DPC 2-3
Installation and Operating Instructions
DPC 2-3 For Three Phase Dual Pumps up to 16A
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SAFETY 4
INTRODUCTION 5
Applications 5
Features 5
Parameters & Specifications 6
INSTALLATION 7
Tools Used in Controller Installation 7
Controller Components 7
- LCD Screen 7
- Meaning Of The Icons Shown In The LCD --------------------------------------------8
Installation – Drainage 10
- Terminals 10
- DIP Switch Settings 11
- Electrical Connections 12
Installation – Boosting 14
- Terminals 14
- DIP Switch Settings 14
- Electrical Connections 16
Installation – Water Transfer 19
- Terminals 19
- DIP Switch Settings 20
- Electrical Connections 21
OPERATION 23
Parameter Calibration 23
Erasing Former Parameters 24
- Erasing The Parameter Calibration 24
Switching to AUTO mode 24
Switching to MANUAL mode 25
Alarm Test 25
Pump Protection 25
Last Five Failure Records 25
Pump Accumulative Running Time 26
COMMUNICATION LINK 26
Basic Function 27
Special Application 27
Technical Parameters 27
TROUBLE SHOOTING 28
SAFETY
Following are the safety instructions which must be followed by the service
partners or user while installing & operating the product. If ignored, physical
injury or even death may happen. Read the safety instructions before handling the
system.
WARNING
If these safety instructions are not observed, it may result in
malfunction or damage to the equipment.
All electrical connections must be carried out by skilled and qualified
personnel.
Never connect AC power to output U, V or W terminals.
Ensure the motor, controller and power specifications are matching.
CAUTION
If these safety instructions are not observed, it may result in
personal injury.
Before carrying out any installation or maintenance operation, the controller
must be disconnected from the power supply.
Don’t open the cover while the pump is running.
Don’t put wire, metal bar filament etc. into the controller.
NOTE (Notes or attention to ensure safe operation)
Important
The manufacturer is not liable for malfunctioning if the product is not correctly
installed, damaged, modified and/or put to run beyond the working range as
given in this manual.
The manufacturer reserves the right to make any modifications to this product
from time to time.
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INTRODUCTION
The digital Pump Controller model is easy to use, programmable controller and
protection device for direct start with three phase two pumps with output power
from 0.75kW – 7. 5kW (1.5 - 16A) each.
The controller has many operation modes for adapting different pumping
applications. Important features that distinguish the DPC Series Digital Pump
Controllers from other controllers are the push button calibration for overload and
the ability of dry run protection without float switches. It shows pump parameter,
status and faults, etc.
APPLICATIONS:
The controller is useful in all cases where there is a need to control and
protect two pump installations and managing the automatic operation by a
variety of switching methods.
Typical applications:
Water supply
Irrigation
Sewage
Booster sets
Rainwater reuse
Stormwater
FEATURES:
Built-in function switch for:
- Drainage by liquid level control through float switches
- Boosting water supply by pressure control through pressure switch and tank
- Transfer of water by liquid level control through float switches
Dry run protection without float switches
Auto/ manual switch with screen lock in AUTO mode
Dynamic LCD displaying for pump running status
Protect the pump against many faults
Push button calibration
Pump accumulative run time
Last five fault records
RS485 communication (Modbus)
Starts and stops the pump in accordance with liquid levels or pressure settings
Pump shaft anti rust features
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PARAMETERS AND SPECIFICATIONS:
Following chart shows the main technical parameters & specifications:
Main Technical Characteristics
Double liquid level control
Control characteristic
Pressure control
Working modes Manual / auto
Drainage application By using float switch
Pressure Boosting application By using pressure switch
Water Transfer application By using float switch
Main Technical Data
Rated output power (amperes) 8 A, 12 A and 16 A
Rated input voltage 415 V
Trip response time of overload 5 sec - 5 min
Trip response time of open phase < 2 sec
Trip response time short circuit Less than 0.1 sec
Trip response time of under/over voltage Less than 5 sec
Trip response time of dry run 6 sec (or this can be set manually)
Recovery time of overload 30 min (or this can be set manually)
Recovery time of under/over voltage 5 min
Recovery time of dry run 30 min (or this can be set manually)
Trip voltage of over voltage 115 % of rated input voltage
Trip voltage of under voltage 80 % of rated input voltage
Dry run (without float/ probe)
Overload (auto-calibrated or can be set)
Transient surge
PROTECTIONS COVERED Under voltage
Over voltage
Pump stalled
Short circuit
Phase loss (incoming & outgoing)
Phase reversal
Pump shaft anti rust protection
Other Technical Data
Permissible ambient temperature -5 to +50 deg C
Degree of protection IP 55
Installation position Vertical
Unit dimensions (L X W X H) 320 x 420 x 138 mm
Physical interface RS485 bus interface: Asynchronous
Baud rate 1200, 2400, 4800, 9600 bps (default)
Protocol type MODBUS protocol (RTU)
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INSTALLATION
Please read this manual carefully before starting installation and operation. Any
damage to the equipment caused due to failure to comply with the descriptions
in this manual in installation or operation will be beyond the scope of the
company’s quality guarantee.
TOOLS USED IN CONTROLLER INSTALLATION:
Controller installation and wire installation will need the following tools,
you also can choose the right tools according to your own experience.
ELECTRIC DRILL
CRIMPING PLIER
wall
Back view Side view Mounting CROSS SCREWDRIVER
clamp
CONTROLLER COMPONENTS:
LCD SCREEN
Voltage Displaying Ampere Displaying
Area Area
Fault Displaying Pump Running Status
Area Displaying Area
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MEANING OF THE ICONS SHOWN ON THE LCD:
The parameter configuration icon,
when this icon appears, controller is in
manual parameter adjustment mode.
Time displaying icon, when this icon
appears, it mean controller is displaying
some parameter of time, eg: pump dry
run trip time(units: seconds).
Pump fault icon, when this icon
appears, it means controller is
displaying some fault condition.
Network connection error icon, when this
icon appears, it means there is no network
connection or network connection error
between pump controller and
computer/SCADA/BMS.
Network normal connection icon, when
this icon appears, it means the network
connection between pump controller and
computer/SCADA/BMS.
Voltage v
M Minute
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Second
S
H Hour
Ampere
A
% Percent
Pump running
Pump stopped
Low pressure or lack of pressure in the
pipeline or pressure tank.
High pressure or full of pressure in the
pipeline or pressure tank.
Pump A
A
B Pump B
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INSTALLATION - DRAINAGE:
Please read this manual carefully before starting installation and operation.
Any damage to the equipment caused due to failure to comply with the
descriptions in this manual in installation or operation will be beyond the
scope of the company’s quality guarantee.
TERMINALS
Using float switch
DANGER Electric shock risk.
Before carrying out any installation or maintenance operation, the
controller should be disconnected from the power supply and the
person should wait at least 2 minutes before opening the controller.
Never connect AC power to output U1 V1 W1 terminals.
Ensure the motor, controller, and power specifications match.
The electrical and hydraulic connections must be carried out by
competent, skilled, qualified personnel.
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DIP SWITCH SETTINGS
Users can set the function switch to suit different applications. Before setting
the function switch, The unit should be disconnected from the power supply.
After completing the settings of dip switches, Power may be applied to the
unit. Following signs will be displayed in voltage displaying area on the LCD
conforming to the following list:
ON
1 2 3
Drainage Setting Drainage Symbol
Switches Down
Connections for pump over temperature protection (where supplied with pump)
14 15 19 20 Jumpers Lead
Pump Shell Pump Shell
Over Temperature Over Temperature
(Thermal)Switch (Thermal)Switch
Pump B Pump A
NOTE: To enable the pump’s over temperature protection connect the
pump’s thermistor leads to terminals 14 and 15, 19 and 20 and remove the
jumper.
If the pump is without thermistor switch, please use jumper to connect
terminals 14 and 15, 19 and 20.
Do not run or lay the float switch wire, it must be inside the metal pipe.
So, use PVC or PE tubing.
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ELECTRICAL CONNECTIONS
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Start Condition: Liquid level in the sump reaches float switch A (up) the
controller will start the pump and the controller will alternate the pump on
every start cycle.
Stop Condition: Liquid level in the sump is reaches low level (float switch A is
down) the controller will stop the pump.
2nd Pump Start Condition: Liquid level in the sump reaches float switch B
(up) the controller will run the second pump. Pumps run simultaneously until
liquid level reaches low level (float switches A and B down).
Alarm Condition: While pumping, if the liquid level rises in the sump to high
level (float switch C up), the controller will sound the alarm to warn the user
to take further action.
Auto Antirust function: Under Auto mode, if controller observes that
pumps didn’t run for ten days then the controller will run the pump A for 3
seconds and stop, after 10 seconds interval, controller will run pump B for 3
seconds and stop. Auto antirust can prevent pump rusting and jamming of
impeller due to pumps not running for a long time.
Meanings of the messages & graphic shown on the LCD screen
Messages & Graphics
Description
No water
Lack of water in sump
Overflow in sump
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INSTALLATION - BOOSTING:
TERMINALS
DANGER Electric shock risk.
Before carrying out any installation or maintenance operation, the
controller should be disconnected from the power supply and the
person should wait at least 2 minutes before opening the controller.
Never connect AC power to output U1 V1 W1 terminals.
Ensure the motor, controller and power specifications match.
The electrical and hydraulic connections must be carried out by
competent, skilled, qualified personnel.
DIP SWITCH SETTINGS
Users can set the function switch to meet different applications. Before
setting the function switch, the controller should be disconnected from the
power supply.
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After completing the setting, apply power to the controller and observe the
application sign displayed on the LCD conforming to the BOOSTING symbol.
ON
1 2 3
Boosting Setting Boosting Symbol
Switches UP
Connections for pump over temperature protection (where supplied with pump)
14 15 19 20 Jumpers Lead
Pump Shell Pump Shell
Over Temperature Over Temperature
(Thermal)Switch (Thermal)Switch
Pump B Pump A
NOTE: To enable the pump’s over temperature protection, connect
the pump’s thermistor leads to terminals 14 and 15, 19 and 20 and
remove the jumper.
If the pump is without thermistor switch, please use jumper to
connect terminals 14 and 15, 19 and 20.
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ELECTRICAL CONNECTIONS
WATER SUPPLY BY USING PRESSURE CONTROL THROUGH
PRESSURE SWITCH
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WATER SUPPLY BY PRESSURE CONTROL THROUGH
PRESSURE SWITCH AND DRY RUN THROUGH FLOAT SWITCH
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Normal Demand: When pressure in the pipeline is lower than the pressure
switch B setting, controller will order single pump to run; pressure in the pipeline
reaches the pressure switch B setting, single pump stops running; controller will
alternate double pumps running automatically when pressure in the pipeline
varies in the range of pressure switch B.
Extra Demand: When single pump is running, pressure in the pipeline still
decrease to the pressure switch A setting, controller will give command to
second pump to run simultaneously, till pressure in the pipeline reaches the
pressure switch B setting, both pumps will not stop unless the pressure in the
pipe line reaches the pressure switch A setting.
NOTE: Pressure Switch A = Low Pressure Switch, Pressure Switch B =
High Pressure Switch.
Meanings of the messages & graphic shown on the LCD screen
Messages & Graphics Description
Low water level in source tank
Enough water in source tank
High pressure in pipeline or pressure
tank
Low pressure in pipeline or pressure
tank
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INSTALLATION - WATER TRANSFER:
TERMINALS
Using float switch
DANGER Electric shock risk.
Before carrying out any installation or maintenance operation, the
controller should be disconnected from the power supply and one
should wait at least 2 minutes before opening the controller.
Never connect AC power to output U1 V1 W1 terminals.
Ensure the motor, controller and power specifications.
The electrical and hydraulic connections must be carried out by
competent, skilled, qualified personnel.
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DIP SWITCH SETTINGS
Users can set the function switch to meet different applications. Before
setting the function switch, the controller should be disconnected from the
power supply.
After completing the setting, apply power to the controller and observe the
application sign displayed on the LCD conforming to the TRANSFER symbol.
ON
1 2 3
Transfer Setting Transfer Symbol
Connections for pump over temperature protection (where supplied with pump)
14 15 19 20 Jumper’s lead
Pump shell Pump shell
Over temperature Over temperature
(thermal)switch (thermal)switch
Pump B Pump A
NOTE: To enable the pump’s over temperature protection connect the
pump’s thermistor leads to terminals 14 and 15, 19 and 20 and remove
the jumper.
If the pump is without thermistor switch, please use jumper to connect
terminals 14 and 15, 19 and 20.
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ELECTRICAL CONNECTIONS
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Normal Demand: when the liquid level in the overhead water storage tank is
lower than (float switch A: Down), controller will order single pump to run;
Liquid level reaches tank full level (float switch A: Up), pump stops running;
controller will alternate both pumps on every start cycle.
Extra Demand: When single pump is running and liquid level is still
decreasing to low level in overhead tank (Float Switch B: Down), controller will
command second pump to run simultaneously, until liquid level reaches tank
full level (Float Switch A & B: Up), both pumps will now stop.
Messages & Graphics Description
Low water level in source tank
Enough water in source tank
Low level in overhead tank
Overhead tank full
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OPERATION
BEFORE YOU START - Parameter calibration and erasing
To achieve best level of protection of the pump, it is essential that parameter
calibration be done immediately after successful pump installation or pump
maintenance.
PARAMETER CALIBRATION:
Pump/s must be able to pump water to enable correct calibration. If pumps
are calibrated without water, overload and pump stalled errors may occur
1. Press the MODE key to switch to manual 2. Press the A START key to run pump
mode. If the controller is locked press A, confirm the pump and all pipe
MODE and STORE keys at the same time to network is in normal working state
unlock and go into manual mode. Make (including voltage, amps etc.) with
sure that the pump is not running, and LCD LCD screen displaying:
screen is displaying:
3. Press the A START key. The controller 4. The pump stops running and
makes a “beep” and a countdown starts parameter calibration is completed
with the LCD displaying: Controller now with LCD displaying:
counts down from 8 seconds:
6. Press the B START key to repeat
calibration for pump B. And follows
5. Pump A is ready for running. the same procedure.
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ERASING FORMER PARAMETERS:
When pump is reinstalled after maintenance or a new pump is installed, user
must erase the former calibration and a new calibration must be done.
ERASING THE PARAMETER CALIBRATION:
1. Press the MODE key to switch to manual 2. Press the A STOP key for 3 seconds;
mode. If the controller is locked press the controller makes a “beep” sound,
MODE and STORE keys at the same time to and the controller recovers the default
unlock and go into manual mode. Make factory setting and A PUMP no
sure that the pump is not running and LCD calibration flashing will appear in the
screen is displaying: LCD displays:
3. Repeat for pump B by using the B STOP key for 3 seconds.
SWITCHING TO AUTO MODE:
To switch between MANUAL and AUTO mode press MODE key. AUTO mode
automatically locks controller. Under AUTO mode the controller will run or
stop the pump according to the signal from the float switch.
NOTE:
Under AUTO mode, if the pump is running and user wants to stop the pump,
press the MODE key to switch to MANUAL mode and the pump stops.
Under AUTO mode, if the input power is cut off and resumed, the controller
will come into operating state after a 10 seconds countdown.
No matter if the controller is AUTO or MANUAL state, if the input power is cut
off and resumed again, the control panel will resume its operation in the same
state as before the power being cut off.
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SWITCH TO MANUAL MODE:
To switch between AUTO and MANUAL model press MODE and STORE keys at
the same time to unlock and go into MANUAL mode. Press the START key to
start the pump and the STOP key to stop the pump.
ALARM TEST:
Under MANUAL mode and pump/s not operating press STORE for 3 seconds to
test the alarm.
PUMP PROTECTION:
During pump running, if dry run, overload, over voltage, etc. failures occur, the
controller will immediately shut down the running pump and automatically
execute a check for restarting conditions after a built-in time delay has
elapsed. The controller will not recover automatically until all the abnormal
situations have been cleared. If pump stalled, open phase or other serious
failure has occurred, pump user must immediately check pump and motor.
LAST FIVE FAILURE RECORD:
The control panel can memorize the last five failures of pump, so it is very
convenient for the users to analyze the pump running conditions.
DISPLAYING THE LAST FIVE:
1. Press the MODE key to switch to MANUAL mode, make sure the pump is not running
and the LCD screen is displaying:
2. Press and hold A STOP key and MODE key, the controller makes a “beep” sound and
displays pump A failure record.
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3. Press the A STOP key to quit the failure record display:
NOTE: The failure displayed above is PUMP STALLED. Repeat for
pump B by using B STOP key.
PUMP ACCUMLATIVE RUNNING TIME:
The controller can memorize how many hours that pump has run, so it is very
convenient for the pump user to analyze the pump running conditions and do
maintenance.
DISPLAYING THE PUMP ACCUMLATIVE RUNNING TIME:
1. Press the MODE key to switch to manual 2. Press and hold the STORE key and
mode, make sure that the pump is not A STOP key. The controller makes a
running and the LCD screen is displaying: “beep” sound and displays the
accumulative run time. The pump has
run for 23 hours.
3. Press the A STOP key to quit the 4. Repeat for pump B by using B STOP key.
accumulative running time display.
COMMUNICATION LINK
The controller has communication interface, between the pump controller
and computer/SCADA/BMS, users can realize a long-distance monitoring
function.
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This function applies to where the controller is installed in the basement or
pumping room, but users require to monitor and control the pump on the
ground or in a control room.
BASIC FUNCTION:
Computer/SCADA/BMS (Optional) with communication interface can
realize long distance monitoring. In the control room, users can realize all
the functions of the master controller through the slave controller, except
parameter calibration and adjusting.
SPECIAL APPLICATION:
As adopting communication interface, the communication distance
through wire is less than 1200 meters. whereas for a longer communication
distance like mine, water tower, across railway road and bridge etc., users
can adopt RS485 extender.
TECHNICAL PARAMETER:
The following chart shows main technical parameters of communication
between the pump controller and Computer/SCADA/BMS.
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)
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 meters max by shield twisted pair cable (STP)
for RS485 & CAN
5000 meters max by shield twisted pair cable (STP) and
RS485 extender
STP STP-120U one pair 20AWG for RS485 & CAN
RS485 extender 5000 meters (9600bps)
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TROUBLE SHOOTING GUIDE
Fault message Possible cause Solutions
Flashing of UNDER V The real running voltage is Report low line voltage to the
lower than the set voltage, power supply company.
pump is in under voltage
protection state.
Control will attempt to restart
the pump every 5 min until line
voltage is restored to normal.
Flashing of OVER V The real running voltage is Report high line voltage to the
higher than the set voltage, power supply company.
pump is in over voltage
protection state.
Controller will attempt to
restart the pump every 5 min
until line voltage is restored to
normal.
Flashing of OVERLOAD The real running ampere is Controller will attempt to
higher than the restart the pump every 30 min
calibrated/set running until running ampere is
ampere, pump restored to normal.
is in overload protection
Inspect pump and motor winding.
Flashing of Parameter calibration not Refer to parameter calibration
PUMP NO CALIBRATION completed. setting.
Flashing of DRY RUN Liquid level in the well/ Controller will attempt to
sump is below the pump restart the pump every 30 min
intake, pump stops running. until liquid level is above the
pump.
Flashing of Pump running amps Cut off power supply and repair
PUMP STALLED exceeded normal run amps or replace pump.
by more than 200%.
Flashing of Pump starts more than 5 Check pressure tank pre charge
REPEATED START times per minute. Check pressure tank bladder
Check pressure switch settings
Check pressure switch for
defects.
No communication link Connect the control to SC /
between SC / computer and computer to realize long
control. distance monitoring.
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Version: 02.0522
Version: 02.0522
Version: 02.0522
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