Matelec FPC-30010 User manual

Dual Pump Controller Installation and
Operating Instructions
PUMP CONTROL
OFF
ON
Dual Pump
Controller
PUMP 1 PUMP 2
AUTO
OFF
AUTO
OFF
MAN MAN
MUTE/
RESET
PUMP ONPUMP ON
FAULT FAULT
LEVEL
ALARM
POWER
ON
DANGER - HIGH VOLTAGE
DO NOT REMOVE COVER. AUTHORIZED PERSONS ONLY
Steady - Overload
Flash - Prime Loss
Steady - Overload
Flash - Prime Loss
Press and hold
for 3 secs to reset
Steady - High Level
Flash - Low Level
DOC: DPC 30010 REVISED: 220210

INSTALLATION 3
Mounting
Connection
WELCOME TO DUAL PUMP CONTROL
Your Dual Pump Controller reflects the superior quality and attention to detail
in design, engineering and manufacturing that has distinguished MATelec
Products for decades. The controller incorporates the very latest in micro-
processor technology, ensuring you, the owner/operator, of many years of
functional, reliable and ‘user friendly’ operation.
Please read this manual prior to installation and operation of the controller.
GETTING STARTED 4
Operations
Features
WARNING: All electrical connections must be carried out by a suitably qualified
and registered electrician.
• Prior to Installation, ensure power supply is isolated.
• Power supply must be Circuit Breaker Protected. (Qualified Electrician to determine appropriate amp
rating.)
• Electrical connection to the panel must be carried out in accordance with ‘Connection Instructions’,
see page 3.
• Additions or modifications to the control panel are not permitted and will void warranty.
• The controller is not intended for use by children or infirm persons without supervision.
• Repairs to the Controller must only be carried out by a suitably qualified Electrician.
2
SAFETY 2 CIRCUIT DIAGRAM 7
AT A GLANCE 8
Indicators
Push Buttons

3
1. Controller enclosure must be
mounted in a vertical position.
2. Ensure mounting method
does not compromise enclosure
weather proof rating.
3. Ensure access to main isolator
is not restricted.
4. Ensure cables/conduits
entering the panel have
mechanical protection and that
the penetrations are
sealed and do not compromise
the weather proof rating of the
enclosure.
MOUNTING
FRONT VIEW SIDE VIEW
Top
Bottom
Top
Bottom
Mounting
Frame/
Wall
CONNECTION
NOTE: Controller must be earthed and all electrical connections must be carried out by a suitably qualified
Electrician
OFF
ON
Dual Pump
Controller
PUMP 1 PUMP 2
AUTO
OFF
AUTO
OFF
MAN MAN
MUTE/
RESET
PUMP ONPUMP ON
FAULT FAULT
LEVEL
ALARM
POWER
ON
DANGER- HIGH VOLTAGE
DONOT REMOVE COVER. AUTHORIZEDPERSONS ONLY
Steady- Overload
Flash- Prime Loss
Steady- Overload
Flash- Prime Loss
Pressand hold
for3 secs to reset
Steady- High Level
Flash- Low Level
PUMP 1 PUMP 2
240Vac
MAINS POWER
SUPPLY
SUPPLY
High
Active
Active
Neutral
INPUT SWITCHES
Level Level Level
Neutral
Input 2 Input 3
Earth
Active
Neutral
240Vac 12Vdc Connections
Note:
Applications, connect to "Start (Input 3)" terminals only,
and NO
PUMP 1 Earth PUMP 2 Earth
Input 4
Stop Start
PUMP 1 PUMP 2
BLUE NOT
REQUIRED
STOP/
LOW
LEVEL
COMMON
N/O CLOSE ON RISE
START/
MEDIUM
LEVEL
COMMON
N/O CLOSE ON RISE
STANDBY/
HIGH
LEVEL
COMMON
N/O CLOSE ON RISE
SET THERMAL OVERLOADS TO SUIT PUMP

This controller can perform control functions for most Dual Pumppumping applications. It is more than likely that the
control parameters have already been set up for your particular applicationhowever; hereunder you will find details of
the set up and configuration options.
There are6 DIP switcheslocated on the lower side of the control module, which allow s for selecting “mode” and
“feature” options, as per the following table:
Operation Selection Table
DIP Switch Position Function
1/2
Off/Off Mode A:
Off/On Mode B:
On/Off Mode C:
On/On Mode D:
3
Off
On
4 Off Anti-seize timer disabled
On Anti- seize timer 10 seconds every 7 days enabled
5 Off When placedin Manual mode pump remains in Manual mode
On When placed in Manual mode after 5 minutes, the pump will revert to Auto
6
Off High Level alarm Auto matically resets upon open circuit of high level input.
High level alarm has15 Minute delay.
On High level alarm can only be reset Manual ly . High level alarm has 5 minute
delay.
Mode A: Standard configuration
Start/Stop/High level operation. When the pump start input is closed contact (triggered), the duty pump will be
Standard typical float switch configuration (Start, Stop and High Level).
No low level.
Standard configuration plus low level (Start, Stop, High level and Low
level).
Standard configuration plus Prime Loss enabled, on Low level (Input 1)
Pressure Pumping configuration (Lead, Lag and Low pressure)
Operating pump alternates after 6 hours continuous running
Operating pump alternates each time a pump start is triggered, or after 30
minutes continuous running.
turned on. The pump will remain on until both the pump start and pump stop inputs have turned off (open circuited).
Upon high level both pumps will run until the pump stop input turns off.
In addition to this, there is a maximum idle timer, which will trigger a pump start condition, if either pump has not
run for 4 hours, and the stop float contacts are closed. The pump will continue to run until the stop float contacts open.
Input functions are as follows:
Mode B: Standard Configuration plus Low Level Alarm
As per Mode A, except it has an active Low Level input. The low level input must be closed, for pump start and pump
stop inputs to function. The High level input however, will still override the low level and run both pumps.
Input functions are as follows:
The basic logic on which a High or Low Level Alarm is determined, is set out in the Table A.
Input Function
Input 1 Low Level
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
Input Function
Input 1 Not Used
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
4

5
Table A
Input 1
Low Level
Input 2
Pump Stop
Input 3
Pump Start
Input 4
High Level
Pump
State
Alarm
Closed Open/Closed Open Open Off -
Closed Open/Closed Closed Open On -
Closed Open/Closed Closed Closed Both on High level (after timeout)
Closed Open/Closed Open Closed Both on High level (after timeout)
Open Open/Closed Open Open Off -
Open Open/Closed Closed Open Off Low level
Open Open/Closed Open Closed Off Low level
Open Open/Closed Closed Closed Both on High level (after timeout)
Mode C: Standard Configuration plus Prime Loss
As per Mode A, except Input 1 is connected to a prime loss/flow switch. If at any stage, after pump start
or whilst a pump is running, the prime loss input closes, for a continuous 2 minute period, a fault is immediately
triggered for that pump and duty alternates. Input functions are as follows:
Input Function
Input 1 Prime Loss
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
Mode D: Pressure Pumping Configuration
Duty Pump: Lead Pump
Standby Pump: Lag Pump
Input functions are as follows:
Input Function
Input 1 Not used
Input 2
Input 3
Input 4
If there is a low level alarm , then both pumps will be locked out until the alarm is manually reset.
This lockout will only be overidden upon a high level condition where both the Pump Start and High
Level inputs are closed.
Note that after a high level is triggered, the pumps will both run until the pump Start and Stop
inputs are opened.
Typical operation for Mode D
Low pressure switch (set at say 200kPa)
Lag pump pressure switch (set at say 350kPa)
Lead pump pressure switch (set at say 350kPa)
Pressure drops to 400kPA: Lead (for this cycle) Pump cuts in.
Pressure increases and Pump cuts out.
Cycle continues with duty (Lead and Lag) alternating between the two pumps.
If pressure drops to 350kPA, Lag Pump will cut in and remain running until Lead Pressure switch
opens circuit. Then duty alternates.
No faults are logged against the Lead Pump if the Lag Pump starts.
The controller has inbuilt timers for”Delayed” Start and Stop to obviate pump chatter. Upon Input 1
contact closure, the pump will not start (delay start) for 3 seconds and will not stop (minimum run time)
for 30 seconds (or 33 seconds from close of Input contacts). This “run on” occurs even if Lead Pressure
switch opens circuit during this initial period. If however run time exceeds 33 seconds,
the pump will stop immediately upon “open circuit” occuring.
If the Lead Pressure Switch input closes circuit as well as the Low Pressure Switch input, both
pumps will be turned on and the Low Pressure Timer will begin counting.If this condition exists for a
period of 60 seconds, then both pumps are shut down and the system signals a level alarm. This
would be typical of a Loss of Prime or Burst Main situation.
Pressure switches are normally Closed and Open on High pressure

6
Maximum Run and Alternation Mode
With DIP Switch 3 set to “Off” the unit will alternate as usual each time a pump start condition occurs.
Additionally, the controller will automatically alternate pump duty if a pump has been running continuously for
30 minutes (maximum run timer)
Setting this DIP switch to “On” will cause the controller to operate in “Circulation Mode” where duty will only
alternate once the pump has run for 6 hours of accumulated time.
Anti-seize Timer
With DIP Switch 4 set to “On”, the Anti-seize timer wil automatically run the pumps for 10 seconds, every 7 days.
This pump operation will completely override all inputs including the low level (if enabled). This feature will only
run pumps that are set in Auto. This “Pump Run”, will alternate between Pump 1 and Pump 2. A pump that has
been locked out due to a fault will not run.
Manual Mode Timeout
With DIP switch 5 set to “On” the pump will only remain in Manual Mode for 5 minutes, after which time, it
automatically reverts to Auto.
Audible and Visual Alarm Test
By pressing the Mute/Reset button on the keypad continuously for a period of 5 seconds, the Strobe, Siren and
Indicator Lights will be powered up for inspection
Fault Reset
To reset all faults on the controller, press and hold the Mute/Reset button on the keypad continuously for a period
of 3 seconds until an acknowledgement beep is heard.
Pump Fault
A Pump Fault is indicated for two types of Faults. A Thermal Overload will be indicated by way of a steady Fault
Indicator light. A Prime Loss fault will be indicated by way of a flashing Fault Indicator Light. Both types of faults can
be reset by way of the Fault Reset button.
Level Alarms
A High Level Alarm is indicated by way of a steady Level Alarm Indicator Light.
A Low Level/Low Pressure Alarm is indicated by way of a Flashing Level Alarm Light.
Auto Silencing Alarm Feature
The audible Alarm is programmed to sound for 5 minutes continuously, unless muted and will thereafter automatically
silence and enter “Chirp” mode. In Chirp Mode, the Audible Alarm will sound briefly (2 Seconds)
every 5 minutes
High Level Alarm Reset
With DIP Switch 6 set to “Off”, the high level alarm will automatically reset once the high level input opens circuit.
The controller will also use the alternate high level alarm delay. Typically used for Storm Water applications. High
Level Alarm delay in this mode is 15 minutes.
Setting this DIP switch to “On”, will cause the high level alarm to remain active until the controller is reset. The
high level alarm will use the standard high level alarm activation delay. Typically used for Sewerage applications.
High Level Alarm delay in this mode is 5 minutes.

7
MODE
SELECT INPUT2
INPUT1
4-20mA
+ -
INPUT3 INPUT4 BMS/
REMOTE
STROBE
- +
SIREN
- +
POWER
12Vac
PUMP 1 PUMP 2
PUMP 2
FAULT
PUMP 1
FAULT
KEYPAD CONNECTION
PIN 1
500mA
DUAL PUMP
CONTROLLER
COM-30089
240V 10A MAX
Australia
®
IMPORTANT: READ INSTALLATION AND OPERATION MANUAL BEFORE USE
TOL TOL
TOL
TOL
A1 A2 A2
98979897
A1
A
N
E
CONTACTOR
COILS
PUMP 1
CONTACTOR 1
20amp
2 POLE
PUMP 1
ISOLATOR
20amp
2 POLE
PUMP 2
ISOLATOR
CONTACTOR 2
PUMP 2
DATA
OUTPUT
2amp
CONTROL
CIRCUIT
BREAKER
ISOLATOR
SWITCH
STROBE BUZZER
TRANSFORMER
12Vac
12Vdc
240Vac
INPUT 1
SWITCH
INPUT 2
SWITCH
INPUT 3
SWITCH
INPUT 4
SWITCH
12Vdc
12Vdc
Dual Pump
Controller
PUMP 1 PUMP 2
AUTO
OFF
AUTO
OFF
MAN MAN
MUTE/
RESET
PUMP ONPUMP ON
FAULT FAULT
LEVEL
ALARM
POWER
ON
DANGER - HIGH VOLTAGE
DO NOT REMOVE COVER. AUTHORIZED PERSONS ONLY
Steady - Overload
Flash - Prime Loss
Steady - Overload
Flash - Prime Loss
Press and hold
for 3 secs to reset
Steady - High Level
Flash - Low Level

MANUFACTURED BY MATelec AUSTRALIA EMAIL: [e-mail]
MATelec reserves the right to alter technical specifications without notice
A quick reference to the controller’s
Keypad and Indicator functions and
meanings.
KEYPAD
INDICATORS PUSH BUTTONS
POWER ON
Power is turned on
ON STEADY
A high level alarm has been
present for the preset time
FLASHING
A low level alarm is present
ON STEADY
A pump fault/overload has
occured
FLASHING
A prime loss fault has occured
The pump is set to Automatic
Pumping Mode
The pump is set to Manual
Pumping Mode
To turn pump off
DISTRIBUTED BY:
8
INSTALLATION DATE:
SERIAL NUMBER:
Dual Pump
Controller
PUMP 1 PUMP 2
AUTO
OFF
AUTO
OFF
MAN MAN
MUTE/
RESET
PUMP ONPUMP ON
FAULT FAULT
LEVEL
ALARM
POWER
ON
DANGER - HIGH VOLTAGE
DO NOT REMOVE COVER. AUTHORIZED PERSONS ONLY
Steady - Overload
Flash - Prime Loss
Steady - Overload
Flash - Prime Loss
Press and hold
for 3 secs to reset
Steady - High Level
Flash - Low Level
MUTE/
RESET
AUTO
OFF
MAN
RUNNING
FAULT
ON STEADY
Pump is switched on to run
MOMENTARY PRESS
To mute audible buzzer
PRESS FOR 3 SECS
To reset alarms and faults
PRESS CONTINUOUS
To test indicator lights, strobe
and siren
POWER
ON
HIGH
LEVEL