CONTROL EQUIPMENT

DIGITAL STARTER PROTECTOR

3 PHASE, 380V

24-01
PUMP CONTROLLER

DIGITAL STARTER PROTECTOR 3 PHASE, 380V GEN1

General description

The 3 phase pump controller is an electronic control/protector for most pump motors and its
operation and installation will be explained in the following pages:

1. Over current/under voltage protection is performed automatically by switching the main supply to
the pump motor off.

2. In the event of a power failure or input voltage lower than 160V, the controller will switch off the
power to the pump motor in 4 seconds.

3. The unit can also determine water levels in tanks or reservoirs and control the pump according
to demand.

Technical features

Rated Voltage: 380V ± 15%

Output Power: 7.5kW
Operating Temperature: -10 to 40°C
Control Distance: 1km
Humidity: ≤ 90%
Height above Sea Level: 2000m
Protection function: Time extension feature

OVERLOAD PROTECTION TIME

(TIMES) (SECONDS)
1.3 50
1.5 30
2 15
3 6
5 1

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Operation

1. Water level control: one reservoir/ water tank can be controlled via the wiring connection at the
bottom of the controller.

2. Over load protection: At the loss of any one phase, the phase detection CCT will signal the
power contactor to drop out and switch the power supply to the pump motor off. Should for any
reason the motor draw too much (high) current (see current setting) the over current protection
CCT will signal the power contactor to drop out and switch of the power to the motor. This is
done automatically in the time set by the installer, see Setting and Adjustments for high current
and fast switch off times (anti-time overload protection). The overload LED / light will light up
(blink) in the event of a power failure. Also refer to the failure enquiry feature.

3. Short CCT protection: The controller will react the same as in the case of an overload, high
current condition occurring and power to the pump motor will be switched off within the same
time limit as set by the installer.

4. Over/under Voltage protection: The small LED on the PCB

will blink if this function is switched on. The voltage may vary as
specified - 380V ± 15%. The controller will self protect within 20
seconds when the voltage drops below 280V.

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Installation

1. Fit the controller vertically to the appropriate

area. Avoid dust, sun light and rain.

2. Connect the input power to the 3 phase input

terminal market A,B and C.

3. Connect the pump motor cable wiring to the

output terminals also marked A, B and C.
They are to the right of the input connections.

4. Connect the water reservoir/tank probe

cables to the terminals marked high, med
and low at the right bottom of the PC board. Also note the small switch below the green LED, on
far right-hand side just above the tank terminals. A selection can be made for the upper or lower
tank.

Lower Tank/Cistern:
Max water level: Power on
Min water level: Power off

Upper Tank / Cistern:

Min water level: Power on
Max water level: Power off

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5. Lack of water: Switch to lower cistern. Should the lower tank lack water, whilst the pump is still
running, the pump motor current will be low and the controller will sense this low current or no-
load situation as there is no water in the tank and will therefore switch power to the motor off
within 10 seconds.

6. Should the pump be in power-on mode

but it has been switched off for a no-load
fault and the tanks are now full of water,
the probes in the tank will signal that the
tank is full and the contactor will supply
power to the motor. The unit will also do
a self test every 30 minutes (adjustable),
provided that no-load switch is on.

7. The water full LED will come on as the tank probes signal that the
water is at a high level.

8. Reset on the front panel should only be used to get the pump’s
motor running again, in the event of the controller switching off, after
the installation has gone through a fault finding test.

9. The user may also select water level or pressure control by switching to either function on the
small PCB’s second last switch, marked “pressure” and “water”.

10. Switch to upper cistern, pump will not run. Lack of water will send a
signal to switch on the power to pump motor.

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Settings and adjustments
1. This unit has 10 failure data reports and by pressing the failure enquiry button on the front panel
the user can select, with the arrows, any report that will be displayed on the digital current
indicator A.

Should a failure light blink, pressing the failure enquiry button will result in the current indicator
showing that particular fault condition. Overload will show overload current.

2. Should a phase loss be indicated on the front panel, the user will see the following on the
current indicator when pressing the failure enquiry button:
011 - phase A loss
101 - phase B loss
110 - phase C loss
111 - this code with the light on means that the input connections are not wired
properly or the pressure mode senses low pressure which causes switch
off condition and one has to re-set continuously until the fault has been fixed.

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3. The on/off switch on the front panel may also be used to stop the function of the controller or
switch the pump motor back on again.

4. The “all complete / enter” button: after running the

pump motor normally for 60 seconds the user may
press the “enter” button mentioned above. This is
found on the PCB above the level connectors.
Note that the overload LED on the front panel will
flicker for 6 seconds and the turn off.

This means that the running and overload current

settings with other functions has been memorized
and the controller is in the ready state.

5. By selecting “lower or upper tank/cistern”, “pressure or water” the installer/user will notice
that the LED corresponding to that switch will be on if the switch
is in the lower position. The LED will go off in the upper position.
Also note that the factory default signal to the controller is set on
the “upper cistern”.

6. Over-load setting: Switch the controller on and take note of the

running current, then press the overload set/confirm (O/L SET/
EN) with the LED now ON.
Press the up/down arrow button to select or adjust the digital
indicator to the value recorded and a bit more, then press the O/L
SET/EN button with the LED now off.

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7. No-load setting. Start the pump motor and run for 60 seconds with “no load” . The current
should be low. Record this value and press the set/confirm (N/L SET/EN) button on the front
panel. With the LED above now “on”, select and adjust with the up/down arrow buttons the
current setting as displayed on the digital display.

Press the N/L SET/EN button again with

the LED off. The value has been recorded
and memorized. The no-load current
can be set directly as 0.85 times that of the
normal operating/running current. The
factory default no-load setting is 0.1 amp.

8. No-load reset time. After running the pump motor, switch the “no-load lack water extended set
to “on”, located below the red LED. The current digital indicator now shows the no-load reset time
in minutes. By adjusting with the “up/down” arrows, select the time required. Then switch to “off”.
The time has now been recorded and memorized. Suggested time is 20 minutes as the factory
default time is 30 minutes.

9. Over/Under voltage. After running the pump motor, switch the “high/low voltage” switch to “on”.
This is located under the yellow LED on the board and the light will be on. This will ensure that

the high/low voltage protection function/protector is ON and will protect as per the specification
of 380V ± 15%.

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FLOAT LEVEL CONNECTIONS

Tank Filling - upper tank connections:

Float Level FSK-1

ON No load
ON Pressure Upper Tank
High Voltage
Lack water Low Voltage
Extended time protection
Set0
OFF OFF Water Lower Tank

All complete button

High Med Low

Not Used

When tank is empty there

should be an open circuit Low
and Med-High, pump will then
start.

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Fault finding
If the control unit is connected to the water pressure system and the pump motor does not switch
on at the minimum pressure, check the following:

1. Ensure that the wiring is done correctly, see diagram.

ON No load ON Pressure Upper Tank

Lack water High Voltage
Extended time Low Voltage
Set protection
OFF OFF Water Lower Tank

All complete button

High Med Low

Loop Water
Min pressure point

Max pressure point

2. If the wiring is correct and the system still does not operate correctly, remove the wiring
and short CCT the terminals H, M and L.
Start the pump motor.
If the motor runs, it is an indication that the wiring to the pressure system is faulty or the
probes are defective.
Repeat by shorting and disconnecting to make sure the unit is fine.

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