ICON BIA-iPROTECT User manual

iCON iPROTECT Instruction Manual Rev 4.4 1
Auto Restart Pump Controller
BIA-iPROTECT
Single-Phase Pump Control and Protection module PN 802697
Installation and Operation Manual

2iCON iProtect Instruction Manual Rev 4.4
1. Introduction
Thank you for choosing a Bianco iCon iPROTECT Intelligent Pump Controller.
An iPROTECT provides significant protection for direct start (DOL), single phase pumps from
0.37kW – 2.2kW with PSC MOTORS (Permanent-Split Capacitor) with start and run
windings). It also offers a number of control and operation modes to suit a variety of
applications.
The controller is easy to set up with a push button calibration for over and under-load.
The iPROTECT also allows for dry-run protection without float switches or probes.
The LCD screen displays the pump running state and provides the user a wealth of useful
information.
The iPROTECT is particularly useful where there is the need to control and protect single
pump installations managing the automatic operation by a variety of switching methods.
2. Contents
1. Introduction ............................................................................................... 2
2. Contents .................................................................................................... 2
3. Technical Specifications ............................................................................ 3
4. Warnings and Cautions .............................................................................. 3
5. Display ....................................................................................................... 4
6. Operation and Programming - navigation .................................................. 5
7. Program Parameters .................................................................................. 6
8. Programming for Cutter/Grinder/Macerating pumps ................................. 8
9. Drainage Mode - Electrical Connections; floats or probes ........................ 9
10. Drainage Mode – Control via Pump Float ................................................. 10
11. Drainage Mode – LCD running state images ............................................ 10
12. Transfer Mode - Electrical Connections; floats or probes ....................... 11
13. Transfer Mode - LCD running state images ............................................. 12
14. Boosting Mode - Electrical Connections; floats or probes....................... 13
15. Boosting Mode - LCD running state images............................................. 14
16. Bore Pumps - Connecting 2 wire and 3 wire bore pumps........................ 15
17. Communication link – RS485 ................................................................... 16
18. Fault messages – possible causes and solutions..................................... 18
19. Warranties – Terms and Conditions ......................................................... 19

iCON iPROTECT Instruction Manual Rev 4.4 3
3. Technical Specifications
Controller Modes
Automatic or Manual pump operation.
Liquid level control via float switch, level transducer or pulse
electrode probes.
Pressure control via pressure switch or transducer.
Protection functions: Dry run (underload), Overload, Pump Stalled,
Transient surge, Under voltage, Over voltage,
Repeated start, Over temperature, Short circuit
Input Voltage 230V +5% -10%
Rated output power 0.37 – 2.2kW P2 power (rated up to 25A input)
Working temp
-25 to +55 deg C
20% to 90% relative humidity, non-condensing
Enclosure 250mm tall, 197mm wide, 115 deep. 1.6kg. IP54
Trip response times (set) Open phase – Less than 2 sec
Short circuit – less than 0.1 sec
Trip Voltage
(User adjustable)
Over voltage – 115% of rated input voltage default
Under voltage – 80% of rated input voltage default
Trip response times
(User adjustable)
Dry run (Under-load) 6 sec
Overload 5 sec
Under Voltage Less than 5 sec
Over voltage Less than 5 sec
Recovery times
Dry run (Under-load) 30 min default
Overload 30 min default
Under Voltage 5 min – non adjustable
Over voltage 5 min – non adjustable
RS485 Technical interface
RS485 Bus Interface: asynchronous semi duplex
1200,2400,4800,9600 bps (default 9600bps)
MODBUS protocol (RTU)
Alarms Internal audible alarm only. External alarm connection unsupported
4. Warnings and Cautions
Please read the manual fully and carefully before starting.
Retain the manual for future reference.
This appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person
responsible for their safety. Children should be supervised to ensure
that they do not play with the appliance.

4iCON iProtect Instruction Manual Rev 4.4
5. Display
The iProtect display provides a real time indication of the operational mode and the
current state of the controller, including real-time voltage/load and any error messages.
Drainage
Boosting
Transfer
Control by floats
or probes
Control by pressure
switch
Control by floats
or probes
Control by level
transducer
Control by pressure
transducer
Control by level
transducer
Function switch located upper right-hand side of main board. Cycle power after changing.
Error
messages
display in the
RH pane
Voltage
Output
power
Transducer
values
Pump running status displays in the middle pane
Parameter configuration mode
Fault information displaying
Time information displaying

iCON iPROTECT Instruction Manual Rev 4.4 5
6. Operation and Programming - navigation
In situations where it isn’t possible to run the pump to achieve a real-world
calibration, enter the P1 kW rating manually at Parameter 008
See Pg 17 for additional notes regarding calibration

6iCON iProtect Instruction Manual Rev 4.4
7. Program Parameters
Note that earlier versions of firmware will have fewer parameters. Ensure the screen is displaying the
image that corresponds with your desired change.
The controller ID
Range 0 - 254
Default = 1
RS 485 Speed
01 = 1200 bps
02 = 2400 bps
03 = 4800 bps Range 0 - 4
04 = 9600 bps Default 4 = 9600 bps
Odd-Even parity
00 = no parity
01 = odd parity
02 = even parity
Default setting 00 = no parity
Dry run protection trip response time in seconds (S)
Range 0 seconds – 60 seconds
Default value 6 seconds
Recovery time for dry run protection in minutes (M)
Range 0 - 254 minutes
Default value is 30 minutes
Overload trip response time in minutes (M)
Range 0 - 60 minutes
Default value is 5 minutes
Under / Over voltage trip response time in minutes (M)
Range 0 – 60 minutes
Default value is 2 minutes

iCON iPROTECT Instruction Manual Rev 4.4 7
Rated power output to the pump (P1 power)
Range 0 – 2.99kW
Default setting is 3.00kW
Button Press calibration saves the running value to this location
The trip response ratio of the dry-running (underload)
protection as a percentage of the rated current
Range 0 – 95%
Default setting is 70%
Control by means of a float attached directly to the pump: set to 0%
.
The trip response ratio of the Overload Protection as a
percentage of the rated current.
Range 0 – 135%
Default setting is 135%
The trip response ratio of the Pump-Stalled Protection as a
percentage of the rated current.
Range 0 – 240%
Default setting is 200%
A pump-stalled event is a ‘critical error’ and has no auto-restart time
The trip voltage of the Under Voltage Protection (V)
Range 0 – 192V
Default setting is 176V
The trip voltage of the Over Voltage Protection (V)
Range 0 – 276V
Default setting is 253V
Note: Only Applicable to Drainage Mode
Anti-seize parameter.
In auto mode, if pump has not run for XX hours, controller will run the
pump for 3 seconds.
Range 0 – 254 hours
Default setting is 240 hours.
LCD Button operation lock function
00 = LCD and button function inactive
01 = LCD and button function activated Default setting is 00 = inactive
If this function is activated, to unlock the controller hold MODE button then
press and hold the STORE/SET button. The controller will count down 6 – 10
seconds. Release all buttons and the controller will switch to manual mode
with all buttons unlocked

8iCON iProtect Instruction Manual Rev 4.4
Delay time for starting the pump in seconds
In auto mode, when the controller has met the conditions to start the
pump, there will be a delay equal to setting 016 parameter
Default setting is 0 seconds
Delay time for stopping the pump in seconds
In auto mode, when the controller has met the conditions to start the
pump, there will be a delay equal to setting 016 parameter
Default setting is 0 seconds
If a replacement pump is installed, the previous calibration should be removed
and a new calibration performed.
Consult White International prior to changes to parameters 001 to 017.
Changes without consulting White International may void your pump warranty.
8. Programming for Cutter/Grinder/Macerating pumps
Pumps fitted with a cutting, grinding or macerating mechanism are at risk of jamming or
attempting to start in a ‘locked rotor’ state.
The iProtect, due to its rapid response, the provides superior pump protection compared
to traditional overload setups.
For pumps with a cutting, grinding or macerating mechanism, the installer may elect to
manually enter the pump nameplate kW at Parameter 008 to ensure the pump can
achieve its maximum torque.
Note: if the running power is less than 75% of the rated full load power check the pump sizing or system.
For pumps controlled by their own float, see Section 9. Program parameter 009 to 0%

iCON iPROTECT Instruction Manual Rev 4.4 9
9. Drainage Mode - Electrical Connections; floats or probes
The controller is rated IP54. It should be installed vertically where it has excellent
ventilation away from direct sunlight or exposure to adverse weather. Installation inside a
separate open fronted enclosure is suggested.
Any electrical alterations or additional connections should be carried out by a
suitably qualified technician. Ensure suitably rated circuit breakers are installed.
Isolate the controller before opening the cover to access the low voltage circuit
connections.
When operating a pump with its own float fitted,
ensure it is lower than the control float OR tie the
float in the upward (permanently on) position
Terminals 1 and 2 are for connection to motor thermal
protection. If not available leave the jumper wire in.
Terminals A+ and B- are for MODBUS communication
(RS485).
Probes are not recommended for
use with black water or contaminated liquids.

10 iCON iProtect Instruction Manual Rev 4.4
10. Drainage Mode – Control via Pump Float
Even when using pumps with floats permanently attached, to
achieve maximum pump protection and control, use control floats
or probes wired to the iProtect.
Disable the pump float by tying it in the upward (on) position.
The iProtect monitors current. While supplying power to the pump should the
pump float switch the pump off the current drops to zero. The controller
interprets this as less than the underload response value. (Default setting for dry run
protection is 70% of normal run current)
This in turn causes a ‘Dry Run’ error, and the controller will initiate the dry-run recovery time
countdown before attempting to start the pump again. (Default setting 30 min Parameter 004)
If the installer’s preference is to use the float attached to the pump as the
method of pump control, terminals 4, 5 and 6 must be bridged AND the
dry run parameter 009 set to 0%
With the dry run parameter inactive the controller still provides protection against overload,
locked rotor, under voltage and over voltage conditions. Additional benefits to the user are
the anti-seize function, accumulated run time and the last 5 error record.
Connecting an external alarm device
Connection of an external alarm device directly to the iProtect is not currently supported.
11. Drainage Mode – LCD running state images
The controller is receiving a
high level signal. The alarm will
sound.
The pump will run if the
controller is in Auto mode
Related to terminals 10 and 12
There is no water at the source.
The pump will not run.
Related to terminals 4, 5 and 6
There is sufficient water at
the source for the float or
probes to send a run state
signal
The pump starts and runs.
Pump calibration:
(see pg 5)
Switch to manual mode 10 sec.
Start the pump
Allow the pump to reach a stable power.
Press to store. Press to exit.
Ensure the controller is set to
AUTO MODE when finished

iCON iPROTECT Instruction Manual Rev 4.4 11
12. Transfer Mode - Electrical Connections; floats or probes
The controller is rated IP54. It should be installed vertically where it has excellent
ventilation away from direct sunlight or exposure to adverse weather. Installation
inside a separate open fronted enclosure is suggested.
Any electrical alterations or additional connections should be carried out by a
suitably qualified technician. Ensure suitably rated circuit breakers are installed.
Isolate the controller before opening the cover to access the low voltage circuit
connections.
Bridging terminals 4,5 and 6 allows for
control by the destination inputs only.
The display screen will show the water
source as full.
Probes are not recommended
for use with black water or
contaminated liquids.

12 iCON iProtect Instruction Manual Rev 4.4
13. Transfer Mode - LCD running state images
Source liquid is below
the low-level setting.
The pump will not run.
Source liquid is above
the high-level setting
Pump available to run
Destination liquid below the
low-level setting.
If there is sufficient liquid at
the source the pump will
start
Destination liquid is above
the high-level setting.
The controller will turn the
pump off
The iProtect has a reliable automatic
stop function against pump dry-run.
When used with pumps where it is
inconvenient to install source floats
or probes, the installer can fit jumpers
between terminals 4,5 and 6.
Pump calibration:
(see pg 5)
Switch to manual mode 10 sec.
Start the pump
Allow the pump to reach a stable power.
Press to store. Press to exit.
Ensure the controller is set to
AUTO MODE when finished

iCON iPROTECT Instruction Manual Rev 4.4 13
14. Boosting Mode - Electrical Connections; floats or probes
The controller is rated IP54. It should be installed vertically where it has excellent
ventilation away from direct sunlight or exposure to adverse weather. Installation
inside a separate open fronted enclosure is suggested.
Any electrical alterations or additional connections should be carried out by a
suitably qualified technician. Ensure suitably rated circuit breakers are installed.
Isolate the controller before opening the cover to access the low voltage circuit
connections.
Fitting floats or probes to
register the pump inlet
source liquid level will
achieve the maximum
protection against pump
dry-running.
The under-load function of
the iPROTECT also acts as
a reliable automatic stop
function against pump dry-
running. Jumpers can be
fitted between terminals 4,5
and 6 if preferred

14 iCON iProtect Instruction Manual Rev 4.4
15. Boosting Mode - LCD running state images
Source liquid is below
the low-level setting.
The pump will not run.
Source liquid is above
the high-level setting
Pump available to run
The Pressure switch is
registering line pressure
above the cut-out
pressure. The switch
circuit is open
If there is sufficient liquid at
the source the pump will start
The Pressure switch is
registering line pressure
below the cut-in pressure.
The switch circuit is closed
If there is sufficient liquid at the source
the pump will start
In BOOSTING mode, terminals 10 and 11 are the main control inputs.
Circuit closed = ON. Circuit open = OFF.
The user can exploit this knowledge to control the pump with an external device such as a
timer or connection to an irrigation control unit. A relay may be necessary.
Never connect 240V supply to control terminals 1 – 12 or to N1, N2 or C
When the iProtect is used in BOOSTING
MODE and the pump is controlled by a
pressure switch, ensure that a suitably
sized pressure vessel is installed in the
system.
A Pressure vessel sized properly and
set with the correct pre-charge
pressure is intended to prevent the
pump from starting more than 30 times
per hour (20 times per hour for bore
pumps)
Pressure tank pre-charge should be set
to 66% of full system pressure
Pump calibration:
(see pg 5)
Switch to manual mode 10 sec.
Start the pump
Allow the pump to reach a stable power.
Press to store. Press to exit.
Ensure the controller is set to
AUTO MODE when finished

iCON iPROTECT Instruction Manual Rev 4.4 15
16. Bore Pumps - Connecting 2 wire and 3 wire bore pumps

16 iCON iProtect Instruction Manual Rev 4.4
17. Communication link – RS485
The control panel has a communication interface. The wire communication distance is less than
1200 metres.
For those installations or environments which require a longer distance communication, users can
use RS485 extender, wireless communication or GSM units.
Please contact White International for more information.
Technical data
Physical interface RS485 Bus Interface: asynchronous semi duplex
Data format 1 start bit, 8 data bit, 1 stop bit, no verify
1 start bit, 8 data bit, 2 stop bit, no verify
Default: 1 start bit, 8 data bit, 1 stop bit, no verify
Baud rate 1200,2400,4800,9600 bps (default 9600bps)
Communication address Setting range of controller address: 1-126
127: broadcast address, host computer broadcasting,
slave machine response forbidden
Protocol type MODBUS protocol (RTU)
Rated input voltage for SC AC 240V/50Hz, single phase
Installation data
Wire communication distance 1200 metres max by shield twisted pair cable (STP)
for RS485 & CAN
5000 metres max by STP and RS485 extender
STP STP-120U one pair 20AWG for RS485 & CAN
RS485 extender 5000 metres (9600bps)
Function
switch
Capacitor
terminals
Capacitor
connection
prewired
NEVER
connect 240V
to terminals
N1, N2, C
or
# 1 - #12

iCON iPROTECT Instruction Manual Rev 4.4 17
15. Additional notes regarding calibration
The iProtect looks at the Power Factor of the power being used, not just the Voltage and
Amperage. If the iProtect reads the Power Factor incorrectly it can be difficult to get the
controller to accept its calibration.
The most reliable means of ensuring the unit is reading a stabilized power supply and that
manually programmed parameters are saved correctly is to follow this procedure:
•Reset iProtect (remove calibration)
•Change to Manual mode
•Start the pump uncalibrated and run until kW stabilizes
•Turn the iProtect off
•Turn the iProtect on
•Auto Calibrate and save
•Run the pump manually
•Cycle the power (on/off) and check the values are as required.
•Alter parameters manually as necessary.

18 iCON iProtect Instruction Manual Rev 4.4
18. Fault messages – possible causes and solutions
Fault Message
Possible Cause
Solutions
Flashing
Parameter 007 or perform the
auto calibration sequence
Pump calibration has not been
completed.
See Pg 6 for calibration
instructions.
Flashing
Parameter 004 and 008
Water level in the well/sump is
below pump intake, pump stops
running.
Broken outlet pipe
iPROTECT will attempt to
restart the pump every 30
minutes until water level
restored.
Flashing
Parameter 005 and 009
Pump running amps greater than
calibrated running amps, pump is
in overload protection state.
Pump damage, dragging impeller
or bearing, possible clogging.
Pump calibrated without water or
with a nominal kW value
iPROTECT will attempt to
restart the pump every 30
minutes until running amps
restored to normal.
Inspect and/or repair pump.
Erase previous calibration
and recalibrate with water.
Flashing
Parameter 010
Pump running amps greater than
200% of calibrated running amps
Pump Stalled protection is especially
important for pumps with cutting or
macerating mechanisms
Cut off power supply,
inspect, repair or replace
pump.
Flashing
Parameter 011
Voltage is lower than the
calibrated voltage.
The pump is in under voltage
protection state.
iPROTECT will attempt to
restart the pump every 5
minutes until normal
voltage is restored.
Flashing
Parameter 012
Voltage is higher than the
calibrated voltage.
The pump is in the over-voltage
protection state.
iPROTECT will attempt to
restart the pump every 5
minutes until normal
voltage is restored.
Flashing
Pump starts more than 5 times
per minute.
It is less likely that this could
occur in drainage or transfer
mode unless there is a wiring
fault.
Check pressure switch
settings are correct for
application.
Check pressure tank pre-
charge pressure and
condition of diaphragm.
Check the volume of sump
is not too small.
Flashing
The jumper on temperature
protection terminals has been
removed.
Pump motor temperature high
and pump thermal switch in open
state (if connected).
Reinstall jumper on
temperature protection
terminals.
Wait until pump motor
temperature reduces.
Investigate cause for
Overheating.

iCON iPROTECT Instruction Manual Rev 4.4 19
19. Warranties – Terms and Conditions
This warranty is given in addition to the consumer guarantees found within the Australian
Competition and Consumer Act 2010 (Cth) for goods purchased in Australia and the
Consumer Guarantees Act 1993 NZ for goods purchased in New Zealand:
1) White International Pty Ltd / White International NZ Ltd (White International) warrant that all products distributed
are free from defects in workmanship and materials, for their provided warranty period as indicated on the top or
opposite side of this document. Subject to the conditions of the warranty, White International will repair any
defective products free of charge at the premises of our authorised service agents throughout Australia and New
Zealand if a defect in the product appears during the warranty period. If you believe that you have purchased a
defective product and wish to make a claim under this warranty, contact us on our Sales Hotline on 1300 783 601,
or send your claim to our postal address or fax line below and we will advise you as to how next to proceed. You
will be required to supply a copy of your proof of purchase to make a claim under this warranty.
2) This warranty excludes transportation costs to and from White International or its appointed service agents and
excludes defects due to non-compliance with installation instructions, neglect or misuse, inadequate protection
against the elements, low voltage or use or operation for purposes other than those for which they were designed.
For further information regarding the suitability of your intended application contact us on our Sales Hotline on
1300 783 601. If you make an invalid claim under this warranty, the original product will be sent back to you
unrepaired.
3) This warranty refers only to products sold after the 1st January 2012, and is not transferable to another product
type and only applies to the original owner, purchaser or end user, and is in addition to the consumer guarantees
found within the Competition and Consumer Act 2010 (Cth) for goods purchased in Australia and the Consumer
Guarantees Act 1993 (NZ) for goods purchased in New Zealand.
4) Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled
to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or
damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality
and the failure does not amount to a major failure. 2 YEAR WARRANTY
5) To the fullest extent permitted by law, White International excludes its liability for all other conditions or
warranties which would or might otherwise be implied at law. To the fullest extent permitted by law, White
International’s liability under this warranty and any other conditions, guarantees or warranties at law that cannot
be excluded, including those in the Competition and Consumer Act 2010 (Cth), is expressly limited to: (a) in the
case of products, the replacement of the product or the supply of equivalent product, the payment of the cost of
replacing the product or of acquiring an equivalent product or the repair of the product or payment of the cost of
having the product repaired, is at the discretion of White International or a 3rd party tribunal elected under the
Competition and Consumer Act 2010 (Cth) for goods purchased in Australia and the Consumer Guarantees Act
1993 (NZ) for goods purchased in New Zealand; and
6) To the fullest extent permitted by law, this warranty supersedes all other warranties attached to the product or
its packaging.
7) In the case of services, supplying the services again or the payment of the cost of having the services supplied
again, is at the discretion of White International or a 3rd party tribunal elected under the Competition and Consumer
Act 2010 (Cth) for goods purchased in Australia and the Consumer Guarantees Act 1993 (NZ) for goods purchased
in New Zealand. 8) Our warranty commences from the date of purchase of the above-mentioned pumps. Proof of
purchase is required before consideration under warranty is given.
Record your date of purchase in the space below and retain this copy for your records.
Date of Purchase ..................................................Model Purchased ..............................................

20 iCON iProtect Instruction Manual Rev 4.4
www.whiteint.com.au 1300 783 601
www.whiteint.co.nz 0800 509 506
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International Pty Ltd.