ICON DPC1 User manual

BIA-DPC1 rev 4 Page 1
Installation and Operation Manual
DPC1

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Conventions used in this manual.
In the manual the following symbols will be used:
Generic danger. Failure to comply with the safety regulations that follow can irreparably
damage the controller or equipment.
Electric shock risk. Failure to comply with the safety regulations that follow can cause death
or serious injury.
WARNINGS
Read this manual carefully before any operation.
Please keep this manual for future use.
WARNING!!
1. Installation must be carried out by a suitably qualified electrician.
2. Before carrying out any installation or maintenance operation, controller must be
disconnected from the power supply.
3. Do not open the cover during running the controller.
4. Do not splash water or other liquid over the controller.
5. Do not allow children or infirm persons to operate the control.
6. Qualified electrician is to correctly size and install circuit breakers to protect power supply.
CAUTION!!
1. The electrical and hydraulic connections must be carried out by competent, skilled, qualified
personnel.
2. Never connect AC power to the output terminals.
3. Ensure the pump and controller characteristics match.
4. Do not install the controller in the following conditions:
a. Vibration and mechanical shock.
b. Corrosive gasses and liquids.
c. Extreme heat and cold, operating range -25oC - +55oC.
d. Salt mist corrosion.
e. Rain and moisture.
f. Flammable materials, solvents.

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TABLE OF CONTENTS
Page
1.0 INTRODUCTION
1.1 Applications 5
1.2 Technical parameters and features 5
1.3 Meanings of the icons shown on the LCD 7
2.0 INSTALLATION –DRAINAGE
2.1 Electrical connection to the power supply and pump 8
2.2 Function switch setting 9
2.3 Connections for pump over temperature protection (where supplied) 10
2.4 Installing float switches and probes 10
2.5 Diagrams for drainage by liquid level through float switches or probes 11
2.0a INSTALLATION –DRAINAGE
WITH AUTOMATIC PUMPS
2.1a Electrical connection to the power supply and pump 15
2.2a Function switch setting 16
2.3a Connections for pump over temperature protection (where supplied) 17
2.4a Installing float switches and probes 17
2.5a Diagram for drainage by liquid level 18
3.0 INSTALLATION –BOOSTING
3.1 Electrical connection to the power supply and pump 20
3.2 Function switch setting 21
3.3 Connections for pump over temperature protection (where supplied) 22
3.4 Installing float switches and probes 22
3.5 Diagrams for boosting by liquid level through float switches or probes 23

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Cont....
TABLE OF CONTENTS cont.
4.0 INSTALLATION –TRANSFER
4.1 Electrical connection to the power supply and pump 27
4.2 Function switch setting 28
4.3 Connections for pump over temperature protection (where supplied) 29
4.4 Installing float switches and probes 29
4.5 Diagrams for transfer by liquid level through float switches or probes 30
4.0a INSTALLATION –TRANSFER
HOT WATER CIRCULATION
4.1a Electrical connection to the power supply and pump 33
4.2a Function switch setting 34
4.3a Connections for pump over temperature protection (where supplied) 35
4.4a Installing float switches and probes 35
4.5a Diagrams for transfer by liquid level through float switches or probes 36
5.0 OPERATION
5.1 BEFORE YOU START –Parameter calibration and erasing 37
5.2 Switching to AUTO mode 38
5.3 Switching to MANUAL mode 38
5.4 Alarm Test and MUTE 38
5.5 Pump protection 38
5.6 Last five failure record 39
5.7 Pump accumulated running time 39
5.8 Pump disable 39
6.0 COMMUNICATION LINK 40
6.1 Basic Function 41
6.2 Special application 41
6.3 Technical parameters 41
7.0 TROUBLE SHOOTING GUIDE 42

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1.0 Introduction
Thank you for choosing a Bianco Icon Series Intelligent Pump Controller.
The Intelligent Pump Controller model is an easy to use, programmable controlling and protection
device for direct start, single phase pumps with output power from 0.37kW –2.2kW.
The Controller has many operation modes by adopting different electrical installations. Important
features that distinguish the Bianco Icon Series Intelligent Pump Controllers from some other
controllers are the push button calibration of overload and ability for dry run protection without
float switches or probes.
1.1 Applications
The Controller is useful in all cases where there is the need to control and protect single pump
installations managing the automatic operation by a variety of switching methods.
Typical usage scenarios include:
•Stormwater
•Sewage
•Booster sets
•Rainwater reuse
•Irrigation
•Water supply
1.2 Technical parameters and features
•Built in function switch for
oDrainage by liquid level control through float switches or probes
oBoosting water supply by pressure control through pressure switch and tank
oTransfer water by liquid level control through float switches and probes
•Dry run protection without float switches or probes
•Auto/Manual switch
•Dynamic LCD displaying pump running state
•Protect the pump against many faults
•Push button calibration
•Pump accumulative running time
•Last five fault record
•RS485 communication
•Starts and stops the pump in accordance with liquid levels and pressure settings

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The following chart shows main technical parameters for the Controller DPC1
Main technical characteristic
Control characteristic
Double liquid level control
pressure control
Control method
Manual/Auto
Liquid level control characteristic
pulse electrode probe and float switch
Pressure control characteristic
pressure switch and pressure tank
Main technical data
Rated output power
0.37 –2.2 kW (0.5 –3.0 hp)
Rated input voltage
240V
Trip response time of overload
5 sec - 5 min
Trip response time of open phase
< 2 sec
Trip response time of short circuit
< 0.1 sec
Trip response time of under/over voltage
< 5 sec
Trip response time of dry run
6 sec
Recovery time of over load
30 min
Recovery time of under/over voltage
5 min
Recovery time of dry run
30 min
Trip voltage of over voltage
115% of rated input voltage
Trip voltage of under voltage
80% of rated input voltage
Liquid level transfer distance maximum
1000m
Protection functions
Dry run
Over load
Transient voltage
Under voltage
Over voltage
Pump stalled
Short circuit
Main installation data
Working temperature
-25 to +55 deg C
Working humidity
20% to 90% Relative Humidity, non-condensing
Degree of protection
IP54
Install position
Vertical
Unit dimensions (L x W x H)
30.2 x 24.0 x 12.0 cm
RS485 technical data
Physical interface
RS485 Bus Interface: asynchronous semi duplex
Baud rate
1200,2400,4800,9600 bps (default 9600bps)
Protocol type
MODBUS protocol (RTU)

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1.3 Meanings of the icons shown on the LCD.
Icon Meaning / Description
pump parameter configuration icon, when this icon appears, pump control box
is parameter setting
time displaying icon, when this icon appears, it means pump control box is
displaying some parameter of time, eg: pump accumulated running time (unit:
hour); counting down etc
pump fault icon, when this icon appears, it means pump control box is displaying
some fault information
network connection error icon, when this icon appears, it means there is no
network connections or network connection error between pump control box
and SC(slave controller) or computer
network normal connection icon, when this icon appears, it means the network
connection between pump control box and SC (slave controller) or computer is
normal
V voltage
M minute
S second
H hour
% percent
A ampere
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
pump B (for dual pump controllers)

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2.0 Installation –DRAINAGE
2.1 Electrical connection to the power supply and pump
DANGER. Electric shock risk.
Before carrying out any installation or maintenance operation, the control panel should be
disconnected from the power supply and one should wait at least 2 minutes before opening the
control panel.
Never connect AC power to output L and N terminals.
Ensure the motor, controller and power specifications match.
The electrical and hydraulic connections must be carried out by competent, skilled, qualified
personnel.
Main Circuit Breaker

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2.2 Function switch setting - DRAINAGE
Installers can set the function switch to meet different applications. Before setting the function
switch, the control panel should be disconnected from the power supply.
After completing the setting, apply power to the control panel and observe the application sign
displayed on the LCD conforming to the DRAINAGE symbol.
DRAINAGE SETTING DRAINAGE SYMBOL
SWITCHES DOWN
MCB

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2.3 Connections for pump over temperature protection (where supplied with pump).
Note: to realize the pump motor winding over temperature protection, it requires that there must be over-
temperature switches embedded in the pump motor winding (microtherms as fitted to Zenit 3ph pumps 2.2
kW or greater). To utilise the pump’s over temperature protection connect the pump’s microtherm leads to
terminals 9 and 11, 10 and 12 and remove the jumper.
Note: if the pump is without over temperature switch, please use jumper to connect terminals 9 and 11, 10
and 12.
2.4 Installing float switches and probes.
Float switch installation.
Do not encase sensor leads, float switches or signal cables in metal pipes. Use PVC or PE tubing.
Liquid probe installation.
Jumper Leads

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In event of high risk of electrical storms (lightning) or when liquid medium in sump, well or tank is very
dirty, it is recommended to use float switches.
2.5 Electrical connections for DRAINAGE applications
2.5.1 Drainage by liquid level control through float switches or probes
Note: for 4 float switch installation connect float switch A (pump off) to terminals 1 and 3, float switch B (1st
pump on) to terminals 1 and 5, float switch C (2nd pump on) to terminals 2 and 4 and float switch D (alarm) to
terminals 2 and 6.

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2.5.1 Drainage by liquid level control through float switches or probes (cont)
Note: for 4 float switch installation connect float switch A (pump off) to terminals 1 and 3, float switch B (1st
pump on) to terminals 1 and 5, float switch C (2nd pump on) to terminals 2 and 4 and float switch D (alarm) to
terminals 2 and 6.

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2.5.1 Drainage by liquid level control through float switches or probes (cont)

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Stop condition
Liquid level in the sump is reaches probe 2, (float switch A down) the control panel will stop the pump.
Start condition
Liquid level in the sump reaches probe 3, (float switch A up) the control panel will run a pump. Control panel
will alternate the pumps when the liquid level varies between probe 2 and probe 3 (float switch A up and
down).
2nd pump start condition
Liquid level in the sump reaches probe 4, (float switch B up) the control panel will run the second pump.
Pumps run simultaneously until liquid level reaches probe 2, (float switches A and B down).
Alarm condition
While pumping, if the liquid level rises in the sump to probe 5, (float switch C up), the control panel will sound
the alarm to warn the user to take further action.
Meanings of the messages & graphic shown on the LCD screen

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2.0a Installation –DRAINAGE WITH AUTOMATIC PUMPS
2.1a Electrical connection to the power supply and pump
DANGER. Electric shock risk.
Before carrying out any installation or maintenance operation, the control panel should be
disconnected from the power supply and one should wait at least 2 minutes before opening the
control panel.
Never connect AC power to output L and N terminals.
Ensure the motor, controller and power specifications match.
The electrical and hydraulic connections must be carried out by competent, skilled, qualified
personnel.
Main Circuit Breaker

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2.2a Function switch setting –DRAINAGE WITH AUTOMATIC PUMPS
Installers can set the function switch to meet different applications. Before setting the function
switch, the control panel should be disconnected from the power supply.
After completing the setting, apply power to the control panel and observe the application sign
displayed on the LCD conforming to the DRAINAGE symbol.
DRAINAGE SETTING DRAINAGE SYMBOL
FOR AUTOMATIC PUMPS
MCB

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2.3a Connections for pump over temperature protection (where supplied with pump).
Note: to realize the pump motor winding over temperature protection, it requires that there must be over-
temperature switches embedded in the pump motor winding (microtherms as fitted to Zenit 3ph pumps 2.2
kW or greater). To utilise the pump’s over temperature protection connect the pump’s microtherm leads to
terminals 9 and 11, 10 and 12 and remove the jumper.
Note: if the pump is without over temperature switch, please use jumper to connect terminals 9 and 11, 10
and 12.
2.4a Installing float switches and probes.
Float switch installation.
Do not encase sensor leads, float switches or signal cables in metal pipes. Use PVC or PE tubing.
Liquid probe installation.
Jumper Leads

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In event of high risk of electrical storms (lightning) or when liquid medium in sump, well or tank is very
dirty, it is recommended to use float switches.
2.5a Electrical connections for DRAINAGE applications WITH AUTOMATIC PUMPS
2.5.1a Drainage by liquid level control.
Note: for “3 wire” floats use black and brown wires. Terminate blue wire with closed end connector.
Alarm float C connected to terminals 2 and 6.
If the system activates the high level alarm connected to the control panel the second pump will start
and the alarm will activate until the high level float deactivates.
If a pump fail situation is detected then the pump will switch to the second pump.
Warning –DRY RUN Protection not active in Drainage with Automatic Pump Mode.
High Level Alarm Delay
High Level Alarm delayed by 15 minutes after activation of High Level Float to allow 2nd Pump to turn on
and assist with pump out.
Note, For 30 minutes after High level Alarm activated, both pumps work concurrently.
Note: for drainage
with automatic
pumps, floats A & B
are not used and
terminals 1, 3, 5 and
2,4 are bridged.

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2.5.1a Drainage by liquid level control WITH AUTOMATIC PUMPS
Stop condition
Liquid level in the sump is below automatic pump float switch off position which will stop both pumps.
Start condition
The control panel alternates power supply between pumps every 240 hours. When liquid level in the sump is
above the automatic pump float switch on position, the pump that is being supplied power will run.
Alarm condition
While pumping, if the liquid level rises in the sump to float switch C up, the control panel will sound the alarm
to warn the user to take further action.
Meanings of the messages & graphic shown on the LCD screen

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3.0 Installation –BOOSTING
3.1 Electrical connection to the power supply and pump
DANGER. Electric shock risk.
Before carrying out any installation or maintenance operation, the control panel should be disconnected from
the power supply and one should wait at least 2 minutes before opening the control panel.
Never connect AC power to output L and N terminals.
Ensure the motor, controller and power specifications match.
The electrical and hydraulic connections must be carried out by competent, skilled, qualified personnel.
Main Circuit Breaker