Icon DPC1 Operating instructions

BIA-DPC1 rev 4 Page 1

Installation and Operation Manual

DPC1

BIA-DPC1 rev 4 Page 2

Conventions used in this manual.

In the manual the following symbols will be used:

Generic danger. Failure to comply with the safety regulations that follow can irreparably

damage the controller or equipment.

Electric shock risk. Failure to comply with the safety regulations that follow can cause death

or serious injury.

WARNINGS

Read this manual carefully before any operation.

Please keep this manual for future use.

WARNING!!

1. Installation must be carried out by a suitably qualified electrician.

2. Before carrying out any installation or maintenance operation, controller must be

disconnected from the power supply.

3. Do not open the cover during running the controller.

4. Do not splash water or other liquid over the controller.

5. Do not allow children or infirm persons to operate the control.

6. Qualified electrician is to correctly size and install circuit breakers to protect power supply.

CAUTION!!

1. The electrical and hydraulic connections must be carried out by competent, skilled, qualified

personnel.

2. Never connect AC power to the output terminals.

3. Ensure the pump and controller characteristics match.

4. Do not install the controller in the following conditions:

a. Vibration and mechanical shock.

b. Corrosive gasses and liquids.

c. Extreme heat and cold, operating range -25oC - +55oC.

d. Salt mist corrosion.

e. Rain and moisture.

f. Flammable materials, solvents.

BIA-DPC1 rev 4 Page 3

TABLE OF CONTENTS

Page

1.0 INTRODUCTION

1.1 Applications 5

1.2 Technical parameters and features 5

1.3 Meanings of the icons shown on the LCD 7

2.0 INSTALLATION – DRAINAGE

2.1 Electrical connection to the power supply and pump 8

2.2 Function switch setting 9

2.3 Connections for pump over temperature protection (where supplied) 10

2.4 Installing float switches and probes 10

2.5 Diagrams for drainage by liquid level through float switches or probes 11

2.0a INSTALLATION – DRAINAGE

WITH AUTOMATIC PUMPS

2.1a Electrical connection to the power supply and pump 15

2.2a Function switch setting 16

2.3a Connections for pump over temperature protection (where supplied) 17

2.4a Installing float switches and probes 17

2.5a Diagram for drainage by liquid level 18

3.0 INSTALLATION – BOOSTING

3.1 Electrical connection to the power supply and pump 20

3.2 Function switch setting 21

3.3 Connections for pump over temperature protection (where supplied) 22

3.4 Installing float switches and probes 22

3.5 Diagrams for boosting by liquid level through float switches or probes 23

BIA-DPC1 rev 4 Page 4

Cont....

TABLE OF CONTENTS cont.

4.0 INSTALLATION – TRANSFER

4.1 Electrical connection to the power supply and pump 27

4.2 Function switch setting 28

4.3 Connections for pump over temperature protection (where supplied) 29

4.4 Installing float switches and probes 29

4.5 Diagrams for transfer by liquid level through float switches or probes 30

4.0a INSTALLATION – TRANSFER

HOT WATER CIRCULATION

4.1a Electrical connection to the power supply and pump 33

4.2a Function switch setting 34

4.3a Connections for pump over temperature protection (where supplied) 35

4.4a Installing float switches and probes 35

4.5a Diagrams for transfer by liquid level through float switches or probes 36

5.0 OPERATION

5.1 BEFORE YOU START – Parameter calibration and erasing 37

5.2 Switching to AUTO mode 38

5.3 Switching to MANUAL mode 38

5.4 Alarm Test and MUTE 38

5.5 Pump protection 38

5.6 Last five failure record 39

5.7 Pump accumulated running time 39

5.8 Pump disable 39

6.0 COMMUNICATION LINK 40

6.1 Basic Function 41

6.2 Special application 41

6.3 Technical parameters 41

7.0 TROUBLE SHOOTING GUIDE 42

BIA-DPC1 rev 4 Page 5

1.0 Introduction

Thank you for choosing a Bianco Icon Series Intelligent Pump Controller.

The Intelligent Pump Controller model is an easy to use, programmable controlling and protection

device for direct start, single phase pumps with output power from 0.37kW – 2.2kW.

The Controller has many operation modes by adopting different electrical installations. Important

features that distinguish the Bianco Icon Series Intelligent Pump Controllers from some other

controllers are the push button calibration of overload and ability for dry run protection without

float switches or probes.

1.1 Applications

The Controller is useful in all cases where there is the need to control and protect single pump

installations managing the automatic operation by a variety of switching methods.

Typical usage scenarios include:

• Stormwater

• Sewage

• Booster sets

• Rainwater reuse

• Irrigation

• Water supply

1.2 Technical parameters and features

• Built in function switch for

o Drainage by liquid level control through float switches or probes

o Boosting water supply by pressure control through pressure switch and tank

o Transfer water by liquid level control through float switches and probes

• Dry run protection without float switches or probes

• Auto/Manual switch

• Dynamic LCD displaying pump running state

• Protect the pump against many faults

• Push button calibration

• Pump accumulative running time

• Last five fault record

• RS485 communication

• Starts and stops the pump in accordance with liquid levels and pressure settings

BIA-DPC1 rev 4 Page 6

The following chart shows main technical parameters for the Controller DPC1

Main technical characteristic

Control characteristic

Double liquid level control

pressure control

Control method

Manual/Auto

Liquid level control characteristic

pulse electrode probe and float switch

Pressure control characteristic

pressure switch and pressure tank

Main technical data

Rated output power

0.37 – 2.2 kW (0.5 – 3.0 hp)

Rated input voltage

240V

Trip response time of overload

5 sec - 5 min

Trip response time of open phase

< 2 sec

Trip response time of short circuit

< 0.1 sec

Trip response time of under/over voltage

< 5 sec

Trip response time of dry run

6 sec

Recovery time of over load

30 min

Recovery time of under/over voltage

5 min

Recovery time of dry run

30 min

Trip voltage of over voltage

115% of rated input voltage

Trip voltage of under voltage

80% of rated input voltage

Liquid level transfer distance maximum

1000m

Protection functions

Dry run

Over load

Transient voltage

Under voltage

Over voltage

Pump stalled

Short circuit

Main installation data

Working temperature

-25 to +55 deg C

Working humidity

20% to 90% Relative Humidity, non-condensing

Degree of protection

IP54

Install position

Vertical

Unit dimensions (L x W x H)

30.2 x 24.0 x 12.0 cm

RS485 technical data

Physical interface

RS485 Bus Interface: asynchronous semi duplex

Baud rate

1200,2400,4800,9600 bps (default 9600bps)

Protocol type

MODBUS protocol (RTU)

BIA-DPC1 rev 4 Page 7

1.3 Meanings of the icons shown on the LCD.

Icon Meaning / Description

pump parameter configuration icon, when this icon appears, pump control box

is parameter setting

time displaying icon, when this icon appears, it means pump control box is

displaying some parameter of time, eg: pump accumulated running time (unit:

hour); counting down etc

pump fault icon, when this icon appears, it means pump control box is displaying

some fault information

network connection error icon, when this icon appears, it means there is no

network connections or network connection error between pump control box

and SC(slave controller) or computer

network normal connection icon, when this icon appears, it means the network

connection between pump control box and SC (slave controller) or computer is

normal

V voltage

M minute

S second

H hour

% percent

A ampere

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

pump B (for dual pump controllers)

BIA-DPC1 rev 4 Page 8

2.0 Installation – DRAINAGE

2.1 Electrical connection to the power supply and pump

DANGER. Electric shock risk.

Before carrying out any installation or maintenance operation, the control panel should be

disconnected from the power supply and one should wait at least 2 minutes before opening the

control panel.

Never connect AC power to output L and N terminals.

Ensure the motor, controller and power specifications match.

The electrical and hydraulic connections must be carried out by competent, skilled, qualified

personnel.

Main Circuit Breaker

BIA-DPC1 rev 4 Page 9

2.2 Function switch setting - DRAINAGE

Installers can set the function switch to meet different applications. Before setting the function

switch, the control panel should be disconnected from the power supply.

After completing the setting, apply power to the control panel and observe the application sign

displayed on the LCD conforming to the DRAINAGE symbol.

DRAINAGE SETTING DRAINAGE SYMBOL

SWITCHES DOWN

MCB

BIA-DPC1 rev 4 Page 10

2.3 Connections for pump over temperature protection (where supplied with pump).

Note: to realize the pump motor winding over temperature protection, it requires that there must be over-

temperature switches embedded in the pump motor winding (microtherms as fitted to Zenit 3ph pumps 2.2

kW or greater). To utilise the pump’s over temperature protection connect the pump’s microtherm leads to

terminals 9 and 11, 10 and 12 and remove the jumper.

Note: if the pump is without over temperature switch, please use jumper to connect terminals 9 and 11, 10

and 12.

2.4 Installing float switches and probes.

Float switch installation.

Do not encase sensor leads, float switches or signal cables in metal pipes. Use PVC or PE tubing.

Liquid probe installation.

Jumper Leads

BIA-DPC1 rev 4 Page 11

In event of high risk of electrical storms (lightning) or when liquid medium in sump, well or tank is very

dirty, it is recommended to use float switches.

2.5 Electrical connections for DRAINAGE applications

2.5.1 Drainage by liquid level control through float switches or probes

Note: for 4 float switch installation connect float switch A (pump off) to terminals 1 and 3, float switch B (1st

pump on) to terminals 1 and 5, float switch C (2nd pump on) to terminals 2 and 4 and float switch D (alarm) to

terminals 2 and 6.

BIA-DPC1 rev 4 Page 12

2.5.1 Drainage by liquid level control through float switches or probes (cont)

Note: for 4 float switch installation connect float switch A (pump off) to terminals 1 and 3, float switch B (1st

pump on) to terminals 1 and 5, float switch C (2nd pump on) to terminals 2 and 4 and float switch D (alarm) to

terminals 2 and 6.

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2.5.1 Drainage by liquid level control through float switches or probes (cont)

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Stop condition

Liquid level in the sump is reaches probe 2, (float switch A down) the control panel will stop the pump.

Start condition

Liquid level in the sump reaches probe 3, (float switch A up) the control panel will run a pump. Control panel

will alternate the pumps when the liquid level varies between probe 2 and probe 3 (float switch A up and

down).

2nd pump start condition

Liquid level in the sump reaches probe 4, (float switch B up) the control panel will run the second pump.

Pumps run simultaneously until liquid level reaches probe 2, (float switches A and B down).

Alarm condition

While pumping, if the liquid level rises in the sump to probe 5, (float switch C up), the control panel will sound

the alarm to warn the user to take further action.

Meanings of the messages & graphic shown on the LCD screen

BIA-DPC1 rev 4 Page 15

2.0a Installation – DRAINAGE WITH AUTOMATIC PUMPS

2.1a Electrical connection to the power supply and pump

DANGER. Electric shock risk.

Before carrying out any installation or maintenance operation, the control panel should be

disconnected from the power supply and one should wait at least 2 minutes before opening the

control panel.

Never connect AC power to output L and N terminals.

Ensure the motor, controller and power specifications match.

The electrical and hydraulic connections must be carried out by competent, skilled, qualified

personnel.

Main Circuit Breaker

BIA-DPC1 rev 4 Page 16

2.2a Function switch setting – DRAINAGE WITH AUTOMATIC PUMPS

Installers can set the function switch to meet different applications. Before setting the function

switch, the control panel should be disconnected from the power supply.

After completing the setting, apply power to the control panel and observe the application sign

displayed on the LCD conforming to the DRAINAGE symbol.

DRAINAGE SETTING DRAINAGE SYMBOL

FOR AUTOMATIC PUMPS

MCB

BIA-DPC1 rev 4 Page 17

2.3a Connections for pump over temperature protection (where supplied with pump).

Note: to realize the pump motor winding over temperature protection, it requires that there must be over-

temperature switches embedded in the pump motor winding (microtherms as fitted to Zenit 3ph pumps 2.2

kW or greater). To utilise the pump’s over temperature protection connect the pump’s microtherm leads to

terminals 9 and 11, 10 and 12 and remove the jumper.

Note: if the pump is without over temperature switch, please use jumper to connect terminals 9 and 11, 10

and 12.

2.4a Installing float switches and probes.

Float switch installation.

Do not encase sensor leads, float switches or signal cables in metal pipes. Use PVC or PE tubing.

Liquid probe installation.

Jumper Leads

BIA-DPC1 rev 4 Page 18

In event of high risk of electrical storms (lightning) or when liquid medium in sump, well or tank is very

dirty, it is recommended to use float switches.

2.5a Electrical connections for DRAINAGE applications WITH AUTOMATIC PUMPS

2.5.1a Drainage by liquid level control.

Note: for “3 wire” floats use black and brown wires. Terminate blue wire with closed end connector.

Alarm float C connected to terminals 2 and 6.

If the system activates the high level alarm connected to the control panel the second pump will start

and the alarm will activate until the high level float deactivates.

If a pump fail situation is detected then the pump will switch to the second pump.

Warning – DRY RUN Protection not active in Drainage with Automatic Pump Mode.

High Level Alarm Delay

High Level Alarm delayed by 15 minutes after activation of High Level Float to allow 2nd Pump to turn on

and assist with pump out.

Note, For 30 minutes after High level Alarm activated, both pumps work concurrently.

Note: for drainage

with automatic

pumps, floats A & B

are not used and

terminals 1, 3, 5 and

2,4 are bridged.

BIA-DPC1 rev 4 Page 19

2.5.1a Drainage by liquid level control WITH AUTOMATIC PUMPS

Stop condition

Liquid level in the sump is below automatic pump float switch off position which will stop both pumps.

Start condition

The control panel alternates power supply between pumps every 240 hours. When liquid level in the sump is

above the automatic pump float switch on position, the pump that is being supplied power will run.

Alarm condition

While pumping, if the liquid level rises in the sump to float switch C up, the control panel will sound the alarm

to warn the user to take further action.

Meanings of the messages & graphic shown on the LCD screen

BIA-DPC1 rev 4 Page 20

3.0 Installation – BOOSTING

3.1 Electrical connection to the power supply and pump

DANGER. Electric shock risk.

Before carrying out any installation or maintenance operation, the control panel should be disconnected from

the power supply and one should wait at least 2 minutes before opening the control panel.

Never connect AC power to output L and N terminals.

Ensure the motor, controller and power specifications match.

The electrical and hydraulic connections must be carried out by competent, skilled, qualified personnel.

Main Circuit Breaker

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Icon DPC1 Operating instructions

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