nxt BIA-nXt-DPC 3-40 User manual

BIA-nXt-DPC3 Instruction Manual V1.0 1
Auto Restart Pump Controller
Dual Pump Protection and Control Module
BIA-nXt-DPC 3-40 PN 811200
BIA-nXt DPC 3-11 PN 811201
Installation and Operation Manual

2BIA-nXt-DPC3 Instruction Manual V1.0
A. Shortcuts
Switching to
Manual if the
controller is in
LOCK MODE:
PRESS and HOLD the MODE
button for 5 seconds
Lock parameter # 014 in the
Expert Menu Pg 13
Alarm Test:
Inside the controller
on the display PCB is
an ALARM TEST
button
Error log:
•Switch to MANUAL mode
•Ensure no pumps are
running.
•PRESS and HOLD the A-
STOP or B-STOP button,
then SHORT PRESS the
MODE button
•Press MODE to scroll
•Press A-STOP or B-STOP to
exit
Accumulated
Run time:
Controller in manual
state. Press and hold
STORE then press A-
START
Switching
between AUTO
and MANUAL:
PRESS and release the MODE
button
Alarm Mute:
At any time press the
A-STOP
button to mute
the alarm. It will now
beep every 5 minutes.
Resets after 24Hrs

BIA-nXt-DPC3 Instruction Manual V1.0 3
B. Shortcuts cont
Programming:
STORE advances to the next
parameter
A-START increases a value
A-STOP decreases a value
Short press MODE to store a value
and return to the main menu
Press STORE for 5 sec to save
changes and exit the parameter
menu
To clear the
calibration
With the pump stopped and
the controller in manual mode,
PRESS and HOLD the A STOP
or B STOP for 30 seconds
Calibrating the
controller to the pump
In manual mode, short press A START or
B START. Allow the pump to run and the
current draw to stabilise.
Once you are satisfied the pump is in its
‘normal’ operating range short press
STORE The controller should chirp.
The controller calibration value can be
checked and adjusted from the User Menu
Parameter #018, 019 in the User Menu
USER
programming
menu
In manual mode, press
and hold the STORE
button for 5 sec.
Page 14
EXPERT
programming
menu
In manual mode, press
STORE + MODE buttons
for 5 seconds
Page 13

4BIA-nXt-DPC3 Instruction Manual V1.0
1. Introduction
Thank you for choosing a Bianco nXt-DPC (Dual Pump Control and protection module.
The Bia nXt-DPC is a module intended to control and protect dual three phase pumps. The
user can select a control logic sequence to match their application and enjoy the benefits of
superior control and protection for the pumps.
There are 3 primary control logic modes:
•‘Drainage’ where control is concentrated at the source
•‘Boosting’ which references pressure switching on the delivery side for control
•‘Transfer’ which is a mix of source and destination control
nXt-DPC has 2 x passive dry contacts and is equipped with a RS485 modbus interface to
connect to a BMS
The LCD screen displays the pump running state and provides the user a wealth of useful
information.
The controller is easy to set up with an initial push button calibration and individual
parameters can be fine-tuned.
A nXt-DPC controller is particularly useful where there is the need to control and protect
pump installations managing the automatic operation through a variety of switching
methods without the need to create a bespoke control solution.
2. Warnings and Cautions
Read the manual carefully before starting
Prior to starting installation or maintenance the controller must be
disconnected from the power supply.
Any changes or modification to the wiring must be carried out by
competent, skilled and suitably qualified personnel only.
A qualified electrician should correctly size and install circuit breakers
to protect the power supply. The fitment of additional surge protection
is recommended as good practice.
Never open the cover while controller is connected to electrical supply.
Disconnect and allow the internal electronics to discharge before
opening the cover
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.
Ensure the controller is a suitable size for the pump motor (see
Section 6, Page 7: Technical Data). Size according to full load
current amperage.

BIA-nXt-DPC3 Instruction Manual V1.0 5
3. Contents
A. Shortcuts .................................................................................................. 2
1. Introduction .............................................................................................. 4
2. Warnings and Cautions ............................................................................. 4
3. Contents ................................................................................................... 5
4. ISO 7010 Symbols used in this manual ..................................................... 5
5. Modes of Operation................................................................................... 6
6. Technical Specifications ........................................................................... 7
7. Display ...................................................................................................... 8
8. Electrical Connections............................................................................ 10
9. Modbus ................................................................................................... 12
10. Parameter Calibration............................................................................. 12
11. Program Parameters ............................................................................... 13
12. Quick guide: Drainage Mode, float connected to pump .......................... 16
13. Quick guide: Drainage Mode, floats connected to control...................... 17
14. Quick guide: Transfer – source/destination control................................ 18
15. Quick guide: Pressure Boosting – switched input................................... 19
16. Quick guide: Drainage Mode, 4–20mA level transmitter ......................... 21
17. Quick guide: Transfer – source/destination control 4-20mA .................. 22
18. Quick guide: Pressure Boosting 4-20mA ................................................ 23
19. Backup power supply.............................................................................. 24
20. Fault Messages ....................................................................................... 25
21. Warranties – Terms and Conditions ........................................................ 26
4. ISO 7010 Symbols used in this manual
Warning - Electrical safety
Warning – Potential consequences of use outside of intended
application(s). Includes environmental condition warnings.
Mandatory warning
Warning to disconnect power
Read carefully

6BIA-nXt-DPC3 Instruction Manual V1.0
5. Modes of Operation
On the main PCB there is a 4 position ‘Dip Switch’
To alter the control logic to suit an application, the
installer must select the appropriate switch position.
After selecting the desired switch position, cycle the
controller power to apply the setting.
Binary
Switch position
Control logic - Applications
000
‘Drainage’ Mode where the control inputs (generally level
floats or probes) are located at the source. (default)
010
‘Drainage’ Mode where the level control input is managed by
a flexible float on the pump. No bridge – terminals #5 and #7
111
‘Pressure Boosting’ Mode. Main control via (N/C) pressure
switch. Supports run / no run level protection at the source
via floats or probes.
101
‘Transfer’ Mode. Main control via control inputs (floats or
probes) at destination or by a pressure switch on the delivery
line. Supports run / no run level protection at the source.
0*
OTA/OTB terminal enabled (default)
1*
Enables the connection of a PT00 temperature sensor (i.e.
pump over-temp sensor) A separate PT100 temperature
sensor expansion module is required
011*
‘Drainage’ Mode with overflow alarm through a 4-20mA level
transmitter.
001*
‘Pressure Boosting’ Mode controlled via a 4-20mA pressure
transmitter. Supports run / no run level protection at the
source via floats or probes.
100*
‘Transfer Mode’ with 4-20mA level transmitter at the
destination. Supports run / no run level protection at the
sources via floats or probes.
When first powered on the nXt-DPC will display the
current dipswitch operating mode (binary code), the
hardware and the software version.

BIA-nXt-DPC3 Instruction Manual V1.0 7
6. Technical Specifications
Controller Modes
Automatic or Manual pump operation.
Liquid level control via float switch, electrode probes OR 4-
20mA level transducer.
Pressure control via pressure switch or 4-20mA transducer
Protection functions: Dry run (Underload), Overload, Pump Stalled,
Transient surge, Under voltage, Over voltage,
Phase reversal, Open phase protection
Repeated start, Short circuit, Over temperature
Over temperature requires an optional relay
Input Voltage 415V +10% -6%
Rated output power
Per pump
DPC 3-40 nominal 0.37 to 4 kW P2 power (max 12A input)
DPC 3-11 nominal 2.2 to 11 kW P2 power (max 25A input)
Minimum working current (per pump) DPC 3-40 = 1 amp DPC 3-11 = 5 amp
Working temp -25 to +55 deg C
20% to 90% relative humidity, non-condensing
Controller size 342mm wide, 253mm tall, 130 deep. IP54
Trip response times (set) Open phase – Less than 2 sec
Short circuit – less than 0.1 sec
Trip Voltage
(User adjustable)
Over voltage – Default = 437V
Under voltage – Default = 304V
Trip response times
(User adjustable)
Dry run (Under-load) 5 sec
Under Voltage Less than 5 sec
Over voltage Less than 5 sec
Recovery times
(User adjustable)
Dry run (Under-load) 45 min default
Overload 4 min default
Under Voltage 4 min default
Over voltage 4 min default
RS485 Technical interface
RS485 Bus Interface: asynchronous semi duplex
1200,2400,4800,9600 bps (default 9600bps)
MODBUS protocol (RTU)
Alarms Visual and audible alarm. Supports external alarm connection
To avoid ‘nuisance’ alarming, many of the default protection parameters
have values with a wide tolerance. The installer is encouraged to optimise
the settings to achieve optimum results

8BIA-nXt-DPC3 Instruction Manual V1.0
7. Display
The DPC display provides a real time indication of the operational mode and the current
state of the controller, including real-time voltage/current and any error messages.
Only the icons relevant to the selected operational mode will display.
Operational
state
Error
messages
Controller
status
Amperage,
Voltage and
other values.
Current monitoring
Operating logic
selection
Low voltage
input/output
connections
Contactors
Master Circuit Breaker
Power output connections
High decibel
audible alarm
Audible alarm
Visual alarm
Critical fault
messages

BIA-nXt-DPC3 Instruction Manual V1.0 9
7. Display con’t
The nXt-DPC controller operates according to the pre-programmed logic for each ‘mode’.
Changing the Dip Switches inside the controller then cycling the power will activate the
selected logic mode.
Examples of common applications are detailed later in this manual but with an
understanding of how the controller responds to various inputs in each of the modes the
controller can be used for application other than what is suggested.
The appearance of the front display changes according to each mode and provides a visual
indication to the state of the input signals.
Lack of source
water
High pressure
Low pressure
Source water
full
Destination low
Overflow Destination full
Avoid installing the nXt-DPC where it could experience the following conditions:
i. Where there is significant vibration and/or mechanical shock.
ii. Where it could be exposed to corrosive liquids or gasses, or to flammable
materials, solvents etc.
iii. Extreme heat and cold. Operating range -25oC - 55oC.
iv. Protect the controller from rain, moisture, humidity or dust

10 BIA-nXt-DPC3 Instruction Manual V1.0
8. Electrical Connections
Always use an electrical outlet that is protected by Residual Current Device (RCD)
Safety Switch with a trip current of 30mA or less. A Safety switch is required by
Australian/New Zealand Standard AU/NZS 60335.1-2011.
All high voltage wiring must be connected by a suitably qualified technician.
Output Terminals
The nXt DPC has two ‘Dry Contact’ terminals.
D1, D2 activate in the event of a critical fault
D3, D4 activate briefly whenever the controller is changed between its
Automatic and Manual state (which requires physical intervention)
It is the responsibility of the installing electrical technician to ensure that the
cable cross section (mm2) meets the requirements of AS/NZS 3008; taking
into consideration the cable type, the cable length, the current draw and
other relevant factors.
If in doubt online resources exist i.e. Cable Size Calculator AS/NZS 3008 or seek advice
from an electrical engineer or other suitably qualified person(s)

BIA-nXt-DPC3 Instruction Manual V1.0 11
8. Electrical Connections cont
Pump over temperature protection sensor wiring terminal
Terminal Definition
9(OT) + 10(OTA)
See Pg 6 . Dip switch to 0*
Pump over-temp protection sensor. Set to 0* is a N/O circuit, bridged unless
connected. Standard thermals will open to peak signal and stop pump on overheat
9(OT) + 10(OTA)
See Pg 6 . Dip switch to 1*
PT100 connection. Set to 1* the circuit looks for the variable signal from a
PT100 sub-board
Pump moisture protection sensor wiring terminal
Terminal Definition
13(COM) + 16(LKA) Pump leakage protection sensor
Dry contact (passive contact) point wiring terminal
Terminal Definition
D1 + D2 Dry contact point for pump failure indication
N/O circuit. Activates when there is a critical fault
D3 + D4 Dry contact for auto/manual status indication
N/C circuit
4-20mA transmitter wiring – Modes 011 Drainage, 001 Boosting and 100 Transfer
Terminal Definition
3(P+) + 4(P-) 4-20mA level/pressure transmitter
RS485 communication terminal
Terminal Definition
11(A+) + 12(B-) RS 485
Full factory reset_
•Turn off power to the control panel,
•Press and hold the A-STOP button and reapply power
•When the display shows 099, release the A-STOP button.

12 BIA-nXt-DPC3 Instruction Manual V1.0
9. Modbus
Main 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
Main installation data
Wire communication distance 1200 m max by shield twisted pair cable (STP)for RS485 & CAN
5000 m max by STP and RS485 extender
STP STP-120U one pair 20AWG for RS485 & CAN
10. Parameter Calibration
The pumps must be able to pump water to enable correct calibration. Calibrated
without water, overload and pump stalled errors may occur later.
Calibration can be performed automatically as explained on Page 3 OR by
accessing the User parameter menu #018, 019 and manually inputting the
desired values
When a new pump is installed, or an existing pump reinstalled after
maintenance, erase the former calibration and a perform a fresh calibration.
To access parameter settings the
controller should be in Manual Mode
and the pump(s) should NOT be
running.
User Menu – Press the STORE button
Expert Menu – Press the STORE and MODE
buttons for 5 seconds
To enter a parameter, press the STORE button to advance to the next parameter and
display the current value.
To change the value, press the A-START or A-STOP buttons respectively to increase or
decrease the value.
To store the value and return to the main menu press MODE button.
To store all changes and exit the parameter menu hold the MODE button for 5 sec

BIA-nXt-DPC3 Instruction Manual V1.0 13
11. Program Parameters
Controller unlocked
Press to switch between AUTO and MANUAL mode
Controller locked (Parameter 014 active)
Press and hold to switch to MANUAL mode
The controller operating mode will be displayed in the top left corner of the display
EXPERT MENU – Parameters 001 - 017
ITEM DEFAULT OPERATION
001 3 sec Pump stall delay time before applying protection
To make provision for inrush current on pump start. Range 0 - 60
002 OFF Repeated start protection. Options ON/OFF
003 ON Over-temp protection.
Related to terminal connection 9 and 10. Dip switch #4 in the up position
004 ON Phase Reversal Protection
When using the nXt SPC in conjunction with a VFD set to OFF
005 ON Open Phase Protection
When using the nXt SPC in conjunction with a VFD set to OFF
006 ON Pump Enable/Disable function (Both pumps)
007 AUTO
Pump A and Pump B Auto and Manual set separately
Press START or STOP once or twice to disable a pump (A or B)
008 OFF Time setting for pump alternation Range: Off or 0 – 254 min
009 96 hour Anti Seize Protection: Cycle time. Range: Off or 1 – 254 hr
010 OFF Boosting mode only - Start delay time Range: Off or 1 – 254 sec
011 OFF Boosting mode only – Stop delay time Range: Off or 1 – 254 sec
012 OFF Boosting mode only – Maximum run time Off or1 – 254min
013 OFF Fault alarm recovery Off: 1 – 24hrs
014 OFF Button lock function Off / On
015 01 Controller ID 00 – 254
016 04 RS485 Speed 01 =-1200, 02 = 2400,03 = 4800, 04 =9600 bps (default 9600bps)
017 00
Parity check 00 = None
01 = Odd parity
02 = Even parity
MODE
MODE

14 BIA-nXt-DPC3 Instruction Manual V1.0
11a.Program Parameters cont
USER MENU – Parameters 018 - 034
ITEM DEFAULT OPERATION
018 Controller
Dependant Rated output. Pump calibration value Pump A
019 Controller
Dependant Rated output. Pump calibration value Pump B
020 75% Trip response ratio – Dry run (underload) protection
Range: Off – 95%
021 130% Trip response ratio – Over-load protection
Range: Off – 170%
022 180% Trip response ratio – Pump stalled / locked rotor protection
Range: Off – 195%
023 20% Trip response ratio – Phase imbalance
Range: Off – 50%
024 332V Trip voltage – Under Voltage Protection
025 477V Trip voltage – Over Voltage Protection
026 5 sec Trip response time – Dry run Protection Range 1 – 60 sec
027 45 min Recovery time – Dry run Protection Range 1 – 254 min
028 4 min Recovery time – Overload protection Range 1 – 60 min
029 4 min Recovery time – Under/Over Voltage, Phase Imbalance
Range 00 – 60 min
4-20mA Input Mode 011 / 001 / 100 See Section 5 – Modes of Operation
030 Mode
Dependant Level Sensor range Drainage/Transfer 0-200cm, Boosting 0 – 25 bar
031 Mode
Dependant Pump stop setting
032 Mode
Dependant Start pump setting
033 Mode
Dependant Second pump cut in setting
034 Mode
Dependant Overflow/Over pressure setting
If a replacement pump is installed, the previous calibration
should be removed and a new calibration performed.

BIA-nXt-DPC3 Instruction Manual V1.0 15
nXt-DPC controllers are a cost
effective, reliable means to provide
better control and protection without
the need for costly bespoke
switchboards
The following quick guides provide
information regarding common
applications.
The pumps illustrated in the following
quick guides are all of a submersible
type but the nXt-DPC controller not
limited to this type of pump.
With an understanding of how the
controller responds to various inputs in each of the modes the controller can be used for
applications beyond what is suggested.
For example, the controller can be connected in series with a VFD controlled pump to
provide additional control inputs or to utilise the nXt-DPC controller delay times.
For even greatly flexibility in your installation the nXt-DPC controller can be used as a
‘module’ in a more complex control environment.
Floats
3 wire’ floats allow for NO or NC wiring.
Connecting to the
controller using the
black and brown wires
the circuit is closed
when the float is up,
open circuit when the
float is down.
For greater differential,
dual floats can be
attached on the source
inputs 5, 6 and 7.
When using a single
float on the source
input terminals #6 and
#7 need to be bridged

16 BIA-nXt-DPC3 Instruction Manual V1.0
12. Quick guide: Drainage Mode, float connected to pump
Set to this operational mode, effectively there is power supplied to the pump continuously.
The stop/start function is controlled by the float connected to each pump. In this mode, the
pumps will not alternate nor is underload (dry run) protection possible.
Pump On/Off operation is controlled by the float fitted to each pump.
The Controller provides additional protections excluding dry run, start/stop delay
times and pump start alternation.
A float connected to the controller can provide high level alarm function.
Parameter 020 must remain set to 0.0A to prevent underload alarming when the
pump float interrupts pumping operation
Set the dip switches on the
main PCB and cycle the
master circuit breaker

BIA-nXt-DPC3 Instruction Manual V1.0 17
13. Quick guide: Drainage Mode, floats connected to control
A pump with its own float can be used in this
configuration so long as the operational level
of Pump Stop Switch #1is HIGHER than
the float attached the pump.
Switched input - bridge terminals 6 and 7.
First pump switches on when the Lower float switch reaches its On (Up) position
Pump will run until the Lower float switch returns to its Off (Down) position
If the liquid level continues to climb and the Upper float switch reaches its On (Up) position the
second pump will start. It will run until the Lower float switch returns to its Off (Down) position.
The High-Level alarm triggers when the High-Level alarm float switch reaches its On (Up) position.
The alarm will turn off when the High-Level alarm switch returns to the Off (Down) position.
Both pumps continue to run until the Lower Pump float switch is in the Off (Down) position.
The controller alternates
whichever pump starts first
every startup cycle.
Should the first pump shut
down due to an alarm
condition, the controller will
automatically transfer duty to
the second pump.
Set the dip switches on the
main PCB and cycle the
master circuit breaker

18 BIA-nXt-DPC3 Instruction Manual V1.0
14. Quick guide: Transfer – source/destination control
Switched input:
Bridge terminals 14 and 15
Pump On/Off operation is requested by the floats at the destination.
A float switch or probes at the source controls whether the pump will run or not
depending on the liquid level.
Should the level continue to drop despite a single pump running, the second pump will
start when the level falls to the L2 (#7) position
Set the dip switches on the
main PCB and cycle the
master circuit breaker

BIA-nXt-DPC3 Instruction Manual V1.0 19
15. Quick guide: Pressure Boosting – switched input
Switched input
Pump On/Off operation is controlled via pressure switches on the delivery line.
Additional (optional) run/no run protection can be fitted at the source
When the controller is set to Boosting Mode, Parameters 005 – 007 become
available and can be employed to provide additional control.
•Start delay time Parameter 010 – Default Off
•Stop delay time: Parameter 011 – Default Off
•Maximum run time: Parameter 012 – Default Off
Set the dip switches on the
main PCB and cycle the
master circuit breaker

20 BIA-nXt-DPC3 Instruction Manual V1.0
When using pumps of dissimilar performance i.e. a jockey and a primary pump,
ensure Parameter 008 = 0 (Never alternate)
Selecting the Cut in and Cut out pressures for 2 identical pumps:
1. Pump A (Duty pump) Set the Cut-Out pressure. Ensure set point doesn’t exceed the
pump maximum head.
2. Pump B (Assist pump) Set the Cut-In Pressure toward the lower end of the Duty
pump performance. Ensure there is no risk of Duty pump cavitation.
3. Set the Pump A (Duty pump) Cut-In and the Pump B (Assist pump) Cut-Out halfway
between the maximum and minimum settings.
In this example Pump A (Duty pump) will start when the system pressure drops below 4.0 bar.
If Pump A (Duty pump) cannot keep up with the demand flow and pressure drops to below 2.5 bar,
Pump B (Assist pump) will start.
As demand flow reduces, the system pressure will increase. Pump B (Assist pump) will switch off
when system pressure reaches 4.0 bar leaving Pump A (Duty pump) to supply demand.
When demand flow further decreases Pump A will turn off when system pressure reaches 5.5 bar.
A suitably sized pressure vessel should be incorporated in the system to ensure pump
starts don’t exceed 20 starts/hour OR the manufacturers recommendation.