Grundfos DPC 2-1 User manual

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DPC 2-1
Installation and Operating Instructions
DPC 2-1 For Single Phase Pumps up to 15A

SAFETY 4
INTRODUCTION 5
Applications 5
Features 5
Parameters & Specifications 6
INSTALLATION 7
Tools Used in Controller Installation 7
Controller Components 7
- LCD Screen 7
- Meaning Of the icons shown In the LCD ------------------------------------------------------ 8
Power Terminal 10
Control PCB connection 11
Installation – Drainage 11
- Terminals 11
- DIP Switch Settings 12
- Electrical Connections 13
Installation – Boosting 16
- Terminals 17
- DIP Switch Settings 18
- Electrical Connections 19
Installation – Water Transfer 20
- Terminals 21
- DIP Switch Settings 22
- Electrical Connections 23
OPERATION 24
Parameter Calibration 24
Erasing Former Parameters 25
- Erasing The Parameter Calibration 25
Switching to AUTO mode 25
Switching to MANUAL mode 25
Pump Protection 25
Last Five Failure Records 26
Pump Accumulative Running Time 27
COMMUNICATION LINK 28
Basic Function 29
Special Application 29
Technical Parameters 29
TROUBLE SHOOTING 30

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Following are the safety instructions which must be followed by the service
partners or user while installing & operating the product. If ignored, physical
injury or even death may happen. Read the safety instructions before handling the
system.
NOTE (Notes or attention to ensure safe operation)
Important
The manufacturer is not liable for malfunctioning if the product is not correctly
installed, damaged, modified and/or put to run beyond the working range as
given in this manual.
The manufacturer reserves the right to make any modifications to this product
from time to time.
SAFETY
WARNING
If these safety instructions are not observed, it may result in
malfunction or damage to the equipment.
All electrical connections must be carried out by skilled and qualified
personnel.
Never connect AC power to output L1 & N1 / L2 & N2 terminals.
Ensure the motor, controller and power specifications are matching.
CAUTION
If these safety instructions are not observed, it may result in
personal injury.
Before carrying out any installation or maintenance operation, the controller
must be disconnected from the power supply.
Don’t open the cover while the pump is running.
Don’t put wire, metal bar filament etc. into the controller.

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Thank you for choosing a DPC Series Digital Pump Controller.
The Digital Pump Controller model is easy to use, programmable controller and
protection device for direct start with single phase two pumps with output power
from 0.37kW - 1.5 kW (1.5 - 15A) each.
The controller has many operation modes for adapting different pumping
applications. Important features that distinguish the DPC Series Digital Pump
Controllers from other controllers are the push button calibration for overload and
the ability of dry run protection without float switches. It shows pump parameter,
status and faults, etc.
APPLICATIONS:
The controller is useful in all cases where there is a need to control and
protect two pump installations and managing the automatic operation by a
variety of switching methods.
Typical applications:
Water supply
Irrigation
Sewage
Booster sets
Rainwater reuse
Stormwater
FEATURES:
Built-in function switch for:
- Drainage by liquid level control through float switches
- Boosting water supply by pressure control through pressure switch and tank
- Transfer of water by liquid level control through float
switches Dry run protection without float switches
Auto/ manual switch with screen lock in AUTO mode
Dynamic LCD displaying for pump running status
Protect the pump against many faults
Push button calibration
Pump accumulative run
time Last five fault records
RS485 communication Modbus
Starts and stops the pump in accordance with liquid levels or pressure settings
Pump shaft anti rust feature
INTRODUCTION

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PARAMETERS AND SPECIFICATIONS:
Following chart shows the main technical parameters & specifications:
Main Technical Characteristics
Control characteristic
Double liquid level control
Pressure control
Working modes
Manual / auto
Drainage application
By using float switch
Pressure Boosting application
By using pressure switch
Water Transfer application
By using float switch
Main Technical Data
Rated output power (amperes)
1.5 to 15A for each pump
Rated input voltage
AC 220V / 50 Hz / Single Phase
Trip response time of overload
5 sec - 5 min
Trip response time short circuit
Less than 0.1 sec
Trip response time of under/over voltage
Less than 5 sec
Trip response time of dry run
6 sec (or this can be set manually)
Recovery time of overload
30 min (or this can be set manually)
Recovery time of under/over voltage
5 min
Recovery time of dry run
30 min (or this can be set manually)
Trip voltage of over voltage
115 % of rated input voltage
Trip voltage of under voltage
80 % of rated input voltage
PROTECTIONS COVERED
Dry run (without float/ probe)
Overload (auto-calibrated or can be set)
Transient surge
Under voltage
Over voltage
Pump stalled
Short circuit
Pump shaft anti rust protection
Other Technical Data
Permissible ambient temperature
-5 to +50 deg C
Degree of protection
IP 55
Installation position
Vertical
Unit dimensions (L X W X H)
320 x 420 x 138 mm
Physical interface
RS485 bus interface: Asynchronous
Baud rate
1200, 2400, 4800, 9600 bps (default)
Protocol type MODBUS protocol (RTU)

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Please read this manual carefully before starting installation and operation. Any
damage to the equipment caused due to failure to comply with the descriptions
in this manual in installation or operation will be beyond the scope of the
company’s quality guarantee.
TOOLS USED IN CONTROLLER INSTALLATION:
Controller installation and wire installation will need the following tools,
you also can choose the right tools according to your own experience.
Back view Side view
wall
Mounting
clamp
CONTROLLER COMPONENTS:
Voltage Displaying
Area
Ampere Displaying
Area
Fault Displaying
Area
Pump Running Status
Displaying Area
INSTALLATION
LCD SCREEN

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MEANING OF THE ICONS SHOWN ON THE LCD:
The parameter configuration icon,
when this icon appears, controller is in
manual parameter adjustment mode.
Time displaying icon, when this icon
appears, it mean controller is displaying
some parameter of time, eg: pump dry
run trip time(units: seconds).
Pump fault icon, when this icon
appears, it means controller is
displaying some fault condition.
Network connection error icon, when this
icon appears, it means there is no network
connection or network connection error
between pump controller and
computer/SCADA/BMS.
Network normal connection icon, when
this icon appears, it means the network
connection between pump controller and
computer/SCADA/BMS.
Voltage
v
M
Minute

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Second
S
H
Hour
Ampere
A
Percent
Pump running
Pump stopped
Low pressure or lack of pressure in the
pipeline or pressure tank.
High pressure or full of pressure in the
pipeline or pressure tank.
Pump A
A
B
Pump B

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POWER TERMINAL CONNECTIONS:
Single Phase (without running capacitor) Single Phase (with running capacitor)

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CONTROL PCB TERMINAL CONNECTIONS:
The control terminal connection
varies based on the app
INSTALLATION - DRAINAGE:
Using one float switch
Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will
start pump A. Panel will alternate between pump A and pump B after previous
cycle is completed. LCD screen will display RUN whichever pump in running.
Stop condition:
If the liquid level in the pit/tank falls, ie. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.
TERMINALS

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Using two float switches
Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will
start pump A. Panel will alternate between pump A and pump B after previous
cycle is completed. LCD screen will display RUN whichever pump in running.
If the liquid level in the pit/tank rises even further after first pump is running ie.
Float Switch A and Float switch B are in up position. As soon as Float switch B
reaches up position, panel will start whichever pump is in standby. E.g., If pump A
was running and liquid level rose even further and Float B comes in up position,
pump B will also start operating in parallel to pump A.
Stop condition:
If the liquid level in the pit/tank falls, i.e.. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.
If both pumps, we're running, then both pumps will stop simultaneously when
float switch A is in down position. LCD screen will display No water.
Using three float switches

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Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will start
pump A. Panel will alternate between pump A and pump B after previous cycle is
completed. LCD screen will display RUN whichever pump in running.
If the liquid level in the pit/tank rises even further after first pump is running ie.
Float Switch A and Float switch B are in up position. As soon as Float switch B
reaches up position, panel will start whichever pump is in standby. Eg. If pump A
was running and liquid level rose even further and Float B comes in up position,
pump B will also start operating in parallel to pump A.
Alarm condition:
If the liquid level in the pit/tank rises even further after both pumps are running
and Float switch C is in up position. In this situation in addition to both pumps
running, an overflow alarm will generate an audio-visual sound with fault indica-
-tion on LCD screen showing Overflow. This fault will reset itself only when liquid
level in pit/tank falls below Float C, and Float C is in down position.
Stop condition:
If the liquid level in the pit/tank falls, ie. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.
If both pumps, we're running, then both pumps will stop simultaneously when
float switch A is in down position. LCD screen will display No water.
DANGER
Electric shock risk.
Before carrying out any installation or
maintenance operation, the
controller should be disconnected from the power supply and the
person should wait at least 2 minutes before opening the controller.
Never connect AC power to output L1&N1 / L2&N2 terminals.
Ensure
the motor, controller and power specifications match.
The
electrical and hydraulic connections must be carried out by
competent, skilled, qualified personnel.

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Users can set the function switch to suit different applications. Before
setting the function switch, the unit should be disconnected from the
power supply. After completing the settings of dip switches, power may be
applied to the unit. The symbol corresponding to the application will be
displayed on the LCD Screen.
Drainage Setting
Switches Down
Drainage Symbol
Pump connection for over temperature protection (where supplied with pump)
Pump Shell
19 20
Jumpers Lead
Pump Shell
Over Temperature
(Thermal)Switch
Pump A Pump B
Over Temperature
(Thermal)Switch
DIP SWITCH SETTINGS
NOTE: To enable the pump’s over temperature protection connect the
pump’s thermistor leads to terminals 14 and 15, 19 and 20 and remove
the jumper.
If the pump is without thermistor switch, please use jumper to connect
terminals 14 and 15, 19 and 20.
14 15
ON
1 2 3

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Meanings of the messages & graphic shown on the LCD screen
Messages & Graphics
No
water
Description
Lack of water in sump
Over flow
Overflow in sump

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INSTALLATION - BOOSTING:
Using 1 Float Switch and 1 Pressure Switch
Start condition:
If the water level in source tank is high and the float switch A in the source
tank is in up position and the Pressure in the line is below the cut-in pressure
setting on the pressure switch A the pump starts. Panel will alternate between
pump A and pump B, when previous demand cycle is completed, and pump(s)
have stopped. LCD screen displays RUN indicating pump is running.
Stop condition:
If the water level in the source tank is low and Float switch A in the source tank
is in down position, the pump stops. LCD screen displays NO WATER, that means
there is no water in the source tank and can lead to a dry run situation.
If the Pressure in the line is equal to or above the cut-out pressure setting on
the pressure switch A installed, the pump stops. LCD screen displays FULL, that
means there is no demand of water.
Using 1 Float Switch and 2 Pressure Switch
TERMINALS

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Start condition:
If the water level in source tank is high and the float switch A in the source
tank is in up position and the Pressure in the line is below the cut-in pressure
setting on the pressure switch A the pump starts. Panel will alternate between
pump A and pump B, when previous demand cycle is completed, and pump(s)
have stopped. LCD screen displays RUN indicating pump is running.
If the pressure in the line is below cut-in pressure setting of pressure switch B,
then panel will start the standby pump to run in addition to operating pump.
Both pumps will run simultaneously in parallel operation.
Note: Cut in pressure of Pressure switch B < Cut in pressure of Pressure switch A
Stop condition:
If the water level in the source tank is low and Float switch A in the source tank
is in down position, the pump(s) stops. LCD screen displays NO WATER, that means
there is no water in the source tank and can lead to a dry run situation.
If the Pressure in the line is equal to or above the cut-out pressure setting on the
pressure switch A installed, the pump(s) stops. LCD screen displays FULL, that means
there is no demand of water.
If both pumps, we're running then both pumps will stop simultaneously when cut-
-out pressure switch of Pressure switch A is achieved.

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Users can set the function switch to meet different applications. Before
setting the function switch, the controller should be disconnected from the
power supply.
After completing the setting, apply power to the controller and observe the
application sign displayed on the LCD conforming to the BOOSTING symbol.
Boosting Setting
Switches UP
Boosting Symbol
DANGER Electric shock risk.
Before carrying out any installation or maintenance operation, the
controller should be disconnected from the power supply and the
person should wait at least 2 minutes before opening the controller.
Never connect AC power to output L1 & N1 / L2 & N2 terminals.
Ensure the motor, controller and power specifications match.
The electrical and hydraulic connections must be carried out by
competent, skilled, qualified personnel.
1 2 3
DIP SWITCH SETTINGS

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Connections for pump over temperature protection (where supplied with pump)
Jumpers Lead
Pump Shell Pump Shell
Over Temperature
(Thermal)Switch
Pump B Pump A
Over
Temperat
ure
(Thermal)
Switch
Meanings of the messages & graphic shown on the LCD screen
Messages & Graphics
Description
Low water level in source tank
Enough water in source tank
High pressure in pipeline or
pressure tank
Low pressure in pipeline or
pressure tank
NOTE: To enable the pump’s over temperature protection, connect
the pump’s thermistor leads to terminals 14 and 15, 19 and 20 and
remove the jumper.
If the pump is without thermistor switch, please use jumper to
connect terminals 14 and 15, 19 and 20.
NOTE: Pressure Switch A = Low Pressure Switch, Pressure Switch B =
High Pressure Switch.
19 20
14 15

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INSTALLATION - WATER TRANSFER:
Using 2 Float switch (one float in UG tank, one float in OH tank)
Start condition:
If water level in UG tank is high ie. Float A is up and water level in OH tank is
low ie. Float B is down, panel will start pump A. Panel will alternate between
pump A and pump B, after previous cycle is completed. LCD screen will display
pump A/B run on screen.
Stop condition:
If the water level in UG tank is low ie. Float A is down, if any of the pump(s) are
running, panel will stop the pump(s) indicating that there is not enough water
in UG tank. LCD screen will display No water.
If the water level in OH tank is high ie. Float A is up. Panel will stop the pump(s)
that are running indicating that the OH tank is full. LCD screen will display Full.
On any of the situation stated above occur, pump(s) will stop running.
TERMINALS