DPC 2-1

Installation and Operating Instructions

DPC 2-1 For Single Phase Pumps up to 15A

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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
Power Terminal 10
Control PCB connection 11
Installation – Drainage 11
- Terminals 11
- DIP Switch Settings 12
- Electrical Connections 13
Installation – Boosting 16
- Terminals 17
- DIP Switch Settings 18
- Electrical Connections 19
Installation – Water Transfer 20
- Terminals 21
- DIP Switch Settings 22
- Electrical Connections 23
OPERATION 24
Parameter Calibration 24
Erasing Former Parameters 25
- Erasing The Parameter Calibration 25
Switching to AUTO mode 25
Switching to MANUAL mode 25
Pump Protection 25
Last Five Failure Records 26
Pump Accumulative Running Time 27
COMMUNICATION LINK 28
Basic Function 29
Special Application 29
Technical Parameters 29
TROUBLE SHOOTING 30
 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 L1 & N1 / L2 & N2 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
Thank you for choosing a DPC Series Digital Pump Controller.
The Digital Pump Controller model is easy to use, programmable controller and
protection device for direct start with single phase two pumps with output power
from 0.37kW - 1.5 kW (1.5 - 15A) 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 feature

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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) 1.5 to 15A for each pump
Rated input voltage AC 220V / 50 Hz / Single Phase
Trip response time of overload 5 sec - 5 min
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)

PROTECTIONS COVERED Transient surge
Under voltage
Over voltage
Pump stalled
Short circuit
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.

wall
Back view Side view Mounting
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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 POWER TERMINAL CONNECTIONS:

Single Phase (without running capacitor) Single Phase (with running capacitor)

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 CONTROL PCB TERMINAL CONNECTIONS:

The control terminal connection

varies based on the app

INSTALLATION - DRAINAGE:
TERMINALS
Using one float switch

Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will
start pump A. Panel will alternate between pump A and pump B after previous
cycle is completed. LCD screen will display RUN whichever pump in running.

Stop condition:
If the liquid level in the pit/tank falls, ie. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.
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 Using two float switches

Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will
start pump A. Panel will alternate between pump A and pump B after previous
cycle is completed. LCD screen will display RUN whichever pump in running.

If the liquid level in the pit/tank rises even further after first pump is running ie.
Float Switch A and Float switch B are in up position. As soon as Float switch B
reaches up position, panel will start whichever pump is in standby. E.g., If pump A
was running and liquid level rose even further and Float B comes in up position,
pump B will also start operating in parallel to pump A.

Stop condition:
If the liquid level in the pit/tank falls, i.e.. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.

If both pumps, we're running, then both pumps will stop simultaneously when
float switch A is in down position. LCD screen will display No water.

Using three float switches

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 Start condition:
If the liquid level in the pit/tank rises, ie. Float A is in up position. Panel will start
pump A. Panel will alternate between pump A and pump B after previous cycle is
completed. LCD screen will display RUN whichever pump in running.

If the liquid level in the pit/tank rises even further after first pump is running ie.
Float Switch A and Float switch B are in up position. As soon as Float switch B
reaches up position, panel will start whichever pump is in standby. Eg. If pump A
was running and liquid level rose even further and Float B comes in up position,
pump B will also start operating in parallel to pump A.

Alarm condition:
If the liquid level in the pit/tank rises even further after both pumps are running
and Float switch C is in up position. In this situation in addition to both pumps
running, an overflow alarm will generate an audio-visual sound with fault indica-
-tion on LCD screen showing Overflow. This fault will reset itself only when liquid
level in pit/tank falls below Float C, and Float C is in down position.

Stop condition:
If the liquid level in the pit/tank falls, ie. Float A is in down position. Panel will
stop whichever pump is running. This means that there is not enough water to
pump. LCD screen will display No water.

If both pumps, we're running, then both pumps will stop simultaneously when
float switch A is in down position. LCD screen will display No water.

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 L1&N1 / L2&N2 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. The symbol corresponding to the application will be
displayed on the LCD Screen.

ON
Drainage Setting Drainage Symbol
Switches Down

1 2 3
Pump connection for over temperature protection (where supplied with pump)

14 15 19 20
Jumpers Lead

Pump Shell Pump Shell

Over Temperature Over Temperature

(Thermal)Switch Pump A Pump B (Thermal)Switch

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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Meanings of the messages & graphic shown on the LCD screen

Messages & Graphics

Description

Lack of water in sump

No
water

Overflow Overflow in sump

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 INSTALLATION - BOOSTING:

TERMINALS
Using 1 Float Switch and 1 Pressure Switch

Start condition:
If the water level in source tank is high and the float switch A in the source
tank is in up position and the Pressure in the line is below the cut-in pressure
setting on the pressure switch A the pump starts. Panel will alternate between
pump A and pump B, when previous demand cycle is completed, and pump(s)
have stopped. LCD screen displays RUN indicating pump is running.
Stop condition:
If the water level in the source tank is low and Float switch A in the source tank
is in down position, the pump stops. LCD screen displays NO WATER, that means
there is no water in the source tank and can lead to a dry run situation.
If the Pressure in the line is equal to or above the cut-out pressure setting on
the pressure switch A installed, the pump stops. LCD screen displays FULL, that
means there is no demand of water.

Using 1 Float Switch and 2 Pressure Switch

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 Start condition:
If the water level in source tank is high and the float switch A in the source
tank is in up position and the Pressure in the line is below the cut-in pressure
setting on the pressure switch A the pump starts. Panel will alternate between
pump A and pump B, when previous demand cycle is completed, and pump(s)
have stopped. LCD screen displays RUN indicating pump is running.

If the pressure in the line is below cut-in pressure setting of pressure switch B,
then panel will start the standby pump to run in addition to operating pump.
Both pumps will run simultaneously in parallel operation.

Note: Cut in pressure of Pressure switch B < Cut in pressure of Pressure switch A

Stop condition:
If the water level in the source tank is low and Float switch A in the source tank
is in down position, the pump(s) stops. LCD screen displays NO WATER, that means
there is no water in the source tank and can lead to a dry run situation.

If the Pressure in the line is equal to or above the cut-out pressure setting on the
pressure switch A installed, the pump(s) stops. LCD screen displays FULL, that means
there is no demand of water.

If both pumps, we're running then both pumps will stop simultaneously when cut-
-out pressure switch of Pressure switch A is achieved.

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 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 L1 & N1 / L2 & N2 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.
After completing the setting, apply power to the controller and observe the
application sign displayed on the LCD conforming to the BOOSTING symbol.

1 2 3
Boosting Setting
Switches UP
Boosting Symbol

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

14 15 19 20 Jumpers Lead

Pump Shell Pump Shell

Over Temperature Over

(Thermal)Switch Temperat
ure
Pump B Pump A (Thermal)
Switch

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.

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

NOTE: Pressure Switch A = Low Pressure Switch, Pressure Switch B =

High Pressure Switch.

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 INSTALLATION - WATER TRANSFER:

TERMINALS

Using 2 Float switch (one float in UG tank, one float in OH tank)

Start condition:
If water level in UG tank is high ie. Float A is up and water level in OH tank is
low ie. Float B is down, panel will start pump A. Panel will alternate between
pump A and pump B, after previous cycle is completed. LCD screen will display
pump A/B run on screen.

Stop condition:
If the water level in UG tank is low ie. Float A is down, if any of the pump(s) are
running, panel will stop the pump(s) indicating that there is not enough water
in UG tank. LCD screen will display No water.

If the water level in OH tank is high ie. Float A is up. Panel will stop the pump(s)
that are running indicating that the OH tank is full. LCD screen will display Full.

On any of the situation stated above occur, pump(s) will stop running.

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 Using 3 Float switch (one float in UG tank, two floats in OH tank)

Start condition:
If water level in UG tank is high ie. Float A is up and water level in OH tank is
low ie. Float B is down, panel will start pump A. Panel will alternate between
pump A and pump B, after previous cycle is completed. LCD screen will display
pump A/B run on screen.

If the water level in the OH tank goes down even further below, and Float C is
down panel will start the standby pump along with the duty pump which is
running. ie. If pump A was running earlier when float B was down, and water
level in OH tank has gone even more down due to rising demand and Float C
is also now in down position, panel will start pump B also.

Stop condition:
If the water level in UG tank is low ie. Float A is down, if any of the pump(s) are
running, panel will stop the pump(s) indicating that there is not enough water
in UG tank. LCD screen will display No water.

If the water level in OH tank is high ie. Float A is up. Panel will stop the pump(s)
that are running indicating that the OH tank is full. LCD screen will display Full.

If both pumps, ie. Pump A and Pump B are running and water level in OH tank is
high which means Float B and Float C are up. Both pumps will stop simultaneously
only when the higher float ie. Float B is in up position.

On any of the situation stated above occur, pump(s) will stop running.

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 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 L1&N1 / L2&N2 terminals.

Ensure the motor, controller and power specifications.

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.
After completing the setting, apply power to the controller and observe the
application sign displayed on the LCD conforming to the TRANSFER symbol.

Transfer Setting Transfer Symbol

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Connections for pump over temperature protection (where supplied with pump)
Jumper’s lead

14 15 19 20

Pump shell Pump shell

Over temperature (thermal)switch

Over temperature
(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.

Messages & Graphics Description

Low water level in

underground tank

Enough water in underground

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
Press the A START key to run pump A,
1. Press the MODE key to switch to manual confirm the pump and all pipe
mode. If the controller is locked press network is in normal working state
MODE and STORE keys together and hold (including voltage, amps etc.) with
until the countdown timer stops and mode LCD screen displaying:
switched from Auto to Manual Make sure
that the pump is not running and LCD
screen is displaying:

2.

3. Press and hold the START key and release 4. The pump stops running and
when the countdown starts. The controller parameter calibration is completed
makes a “beep” and a countdown starts with LCD displaying:
with the LCD displaying: Controller now
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:

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 in to 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 from Auto mode to manual mode, and if the controller is under Auto
screen lock, then press MODE and STORE button simultaneously until the
countdown timer stops and mode switches back to manual. Press the START
key to start the pump and the STOP key to stop the pump.

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.
3. Press the A STOP key to quit the failure record display:

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 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 4. Repeat for pump B by using B STOP key.
the accumulative running time
display.

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 COMMUNICATION LINK
The controller has communication interface, between the pump controller
and computer/SCADA/BMS, users can realize a long-distance monitoring
function. 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.

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 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 power supply company.
voltage, 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 calibrated restart the pump every 30
/ set running ampere, pump min until running ampere is
is in overl o a d protection restored to normal.
Inspect pump and motor
winding.
Flashing of Parameter calibration not Refer to parameter
PUMP NO completed. calibration setting.
CALIBRATION
Flashing of DRY RUN Liquid level in the well/ Controller will attempt to
sump is below the pump restart the pump every 30
intake, pump stops min until liquid level is above
running. 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 precharge
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.

NOTE: Float/pressure switch should be ordered separately.

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Version: 02.0522
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