MATelec AUSTRALIA JM3550 Hydro Start Pump Controllers User Guide
- September 20, 2024
- MATELEC AUSTRALIA
Table of Contents
JM3550 Hydro Start Pump Controllers
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Specifications:
- Product Name: HydroSTART Pump Controllers
- Model Number: FPC-8XX4X
- Version: V1.3
- Power Input: 12Vdc
Product Usage Instructions:
Step 1 – Installation:
Mount the control panel on a suitable Mounting Frame/Wall
ensuring it is securely fixed.
Step 2 – Connections:
Level Control Connections – Single Pump:
Connect Input 1 to Low Level, Input 2 to Duty, Input 3 to Alarm,
Input 5 to Enable.
Level Control Connections – Dual Pump:
Connect Input 1 to Low Level, Input 2 to Duty, Input 3 to
Standby, Input 4 to Alarm, Input 5 to Enable.
Pressure Control Connections Single Pump:
Connect Input 1 to Low Level, Input 2 to Duty, Input 3 to Alarm,
Input 5 to Enable.
Pressure Control Connections Dual Pump:
Connect Input 1 to Low Level, Input 2 to Duty, Input 3 to
Standby, Input 4 to Alarm, Input 5 to Enable.
VF Connections:
Connect Common Fault BMS and N/O close on flow.
FAQ:
Q: Can I install the control panel in a residential
setting?
A: The control panel is designed for Commercial and/or
Industrial applications. For Residential use, ensure compliance
with relevant standards by a qualified electrician.
Q: What should I do if I encounter an electrical risk
warning?
A: Stop the installation process and seek assistance from a
qualified and registered electrician.
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FPC-8XX4X
QUICK START GUIDE
HydroSTART Pump Controllers
V1.3
MATelec Australia’s HydroSTART Controller brings the features of the standard
single and dual pump controllers into a new age with a redesigned capacitive
touch keypad and control module with pump current sensing, providing wide
range electronic overload protection which now functions with both single and
three phase pumps. Additional control inputs and functionality has been
incorporated into the new design to enhance the controller’s flexibility and
cover an even wider range of pumping applications. The HydroSTART is the new
standard for pump controls.
SAFETY
This control panel has been designed and built for applications that are
Commercial and/or Industrial in nature, operation, function and location. If
the control panel is to be used in Domestic/Residential applications, where
specific Wiring Rules in respect of `electrical supply’ protection may apply,
it is the responsibility of the installing electrician to ensure compliance
with relevant standards.
· 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 the following pages. · Additions 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.
This quick start guide makes use of the following symbols to indicate warnings that must be paid specific attention to:
Damage to equipment or personal harm may occur if this instruction is not followed
Electrical risk (electrocution hazard) may occur if this instruction is not followed
STEP 1 – INSTALLATION
· Controller enclosure must be mounted in a vertical position. · Ensure
mounting method does not compromise enclosure weatherproof rating. · IP54
single door controllers are only suitable for mounting indoors, while IP56
controllers with inner door can be mounted outside. · Ensure access to main
isolator is not restricted. · Ensure cables/conduits entering the panel have
mechanical protection and that the penetrations are sealed and do not
compromise the weatherproof rating of the enclosure. · If required, install
buzzer through hole on underside of enclosure and tighten lock ring.
Mounting Frame/Wall
Front View
STEP 2 – CONNECTIONS
Back View
Side View
Mounting Holes
(20mm from each edge)
Warning: All electrical connections must be carried out by a suitably qualified and registered electrician
Level Control Connections – Single Pump
C
C
C
C
C
Input 1 Input 2 Input 3 Input 5 System
Low Duty Duty Alarm Enable
Level Stop Start Level
INPUT
12Vdc
Level Control Connections – Dual Pump
C
C
C
C
C
C
Input 1 Input 2 Input 3 Input 4 Input 5 System
Low Duty Duty Standby Alarm Enable
Level Stop Start Start Level
INPUT
12Vdc
N/O close on rise Common
N/O close on rise Common
N/O close on rise Common
N/O close on rise Common
N/C close on fall Common
N/O close on rise Common
N/O close on rise Common
N/O close on rise Common
N/O close on rise Common
N/O close on rise Common
N/C close on fall Common
Bridge if not
required
Leave open if not required
Bridge if not
required
Bridge if not
required
Leave open if not required
Bridge if not
required
Low
Duty
Duty
High Destination
Level
Stop
Start
Level Tank High
2
Float
Float
Float
Float Level Float
Switch Switch Switch Switch Switch
Low Level Float Switch
Duty Stop Float Switch
Duty Start Float Switch
Standby Start Float Switch
High Destination Level Tank High Float Level Float Switch Switch
Quick Start Quide – HydroSTART Pump Contollers
STEP 2 – CONNECTIONS
Pressure Control Connections Single Pump
C
C
C
C
C
Input 1 Input 2 Input 3 Input 5 System
Low Duty Duty Alarm Enable
Level Stop Start Level
INPUT
12Vdc
Pressure Control Connections Dual Pump
C
C
C
C
C
C
Input 1 Input 2 Input 3 Input 4 Input 5 System
Low Duty Duty Standby Alarm Enable
Level Stop Start Start Level
INPUT
12Vdc
N/O close on rise Common
Close on press drop Common
Close on press drop Common
N/O close on rise Common
Close on press drop Common
Close on press drop Common
Close on press drop Common
Bridge if not
required
Leave open if not required
Bridge if not
required
Low Level Float Switch
Duty Start Pressure Switch
Low Pressure Switch
Irrigation Start
Prime Loss Connection
C Input 1
Low Level INPUT 12Vdc
Bridge if not
required
Leave open if not required
Bridge if not
required
Low Level Float Switch
Duty Start Pressure Switch
Standby Start
Pressure Switch
Low Irrigation Pressure Start
Switch
VF Connections
Common Fault BMS
Volt/Free
N/O close on flow Common
Prime Loss Flow Switch
Leave open if not required
Volt free relay outputs Max 24V 1A supply
Note:
· The above shows the full range of connections available. Not all connections
are necessary for operation.
· Modbus RTU Serial RS485 connections for SCADA are also available on the
HydroSTART control module. Din rail terminals are not provided as standard for
these connections, but they can be wired directly to the module. See the
Operation Manual for further information.
3 MATelec Australia reserves the right to alter technical data without notice
STEP 2 – CONNECTIONS
POWER SUPPLY & PUMP CONNECTIONS
Single Pump, Single Phase
Single Pump, Three Phase
EAN
SUPPLY 240Vac
PUMP 1 Earth
Active Neutral
PUMP
240Vac Connections
E A1 A2 A3 N E P1 P2 P3 T1 T2
SUPPLY
PUMP 1
415Vac Connections
PUMP 1 Thermal
24Vdc
PUMP 1 Earth
Active Neutral Active Neutral
PUMP 2 Earth
Single Phase 230 Vac
Mains Power
Pump 1
Dual Pump, Single Phase
EAN
SUPPLY 240Vac
PUMP 1
PUMP 2
240Vac Connections
Three Phase 400 Vac
Mains Power
Note: Neutral Wire Required A 4 Core and Earth Supply with a Neutral Wire is
required on 3 Phase Supply. If no Neutral Wire is available, a customised
panel
can be supplied to suit.
Pump 1
Bridge if not required
Important! Check direction of pump rotation. Incorrect rotation
could cause damage to the pump.
Dual Pump, Three Phase
E A1 A2 A3 N E P1 P2 P3 E P1 P2 P3 T1 T2 T1 T2
SUPPLY
PUMP 1
415Vac Connections
PUMP 2
PUMP 1 PUMP 2 Thermal Switch 24Vdc
Single Phase 230 Vac
Mains Power
4
Pump 1
Pump 2
Three Phase 400 Vac
Mains Power
Note: Neutral Wire Required A 4 Core and Earth Supply with a Neutral Wire is
required on 3 Phase Supply. If no Neutral Wire is available, a customised
panel
can be supplied to suit.
Pump 1
Pump 1
Bridge if not required
Important! Check direction of pump rotation. Incorrect rotation
could cause damage to the pump.
Quick Start Quide – HydroSTART Pump Contollers
STEP 3A – CURRENT SENSING SETUP
Note – This step applies to HydroSTART controllers using the pump current
sensing for pump protection. Skip to step 3B if the controller features
external thermal overloads.
· Ensure power is isolated before opening the enclosure to access the
HydroSTART control module.
· Check that the current sensing range is correct according to the
controller’s model number suffix of LR (low range, 0.1-6 Amp) or HR (high
range, 5-16 Amp). The range in use is also indicated by the LEDs in between
the overload dials, and is selected via DIP switch 4. Only the overload range
that the panel is designed for should be used.
· Set the pump overload trip settings according to the full load current (FLC)
shown on the pump nameplate, via the overload dials shown in the image below.
The value set corresponds with either the blue or orange scale, depending on
which current sensing range is selected. If the trip value is set too high
there is potential that the pumps may be damaged if an issue occurs. If set
too low the pumps will go into fault prematurely during normal operation.
DIP Switch 4 Off = Low Range (0.1-6 Amp) On = High Range (5-16 Amp)
Current Sensing Range LEDs Blue = Low Range (0.1-6 Amp) Orange = High Range
(5-16 Amp)
Overload Setting Dials
STEP 3B – THERMAL OVERLOAD SETUP
Note – This step applies to HydroSTART controllers using external thermal
overloads for pump protection instead of the pump current sensing. These are
used if an overload rating above 16 Amps is required.
· Ensure power is isolated before opening the enclosure to access the thermal
overloads.
· Set the pump overload trip settings according the full load current (FLC)
shown on the pump nameplate, via the overload dial shown in the image below.
If this value is set too high there is potential that the pumps may be
damaged. If set too low the pump will go into fault prematurely during normal
operation.
· The auto reset button should be left in auto (screwed down) so that the
controller can latch and reset the faults from the keypad without the need to
access the live parts.
CAT.NO. SPEC. FRAME H.P. VOLTS AMPS HZ
THREE PHASE
JM3550
35F84W7
56J
SER. F1295
1 1/2T
E
208-230/460
7.6/2.3
50
Set Full Load Current
Ensure reset button is on auto (screwed down)
5 MATelec Australia reserves the right to alter technical data without notice
STEP 4 – SOFT STARTER SETUP (ABB PSR)
Note – This step applies to HydroSTART controllers with soft starters, skip to
step 5 if soft starters are not in use. The soft starter is rated for 10
starts per hour with 6s acceleration time, 4x FLC at 40°C. Care must be taken
to limit pump starts to within the manufacturer’s specification. Going beyond
these limits will reduce the acceptable number of starts per hour. · Setting
the Start Ramp Time – Set the acceleration ramp time for the motor
to reach full speed. Exceeding 6 seconds will reduce the acceptable number of
starts per hour. · Setting the Stop Ramp Time – If required, adjust
deceleration to reduce water hammer.This will reduce the acceptable number of
starts per hour. · Setting the Initial Voltage – For high starting current
motors, set the initial voltage high enough to get motor rotation started.
STEP 5 – POWERUP
When safe to do so, switch on electrical supply to panel. Check correct supply
voltage before turning on the main isolator.
Three phase input power
Status indication
Three phase output power
6 Quick Start Quide – HydroSTART Pump Contollers
STEP 6 – DIP SWITCH CONFIGURATION
There are 8 DIP switches located on the upper side of the control module which are used to select the control mode and adjust the functions of the HydroSTART controller, as per the table below.
DIP SWITCH 1 2 3 4 5 6
7 8
POSITION Off On
Off On Off On Off On Off On Off On Off
On
Off On
FUNCTION
Level control mode The controller will operate in level empty control mode,
controlled by up to 5 float switches. Input 1 = Low level/prime loss, Input 2
= Duty stop, Input 3 = Duty Start, Input 4 = Standby Start and Input 5 = High
level.
Pressure control mode The controller will operate in pressure boost control
mode, controlled by up to 3 pressure switches. Input 1 = Low level/prime loss,
Input 2 is unused, Input 3 = Duty start, Input 4 = Standby start and Input 5 =
Low pressure.
Prime loss protection Input 1 is configured for prime loss protection. If a
pump is running and input 1 is open for 30 seconds and prime loss fault is
activated for that pump, shutting it down and alternating duty. Manual reset
via the mute/reset button on the keypad is required.
Low level protection Input 1 is configured for low level protection. If input
1 opens for 1 second the low level fault will be activated and the pumps shut
down. Manual reset via the mute/reset button on the keypad is required.
Standard alternation mode Duty pump alternates on every start or after 30
minutes of continuous running.
Recirculation alternation mode Duty pump alternates after an accumulated
running time of 6 hours, irrespective of starting/stopping and the system
being enabled/disabled.
Low current range Pump current sensing is configured for low range 0.1 to 6
Amps. The overload setting dials and CT scaling will use this range.
High current range Pump current sensing is configured for high range 5 to 16
Amps. The overload setting dials and CT scaling will use this range.
Manual mode continuous If a pump is placed in manual mode it will remain
running in manual indefinitely.
Manual mode timeout If a pump is placed in manual mode it will revert to auto
mode after 5 minutes of running in manual.
High level stormwater The high level alarm will activate after the high level
input (input 5) is closed for 15 minutes.The alarm will automatically reset
once the high level input opens.
High level sewage The high level alarm will activate after the high level
input is closed for 1 minute. Manual reset via the mute/reset button on the
keypad is required.
Undercurrent and zero current protection off Undercurrent and zero current
protections are disabled. Use for automatic pumps or pumps with low current.
Undercurrent and zero current protection on Undercurrent and zero current
protections are enabled. Undercurrent – If a pump is running the current being
sensed is less than 50% of the value set on the pump overload dial for 10
seconds, an undercurrent fault will be activated. Zero current – If a pump is
running and the current being sensed is less than 100mA or 10% of the value
set on the pump overload dial (whichever is higher) for 10 seconds, a zero
current fault will be activated.
Alternate duty Duty alternation is enabled as configured by DIP switch 3.
Static duty Duty alternation or fault alternation is disabled. Pump 1 will
always be the duty pump that starts first and pump 2 will always be the
standby pump.
7
MATelec Australia reserves the right to alter technical data without notice
STEP 7 – KEYPAD OPERATION
The status of the HydroSTART controller is displayed via the various indicator
lights on the keypad interface. The keypad features capacitive touch buttons
for muting or resetting faults, testing the keypad and alarm operation, and
selecting the pump mode. The keypad connects to the HydroSTART module via a 3
wire connection (+12V, bus and ground) and communicates via the proprietary
ME-NET protocol.
Single Pump Keypad
Dual Pump Keypad
The meaning of each LED status is explained below. Some LEDs have multiple functions with different flash rates corresponding with different faults or conditions. If multiple conditions are present at once, the On status will take priority, followed by 1 flash, 2 flashes and so on. For example, if there is a prime loss fault (1 flash) and an undercurrent fault (5 flashes) for pump 1, the pump 1 fault light will flash once as the prime loss fault takes precedence.
SYSTEM INDICATOR LIGHTS
Off – Power off On – Power on 1 flash – Alarm fault 2 flash – Settings fail
fault 3 flash – Contact fault 4 flash – Conductivity input fault
Off – System disabled On – System enabled
Off – No faults active On – High level fault 1 flash – Low level fault 2 flash
– Low pressure fault
PUMP INDICATOR LIGHTS
Off – Pump not in auto mode On – Pump in auto mode
Off – Pump not in manual mode On – Pump in manual mode
Note – If both the auto and manual lights are off, the pump is in off mode
Off – Pump not running On – Pump running
Off – Pump healthy
On – Overload fault
1 flash – Input fault
2 flash – Prime loss fault
3 flash – Max run fault
4 flash – Zero current fault
8
5 flash – Undercurrent fault
LEVEL INDICATOR LIGHTS
Off – Input 1 is open On – Input 1 is closed
Off – Input 2 is open On – Input 2 is closed
Off – Input 3 is open On – Input 3 is closed
Off – Input 4 is open On – Input 4 is closed
Off – Input 5 is open On – Input 5 is closed
Note – In tank fill mode, indicator light 4 will correspond with input 2 (duty
stop), while input 2 will correspond with input 4 (standby start), so that
lights reflect the position of the float switches in the tank
BUTTONS
Press for 1 sec – Mutes the audible alarm Press for 3 sec – Resets active
faults, or starts the alarm test in which all indicator lights will illuminate
and alarms will activate. The alarm test will stop when the button is released
or after 10 seconds.
Press for 1 sec – Changes the pump mode from auto to manual, manual to off or
off to auto.
Quick Start Quide – HydroSTART Pump Contollers
HydroSTART BMS VARIATION
The BMS variation of the HydroSTART features the HydroSTART BMS module, providing volt free outputs for power on, high and low level, individual pump run and fault as standard, in addition to the common fault output included on other variations.
BMS MODULE
The HydroSTART BMS module features 7 volt free relay outputs providing status information to BMS systems from a HydroSTART control module. Similarly to the HydroSTART keypad, the BMS module connects to the HydroSTART control module via a 3 wire connection (+12V, bus and ground) and communicates via the proprietary ME-NET protocol.The BMS module also includes an power/status LED to indicate power and communication status. The default functions that these relays are assigned to is shown below:
· Relay 1 = Power On
· Relay 2 = Low Level
· Relay 3 = High Level
· Relay 4 = Pump 1 Run
· Relay 5 = Pump 2 Run
· Relay 6 = Pump 1 Fault · Relay 7 = Pump 2 Fault
Power/status light Solid = Power On Flashing = Communication fail
Common supply for relays 6-7 Relay 6
Relay 7
ME-NET Connection to HydroSTART
control module
Common supply for relays 1-5 Relay 1
Relay 2
Relay 3
Relay 4
Relay 5
Volt Free Connections – Single Pump
Volt Free Connections – Dual Pump
Common
Power On High Level Low Level Pump Run Pump Fault Common Fault
Common
Power On High Level Low Level Pump 1 Run Pump 1 Fault Pump 2 Run Pump 2 Fault
Common Fault
BMS Voltage Free
BMS Voltage Free
Leave open if not required
Volt free relay outputs Max 24V 1A supply
Leave open if not required
Volt free relay outputs Max 24V 1A supply
9 MATelec Australia reserves the right to alter technical data without notice