Inca PSJ2 User manual

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INCA
CONTROL PTY LTD Phone: [phone]
UNIT 14/62 OWEN ST Fax: [phone]
GLENDENNING NSW 2761 Email: [e-mail]
Web: www.incacontrol.com.au
Design & Manufacture of:
Custom-built switchboards
Electronic control equipment
AC/DC pumping controls
Installation & service
INCA MODEL
PSJ2
PRESSURE
CONTROLLER
USER MANUAL
Inca Reference PSJ2
Software Version 1.0
Technical Support
Pumps & Mechanicals –
Controls –Inca Control & Engineering Pty Ltd
Phone [phone]

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TABLE OF CONTENTS
1.0 Control Panel Overview………………………………………………. 3
1.1 Features………………………………………………………… 3
1.2 Description……………………………………………………... 3
2.0 Installation…………………………………………………………….. 4
2.1 Mechanical installation………………………………………… 4
2.2 Sensor installation……………………………………………… 4
2.3 Electrical installation…………………………………………… 4
2.4 Maintenance…………………………………………………….. 4
3.0 Start- up………………………………………………………………… 5
3.1 Notes on value entry…………………………………………... 5
3.2 Power up display………………………………………………. 5
3.3 Screen display layout………………………………………….. 5
4.0 Calibration……………………………………………………………. 6
4.1 Setting low pressure shutdown…………………………………. 6
4.2 Setting low pressure time delay………………………………… 6
4.3 Setting high pressure shutdown……………………………….. 6
4.4 Setting high pressure time delay……………………………….. 6
4.5 Duty start pressure…………………………………………… 6
4.6 Duty stop pressure…………………………………………….. 6
4.7 Standby start pressure………………………………………… 6
4.8 Standby stop pressure………………………………………….. 6
4.9 Pressure sensor calibration.…………………………………….. 7
4.10 Total Flow setting Pump No1…………………………………. 7
4.11 Total Flow setting Pump No2…………………………………. 7
4.12 Irrigation controlled………………………………………….. 7
4.13 Reset Hour run meter………………………………………… 7
4.14 Total flow display……………………………………………… 7
4.15 Pump hour run meter…………………………………………... 7
5.0 Operation……………………………………………………………… 8
5.1 System operation……………………………………………….. 8
5.2 Manual/off/auto selector………………………………………. 8
5.3 Duty Selector Switch P1/Auto/P2……………………………… 8
6.0 Trouble shooting………………………………………………………. 9
7.0 Controller settings sheet………………………………………………. 10
8.0 Warranty Statement…………………………………………………… 11
Drawing supplied separately

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1.0 Control Panel Overview
1.1 Features
JAZZ HMIPLC with user friendly setup & display
Display of system pressure
Low & high pressure pump shutdown with reset button
Low level pump shutdown with automatic reset
Manual/off/auto selectors on JAZZ Face
Duty selector on JAZZ face
Hour run meter (resetable)
Mathematical calculation of Total flow in Kilolitres
Microprocessor controlled
Useable with any 4-20mA loop powered Pressure Transducer
Usable with Irrigation controller input
1.2 Description
The pressure control panel is designed to maintain a system discharge pressure via adjustable control points
entered by the operator. The display shows the actual live pressure input received from the system discharge
pressure transducer. It also displays the pump operating condition & alarm conditions
User Interface
Display An LCD screen displaying 2 lines of text, each 16 characters long
Keypad Operator keyboard, 16 sealed membrane keys
Performance
Range 0 –1000kpa generally, programmable to suit transducer range
Flow Totaliser up to 32000 kilolitres
Inputs 2 wire plus shield connected to terminals located on panel base plate for
pressure transducer.
2 wire plus earth connected to terminals for irrigation controller
2 wire connected to terminals for Low Level float switch
Outputs
Motors 3 wire plus earth sized to suit motor FLC connected directly to motor starters
overload terminals.
Power Supply 415V 3phase neutral & earth power supply sized to suit the total load of the
three motor & must have a protection circuit breaker sized to suit the starting
characteristics of the motor
Mechanical Specification
Enclosure Mild steel powder coated RAL 7032 IP54
Stainless steel is available
Dimension Up to 4kW 400Hx400Wx150D
Larger motor sizes available
Sizes may vary for specials
Pump Unit See Pumping detail by Brooks Irrigation
Environmental Specification
Operating Temp -10 to 50deg C
Relative Humidity Do not install in areas of high humidity
Locate control panel internally where possible to help reduce heat & weather
damage & increase mechanical life.
Vibration Do not install in a location that is subject to large amounts of vibration

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2.0 Installation
Note: If any damage to control panel if found, please notify your pump supplier or Inca Control as
soon as possible prior to installation.
The control panel can be wall mounted separately from the pumping unit; distance is governed by the cable
sizing to the motor.
It is recommended that the control panel is within view of the pumping unit for safety reasons. If not in view
lockable isolating switches must be installed at the pump motors
2.1 Mechanical Installation
Mount the control panel via the mounting holes in each corner at the back of the enclosure using minimum
6mm screws, nuts & locking washers, or masonry anchors
Install in a dry well ventilated location that matches with environmental specification in 1.2 above
2.2 Sensor Installation
Locate the pressure transducer in the discharge pipe work as close as practical to the control panel.
2.3 Electrical Installation
Note: All cable entries must enter via the bottom of the cabinet. If cables are entered via the roof Inca
Control Pty Ltd reserve the right to withdraw warranty because of the possibility of shaving entering
sensitive electronic equipment.
Transducer wiring
The pressure transducer must be wired in 1 pair overall screened data cable. This type of cable provides the
most protection against electrical noise & allows a more accurate outcome
Connect to the sensor as per data supplied by the sensor supplier
At the control panel connect the positive lead to terminal No10 & the return signal to terminal No12.
The screen must be solidly earthed, with a saddle clamp providing the best screening earth.
Float switch wiring
The float switch is wired in the cable supplied with switch. The cable to be connected must close the circuit
when water in the suction tank falls
Connect the float switch as per data supplied by the float switch supplier
At the control panel connect the float switch lead to terminal No10 & terminal No11.
The screen must be solidly earthed, with a saddle clamp providing the best screening earth.
Irrigation control wiring
The control signal from the irrigation controller operates the pumps start signal & must be 24VAC or DC signal
on to start pump & 24VAC/DC signal off to stop pump
At the control panel connect the 24VAC/DC Irrigation control signal directly to the coil on relay R1 at the base
of the control panel. Active lead to terminal No A1+ & the negative to terminal A2-.
Motor Wiring
The motor must be wired in cabling sized to suit the motor power requirement.
The motor is to be connected in star or delta as instructed by the nameplate on the motor.
The cabling entering into the motor terminal box shall be glanded unless a submersible motor is being used in
this case the pump lead is supplied by the pump manufacturer
The cable entering the control panel end can be glanded using standard nylon glands & run directly to the
appropriate overload terminals T1, T2, T3
2.4 Maintenance
Check that all connections are tight as copper is soft & can work loose
Check that all controls are functioning as intended

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3.0 Start up
3.1 Notes on Value Entry
When entering a numeric value, the cursor can be backspaced to correct mistakes by pressing the LEFT
ARROW button.
Decimal points can only be entered on entries with decimal points in the display line. The decimal point is
entered by pressing the +/- . down arrow key on the bottom of the blue buttons
You can only enter a value of as many digits as is displayed on the screen. Example an input that displays 3
digits can only have 3 digit entered
3.2 Power Up Display
On power up the screen will display the main page including the pressure, switch position & operating
information.
3.3 Screen Display Layout
The screen displays two lines of information
The top line displays the live discharge pressure in kPa
The bottom line displays the manual/off/auto switch position & operating condition of the pump

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4.0 Calibration
The calibration of the controller is carried out on pages accessed by pressing & holding in the RIGHT ARROW
Button for 5seconds. The first calibration page will appear. You can move through the calibration pages by
pressing the RETURN ARROW button & then the RIGHT ARROW button to move on. Continuing this process
will move you through the pages with out making any changes. If changes are made the inputted value is
recorded once the enter button has been pressed. The enter button is the return arrow located at the bottom
right corner of the facia. To get out of calibration pages press the RETURN ARROW button twice & return to
the main page.
4.1 Setting Low Pressure Shutdown
Press & hold the RIGHT ARROW button for 5seconds to enter calibration pages. Low pressure on will now be
displayed.
The Cursor will be flashing under the first digit of the LOW PRESSURE ON setting. Simply type in the
appropriate pressure you want the low pressure shutdown to operate at, example 200kPa Press 2, press 0,
press 0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.2 Setting Low Pressure Time Delay
Low pressure time delay will now be displayed.
The Cursor will be flashing under the first digit of the LOW PRESSURE TIME DELAY setting. Simply type in
the appropriate delay time you want after the low pressure set point has been reached, example 45sec Press
0, press 0, press 4, Press 5, & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.3 Setting High Pressure Shutdown
High pressure on will now be displayed.
The Cursor will be flashing under the first digit of the HIGH PRESSURE ON setting. Simply type in the
appropriate pressure you want the High pressure shutdown to operate at, example 800kPa Press 8, press 0,
press 0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.4 Setting High Pressure Time Delay
High pressure time delay will now be displayed.
The Cursor will be flashing under the first digit of the HIGH PRESSURE TIME DELAY setting. Simply type in
the appropriate delay time you want after the High pressure set point has been reached, example 45sec Press
0, press 0, press 4, Press 5, & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.5 Duty Pump Start Pressure
Duty pressure on will now be displayed.
The Cursor will be flashing under the first digit of the DUTY PRESSURE ON setting. Simply type in the
appropriate pressure you want the Pump start pressure to operate at, example 400kPa Press 4, press 0, press
0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.6 Duty Pump Off Pressure
Duty pressure off will now be displayed.
The Cursor will be flashing under the first digit of the DUTY PRESSURE OFF setting. Simply type in the
appropriate pressure you want the Pump stop pressure to operate at, example 500kPa Press 5, press 0, press
0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.7 Standby Pump Start Pressure
Duty pressure on will now be displayed.
The Cursor will be flashing under the first digit of the STANDBY PRESSURE ON setting. Simply type in the
appropriate pressure you want the Pump start pressure to operate at, example 400kPa Press 4, press 0, press
0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.8 Standby Pump Off Pressure
Duty pressure off will now be displayed.
The Cursor will be flashing under the first digit of the STANDBY PRESSURE OFF setting. Simply type in the
appropriate pressure you want the Pump stop pressure to operate at, example 500kPa Press 5, press 0, press
0 & then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page

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4.9 Pressure Sensor Calibration
Calibrate Sensor will now be displayed.
The Cursor will be flashing under the first digit of the CALIBRATE SENSOR setting. Simply type in the 20mA
scale of the pressure transducer to be used, example 1000kPa (10bar) Press 1, Press 0, press 0, press 0 &
then press Return Arrow button.
Press the RIGHT ARROW Button to move onto the next Page
4.10 Total flow Setting Pump No1
Litres per second will now be displayed.
The Cursor will be flashing under the first digit of the LITRES PER SECOND P#1 setting. Simply type in the
flow rate of the pump delivery, example 10l/s Press 1, press 0 & then press Return Arrow button.
With this setting, the JAZZ HMIPLC will display a mathematical calculation of total flow in kilolitres. (Flow is
reset to zero when 32000k/l is displayed)
Press the RIGHT ARROW Button to move onto the next Page
4.11 Total flow Setting Pump No2
Litres per second will now be displayed.
The Cursor will be flashing under the first digit of the LITRES PER SECOND P#2 setting. Simply type in the
flow rate of the pump delivery, example 10l/s Press 1, press 0 & then press Return Arrow button.
With this setting, the JAZZ HMIPLC will display a mathematical calculation of total flow in kilolitres. (Flow is
reset to zero when 32000k/l is displayed)
Press the RIGHT ARROW Button to move onto the next Page
4.12 Irrigation Controlled
Irrigation will now be displayed.
The Cursor will be flashing under the digit identifying on or off.
If selected to ON, pump will only run in auto when a 24VAC/DC input has been received from the irrigation
controller. The pump will then be controlled via the duty pressure on & off settings
If selected to OFF, the pump will run via the duty pressure on & off settings.
To select the Irrigation control enter 1 in the & status Press Return Arrow to accept
To select NO irrigation control enter 0 in the status & press return arrow to accept
Press the RIGHT ARROW Button to move onto the next Page
4.13 Reset Hours run meter
Reset Hours run meter will now be displayed.
To reset the hour meter press & hold #5 button for 5second.There will be no change on the screen so you will
need to check that the reset has been achieved
Press the RETURN ARROW Button to move back to the main page
4.14 Total Flow displays
The JAZZ HMIPLC has a mathematical display of total Flow. This flow is calculated using the litre/second rate
of the pump which is set in 4.10 & 4.11 above.
To access the total flow meters, from the main page press the ARROW UP button. The total flow for Pump
No1 is now displayed.
Press the ARROW UP button again will display the total hours run for pump No1
Press the ARROW UP button again will display the total flow for pump No2
Note, Total flow before display returns to zero is 32000k/l
4.15 Pump Hours run meter
The JAZZ HMIPLC has a pump hour’s run display.
To access the total hours run meter for pump No1, from the main page press the ARROW UP button. The
total flow for Pump No1 is now displayed. Press the ARROW Up button again the total hour run meter for
Pump No1 will now be displayed
Press the ARROW UP button again will display the total flow for pump No2
Press the ARROW UP button again will display the total hours run for pump No2
Note, Total hours run before display returns to zero is 32000Hours.
To reset the hour meter press & hold #5 button for 5second.

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5 Operation
5.1 System Operation
The system is designed to maintain a pressure in the discharge line of a pumping system relating to the
settings entered by the operator. The pump will start when the pressure falls to the duty start set point & will
run until the pump stop set point is reached
If the pressure continues to fall & reaches the standby start pressure the standby pump will be started & will
run until the standby stop pressure has been reached
If the irrigation input signal is to be used the pump will not operate until this signal is on and will then operate
between the start & stop set points.
If the system pressure falls to the low set point for an adjustable time period the pump will be locked out until
manually reset.
If the pressure continues to rise to the high pressure set point for an adjustable time the pump will be locked
out until manually reset
If a low level float switch is connected & closes this input the pump will be shutdown until the level rises to
reset the float switch & automatically restart the pump
5.2 Manual/Off/Auto Selector Switches
Each pump has a Manual/Off/Auto selector switch. Each function of the switch is selected by touching on the
appropriate button on the JAZZ facia.
ManualTouching the MAN button will turn the pump on continuously
Off Touching the OFF button will turn the pump off.
Auto Touching the AUTO button will select the pump on automatic & is then controlled via the set
points within the JAZZ HMIPLC
5.3 Duty Selector (P1 / AUTO / P2) Switch
The panel has a Pump 1/Auto/ Pump2 selector switch. Each function of the switch is selected by touching on
the appropriate button on the JAZZ facia.
P1 Touching the P1 button will select Pump No1 to be duty & Pump No2 to be standby
continuously
Auto Touching the AUTO button will allow the pumps to automatically alternate.
P2 Touching the P2 button will select Pump No2 to be duty & Pump No1 to be standby
continuously

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6 Trouble Shooting
Condition
Do This
1. Unit does not power up.
Check that power supply is on to panel and isolator
is on.
Check that control circuit breaker is on.
2. PLC Controller does not power up but
power is on.
Check that 24VDC power supply is operating, &
power supply plug on PLC controller is fully inserted.
3. Pump does not run but Starter is operating.
Check that all pump circuit breakers are on
4. Pump Fail displayed on screen.
Reset pump overload by pressing overload reset
button on to of overload. If problem continues call for
service
5. System Produces a Low Pressure shutdown.
Press the reset button & allow system to re-
pressurize. If problem continues call for service.
6. System Produces a High Pressure shutdown.
Press the reset button & allow system to re-
pressurize. If problem continues call for service.
7. Pressure displaying a negative value.
Pressure transducer has open circuit 4-20mA loop
or is faulty. Check pressure transducer cabling
connections, replace transducer with the same unit
or call for service

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7 Controller settings sheet
Parameter
Description
Factory settings
User Setting
Low pressure
Shutdown
Pressure at which pumps are
shutdown for low discharge pressure
100kPa
Low pressure Timer
Time delay before pump shuts down
5sec
High pressure
Shutdown
Pressure at which pumps are
shutdown for high discharge pressure
600kPa
High pressure Timer
Time delay before pump shuts down
5sec
Duty Pump on
Duty Pump start set point
400kPa
Duty Pump off
Duty Pump stop set point
500kPa
Standby Pump on
Standby Pump Start set Point
350kpa
Standby Pump off
Standby Pump Stop Set Point
500kpa
Sensor calibration
Sensor 100% (20mA) Pressure
1000kpa
Litres per second Pump
No1
Pump No1 output in litre per second
for total flow calculation
4l/s
Litres per second Pump
No2
Pump No2 output in litre per second
for total flow calculation
4l/s
Irrigation Control
Irrigation control (1) or pressure only
control (0)
0

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9.0 Warranty Statement
The Products manufactured by Inca Control Pty Ltd is guaranteed against faulty workmanship for a period of 12months
from the date of delivery.
Our obligation assumed under this guarantee is limited to the replacement of parts which, by our examination are
proved to be defective & have not been misused, carelessly handled, defaced or damaged. This guarantee is VOID
where the purchaser has modified or repairs have been made or attempted by anyone except an authorised
representative of Inca Control Pty Ltd.
Products for attention under guarantee (unless otherwise agreed) must be returned to the factory freight paid and, if
accepted for free repair, will be returned to the customers address in Australia free of charge.
Equipment supplied by Inca Control Pty Ltd, but manufactured by others is covered by their manufacturers warranty
only.
When returning the product for service or repair, a full description of the fault must be given and the mode of operation
used when the product failed.
In addition to the above, equipment manufactured, installed & commissioned by Inca Control Pty Ltd, within the Sydney
Metropolitan Area, includes onsite replacement.
In any event Inca Control Pty Ltd has no other obligation or liability beyond replacement or repair of this product.
NOTES: