range) is shown on the display, it means that the value is too big to
be shown on the display.
DISPLAY, SYMBOLS AND UNITS
10 Single pump controller Installation and user manual for FPC100

DETAILED SETTINGS
General
Adjustments and settings are done in a single-level menu structure, windows 00-99.
When FPC100 is turned on, press NEXT to proceed to the next window, press + or – to
increase or decrease the value and press ENTER to confirm the new value in each window.
One minute after any key has been pressed, FPC100 returns to:
• window 00 if there is an alarm
• window 01 if the pump is pausing
• window 02 if the pump is pumping
• window 03 if the pump is pumping due to start on high level switch
See
Window parameters (page 15) for a summary of all the menu windows.
Lock and unlock menu settings
It is possible to avoid unintentional change of parameters. Set window 09 to 369 and
confirm with ENTER. A padlock is shown, indicating access only to windows 00-09. Re-
entering value 369 and confirming with ENTER gives access to all windows.
Returning to default settings
If any value differs from the default settings, “Usr” (set by the user) is displayed in window
99. Press + to return to the default settings. “dEF” (default setting) is then shown in the
window. Confirm by pressing ENTER. All user settings are erased and replaced by default
settings according to Window parameters (page 15). New user settings must be
reentered.
Complete set-up
FPC100 stops the pump when the power drops due to snoring. The stop level has to be
set manually by the AUTOSET-key. A correct level is in the range between the full load
power at normal pumping and the power level at snoring.
DETAILED SETTINGS
Single pump controller Installation and user manual for FPC100 11

The stop level can be set in two ways:
1. Pressing AUTOSET at pumping without snoring sets the stop level as a percentage
below the full load power, see Complete set-up at pumping (without snoring) (page
12).
2. Pressing AUTOSET at snoring sets the stop level as a percentage above the snore
power, see Complete set-up at snoring (page 13).
In event of an alarm during the set-up, see PROTECTION AND ALARM (page 19).
Pump power
Manually set power level
Full load power
Stop level
“Snore power”
Time
Stop at underpower
Complete set-up at pumping (without snoring)
1. Install FPC100 according to INSTALLATION (page 5).
2. Set the Hand-0-Auto switch in the 0-position and turn on the supply voltage to
FPC100.
3. If a padlock ( ) is shown on the display, viewing and changing of parameters are
locked. Set window 09 to 369 and confirm with ENTER to remove the padlock and
get access to parameter settings (windows 11- 99).
4. Clear the present stop level by pressing AUTOSET until “SEt” is shown on the display.
The stop level is hence set to 0 % since the pump is off.
5. Set window 13 to ( – ) and confirm with ENTER. FPC100 is now prepared for Auto-set
at pumping without snoring.
6. Set the Hand-0-Auto switch in the Auto-position to start the pump. If necessary, press
START/RESET.
7. Make sure that the pump is working steadily. Press AUTOSET until “SEt” is shown on
the display.
The stop level (window 11) is now set in relation to the measured power (window 04) and
the snore margin (window 12).
Further adjustments can be done according to
Adjustment of the stop level (page 14)—
Window parameters (page 15).
Example:
Stop level (window 11) = Measured full load power (window 04) - Snore margin (window
12)
The pump is pumping water at the measured full load power 68 %. The snore margin is set
to 10 %. Pressing AUTOSET will then give the stop level 58 %.
DETAILED SETTINGS
12 Single pump controller Installation and user manual for FPC100

When the pump starts to snore the measured power will decrease from 68 %. When the
power has decreased below 58 % FPC100 will stop the pump.
Pump power
Full load power (window 04)
Snore margin (window 12)
“Snore” power
Stop level (window 11)
AUTOSET is pressed
Time
Complete set-up at snoring
1. Install FPC100 according to INSTALLATION (page 5).
2. Set the Hand-0-Auto switch in the 0-position and turn on the supply voltage to
FPC100.
3. If a padlock ( ) is shown on the display, viewing and changing of parameters are
locked. Set window 09 to 369 and confirm with ENTER to remove the padlock and
get access to parameter settings (windows 11-99).
4. Clear the present stop level by pressing AUTOSET until “SEt” is shown on the display.
The stop level is hence set to 0 % since the pump is off.
5. Set window 13 to ( _ ) and confirm with ENTER. FPC100 is now prepared for Auto-set
at snoring.
6. Set the Hand-0-Auto switch in the Auto-position to start the pump. If necessary, press
START/RESET.
7. Run the pump until it starts to snore.
8. Press AUTOSET until “SEt” is shown on the display. The power-level for stop is now
set, hence stopping the pump due to the snoring.
The stop level (window 11) is now set in relation to the measured power (window 04) and
the snore margin (window 12).
Further adjustments can be done according to
Adjustment of the stop level (page 14)—
Window parameters (page 15).
Example:
Stop level (window 11) = Measured “snore” power (window 04) + Snore margin (window
12)
The pump is pumping a mix of air and water at the measured “snore” power 28 %. The
snore margin is set to 20 %. Pressing AUTOSET will then give the stop level 48 %, hence
stopping the pump.
From now on FPC100 will stop the pump each pump cycle when the power drops below
48 %.
Pump power
Full load power
AUTOSET is pressed
Time
Snore margin (window 12)
“Snore” power (window 04)
Stop level (window 11)
DETAILED SETTINGS
Single pump controller Installation and user manual for FPC100 13

Adjustment of the stop level
The stop level can always be adjusted in the following two ways:
• Change the snore margin (window 12) and perform a new AUTOSET. The new stop
level will be set in relation to the new snore margin. See examples in Complete set-up
(page 11).
• Change the stop level directly in window 11.
Start conditions and pause time adjustment
In normal operation there are three starting options:
1. Pump start after calculated pause time (window 25 = “on”)
2. Pump start after calculated pause time, or at high level (window 25 = “on”, window
53 = “1”)
3. Pump start at high level only (window 25 = “OFF”, window 53 = “1”)
Note: Option 2 and 3 require connection of a high level switch according to
Digital input
connection (DIG IN) (page 8).
The pump will also start if a non-latched alarm disappears or if the START-button is
pressed during pause.
Calculation of pause time is based on previous pumping- and pause times and is
controlled by the two parameters level setting (window 21) and maximum pause time
(window 22). The parameters can be adjusted to achieve the desired sizes of pause times,
start level and number of starts per hour.
The level setting in window 21 is set for shorter or longer pumping and pause cycles.
Higher value increases the calculated pause time and the amount of accumulated water.
The level setting can preferable be adjusted after some pumping cycles in order to adjust
the pause times, and hence the start level in the pit. See schematic pump cycle example
below.
Maximum pause time for the pump is set in window 22. The calculated pause time will be
limited to this value. In some applications the inflow may increase rapidly during a pause.
To prevent overflow in these situations the maximum pause time can be set in accordance
with the circumstances.
DETAILED SETTINGS
14 Single pump controller Installation and user manual for FPC100

Window parameters
The following table is a summary of all the windows in the single level menu structure.
Window number, function and value ranges are listed as well as the default settings that
are programmed in FPC100 before delivery.
Window Function Value/Range Default setting Own settings and
comments
00
Alarm indication.
Flashes when an
alarm is present.
Symbol
is flashing
See PROTECTION
AND ALARM (page
19)
01
Remaining time to
next calculated pump
start.
Standard window
during pause.
Symbol
is flashing together
with m or S.
720–15 min
900–0 s
02
Pumping time since
the latest pump start.
Standard window
when pumping.
Symbol
is flashing together
with m or S.
0–90 s
15–720 min
12–999 h
03
Pumping time since
the latest pump start
due to start on high
level . Standard
window when
pumping after high
level.
Symbol
is flashing together
with m or S.
0–900 s
15–720 min
12–999 h
04 Measured power in %
of the measuring
range
0–125 %
05 Measured line
voltage
0–999 V
06 Measured peak
power in % of the
measuring range
0–125 % 0 %
DETAILED SETTINGS
Single pump controller Installation and user manual for FPC100 15

Window Function Value/Range Default setting Own settings and
comments
07
Total pumping time
in hours. Symbol
is displayed.
Press + and –
simultaneously for 3
sec to set the value to
0.
0–99999 0
08 Total number of
pump starts. Press +
and – simultaneously
for 3 sec to set the
value to 0.
0–99999 0
09 Parameter lock.
Symbol
is displayed when
parameters are
locked. Enter 369 to
lock/unlock window
11-99.
0–999 0
11 Stop level (power) in
%0–125 % 0 %
12 Snore margin in % 0–125 % 10 %
13
Type of Auto Set.
AUTOSET is pressed at
normal pumping
when pump doesn’t
snore ( ¯ ).
AUTOSET is pressed at
snoring or dry
running ( _ )
¯ or _ ( ¯ )
21 Level setting (used
for pause time
calculation).
Higher value
increases the
calculated pause
time. Example: the
value 3.2 gives 3.2
times longer pause
time than 1.0.
The level setting can
preferable be
adjusted after some
pump cycles in order
to adjust the pause
times, and hence the
level in the pit.
1.0–10.0 1.0
DETAILED SETTINGS
16 Single pump controller Installation and user manual for FPC100

Window Function Value/Range Default setting Own settings and
comments
22
Maximum pause
time. Symbol
is displayed.
If the calculated
pause time is longer
than the Maximum
pause time, the
pump will start after
the Maximum pause
time.
0–900 s
15–720 min
600 s
23
Start-up delay.
Symbol
is displayed.
This is the time from
pump start until
snore detection is
activated.
1–170 s 5 s
24
Stop delay. Symbol
is displayed.
This is the time from
snore detection until
the pump is stopped.
1–90 s 2 s
25
Pump starts when
pause time is
finished .
“OFF” means start
only on high level
(set window 53 to 1)
on / OFF on
31 Terminal 5
supervision, e.g.
temperature
supervision.
on / OFF OFF
32 Terminal 5 alarm
latched “on” or not
latched “OFF”.
Can only be used
when window 31 is
“on”.
on / OFF OFF
41 Permitted
phase
voltage asymmetry
level.
Pressing “–” when the
window shows 5 %
turns off the
supervision (OFF).
OFF/5–50 % 10 %
42 Phase voltage
asymmetry alarm
latched. Can only be
used when window
41 is set between
5-50%.
on / OFF OFF
DETAILED SETTINGS
Single pump controller Installation and user manual for FPC100 17

Window Function Value/Range Default setting Own settings and
comments
51
Alarm relay (terminal
6)
nc = normally closed.
no = normally open
nc / no no
52
Pump relay (terminal
8)
nc = normally closed.
no = normally open
nc / no nc
53
Digital input for
closing contact.
1 = High level switch
(gives immediate
start of the pump)
2 = External Reset
3 = External Auto-set
1, 2, 3 1
61 Measured current on
terminals 1 and 2. 0–70 mA
99
Default settings
(dEF) / User settings
(Usr)
Setting (dEF) returns
to default settings.
dEF / USr dEF
DETAILED SETTINGS
18 Single pump controller Installation and user manual for FPC100