DIGITAL PUMP CONTROLLER. Model Version October 24, 2011

DIGITAL PUMP CONTROLLER Model 9954-1 Version October 24, 2011

9954-1 Controller Interconnection Diagram PROGRAMMABLE VOLT-FREE CONTACT (10A 240vAC) (FACTORY FITTED OPTION) FOR REMOTE SIGNALLING CONTROL OR BMS CONNECTION PUMP-A FUSE PUMP-B FUSE PUMP-C FUSE Mains Supply 220/240vAC Fused 13A BOILER ENABLE 240vAC INPUT (Run Signal) Internal Pump-A (if connected) Internal Pump-B (if connected) Internal Timer Controlled (AUX) Pump-C (if connected) External (Volt-Free Switch type) PUMP FAULT SIGNALS For Pumps A, B & C (for connection to external Overloads/Trips when used)

1. The 9954 is a three Pump automatic Controller that allows two primary Pumps (A & B) to cycle (changeover) their operation (duty) automatically based on User pre-set criteria. A third Auxiliary Pump (C) is provided via daily Timer Control. The Controller has a unique feature whereby it is capable of driving each of the three Pumps directly (5A maximum), or activate remote Contactors to enable external drives. Any combination of Internal or External drives can be selected (eg Pump-A internal and Pump-B external etc). To compliment any external pump connection, a Pump Fault (Volt-Free) signal can be routed back to the Controller from the Pumps Contactor or Trip so that on failure appropriate pump changeover and fault alarms can be activated. Three Buttons, a dual-colour LED, Audible Beeper and a two-line 16 Character Cool-Blue LCD Display completes a stylish User interface in a compact IP65 rated enclosure. 2. Inputs (Please refer to diagram on previous page.) 2.1 Mains Supply (J1) 220/240vAC. A Vertical Plug-In Connector with individual connections marked L (Live), N (Neutral) & E for (Earth). Idling power consumption is Approximately 2W. 2.2 Boiler Enable (J5) This is a 240vAC Mains Input command signal from the Boiler. When this signal is present, the Controller will run the Pumps. A Vertical Plug-In Connector with individual connections marked L (Live), N (Neutral) & E for (Earth). This Boiler Enable Input is completely independent and isolated from the primary mains supply at J1. 2.3 Remote Pump Fault Inputs (J6) Connect between A and COM terminals (for signaling external PUMP-A fault), between B and COM terminals (for signaling external PUMP-B fault) and between C and COM terminals (for signaling external PUMP-C fault). These Volt-Free switch connections when made indicate to the Controller that the respective external Pump has failed. The action of this input can be reversed in software (see - SET-UP) - ie Make the connection to indicate a Pump Fault. Note: The respective Pump FUSE must be fitted at all times - whilst the Fuse itself plays no active role in the connection, it will also signal a Pump Fault condition if it is blown or missing irrespective if Internal or External Pumps have been selected. This external signal is used as a feedback from the AUX switch on the respective Pump Overload or Trip. 3. Outputs (Please refer to diagram on previous page.) 3.1 Main Pump Supply (J2 & J3) Each Pump is individually marked (PUMP-A & PUMP-B) utilising a plug-in vertical Connector with individual connections marked L (Live), N (Neutral) & E for (Earth). The Pump OUTPUTS are rated at the same voltage as the Supply Input (eg 230/ 240vAC). The Fuseholders (one each for PUMP-A and PUMP-B) are rated at 8A so the maximum recommended Fuses would be Time-Delay T5A. The Fuses are 20mm CERAMIC. Do not use glass fuses they can shatter violently at ratings above 2A and cause considerable damage. 3.2 AUX Pump-C Supply (J4) This Pump utilises a plug-in vertical Connector with individual connections marked L (Live), N (Neutral) & E for (Earth). The Pump OUTPUT is rated at the same voltage as the Supply Input (eg 230/240vAC). The Fuseholders is rated at 8A so the maximum recommended Fuse would be Time- Delay T5A. The Fuse is 20mm CERAMIC. Do not use glass fuses they can shatter violently at ratings above 2A and cause considerable damage. 3.3 PROGRAMMABLE Volt Free Relay (J9) This (Factory fitted) Option provides a single fully programmable VOLT-FREE change-over Contact mains rated to 240vAC 10A (Resistive). De-rate as required for inductive loads. The Contacts are COMMON (C), NORMALLY OPEN (NO) and NORMALLY CLOSED (NC). The states (Normally OPEN or Normally CLOSED) are those found when the Relay is NOT energised. There is a FAILSAFE Mode (more explained later), which can REVERSE normal operation.

4. POWER-ON Special Features It takes approximately two Seconds from applying mains power to the Controller before it actually starts operation. During this time it is performing internal Diagnostics and other checks prior to full operation. Whilst in this initial two-second period, if you press and hold any of the Buttons, the Controller will jump into a special mode 4.1 DOWN Button. Pressing and holding the leftmost (DOWN) Button for at least five Seconds will cause the Controller to jump into its internal Diagnostic MATFAC (MAnufacturing Test FACility). 4.2 SET Button. Pressing and holding the SET Button for at least 15 Seconds will erase any USER PIN (set it to all BLANKS which is the default Factory Setting). It will also RESET the CONTRAST and BRIGHT- NESS to the Factory Default values (yes, we have had Customers that have set and saved the Contrast and Brightness to levels whereby you need an operator with telepathic abilities to see what is going on). The page continuing below this line can be REMOVED for SECURITY reasons. Continuing to HOLD this button pressed for a minute will RESET the MASTER/ENGINEERING PIN to all BLANKS. The Factory Defaut for the MASTER PIN is BLANK, M, P, BLANK (_MP_). Continuing to HOLD this Button for TWO minutes will RESET the FACTORY PIN to all BLANKS. The Factory Defaut for the FACTORY PIN is STAR, 6, 6, STAR (*66*).

5. Initial POWER-ON Upon initial Power-ON, the Controller will do one of two things depending on it s SETUP state 5.1 Display STANDBY MODE This is a software ON/OFF switch the Controller is actually Switched OFF and is prompting you to turn it on. Press and hold the rightmost (SET) Button for at least five Seconds and the Controller will switch ON. This is feature can be turned ON or OFF in the software SETUP. 5.2 Start working The Controller will identify itself, display the Company Name and start working accordingly. Any errors or conditions out of normal operation that are detected, will individually rotate through the lower (bottom) line of the two-line display. They will display in PLAIN TEXT, so just stand there for a moment and read what the Controller is telling you. If there is more than one error, then they will display in rotation interspersed with the current Status. If an error is deemed serious, then the Company Name on the top line will be interspersed with a CALL FOR ASSISTANCE message and telephone number. Below is a list of ERROR MESSAGES that may individually or collectively appear on the bottom line of the display 5.2.1 PUMP FAULT (PUMP FAULT-A, -B or -C) 5.2.4 SYSTEM FAILURE Indicates a complete electronics failure of some sort, which should be investigated by qualified engineers. 5.3 STATUS Display During normal Controller operation, a STA- TUS message can also be displayed. The word READY indicates the unit is currently idle awaiting an instruction to run. Run-A or Run-B indicates the appropriate Pump has been commanded to run. Additional characters T or * can appear. These are not secret codes but simply T = The Timer programmable PUMP-C is running. * = The Volt-Free programmable Relay is tripped (see other displayed messages or SETUP for cause). 5.4 FATAL ERROR You should never see this message (usually a result of product abuse). Please return the Controller for Investigation/Repair. These messages reflect the status of the respective PUMP FUSES or Fault Inputs. 5.2.2 SERVICE DUE This message will display if the SERVICE DUE time peiod preset in the SETUP has elapsed. This message is RESET through the MASTER SETUP. 5.2.3 SYSTEM LOCK Displayed when the Control Unit has been manually or automatically LOCKED-OUT from use. This is usually only done for some safety reason.

6. MATFAC (MAnufacturing Test FACility) When in MATFAC, three letters will initially appear on the 2 nd line of the LCD A, B and X. They represent the three Control Buttons. A indicates the left hand button and Pump A, B indicates the middle button and Pump B, and X indicates the right-hand Button. If the BOILER ENABLE signal input is present, the letter B will appear in the top left-hand corner of the display. MATFAC is a useful Factory and Field Diagnostic Tool to check that the entire Controller is functioning. You can immediately check each of the PUMP FUSES, operate each PUMP, check the VOLT-FREE Contact (if fitted), see the Status and verify the correct operation of the BOILER ENA- BLE input. Note : Remember that the actual operation of many of the Inputs are affected by the software SETUPs. If a PUMP FUSE is blown (or one of the Remote FAULT Inputs have been tripped), an F will appear next to the appropriate Pump letter so if PUMP-A FUSE has blown, the display will show AF, and BF if PUMP-B FUSE is blown, CF etc. 6.1 X. SET (Right-Hand Button) Pressing X momentarily will flip the bottom line of the display to show C, V and X (where C indicates the left-hand button and Pump C, and V indicates the middle button and the Volt-Free Relay. Pressing X again will change it back to A, B and X. 6.1.1 Holding the X Button (Date & Time) Pressing and holding the X Button will cause the Controller to display the Current Date and Time. Pressing X (the right-hand SET button) again will allow you to ENTER a new Date and Time, whilst pressing any of the other two buttons will return you to the previous display. Use the Buttons to enter new values, pressing the right-hand SET Button to advance and finally store the new Date & Time. 6.2 A (or C). DOWN (Lefthand) Button Pressing this Button (and whilst it remains depressed) will switch ON simultaneously PUMP- A (or PUMP-C if it is selected) and illuminate the LED GREEN. 6.2 B (or V). UP (Centre) Button Pressing this Button (and whilst it remains depressed) will switch ON simultaneously PUMP- B (or the VOLT-FREE Relay if it is selected) and illuminate the LED RED.

7. NORMAL Operation Control Buttons When operating normally, if you press and hold any of the Buttons, the Controller will respond as follows 7.1 DOWN Button. This button when in normal operation is used to toggle the Status of the Aux (Timer) Pump-C. Be advised that if the Pump is not fitted (Software Setup shows Pump as unavailable) or is otherwise defective (Fuse Blown), then this toggle will have no effect. Likewise if the Boiler is not running, then the Pump will also be Powered OFF and the toggle will have no effect. When either in PIN entry or in any SETUP MENU, if there has been no user activity for 30 seconds, the Controller will revert back to normal operation. Any entries are only saved if the SET (right-hand) Button is pressed, otherwise changes will not be retained. There are a lot of SETUP options. To save time in having to go through right to the end, once you have SAVED (by pressing the SET Button) your changes, you can power-off and restart the Controller if you wish, or you can simply wait until the Controller reverts you back to normal operation. When in any of the SETUP Menus, the DOWN Button will allow you to decrement any value on the display. 7.2 UP Button. Pressing the centre (UP) Button will cause the Controller to MUTE the ALARM audible BEEPER. If the Alarm BEEPER is running continuously and giving folks a headache, press this Button to toggle the BEEPER ON or OFF. When in any of the SETUP Menus, the UP Button will allow you to increment any value on the display. 7.3 SET Button The SET Button has a dual function. Press and release within a Second or so will cause the Controller to prompt ENTER PIN: in order to access the SETUPs. Press and hold this Button for FIVE SECONDS or so, and the Controller will switch OFF and display STANDBY MODE (see Initial POWER-ON section). When in the SETUP Menus, pressing SET momentarily will SAVE the current setting and move FORWARD to the next SETUP item. Pressing and HOLDING the SET Button for about half a second will allow you to go BACK to the previous SETUP item. This feature allows the User to go BACK should an entry mistake have been made.

8.1 SETUP Options - FACTORY SETUP (Entered through a VALID Factory PIN) 8.1.1 Name : A 16 character alphanumeric NAME (usually Company or Organisation name) that is permanently displayed during normal operation. 8.1.2 Telephone : A 16 character TELEPHONE which will be circulated on the display prompting the viewer to call in case of any serious error. 8.1.3 Numeric only PIN: A YES/NO option (Factory Default is NO). Restricts the PIN to only the NUMERALS (0-9). The existing Set-Up's and passwords are unchanged (ie shipped with the PIN set for alphanumerics), and the Customers can set this restriction themselves if they require it. They should be reminded that they should set the FACTORY and MASTER passwords to something numeric (ie numerals 0-9 only), otherwise they will lock themselves out from accessing those sections if they leave alpha characters in the passwords. 8.1.4 Factory PIN : A 4 character alphanumeric Password/PIN.

8.2 SETUP Options - MASTER SETUP (Entered through a VALID Master PIN) 8.2.1 Pump-A Available : A YES/NO answer indicating that Pump-A is installed, connected and good to run. If this Pump is not fitted or broken, simply answer NO and the Controller will ignore it. (Factory Default YES). 8.2.2 Pump-B Available : A YES/NO answer indicating that Pump-B is installed, connected and good to run. If this Pump is not fitted or broken, simply answer NO and the Controller will ignore it. (Factory Default YES). 8.2.3 Pump-C Available : A YES/NO answer indicating that Pump-C (Timer Pump) is installed, connected and good to run. If this Pump is not fitted or broken, simply answer NO and the Controller will ignore it. (Factory Default YES). 8.2.4 Service Due : A value set here will trigger a SERVICE DUE message once the SERVICE HOURS have incremented to this value. (Factory Default is 10200 Hours - approx 14 months). 8.2.5 Safety Stop : A YES here (Factory Default NO) will shut-down the Controller 14 days after a SERVICE DUE message has started to be displayed. This will force the system to be serviced (or it will not continue to run) in those installations where for Health and Safety reasons periodic service is critical. 8.2.6 System Locked : When set to YES (Factory Default NO) will LOCK-OUT the installation from working. If allowing an installation to continue operating is discovered for whatever reason to be dangerous, or in those instances where an installation has been condemned, it can be disabled from operating. 8.2.7 Service Hours : This is the rough cumulative HOURS COUNTER telling you how long a system has been running. You are able to RESET this counter to ZERO by using the UP/DOWN Buttons to display RESET in the window and then pressing SET. 8.2.8 Pump-A Hours : This is the rough cumulative HOURS COUNTER telling you how long Pump-A has been running. You are able to RE- SET this counter to ZERO by using the UP/DOWN Buttons to display RESET in the window and then pressing SET. 8.2.9 Pump-B Hours : This is the rough cumulative HOURS COUNTER telling you how long Pump-B has been running. RESET as described in 8.2.8. 8.2.10 Pump-C Hours : This is the rough cumulative HOURS COUNTER telling you how long Pump-C has been running. RESET as described in 8.2.8. 8.2.11 Pump Error Alarm : This is an ON/OFF function that can disable reporting that the Pump- A, Pump-B or Pump-C Fuses have blown seems kind of pointless, but requested by some Pump Manufacturers. (Factory Default ON). 8.2.12 Standby Mode : If set to NO (Factory Default) will allow the Controller to start operating as soon as Power is applied. If set to YES, will cause a STANDBY MODE message to appear on the LCD and the unit will remain in this mode until manually switched ON by a User (think of it as an ON/OFF Button on your VCR). Press and hold the SET Button for at least FIVE SECONDS to switch ON. Similarly, to switch INTO Standby Mode, press and hold the SET Button for at least FIVE SECONDS (pressing for less than this time will cause the Enter PIN message - for entry into the SET-UP Menu to appear). Caution: In STANDBY MODE the equipment remains LIVE - Don t try to change the Control Panel or any Pumps without completely isolating the equipment at the wall. 8.2.13 Invert Drive Signal : When set to No (the Factory Default) requires a BOILER INPUT (240vAC connection) to be present for any Pumps to Run. When set to Yes, requires the BOILER INPUT signal to be missing for Pumps to Run. 8.2.14 Swap Pumps On : This selects the conditions under which the Controller changes-over the primary pump operation. The Options are : 8.2.14.1 Pump Selection The pumps are rotated every time a Drive INPUT is enabled. The selected Pump will remain thus selected until the Drive INPUT is released at which stage the next Pump will be selected for use. 8.2.14.2 Preset Hours Run The pumps are rotated after a preset number of hours have elapsed with the Pump running (ie not idle). See also 8.2.15.

8.2.14.3 Preset Day/Time The pumps are rotated at a preset (clock) time (this is the Factory Default). See also 8.2.16. 8.2.15 Changeover Hours : If the PRESET HOURS RUN option (8.2.14.2) is selected, then the Pumps will changeover after they have run for the given hours indicated here. (Factory Default is 24, selectable range 1-250). This option will only appear in the SETUP MENU if selected at 8.2.14. 8.2.16 Changeover Day & Time : If the PRESET TIME option (8.2.14.3) is selected, then the Pumps will changeover at the END of the given HOUR and MINUTE and on the DAY of the WEEK (or every day if ALL is selected) entered here. Please ensure the Clock is SET and RUN- NING. This option will only appear in the SETUP MENU if selected at 8.2.14. 8.2.17 Invert A Fault : Inverts the Pump-A Fault signal (eg if the Remote FAULT input is being driven from a system (eg Overload/Trips) that have an OPEN rather than a CLOSED circuit on FAULT). Factory Default - No. 8.2.18 Invert B Fault : As 8.2.17 but for the Pump-B channel. Factory Default - No. 8.2.19 Invert C Fault : As 8.2.17 but for the Pump-C channel. Factory Default - No. 8.2.20 Pump-Test Interval : A time interval set in HOURS before a Pump-Test is scheduled. If pumps are allowed to idle forever and never run, then they run the risk of seizing. So they need to periodically run. One way we do this in a multipump installation is to allow the pumps to cycle, and all good Controllers do just this. The integral PumpTest Feature allows a Pump to run if it has not been run for the length of time preset by this option. The Pumps are PULSED periodically - hopefully just enough to rotate the shaft, but not enough to build any additional Pressure into the system. (Factory Default - 0 - Disabled). 8.2.21 VOLT FREE RELAY : This sets all the conditions that will enable the PROGRAMMABLE Relay (ie the VOLT-FREE CONTACTS). By default the User will Skip Sub-Menu if SET is simply pressed, however by using the UP and DOWN Buttons to change this to Configure and then pressing SET, the User can then enable or disable all the options that will trip this Relay. The FAILSAFE MODE reverses the operation of the STOP Relay (ie so it is normally ON and drops out on Alarm, rather than normally OFF and switching ON for Alarm ). Failsafe allows for the provision of signaling an Alarm on Power-Failure. Naturally the NC/NO contacts as marked on the PCB operate in reverse if the Failsafe setting option is used. The options are inclusive (ie setting more than one to YES will cause the Relay to trip on any of those selected. The available options are:- 8.2.21.1 Pump-A Fault (Factory Default - ON) 8.2.21.2 Pump-B Fault (Factory Default - ON) 8.2.21.3 Pump-C Fault (Factory Default - ON) 8.2.21.4 Boiler OFF (Factory Default - OFF) 8.2.21.5 Service Due (Factory Default - OFF) 8.2.21.6 System Fault (Factory Default - ON) 8.2.21.7 Failsafe Mode (Factory Default - OFF) 8.2.22 BEEPER : This option sets all the conditions that will enable the ALARM BEEPER:- 8.2.22.1 Pump-A Fault (Factory Default - ON) 8.2.22.2 Pump-B Fault (Factory Default - ON) 8.2.22.3 Pump-C Fault (Factory Default - ON) 8.2.22.4 Boiler OFF (Factory Default - OFF) 8.2.22.5 Service Due (Factory Default - ON) 8.2.22.6 System Fault (Factory Default - ON) 8.2.22.7 Keypress (Factory Default - ON) 8.2.23 ALARM LED : This option sets all the conditions that will cause the Status LED to blink RED:- 8.2.23.1 Pump-A Fault (Factory Default - ON) 8.2.23.2 Pump-B Fault (Factory Default - ON) 8.2.23.3 Pump-C Fault (Factory Default - ON) 8.2.23.4 Boiler OFF (Factory Default - OFF) 8.2.23.5 Service Due (Factory Default - ON) 8.2.23.6 System Fault (Factory Default - ON) 8.2.23.7 System Lock (Factory Default - ON) 8.2.24 Set Contrast : Changes the LCD (Display) Contrast Ratio for User comfort. 8.2.25 Set LCD Backlight : Changes the LCD Backlight Level for User comfort. 8.2.26 Master PIN : A 4 character alphanumeric Password/PIN.

8.3 SETUP Options - USER SETUP (Entered through a VALID User PIN) 8.3.1 Set Date & Time : Allows setting of the System Date and Time which is used for the PRESET TIME changeover and for the control of the AUX Pump (Pump-C). 8.3.2 Set AUX PUMP (C) Time : Allows setting of the DAY(s) and TIME(s) that the AUX Pump can operate. Fourteen independent ON/OFF timing periods/events can be programmed. OFF settings take priority over any ON settings. Each period is interactive with each other. Periods can be overlapped and can span hours or even days. 8.3.16 User PIN : Allows entry/setting of the User PIN code. Timer Setting Examples Example 1. To set the Timer to operate EVERY DAY from 8am to 5pm, only one event is required: Select Timer 1 ON period for ALL 08:00 Timer 1 OFF period for ALL 17:00 Example 2. Office which is occupied only Monday to Friday 8am to 5pm and unoccupied at weekends. Three events in this case would be required. Notice that the OFF time is the same as the ON time on Saturday and Sunday, and OFF will take priority:- Select Timer 1 ON period for ALL 08:00 Timer 1 OFF period for ALL 17:00 Timer 2 ON period for Sat 08:00 Timer 2 OFF period for Sat 08:00 Timer 3 ON period for Sun 08:00 Timer 3 OFF period for Sun 08:00

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