PUMP CONTROL FPC-32040 Instructions for use

DOC: FPC 32040 REVISED: 030915
Dual Pump Controller Installation and
Operating Instructions
P U M P CONT R O L
OWNER’S
OPERATION
MANUAL
MODEL: FPC-32040
MAIN ISOLATOR
OFF
ON
PUMP ON
FAULT
PUMP ON
FAULT
SYSTEM
TEST
MAINS WATER
RAIN WATER
SYSTEM FAULT
Rain / Mains Water Controller
DANGER- HIGH VOLTAGE
DONOT REMOVE COVER. AUTHORIZEDPERSONS ONLY

INSTALLATION 3
Mounting
Connection
WELCOME TO DUAL PUMP CONTROL
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.
OPERATION 4
Operations
Features
WARNING: All electrical connections must be carried outby a suitably
• Prior to Installation, ensure power supply is isolated.
rating.)
• Electrical connection to the panel must be carried out in accordance with ‘Connection Instructions’,
seepage 3.
2
SAFETY 2CIRCUIT DIAGRAM 7
AT A GLANCE 8
Indicators
Push Buttons
CONTENTS
SAFETY

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
Top
Bottom
Top
Bottom
Mounting
Frame/
Wall
CONNECTION
INSTALLATION
SIDE VIEW
3
MAINISOLATOR
OFF
ON
PUMPON
FAULT
PUMPON
FAULT
PUMP 1
P1 P 2 P 3
PUMP 2
P1 P 2 P 3
COMMON
N/O CLOSE ON RISE
COMMON
N/O CLOSE ON RISE
COMMON
N/O CLOSE ON RISE
LOW
LEVEL
FLOAT
COMMON
N/O CLOSE ON RISE
PUMP 1 Earth
PUMP 2 Earth
INPUT SWITCHESThermal Sw itches SOLENOI D
12Vdc Connections
BLUE NOT
REQUIRED
®
Australia
PULSE LATCHING
12Vdc SOLENOID
VALVE
PUMP 2
PUMP 1
415Vac
MAINS POWER
SUPPLY
SUPPLY
415Vac Connectio ns
NE A1 A2 A3 Valve
+-
Low
Float
Level
Input 2
Lead
Press.
Input 3
Lag
Press.
Input 4
Low
Press.
T 1 T 2
PUMP 1PUMP 1
T 1 T 2
PUMP 2
BRIDGE
IF NOT
REQUIRED
Pressure
Switch
LEAD
Pressure
Switch
LAG
Pressure
Switch
LOW
SYSTEM
TEST
MAINSWATER
RAINWATER
SYSTEMFAULT
Rain / Mains Water Controller
DANGER-HIGH VOLTAGE
DONOTREMOVECOVER. AUTHORIZEDPERSONS ONLY

OPERATION
4
This controller can perform control functions for most Dual Pump pumping applications. It is more than likely that the con-
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:
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 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 func-
tions are as follows:
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:
Position
Off/Off
Off/On
On/Off
On/On
Off
On
Off
On
Off
On
Off
On
Function
Mode A:
Mode B:
Mode C:
Mode D:
Operating Pump alternates each time a pump start is triggered, or after 30 minutes continuous
running.
Operating Pump alternates after 6 hours continuous running.
Anti-seize Timer disabled
Anti-seize Timer 6 seconds every 7 days enabled
When placed in Manual Mode, pump remains in Manual Mode
When placed in Manual Mode after 5 minutes the pump will revert to Auto
High Level Alarm automatically resets upon open circuit of high level input. High Level alarm
has 15 minute delay.
High Level Alarm can only be reset manually. High Level Alarm has 5 minute delay.
DIP Switch
1/2
3
4
5
6
Input Function
Input 1 Not used
Input 2 Pump Stop
Input 3 Pump Start
Input 4 High Level
Input Function
Input 1 Low Level
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.
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:
Typical Operation for Mode D:
•Pressure drops to 400kPa: Lead (for this cycle) Pump cuts in.
•Pressure increases and Pump cuts out.
•Cycle continues with duty alternating between the two pumps.
•If pressure continues to drop to 350kPa, the Lag Pump will cut in and remain running until the
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 2 contact closure,
the pump will not start (delay start) for 1 second and will not stop (minimum run time) for 10 seconds (or 11 sec-
onds 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.
•P
•Prime Loss functions as per mode Mode C.
ressure switches are normally Closed and Opened on High Pressure.
Input 2
Pump Stop
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Input 1
Low Level
Closed
Closed
Closed
Closed
Open
Open
Open
Open
Input 3
Pump Start
Open
Closed
Closed
Open
Open
Closed
Open
Closed
Input 4
High Level
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Pump
State
Off
On
Both On
Both On
Off
Off
Off
Both On
Alarm
-
-
High Level (after Timeout)
High Level (after Timeout)
-
Low Level
Low Level
High Level (after Timeout)
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)
Lead Pressure Switch
opens circuit.

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 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 automati
cally reverts to Auto.
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. -
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 indica
tor 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 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 when the overload opens the contact for 3 seconds. Prime loss will be indicated by flashing the pump 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.
lly
Auto Silencing Alarm Feature
The audible Alarm is programmed to sound for 5 minutes continuously, unless muted and will thereafter automatica
In pressure pump mode some of the optional features are disabled, including maximum run alternation, anti-seize and
maximum idle timers.
Mode ‘Current Loop’: Level Transducer (4-20mA) Configuration
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 be
received from the pressure transmitter instead of float switches. In this mode the pump stop float switch input will be
ignored however the high level input will still operate as per normal so that a float switch can be used as backup if
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.
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

TOL 1 TOL 2
96959695
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
A1 A2 A2A1
N
A1
A2
A3
E
THERMAL SWITCH 1 THERMAL SWITCH 2
CONTRACTOR
COILS
PUMP 1
MAIN ISOLATOR
TOL 1CONTACTOR 1
PUMP 1
ISOLATOR
2amp
CONTROL
CIRCUIT
BREAKER
TRANSFORMER
12Vac
415Vac
240Vac
STROBE
R1
BUZZER
INPUT 2
LEAD
INPUT 3
LAG
INPUT 4
LOW
12Vdc
12Vdc
ME82
AUX
C NO
PUM P 1 PU MP 2
7
CIRCUIT DIAGRAM
PUMP ON
FAULT
PUMP ON
FAULT
PUMP
ME82
RMC
VALVE
SUPPLY
R1/1
LOW
FLOAT VALVE
FAULT
INPUT B
PRESSURE
INPUT CINPUT A
FLOAT
- +
PUMP 2
TOL 2CONTACTOR 2
415Vac
PUMP 2
ISOLATOR
SYSTEM
TEST
MAINS WATER
RAIN WATER
SYSTEM FAULT
Rain / Mains Water Controller
DANGER - HIGH VOLTAGE
DO NOTREMOVE COVER. AUTHORIZED PERSONS ONLY

RMWC KEYPAD
INDICATORS
PUSH BUTTONS
SYSTEM
TEST
MAINS WATER
RAIN WATER
SYSTEM FAULT
Rain / Mains Water Controller
DANGER - HIGH VOLTAGE
DO NOT REMOVE COVER. AUTHORIZED PERSONS ONLY
SYSTEM
TEST
RAIN WATER
MANUFACTURED BY MATelec AUSTRALIA EMAIL: [e-mail]
A quick reference to the controller’s Keypads and Indicator functions and meanings.
DPC KEYPAD
INDICATORS
PUSH BUTTONS
DISTRIBUTED BY:
8
INSTALLATION DATE:
SERIAL NUMBER:
AT A GLANCE
PUMP ON
FAULT
PUMP ON
FAULT
POWER ON
FLASHING
A prime loss fault has occurred.
FAULT
POWER ON
Power is turned on.
STEADY: HIGH LEVEL
FLASH: LOW LEVEL
LEVEL ALARM
LEVEL ALARM ON
A high level alarm has been
present for the preset time.
FLASHING
A low level alarm is present.
PUMP ON
ON STEADY
A pump fault/overload has
occurred.
ON STEADY
Pump switched on to run.
If selected (the LED indicator
will confirm if on) the pump is
set to Manual Pumping Mode
MAN
If selected (the LED indicator
will confirm if on) the particular
pump is set to Automatic
Pumping Mode
AUTO
Silences the siren and if held
down for 3 seconds, clears all
faults
MUTE/
RESET
PRESS AND HOLD
FOR 3 SECONDS
TO RESET
Turns all pumps off
OFF
Light illuminates when mains
water valve is open
Light illuminates when Rain
Water is available and the
Mains Water valve is closed.
Light illuminates when a pump
fault or a flow fault is present.
Pressing this button will
change the status of the valve
regardless of what state it is
in.
SYSTEM
TEST
SYSTEM FAULT
RAIN WATER
MAINS WATER
SYSTEM
TEST
MAINS WATER
RAIN WATER
SYSTEM FAULT
Rain / Mains Water Controller
DANGER - HIGH VOLTAGE
DO NOT REMOVE COVER. AUTHORIZED PERSONS ONLY