Matelec FPC-30030 Instructions for use

PUMP ON
FAULT
PUMP ON
FAULT
MAIN ISOLATOR
OFF
ON
DOC: FPC-30030 VER 1.0
PUMPCONTROL
OWNER’S
OPERATION
MANUAL
Dual Pump Controller Installation
and Operating Instructions
MODEL: FPC-30030

2
Your Dual Pump Controller reects 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.
WELCOME TO DUAL PUMP CONTROL
SAFETY 2 CIRCUIT DIAGRAM 7
INSTALLATION 3 AT A GLANCE 8
Mounting Indicators
Connection Push Buttons
GETTING STARTED 4
Operations
Features
CONTENTS
SAFETY
• Prior to Installation, ensure power supply is isolated.
• Power supply must be Circuit Breaker Protected. (Qualied Electrician to determine appropriate amp rating.)
• Electrical connection to the panel must be carried out in accordance with ‘Connection Instructions’, see page 3.
• Addition or modications to the control panel are not permitted and will void warranty.
• The controller is not intended for use by children or inrm persons without supervision.
• Repairs to the Controller must only be carried out by a suitably qualied Electrician
WARNING: All electrical connections must be carried out by a suitably qualied and
registered electrician

3
FRONT SIDE VIEW
Top
Bottom
Top
Bottom
DOC: FPC 30030 VER 1.0
WIRING CONNECTION DETAIL
FPC-30030
3 FLOAT SWITCH SYSTEM
2 FLOAT SWITCH SYSTEM
INDICATOR LIGHTS GUIDE
WARNING: HIGH VOLTAGE
ALL ELECTRICAL CONNECTIONS MUST BE CARRIED OUT BY A SUITABLY QUALIFIED ELECTRICIAN
ACCESS BY AUTHORISED PERSONNEL ONLY
NO FLOAT SWITCH
CONNECTED TO INPUT 2
STOP
START
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
STAND BY
HIGH
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
PUMP 1
415Vac
MAINS POWER
SUPPLY
PUMP 2
THERMAL SWITCH
BRIDGE
IF NOT
REQUIRED
P1 P2 P3
PUMP 2
E A1 A2 A3
P1 P2 P3
PUMP 1
PUMP 1 Earth
SUPPLY
415Vac Connections
N
Pump 1
T2T1
Pump 2
T2T1
Input 2
Stop
Level
Input 3
Start
Level
Input 4
High
Level
FLOAT SWITCH CONNECTIONS
12Vdc Connections
PUMP 2 Earth
STOP
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
START
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
HIGH
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
PUMP 1
415Vac
MAINS POWER
SUPPLY
PUMP 2
THERMAL SWITCH
BRIDGE
IF NOT
REQUIRED
P1 P2 P3
PUMP 2
E A1 A2 A3
P1 P2 P3
PUMP 1
PUMP 1 Earth
SUPPLY
415Vac Connections
N
Pump 1
T2T1
Pump 2
T2T1
Input 2
Stop
Level
Input 3
Start
Level
Input 4
High
Level
FLOAT SWITCH CONNECTIONS
12Vdc Connections
PUMP 2 Earth
ON STEADY
A pump fault/overload has occured
FLASHING
A prime loss fault has occured
MOMENTARY PRESS
To mute audible buzzer
PRESS FOR 3 SECS
To reset alarms and faults
PRESS CONTINUOUS
To test indicator lights,
strobe and siren
ON STEADY
Pump is switched on to run
ON STEADY
A high level alarm has been present for the preset time
FLASHING
A low level alarm is present
MUTE/
RESET
PUMP ON
LEVEL ALARM
FAULT
WIRING CONNECTION DETAIL
FPC-30030
3 FLOAT SWITCH SYSTEM
2 FLOAT SWITCH SYSTEM
INDICATOR LIGHTS GUIDE
WARNING: HIGH VOLTAGE
ALL ELECTRICAL CONNECTIONS MUST BE CARRIED OUT BY A SUITABLY QUALIFIED ELECTRICIAN
ACCESS BY AUTHORISED PERSONNEL ONLY
NO FLOAT SWITCH
CONNECTED TO INPUT 2
STOP
START
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
STAND BY
HIGH
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
PUMP 1
415Vac
MAINS POWER
SUPPLY
PUMP 2
THERMAL SWITCH
BRIDGE
IF NOT
REQUIRED
P1 P2 P3
PUMP 2
E A1 A2 A3
P1 P2 P3
PUMP 1
PUMP 1 Earth
SUPPLY
415Vac Connections
N
Pump 1
T2T1
Pump 2
T2T1
Input 2
Stop
Level
Input 3
Start
Level
Input 4
High
Level
FLOAT SWITCH CONNECTIONS
12Vdc Connections
PUMP 2 Earth
STOP
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
START
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
HIGH
LEVEL
COMMON
N/O CLOSE ON RISE
BLUE NOT REQUIRED
PUMP 1
415Vac
MAINS POWER
SUPPLY
PUMP 2
THERMAL SWITCH
BRIDGE
IF NOT
REQUIRED
P1 P2 P3
PUMP 2
E A1 A2 A3
P1 P2 P3
PUMP 1
PUMP 1 Earth
SUPPLY
415Vac Connections
N
Pump 1
T2T1
Pump 2
T2T1
Input 2
Stop
Level
Input 3
Start
Level
Input 4
High
Level
FLOAT SWITCH CONNECTIONS
12Vdc Connections
PUMP 2 Earth
ON STEADY
A pump fault/overload has occured
FLASHING
A prime loss fault has occured
MOMENTARY PRESS
To mute audible buzzer
PRESS FOR 3 SECS
To reset alarms and faults
PRESS CONTINUOUS
To test indicator lights,
strobe and siren
ON STEADY
Pump is switched on to run
ON STEADY
A high level alarm has been present for the preset time
FLASHING
A low level alarm is present
MUTE/
RESET
PUMP ON
LEVEL ALARM
FAULT
Mounting
Frame/
Wall
PUMPON
FAULT
PUMPON
FAULT
MAINISOLATOR
OFF
ON
Note: Controller must be earthed and all electrical connections must be carried out by a suitably qualied
Electrician. For Single Working Level Float Switch Applications, connect to “Start (Input 3)” terminals only, and NO
bridge wire is required in “Stop (Input 2)” terminals.
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.
INSTALLATION
CONNECTION
MOUNTING

4
This controller can perform control functions for most Dual Pump pumping applications. It is more than likely that the
control parameters have already been set up for your particular application, however, hereunder you will nd details
of the setup and conguration options.
DIP
Switch
Position Function
1/2 O󰀨/O󰀨 Mode A: Standard typical oat switch conguration (Start,Stop and High Level). No Low Level
O󰀨/On Mode B: Standard conguration plus low level (Start,Stop and High Level).
On/O󰀨 Mode C: Standard conguration plus Prime Loss enabled, on Low Level (Input 1)
On/On Mode D: Pressure Pumping conguration (Lead, Lag and Low Pressure)
3 O󰀨 Operating Pump alternates each time a pump start is triggered, or after 30 minutes continuous running.
On Operating Pump alternates after 6 hours continuous running.
4O󰀨 Anti-seize Timer disabled
On Anti-seize Timer 6 seconds every 7 days enabled
5O󰀨 When placed in Manual Mode, pump remains in Manual Mode
On When placed in Manual Mode after 5 minutes the pump will revert to Auto
6 O󰀨 High Level Alarm automatically resets upon open circuit of high level input. High Level alarm
has 15 minute delay.
On High Level Alarm can only be reset manually. High Level Alarm has 5 minute delay.
Mode A: Standard Conguration
Start/Stop/High Level operation. When the Pump Start input is closed contact (triggered), the Duty Pump
will be turned on. The pump will remain on until both the Pump Start and Pump Stop Inputs have turned o󰀨
(Open Circuited). Upon High Level, both pumps will run until the Pump Stop Input turns o󰀨.
Input Function
Input 1 Low Level
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
Mode B: Standard Conguration 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:
OPERATION
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:
There are 6 DIP switches located on the lower side of the control module, which allows for selecting “mode” and
“feature”options, as per the following table:
Input Function
Input 1 Standby Start
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level

5
The basic logic on which a High or Low Level Alarm is determined, is set out in the Table below:
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 over ridden 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
Mode C: Standard Conguration plus Prime Loss
Mode D: Pressure Pumping Conguration
Typical Operation Mode D:
As per Mode A, except Input 1 is connected to a prime loss/ow switch. If at any stage, after Pump Start, or whilst a
pump is running, the Prime Loss input opens, for a continuous 2 minute period, a fault is immediately triggered for that
pump and duty alternates. Input functions are as follows:
Duty Pump: Lead Pump
Standby Pump: Lag Pump
Input functions are as follows:
• 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 continues to drop to 350kPa, the 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 1 second and will not stop (minimum run time) for 10 seconds
(or 11 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 11 seconds, the pump will stop immediately upon “Open
Circuit” occurring.
• If the Lead Pressure Switch input closes circuit as well as he 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 Opened on High Pressure.
• Prime Loss functions as per mode Mode C.
Input Function
Input 1 Prime Loss
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
Input Function
Input 1 Prime Loss (BRIDGE IF NOT REQUIRED
Input 2 Lead Pump Pressure Switch (set at say 400kPa)
Input 3 Lag Pump Pressure Switch (set at say 350kPa)
Input 4 Low Pressure Switch (set at say 200kPa)
Input 1 Input 2 Input 3 Input 4 Pump
State Alarm
Low Level Pump Stop Pump Start High Level
Closed Open/Closed Open Open O󰀨 -
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 O󰀨 -
Open Open/Closed Closed Open O󰀨 Low Level
Open Open/Closed Open Closed O󰀨 Low Level
Open Open/Closed Closed Closed Both On High Level (after Timeout)

6
In pressure pump mode some of the optional features are disabled, including maximum run alternation, anti-seize
and maximum idle timers
In order to activate current loop mode the enclosure must be opened and jumper J10 moved to the “current loop
enabled” position (as shown in the following picture). By selecting current loop input mode the pump start input can
be connected to a 4-20mA loop powered pressure transducer. The pump start, stop and high level signals can then
desired. The start, stop and high level current set points will be pre-programmed into the software and therefore cannot
be adjusted. The levels for a 0-4m transducer are Stop= 300mm, Start= 600mm and High= 1000mm.
Maximum Run and Alternation Mode
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 will automatically run the pumps for 6 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.
High Level Alarm Reset
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.
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 old the Mute/Reset button on the Keypad continuously for a period of 3
seconds until an acknowledgment 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
fault light slowly.
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
Figure 1: APC6 PCB Layout and Current Loop Jumper
C
urrent Loop
E
nable Jumper
Dip Switch Setting
Ensure dip switch 1 and 2 are down
in mode A for transducer operation

7
CIRCUIT DIAGRAM
TOL 1 TOL 2
96959695
12Vdc
THERMAL
SWITCH 1
THERMAL
SWITCH 2
1
LOT
2LOT
A1 A2 A2A1
N
A1
A2
A3
E
CONTACTOR
COILS
PUMP 1
1ROTCATNOC
2RO
TCATNOC
PUMP 2
MAIN
ISOLATOR
PUMP 2
ISOLATOR
PUMP 1
ISOLATOR
2amp
CONTROL
CIRCUIT
BREAKER
STROBE BUZZER
TRANSFORMER
12Vac
415Vac 415Vac
240Vac
INPUT 2
SWITCH INPUT 3 SWITCH INPUT 4 SWITCH
12Vdc
12Vdc
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
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
PUMP ON
FAULT
PUMP ON
FAULT

8
AT A GLANCE
PUMP ON
FAULT
PUMP ON
FAULT
INDICATORS PUSH BUTTONS
DISTRIBUTED BY: INSTALLATION DATE:
SERIAL NUMBER:
KEYPAD
MANUFACTURED BY MATelec AUSTRALIA EMAIL: [email protected]
MATelec reserves the right to alter technical specications without notice.
A quick reference to the
controller’s Keypad and
Indicator functions and
meanings.
POWER ON
Power is turned on.
LEVEL ALARM ON
A high level alarm has been
present for the preset time.
FLASHING
A low level alarm is present.
ON STEADY
Pump switched on to run.
ON STEADY
A pump fault/overload has
occurred.
FLASHING A prime loss
fault has occurred.
Silences the siren and if held
down for 3 seconds, clears all
faults
If selected (the LED indicator
will conrm if on) the particular
pump is set to Automatic
Pumping Mode
Turns pump o󰀨
If selected (the LED indicator
will conrm if on) the pump is
set to Manual Pumping Mode
POWER ON
LEVEL ALARM
PUMP ON
FAULT
AUTO
MAN
OFF
MUTE/
RESET