OWNER S OPERATION MANUAL

DUTY P P STDBY Run 1 2 Run STDBY P P FAULT Run 3 4 OK: Change mode PUMPCONTROL OWNER S OPERATION MANUAL Advanced Multi Pump Controller Installation and Operating Instructions MODEL: FPC-15607-S AUTO: RUNNING 475kPa MAIN ISOLATOR DOC: FPC-1507-S VER 1.0

CONTENTS 1. Installation - - - - - - - - - - - - - - - - - - - - - - - 4 2. I/O Specifications - - - - - - - - - - - - - - - - - - - - - - - 5 3. HMI Operation - - - - - - - - - - - - - - - - - - - - - - - 6 3.1 Operational Modes - - - - - - - - - - - - - - - - - - - - - - - 7 3.2 Alarms - - - - - - - - - - - - - - - - - - - - - - - 8 3.3 Logged Data - - - - - - - - - - - - - - - - - - - - - - - 8 3.4 Edit Parameters - - - - - - - - - - - - - - - - - - - - - - - 8 3.5 HMI Config Settings - - - - - - - - - - - - - - - - - - - - - - - 9 3.6 PIN Number - - - - - - - - - - - - - - - - - - - - - - - 9 3.7 4-20mA Display Modes - - - - - - - - - - - - - - - - - - - - - - - 9 3.8 Multi Pump HMI Menu Structure - - - - - - - - - - - - - - - - - - - - - - - 10 4. Functionality - - - - - - - - - - - - - - - - - - - - - - - 11 4.1 Base Operation - - - - - - - - - - - - - - - - - - - - - - - 11 Auto/Off/Manual - - - - - - - - - - - - - - - - - - - - - - - 11 Manual Mode Timeout - - - - - - - - - - - - - - - - - - - - - - - 11 Pump Duty - - - - - - - - - - - - - - - - - - - - - - - 11 Pump Alternate Timer - - - - - - - - - - - - - - - - - - - - - - - 12 Staggered Pump Start - - - - - - - - - - - - - - - - - - - - - - - 12 Staggered Pump Stop - - - - - - - - - - - - - - - - - - - - - - - 12 Anti-Seize Timer - - - - - - - - - - - - - - - - - - - - - - - 12 Pump Fault - - - - - - - - - - - - - - - - - - - - - - - 12 Pump Limiting - - - - - - - - - - - - - - - - - - - - - - - 12 Prime Loss Fault - - - - - - - - - - - - - - - - - - - - - - - 13 Maximum Idle Timer - - - - - - - - - - - - - - - - - - - - - - - 13 Maximum Run Fault - - - - - - - - - - - - - - - - - - - - - - - 13 System Enable Input - - - - - - - - - - - - - - - - - - - - - - - 13 4.2 Level Operation - - - - - - - - - - - - - - - - - - - - - - - 13 Float Operation - - - - - - - - - - - - - - - - - - - - - - - 13 High Level Alarm - - - - - - - - - - - - - - - - - - - - - - - 14 Low Level Alarm - - - - - - - - - - - - - - - - - - - - - - - 14 Analogue Input - - - - - - - - - - - - - - - - - - - - - - - 14 Current Loop Fail Alarm - - - - - - - - - - - - - - - - - - - - - - - 14 4.3 Pressure Operation - - - - - - - - - - - - - - - - - - - - - - - 15 Static Lead Pump - - - - - - - - - - - - - - - - - - - - - - - 15 Current Loop Reverse - - - - - - - - - - - - - - - - - - - - - - - 15 High Pressure Alarm - - - - - - - - - - - - - - - - - - - - - - - 15 Low Pressure Alarm - - - - - - - - - - - - - - - - - - - - - - - 15 2

CONTENTS 5. Parameters Listing - - - - - - - - - - - - - - - - - - - - - - - 16 6. Modbus Communications - - - - - - - - - - - - - - - - - - - - - - - 17 6.1 Modbus Settings - - - - - - - - - - - - - - - - - - - - - - - 17 6.2 Modbus Physical Connection - - - - - - - - - - - - - - - - - - - - - - - 17 6.3 Modbus Poll and Timeout Settings - - - - - - - - - - - - - - - - - - - - - - - 17 6.4 Modbus Diagnostic - - - - - - - - - - - - - - - - - - - - - - - 18 6.5 Modbus Supported Function Codes - - - - - - - - - - - - - - - - - - - - - - - 18 6.6 Address Reference - - - - - - - - - - - - - - - - - - - - - - - 18-20 6.7 Data Types - - - - - - - - - - - - - - - - - - - - - - - 21-23 7. Circuit Diagrams - - - - - - - - - - - - - - - - - - - - - - - 24-25 8. Connection Detail - - - - - - - - - - - - - - - - - - - - - - - 26-27 At a glance - - - - - - - - - - - - - - - - - - - - - - - 26 3

AUTO: RUNNING 475kPa DUTY P P STDBY Run 1 2 Run STDBY P P FAULT Run 3 4 OK: Change mode MAIN ISOLATOR WELCOME TO DUAL PUMP CONTROL Your Advanced Multi Pump Controller reflects the superior quality and attention to detail in 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. 1. INSTALLATION 1.1 MOUNTING 1. Controller enclosure must be FRONT Top SIDE VIEW Top mounted in a vertical position. 2. Ensure mounting method does not compromise enclosure weather proof rating. Mounting Frame/ Wall 3. Ensure access to main isolator is not restricted. 4. Ensure cables/conduits entering Bottom Bottom the panel have mechanical protection and that the penetrations are sealed and do not compromise the weather proof rating of the enclosure. WARNING: All electrical connections must be carried out by a suitably qualified and registered electrician SAFETY Prior to Installation, ensure power supply is isolated. Power supply must be Circuit Breaker Protected. (Qualified Electrician to determine appropriate amp rating.) Electrical connection to the panel must be carried out in accordance with Connection Instructions, see page 3. Addition or modifications to the control panel are not permitted and will void warranty. The controller is not intended for use by children or infirm persons without supervision. Repairs to the Controller must only be carried out by a suitably qualified Electrician 4

2. I/O SPECIFICATIONS All operator control including pump auto/off/manual is done using the HMI on the front of the panel, which connects via a dedicated, optically isolated serial port. Although the basic configuration will be for float switch based level detection, the system will optionally be configurable to use a 4-20mA hydrostatic pressure transducer. I/O Name Signal Name Description A0 Low level Input from low level float switch A1 Pump stop Input from pump stop level float switch A2 Duty start Input from duty start level float switch A3 Standby 1 start Input from standby 1 start level float switch A4 Standby 2 start Input from standby 2 start level float switch A5 Standby 3 start Input from standby 3 start level float switch A6 Priming Input from priming sensor (opens on prime loss) B0 Pump 1 OK Input from Pump 1 overload. Opens on fault B1 Pump 2 OK Input from Pump 2 overload. Opens on fault B2 Pump 3 OK Input from Pump 3 overload. Opens on fault B3 Pump 4 OK Input from Pump 4 overload. Opens on fault B4 System enable Close contact to enable automatic operation C0 Pump 1 run Output to Pump 1 contactor C1 Pump 2 run Output to Pump 2 contactor C2 Pump 3 run Output to Pump 3 contactor C3 Pump 4 run Output to Pump 4 contactor C4 Siren Siren output C5 Strobe Strobe output C6 Low Level Low Level output D0 Common Fault Common Fault output AI IN Level in 4-20mA level transducer input (optional) AV OUT Level out 0-10V level reference output. Simply copies the input. Table 1 : I/O Listing for standard configuration. 5

3. HMI OPERATION AUTO: RUNNING 475kPa DUTY P P STDBY Run 1 2 Run STDBY P P FAULT Run 3 4 OK: Change mode The HMI When power is applied the HMI immediately starts up, displaying a splash screen with the Matelec logo and software revision is displayed for several seconds. Once the splash screen disappears the HMI will then display the main screen which gives an overview of the system. While the HMI is operating it must always be connected to a controller in order to read the necessary data that it needs to display. If it is unable to communicate with the controller the HMI will begin to flash both indicator LEDs and notify the user on the LCD. The user will be unable to operate the HMI until the communication link is restored. During normal operation the user is able to access many different functions related to both the attached controller and the Modbus interface. The following sections present the various menus used by the HMI and describe their use. Navigation between the menu screens is performed using the left and right arrows, which cycles through each of the screens in the following order: 1. Main screen (pump auto/off/manual control) 2. Alarms 3. Input and 4-20mA states 4. View logged data 5. Reset logged data * 6. Edit functional parameters * 7.Edit configuration settings * 8. System information and serial number * * Lines marked with an asterisk require entry of a PIN number for access. See section 3.6 for more info. Note that many of the menu screens feature a prompt along the bottom of the display which outlines basic button functions. 6

3.1 OPERATIONAL MODES The system will have three primary modes of operation, which are selected by pressing the okay button on the main screen and pressing up and down to find the mode and okay to select. These modes are outlined below. AUTO: RUNNING 2.6m Change System Mode: AUTO OK: Change mode Off Mode The controller is disabled and will not activate any of the pumps. All alarm conditions are still valid. Auto Mode When the system is set to Auto each of the four pumps will operate as the level rises in the tank. This can either be by float switches or transducer (4-20mA) input. Transducer is selected by setting parameter current loop en = 1. Upon a pump fault that pump will be locked out and the next available pump will be turned on. AUTO: RUNNING 2.6m DUTY Run STDBY Idle P P 1 2 P P 3 4 OK: Change mode STDBY Run FAULT Manual Mode With the system in protected manual mode each pump will be able to be individually selected to run in manual mode. Despite this manual control of the pumps all pump protection algorithms will still be applicable and a faulty pump will still not run. Manual mode ignores the systems enable input. When in manual mode press the up and down arrows select the pump and the OK button to start and stop pump. To return to auto operation, ensure the selection box is around all the pumps (as pictured above) before pressing OK. SYSTEM MANUAL 2.6m P P OFF 1 2 MANUAL Run OFF P P 3 4 : Select Pump FAULT 7

3.2 ALARMS The alarms screen reports any alarm conditions and provides the user with a method to reset them. This provides an opportunity for the operator to trigger an alarm test. Pressing the OK button will cause the controller to activate its siren and strobe outputs, plus all LEDs on a keypad (if used) for 5 seconds. After this alarm test is completed the alarms will return to normal operation. ALARMS No alarms active High level Alarm Pump 1 fault ALARMS Press OK to reset alarms Alarms screen with no alarms Alarms screen with multiple alarms If any alarms are active the alarm screen will appear as shown on the right image above and list up to 5 of the active alarms. When an alarm triggers the controller will activate its siren and strobe outputs. The alarm LED on the HMI will also flash. The siren will silence after 5 minutes of continual sounding, however it can be immediately silenced by pressing the mute button on the HMI. Most alarms in the controller are latching, that is the alarm remains active even if the alarm condition has passed / corrected. In order to reset the alarm the OK button needs to be pressed when the Alarms screen is selected. 3.3 LOGGED DATA The logged data screen displays a list of all logged data values from the controller. The up and down buttons are used to scroll through all of the values a small up or down arrow will appear on the top or bottom of the left side of the screen while there is more data available in that direction. LOGGED DATA Pump 1 start count Pump 2 start count Pump 3 start count 375 376 377 Logged data screen 3.4 EDIT PARAMETERS The Edit Parameters screen allows the user to modify any of the function parameters in the controller. The parameter that the user wishes to modify is highlighted using the up and down buttons and then OK is pressed in order to edit the selected parameter. Once a parameter has been selected the screen on the image to the right below will be presented and the up and down arrows can then be used to modify the value. The new value can be accepted by pressing OK, otherwise the operation can be canceled by pressing one of the left or right buttons. PARAMETERS Pump stop level 0.5m Pump start level 0.9m Standby 1 level 1.5m PARAMETERS Maximum idle period: 15 mins Use keys to change OK to commit or to cancel Parameter selection screen Parameter modify screen This screen requires entry of the PIN number for editing.(see section 3.6) 8

3.5 HMI CONFIG SETTINGS All of the configuration settings related solely to the HMI can be modified through this screen. The Modbus configuration options are pictured below and there are three additional configuration settings in the list: 1. Set analogue range: this setting specifies the maximum range of the level transducer being used to sense the liquid level, based on the level mode selected. For example, if a 0-10m probe is used, then the range would be set to 10m. Alternately, if a 0-1000kPa probe is used, then the range would be set to 1000kPa. 2. Set analogue type: this setting specifies the level mode for the system - pressure (kpa), level (m). All references to the transducer input will be displayed based on this parameter. 3. Change PIN: selecting this option will allow the PIN number to be changed. Note: There is no way to reset the PIN number if changed, change at your own risk. HMI CONFIGURATION Modbus slave address 1 Modbus speed Modbus parity 19200 baud Even Configuration edit screen 3.6 PIN NUMBER In order to modify anything other than the pump auto/off/manual settings, the operator must enter a 4-digit PIN number. Once the PIN is correctly entered, the system remains unlocked for 15 minutes, after which the PIN will need to be entered once again. While unlocked the PIN number can be modified through the configuration settings edit menu. ENTER PIN NUMBER Enter PIN number to enable editing: 0000 Press OK to accept PIN entry screen To enter the PIN number, simply use the left and right buttons to select the value and the up and down buttons to change the digit. The default PIN number is 1234. Note that there is no penalty for entering an incorrect PIN the HMI will simply return to the previous screen and the opportunity to enter the PIN will again be presented. 3.7 4-20mA Display Modes When the current loop mode is enabled the HMI is able to report the current 4-20mA reading (this is shown on the inputs menu screen). In addition, it can convert this reading into one of two types of scale: meters or kpa. The meters scale can be adjusted for a maximum range of 0.1 to 25.0 meters (in 0.1m increments) and the kpa scale can be adjusted for a maximum range of 10 to 2500kPa in 10kPa increments. 9

3.8 MULTI PUMP HMI MENU STRUCTURE Pin may need to be set to adjust values - Default 1 2 3 4 If not used for a period of time, the pin will need to be entered again. OK OK OK To reset active faults. NUMBER OF PUMPS PUMP 1 START COUNT 10 SYSTEM AUTO OK OK SYSTEM OFF OFF PUMP 4 MAX 0 Reset logged data MANUAL OK STAND BY 3 LEVEL OK CHANGE VALUE 2.4 OK PUMP 1 OFF OK PUMP 1 MANUAL PUMP 2 OFF OK PUMP 2 MANUAL 10

4. FUNCTIONALITY Based on the pump mode, operational state and parameter settings each of the four pumps will operate independently in one of eight states: Pump State Applicable Modes Description Off Off Pump will not run Disabled All Pump is disabled by parameter settings and won t run Fault All The Thermal Overload Relay (TOL) for this pump has indicated a fault and has been shut down Manual Run Manual Pump has been set to run in manual mode Standby Idle Auto Pump is not running but available to run if demand requires Standby Run Auto To meet demand this pump has been started in addition to the duty pump Duty Run Auto Pump is the primary operating pump used to maintain the system pressure about the setpoint. If it is unable to keep up with demand then a standby pump will be started in addition to this pump Duty Sleep Auto This pump is the primary pump operating but has been shut off due to no demand. Table 2: Pump State Descriptions Note that the system can be configured for either 2-4 pumps. If only 3 pumps are used ignore references to the fourth pump and stand by 3 start float. Stand by 2 start float will now have the delay for the high level alarm. 4.1 Base Operation Auto/Off/Manual Auto/off/manual control is performed at a system level. If the system is set to auto then it will operate normally. With the system in off the pumps are not operated (however alarms can still be triggered from fault conditions). If set to manual then each pump can individually be selected for manual running. Again, all alarm conditions are still valid in manual mode. If a pump has been temporarily removed from the system (i.e. for replacement) then it should be disabled via the corresponding pump_enable parameter. Manual Mode Timeout The optional Manual Mode Timeout feature prevents the system from being left in manual mode. If the [manual_timeout] parameter is set to a value other than zero then once the system has been in manual mode for that period (in minutes) it will automatically revert back to automatic mode. Pump Duty In order to distribute wear between pumps the system changes duty whenever the duty pump switches off. Pump selection is done sequentially (wrapping around from 4 to pump 1). 11

Pump Alternate Timer The [duty_change_time] parameter specifies the time in minutes of continuous running at which a pump alternate occurs. Alternately, setting [duty_change_time] to 0 disables this feature. Staggered Pump Start An undesired characteristic of starting motors DOL is the high inrush and startup current. Starting more than one motor simultaneously (such as during a high level) can put strain on the power supply and cause nuisance tripping. To avoid this a staggered pump start function is available. The controller will always apply the delay set by the [staggered_start_delay] parameter between starting of pumps. Staggered Pump Stop While the staggered start function is designed to minimise wear on the electrical supply to the system, it also reduces water hammer in the connected pipework. Such water hammer can also occur when switching off all pumps simultaneously. In order to again minimise this, the controller will apply the delay set by the [staggered_stop_delay] parameter (in seconds) between stopping each pump. This parameter must be used with caution as it can enable the pumps to run dry. Ensure that the minimum level has ample water to facilitate the staggered stop times. Anti-Seize Timer Some installations will be subject to extended periods of no operation and in such cases it is beneficial to briefly run the pumps periodically in order to prevent them from seizing. The anti-seize feature facilitates this. When anti-seize is enabled and the system is in auto mode, the anti-seize timer will begin timing from the last time that a pump runs. Each time [antiseize_period] hours elapses, an anti-seize operation will be triggered and the duty pump will run for [antiseize_run_time] seconds. This operation ignores all of the float switch inputs (including the low level) and staggered start/stop timers. Following each antiseize run a change of duty is triggered so that each pump will be given an anti-seize operation over time. Setting either the [antiseize_period] or [antiseize_run_time] parameters to zero will disable the anti-seize operation. Pump Fault The unit has four inputs for connection to an overload auxiliary contact from each pump. These contacts are normally closed and open on fault. When a pump fault is detected that pump is immediately locked out and an alarm triggered. The lockout remains latched until the fault is reset this allows the system to work with overloads set to auto-reset. Pump Limiting Some applications require the redundancy of multiple pumps but cannot handle the pipeline pressure generated if all pumps were to be running simultaneously. The [pump_limit] parameter can be set to 2, 3, or 4 pumps and will limit the maximum number of pumps that can be running simultaneously to this value. 12

Prime Loss Fault If a pump fails to prime then it should be shut down to prevent damage. A single pressure/flow sensor is used to detect a prime loss condition and thus it is relevant if only the duty pump is running. If only the duty pump is running and the prime loss input is inactive for [prime_loss_delay] seconds then a prime loss fault will be triggered for the duty pump and the system will then alternate. The pump will remain locked out until the fault is reset. If the [prime_loss_delay] parameter is set to zero then the prime loss function is disabled. Maximum Idle Timer The maximum idle timer ensures that the minimum tank level is maintained. When [max_idle_period] minutes has elapsed since any pumps last run and the pump stop input is active then a pump run will be triggered. The duty pump will run until the pump stop input deactivates. Setting [max_idle_period] to zero will disable this feature. Maximum Run Fault A blockage with a pump can cause damage to the pump or the system. When in auto mode the period each pump runs for is timed. If this exceeds [max_run_period] minutes then the system will react as follows. If there are other idle pumps it will immediately alternate and a maximum run alarm for that pump will be triggered. The pump will not be locked out and will run again when called for, but the alarm will remain active until reset. Setting [max_run_period] to 0 disables this feature. If there are no idle pumps available then it will shut down and lock out that pump, requiring manual reset. System Enable Input The system enable input must be closed before the system will operate in automatic mode. Note however that the system mode can still be changed and pumps can still be run in manual mode when the system enable input is open. 4.2 Level Operation Float Operation Up to 6 float switches are used for the base operation: low level, pump stop, duty start, and standby 1-3 start. High level is shared with standby 1,2 or 3 start depending on the number of pumps selected. When in auto mode the operation is based on an order of priority of these float switches, in the order that follows: If the final standby start input is on (standby 2 start in triplex mode, standby 3 start in quadruplex mode) then after the set delay the high level alarm is triggered. If at least one of the other float switch inputs is on then all pumps will be activated. This requirement prevents the pumps from running dry in the event that the high level float were to become stuck on. If the low level input is off and a pump is running then all pumps are immediately switched off. After the set delay the low level alarm is triggered. If [low_level_lockout_en] is set then the pumps will remain locked out until the low level alarm is reset. If the duty start input is active the current duty pump will be turned on. The standby start inputs will activate the corresponding standby pumps in sequence from the duty pump (wrapping around from pump 4 to 1). Note that each input also overrides the input below it. Once activated, pumps remain latched on until the pump stop input turns off. When the duty pump switches off, duty alternates to the next available pump. 13

High Level Alarm If the high level input remains on for the time set by the [high_level_delay] parameter (in seconds) then the high level alarm is triggered. The high level alarm is normally latching, but setting [high_level_alarm_reset] to 1 will allow the system to automatically reset high level alarms once the high level input turns off. Low Level Alarm If the low level input is off and any pump start input is on the system will begin timing a low level alarm delay. If this condition remains for the [low_level_alarm_delay] parameter time (in seconds) then the low level alarm will activate. The low level alarm is latching and can only be manually reset. Additionally, if the [low_level_lockout_en] parameter is set to 1 then the system will shut down until the fault is reset. The low level alarm also applies when pumps are being run in manual mode. Analogue Input As an alternative (or in conjunction with) the float switch inputs, an analogue level transducer can be used with the system. The system accepts a 4-20mA transducer by setting [current_loop_en] to 1. The six fluid levels are set to specific transducer output levels using the following parameters: [low_level_current] [pump_stop_current] [duty_start_current] [standby_1_current] [standby_2_current] [standby_3_current] When the level transducer signal reaches the specified level the controller will translate that the same as if the corresponding digital input was activated. In level mode the float switch inputs still function as normal and can override the level sensor. This will allow for example a backup Low Level and High Level float to be used. Note Low Level input is also required for Low Level current input, if not required then Low Level input must be bridged. Also note however that in level mode the high level interlock rules are disabled, so no inputs in addition to the high level need to be active for the high level condition to be acknowledged. Current Loop Fail Alarm When relying on an analogue level probe for operation it is important to know if the probe is faulty. The [loop_fail_alarm_en] parameter, when enabled, will trigger an alarm if the current loop reading drops below 3.5mA. This will not affect operation of the system, but the resulting alarm will latch until reset. 14

4.3 Pressure Operation Static Lead Pump Setting [static_lead_pump_en] to 1 will cause the system to always select Pump 1 as the duty pump. Current Loop Reverse Setting [current_loop_reverse] to 1 will cause the system to operate in the reverse manner, i.e. maintaining a set pressure or filling a vessel rather than emptying a vessel. High Pressure Alarm If [current_loop_reverse] is enabled then high pressure alarm operation will be enabled and high level alarm operation disabled. If the analogue input level exceeds [high_pressure_alarm_level] for the time set by the [high_pressure_alarm_delay] parameter (in seconds) then the high pressure alarm is triggered. The high pressure alarm is normally latching, but setting [high_pressure_alarm_reset] to 1 will allow the system to automatically reset high pressure alarms once the high pressure condition subsides. Low Pressure Alarm If [current_loop_reverse] is enabled then low pressure alarm operation will be enabled and low level alarm operation disabled. If the analogue input level drops below [low_pressure_alarm_level] for the time set by the [low_pressure_alarm_delay] parameter (in seconds) then the low pressure alarm is triggered. The low pressure alarm is normally latching, but setting [low_pressure_alarm_reset] to 1 will allow the system to automatically reset low pressure alarms once the low pressure condition subsides. 15

5. PARAMETER LISTING Parameter Description Data Range Units Default Number_of_pumps Number of pumps connected to the system 3-4 - 4 Pump_1_enable Enable use of pump 1 0-1 - 1 Pump_2_enable Enable use of pump 2 0-1 - 1 Pump_3_enable Enable use of pump 3 0-1 - 1 Pump_4_enable Enable use of pump 4 0-1 - 1 Duty_change_period Duty is changed after the duty pump has run for this period of time 0-65535 Minutes 60 Staggered_start_delay Minimum time between pump starts 0-65535 Seconds 3 Staggered_stop_delay Minimum time between pump stops 0-65535 Seconds 1 High_level_alarm_delay Delay before activating high level alarm 0-65535 Seconds 5x60 High_level_alarm_reset If set to 1 high level alarm will reset when high level input turns off 0-1 - 0 Low_level_alarm_delay Delay before activating low level alarm 0-65535 Seconds 5 Low_level_lockout_en Enable system lockout on low level alarm 0-1 - 0 Antiseize_period Delay after pump run for triggering anti-seize run 0-65535 Hours 7x24 Antiseize_run_time Pump run time for anti-seize operation 0-65535 Seconds 5 Manual_timeout Maximum time system remains in manual mode 0-65535 Minutes 5 Pump_limit Maximum number of pumps that can be run simultaneously. 1-4 - 4 Prime_loss_delay Delay for prime loss fault. 0 is disabled. 0-65535 Seconds 0 Max_run_period Maximum time that the duty pump can be running for. 0 is disabled 0-65535 Minutes 0 Max_idle_period A pump start is triggered after this period. 0 is disabled. 0-65535 Minutes 30 Current_loop_en Enable current loop function 0-1 - 0 Loop_fail_alarm_en Enable current loop failure alarm 0-1 - 0 0 - ANALOGUE ANALOGUE Low_level_current Analogue input setting for low level 0.12m RANGE RANGE Pump_stop_current Analogue input setting for pump_stop 0.37m Duty_start_current Analogue input setting for pump 1 start 0.56m Standby_1_current Analogue input setting for pump 2 start 0.75m Standby_2_current Analogue input setting for pump 3 start 0.93m Standby_3_current Analogue input setting for pump 4 start & high level 1.12m State Lead Pump En Pump 1 will always be the duty pump 0-1 - 0 Current Loop reverse As the level decrease pumps, turn on 0-1 - 0 High Pressure Alarm Level Analogue input for high pressure alarm 0 - ANALOGUE ANALOGUE RANGE RANGE 8.50m High Pressure Alarm Delay Delay before activating high pressure alarm 0-65535 Seconds 5 sec High Pressure Alarm Reset If set to 1 High Pressure will reset when below High Pressure Alarm level 0-1 - 1 Low Pressure Alarm Level Analogue input for low pressure alarm 0 - ANALOGUE ANALOGUE RANGE RANGE 1.00m Low Pressure Alarm Delay Delay before activating low pressure alarm 0-65535 Seconds 5 sec Low Pressure Alarm Reset If set to 1 Low Pressure will reset when above low pressure alarm level 0-1 - 1 16

6. MODBUS COMMUNICATIONS Modbus is a serial communications protocol originally designed for use PLCs. Simple and robust, it has since become one of the de facto standard communications protocols in the industry, and it is now amongst the most commonly available means of connecting industrial electronic and control devices. Through it s connected ME16 HMI, the ME21 supports Modbus communications as described here. There are several different variations of the Modbus standard based around the transmission mode and data encoding technique. The protocol supported by the ME16 is Modbus RTU, which is a binary format sent over a serial link. The ME16 is configured as a Modbus slave and responds to commands sent to it from the Modbus master. 6.1 Modbus Settings In order to reduce unnecessary complexity, the system will comply only with the BASIC Modbus implementation class but with some additional features, as detailed in the following table. All settings have a default which is valid until the operator changes them via configuration menu. Setting Implemented Default Address Configurable from 1 to 247 1 Baud Rate 9600, 19200 19200 Parity Even, Odd, None Even HMI CONFIGURATION Modbus slave address 1 Modbus speed 19200 baud Modbus parity Even 6.2 Modbus Physical Connection The ME16 provides a three pin pluggable terminal for connection of the three RS- 485 connections required for the Modbus interface: A, B and GND. As with the other ME16 connections the wiring information is printed on the rear label of the unit. 6.3 Modbus Poll and Timeout Settings The poll rate is how often the Modbus master requests information from the slave. Since the processor on the ME16 must also operate the user interface and continually operate the communication link with the connected controller, it is only able to cope with a limited number of Modbus transactions per second. The recommended maximum poll period of 500ms (2 polls per second), however a period of 1 second is preferred. Periods as low as 250ms can be achieved but there can be no guarantee as to the ME16 s ability to respond at this rate (particularly with write commands). Certain Modbus operations require the ME16 to initiate further communications with the attached controller and this can take significantly more time than other operations for the controller to respond. For this reason a timeout period of no less than 1000ms should be used. If the Modbus connection is being used for monitoring only (rather than monitoring and control) then the timeout can be reduced to 500ms. 17

6.4 Modbus Diagnostics The System Information screen on the HMI can be used to diagnose the Modbus communication channel. Whenever a Modbus packet is received the Modbus Diag line will momentarily report Modbus Diag: Data Rx for 500ms. This will prove that the physical RS-485 connection is functional. If the received packet caused a modbus exception to be generated then it will also be temporarily reported as follows: Parity Error: Parity Error Baud Rate/Serial Port Error: UART Error Function Not Supported: Bad Function Illegal Data Address: Data Bad Addr Illegal Data Value: Bad Data Val Slave Device Failure: Slave Failure The error message is displayed for 20 seconds after the event occurs. 6.5 Modbus Supported Function Codes The Modbus protocol uses function codes to perform actions such as reading and writing the different physical data types. Only a portion of the full range of function codes is used, as outlined in the following table: Function Code Description Valid Address Range 01 Read coils 1 to 2016 03 Read holding registers 1 to126 06 Write single register 1 to 105 16 Write multiple registers 1 to 105 6.6 Address Reference The following table lists all valid Modbus coil and register addresses for the ME21 and the data contained within: Logged Values Register Address First Coil Address Data Range Data Type ID_number[0] 1 1 48-255 ASCII ID_number[1] 2 17 48-255 ASCII ID_number[2] 3 33 48-255 ASCII ID_number[3] 4 49 48-255 ASCII ID_number[4] 5 65 48-255 ASCII ID_number[5] 6 81 48-255 ASCII ID_number[6] 7 97 48-255 ASCII ID_number[7] 8 113 48-255 ASCII Number_of_pumps 9 129 1-4 Number Pump_1_enable 10 145 0-1 Number Pump_2_enable 11 161 0-1 Number Pump_3_enable 12 177 0-1 Number Pump_4_enable 13 193 0-1 Number 18

Values Register Address First Coil Address Data Range Data Type Duty_change_period 14 209 0-65535 Minutes Staggered_start_delay 15 225 0-65535 Seconds Staggered_stop_delay 16 241 0-65535 Seconds High_level_alarm_delay 17 257 0-65535 Seconds High_level_alarm_reset 18 273 0-1 Number Low_level_en 19 289 0-1 Number Low_level_alarm_delay 20 305 0-65535 Seconds Antiseize_period 21 321 0-65535 Hours Antiseize_run_time 22 337 0-65535 Seconds Manual_timeout 23 353 0-65535 Minutes Pump_limit 24 369 1-4 Number Prime_loss_delay 25 385 0-65535 Seconds Max_run_period 26 401 0-65535 Minutes Max_idle_period 27 417 0-65535 Minutes Current_loop_en 28 433 0-1 Number Loop_fail_alarm_en 29 449 0-1 Number Low_level_current 30 465 40-200 Current x10 Pump_stop_current 31 481 40-200 Current x10 Duty_start_current 32 497 40-200 Current x10 Standby_1_current 33 513 40-200 Current x10 Standby_2_current 34 529 40-200 Current x10 Standby_3_current 35 545 40-200 Current x10 Spare 36-72 - Logged Values Register Address First Coil Address Data Range Data Type Pump_1_start_count 73 1153 0-65535 Number Pump_2_start_count 74 1169 0-65535 Number Pump_3_start_count 75 1185 0-65535 Number Pump_4_start_count 76 1201 0-65535 Number Pump_1_run_hours 77 1217 0-65535 Hours Pump_2_run_hours 78 1233 0-65535 Hours Pump_3_run_hours 79 1249 0-65535 Hours Pump_4_run_hours 80 1265 0-65535 Hours Pump_1_fault_count 81 1281 0-65535 Number Pump_2_fault_count 82 1297 0-65535 Number Pump_3_fault_count 83 1313 0-65535 Number Pump_4_fault_count 84 1329 0-65535 Number Power_cycle_count 85 1345 0-65535 Number High_level_count 86 1361 0-65535 Number Low_level_count 87 1377 0-65535 Number P1_max_run_count 88 1393 0-65535 Number P2_max_run_count 89 1409 0-65535 Number P3_max_run_count 90 1425 0-65535 Number P4_max_run_count 91 1441 0-65535 Number P1_prime_fault_count 92 1457 0-65535 Number P2_prime_fault_count 93 1473 0-65535 Number P3_prime_fault_count 94 1489 0-65535 Number P4_prime_fault_count 95 1505 0-65535 Number Spare 96 - - - 19

System Values Register Address First Coil Address Data Range Data Type System_mode 97 1537 0: Off NUMBER 1: Auto 2: Manual Pump_1_man_run 98 1553 0-1 NUMBER Pump_2_man_run 99 1569 0-1 NUMBER Pump_3_man_run 100 1585 0-1 NUMBER Pump_4_man_run 101 1601 0-1 NUMBER Fault_reset 102 1617 0-1 NUMBER Mute_flag 103 1633 0-1 NUMBER Spare 104 1649 - - System_state 105 1665 0: Off 1: Manual 2: Startup 3: Running 4: Lockout 5: Disabled 6: Powerup Delay NUMBER Pump_1_state Pump_2_state Pump_3_state Pump_4_state 106 107 108 109 1681 1697 1713 1729 0: Off 1: Disabled 2: Standby Idle 3: Standby Run 4: Duty Idle 5: Duty Run 6: Manual Run 7: Fault 8: Starting 9: Stopping 10: Antisieze Run NUMBER Input_states 110 1745 - BINARY Output_states 111 1761 - BINARY Analog_in 112 1777 0-200 CURRENT x10 Analog_out 113 1793 0-100 VOLTAGE x10 Alarm_states 114 1809 - BINARY System_lockout 115 1825 - BINARY Firmware_rev[0] 116 1841 48-255 ASCII Firmware_rev[1] 117 1857 48-255 ASCII Firmware_rev[2] 118 1873 48-255 ASCII Firmware_rev[3] 119 1889 48-255 ASCII System_powerup_timer 120 1905 48-255 ASCII Spare 121-126 - - Table 3: Modbus registers, firmware revision 1.1. 20

6.7 Data Types Number Number values are numeric values in the range specified. Current Current values represent any parameter relating to the analogue input. Current is used here as it represents the base format of the analogue input. Because Modbus only supports integer values, the numeric value in these registers represents the measured current multiplied by ten. To convert between the register value and other units please use the following table: Units Convert From Register Value Convert To Register Value Actual Current (ma) register_value 10 actual_current x 10 Pressure (kpa) ( register_value - 40) x sensor_range 160 pressure x 160 sensor_range + 40 Level (m) (register_value - 40) x sensor_range 160 level x 160 sensor_range + 40 Temperature ( C) (register_value - 40) x sensor_range 160 temperature x 160 + 40 sensor_range Voltage Voltage values represent parameters relating to the analogue output and pump speed. Voltage is used here because it is the native unit of the analogue output. Because Modbus only supports integer values, the numeric value in these registers represents the measured voltage multiplied by ten. To convert between the register value and other units please use the following table: Units Convert From Register Value Convert To Register Value Actual Voltage (V) Speed (Hz) register_value 10 register_value 10 actual_value x 10 speed x 2 21

ASCII These registers contain the ASCII code for characters used in the unit s ID number (or serial number). These ASCII values have a range of 48 to 255 (0x30 to 0xff), however note that the HMI can only display ASCII characters in the range of 48 to 126 (0x30 to 0x7e). The following ASCII table shows these characters: Binary States Input states, output states, alarm states and fault lockout states have information in binary form as shown in the following table. Each of the individual addresses can be accessed as a coil (using the specified coil address) or as an individual bit of that register (bit 0 is the least significant bit, on the right). Register Bit Coil Address Input State 0 1745 A0 1 1746 A1 2 1747 A2 3 1748 A3 4 1749 A4 5 1750 A5 6 1751 A6 7 1752 B0 8 1753 B1 9 1754 B2 10 1755 B3 11 1756 B4 12-15 - Unused 22

Register Bit Coil Address Output State 0 1761 C0 1 1762 C1 2 1763 C2 3 1764 C3 4 1765 C4 5 1766 C5 6 1767 C6 7 1768 D0 8-15 - Unused Register Bit Coil Address Input State 0 1809 Pump 1 fault 1 1810 Pump 2 fault 2 1811 Pump 3 fault 3 1812 Pump 4 fault 4 1813 High Pressure Fault 5 1814 Low Pressure Fault 6 1815 Pump 1 Max Run 7 1816 Pump 2 Max Run 8 1817 Pump 3 Max Run 9 1818 Pump 4 Max Run 10 1819 Current Loop 11 1820 Pump 1 Prime Loss 12 1821 Pump 2 Prime Loss 13 1822 Pump 3 Prime Loss 14 1823 Pump 4 Prime Loss 15 1824 Bad Data Load 23

1 2 3 4 5 6 FPC-SERIES 7. CIRCUIT DIAGRAM FPC-15607-S Three Phase, Single Pump Controller c/w Floats 415 Vac Supply L1 L2 L3 E N WARNING! MSW1 Main Isolator MAXIMUM OF 10 STARTS PER HOUR FOR EACH PUMP CB2 C1 L1 T1 TOL1 SS1 P1 Circuit Breaker D' Curve 3P L2 T2 L3 T3 Contactor 3P Thermal Overload ABB SOFT STARTER ST A1 A2 P2 P3 P1 415V Pump R1/1 CB1 Circuit Breaker T1 L N PE 24Vdc Power Supply +24 Vdc -24 Vdc + - SS1 COM RUN C1 A1 A2 Contactor 24Vdc R1 PCB1 COM D0 Relay 24Vdc 2P BZ1 Buzzer Common Fault BMS Voltage Free F1 Fuse 1A ST1 X1 X2 Strobe Light COM RX TX +24Vdc -24Vdc PCB1 HMI1 TOL1 96 95 NC Contact Pump 1 Thermals Low Level Stop Level Start Level High Level Float Float Float Float INPUTS 24Vdc 24

1 2 3 4 5 6 FPC-SERIES FPC-15607-S Three Phase, Single Pump Controller c/w Transducer 415 Vac Supply L1 L2 L3 E N WARNING! MSW1 Main Isolator MAXIMUM OF 10 STARTS PER HOUR FOR EACH PUMP CB2 C1 L1 T1 TOL1 SS1 P1 Circuit Breaker D' Curve 3P L2 T2 L3 T3 Contactor 3P Thermal Overload ABB SOFT STARTER ST A1 A2 P2 P3 P1 415V Pump R1/1 CB1 Circuit Breaker T1 L N PE 24Vdc Power Supply +24 Vdc -24 Vdc + - SS1 COM RUN C1 A1 A2 Contactor 24Vdc R1 PCB1 COM D0 Relay 24Vdc 2P BZ1 Buzzer Common Fault BMS Voltage Free F1 Fuse 1A ST1 X1 X2 Strobe Light Optional Analogue OUT COM RX TX +24Vdc -24Vdc 0-10V PCB1 HMI1 E + - Level Transducer 4-20mA TOL1 96 95 NC Contact Pump 1 Thermals Low Level Float High Level Float INPUTS 24Vdc 25

8. CONNECTION DETAIL FPC-15607-S Three Phase, Single Pump Controller c/w Floats E A1 A2 A3 SUPPLY 415Vac Connections N T1 T2 Pump 1 T SWITCH Input 1 Low Level Input 2 Stop Level Input 3 Start Level INPUT SWITCHES 24Vdc Connections Input 4 High Level COMMON FAULT BMS VOLT/FREE PUMP 1 Earth P1 P2 PUMP 1 P3 415Vac MAINS POWER SUPPLY BRIDGE IF NOT REQUIRED BLUE NOT REQUIRED COMMON N/O CLOSE ON RISE BLUE NOT REQUIRED COMMON N/O CLOSE ON RISE BLUE NOT REQUIRED COMMON N/O CLOSE ON RISE BLUE NOT REQUIRED COMMON N/O CLOSE ON RISE REMOVE BRIDGING WIRE TO USE LOW LEVEL LOW LEVEL ALARM STOP LEVEL START LEVEL HIGH LEVEL PUMP 1 26

FPC-15607-S Three Phase, Single Pump Controller c/w Transducer + - E A1 A2 A3 SUPPLY 415Vac Connections N T1 T2 Pump 1 T SWITCH 24Vdc SHIELD EARTH Level Transducer 4-20mA Input 1 Low Level Input 4 High Level INPUT SWITCH 24Vdc Connection COMMON FAULT BMS VOLT/FREE PUMP 1 Earth P1 P2 PUMP 1 P3 BRIDGE IF NOT REQUIRED BLUE NOT REQUIRED COMMON N/O CLOSE ON RISE BLUE NOT REQUIRED COMMON N/O CLOSE COMMON ON RISE 415Vac MAINS POWER SUPPLY SHIELDED TRANSDUCER CABLE Current loop enabled to use transducer (see page 6) LOW LEVEL HIGH LEVEL PUMP 1 HYDROSTATIC LEVEL TRANSDUCER 27

AT A GLANCE A quick reference to the controller s HMI and Indicator functions and meanings. AUTO: RUNNING 475kPa DUTY Run P P 1 2 STDBY Run STDBY Run P P 3 4 FAULT OK: Change mode The HMI - Scroll through main pages - Changes digit when adjusting values - Change pump selection 1 or 2 on main page - Scroll through page list - Changes number when adjusting values - Change pump mode on main page OK - Select and saves value 'to be changed' - Access pump mode adjustment on main page - Reset system faults on alarm page MUTE - Mutes active audible alarm. DISTRIBUTED BY: INSTALLATION DATE: SERIAL NUMBER: MANUFACTURED BY MATelec AUSTRALIA EMAIL: info@matelecaustralia.com.au MATelec reserves the right to alter technical specifications without notice 28