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TPC Automatic Pump Controller Instruction Manual

Automatic Pump Control Switch for Automatic Pressure Pump

Operation

The Electronic Controller orders the automatic start and stop of the water pump when opening or closing any tap or valve of the system. The controller can keep constant pressure and water flow in the system as long as any tap in the system is open during the pumps operation.

Caution

The electronic controller can be used either for drinking water or non-drinking water systems. In installations where both types of water are present, make sure that the drinking water is not mixed with non drinking water.

Construction Characteristics

  • Inlet: Male 1"
  • Outlet: Male 1"
  • Special non return valve to avoid surges
  • Security system avoiding the possibility for the machine to work without water
  • Pressure gauge
  • Manual start switch (RESET)
  • Tension LED (POWER)
  • Pump Working LED (ON)
  • Secirity System LED (FAILURE)

Technical Characteristics

  • Voltage: ~220/240V
  • Maximum Current: 10(6)A
  • Frequency: 50/60Hz
  • Protection Grade: IP65
  • Maximum water temperature: 60°C
  • Starting Pressure for Use: 1.5-3 bar
  • Maximum pressure for use: 10 bar

Installation of the Pressure Gauge - Fig 1

The pressure gauge is provided with an O-Ring, two fixing screws and a screw cap. The pressure gauge is mounted on one side of the controller by introducing the cylindrical connector with the O-ring into the hole in the body of the device and fixing it by means of the two supplied screws. The screw-tap is to be located on the opposite side's pressure gauge vent (without O-ring or teflon).

Fig 1 Automatic Pressure Switch
Figure 2

Hydraulic Connection - Fig 2

Before proceeding with hydraulic connection, it is essential to prime the pump correctly. The controller should always be installed in a vertical position, thus connecting the inlet opening (male 1") directly to the pump outlet and the lateral outlet (male 1") to the network. Avoid outlet non-return valves. The following accessories are recommended: Flexible with a disassembling link for network connection, protecting the set from possible flexion charges and vibrations. Ball valve which permits the isolation of the pump from installation

 
Attention:
The water column between the pump and the highest point of use shall not exceed 15 m and the pumps should supply a minimum pressure of 2.5bar
Figure 3 Automatic Pressure Switch

Electric connection - Fig 3

Check the power supply to be ~220/240v.  First disconnect the power supply, then dismount the cover (1) of the electronic circuit and make the connections as per diagram on plate (2). The controller can be also used for three-phase or single-phase pumps with intensities higher then 10A by means of an auxiliary contact.  In this case, the connections will have to be made according the scheme in fig. 4

 
Figure 4 Automatic Pressure Switch

Warning    
Bad connections may spoil the electronic circuit.
Starting
1.Be sure that the pump is correctly primed, and then gently open the tap.
2.Connect the controller to the clectric supply.  The tension LED will light (POWER)
3.The pump start working automatically and within a period of 20-25 seconds the pressure gauge will reach approximately the maximum pressure provided by the pump.  During its working the corresponding LED(ON) will be on.
4.Close the tap indicate on point 1.After 7-9 seconds the pump will stop.  The tension LED(POWER) will be the only one to remain on.
Any problem after this procedure will be due to defective pump priming.
Figure 5 Automatic pressure switch

The Adjustment of the starting pressure is made by the screw placed in the top of the control (fig5)

 

Read the indicated pressure shown in the pressure gauge when the pumps starts and perform on the screw according to the wished side (pressure adjusting must be performed by professional).  As per standards the starting pressure should be 0.2 bar higher than the manometric one, and the pump will have to give at least a pressure 0.8 bar higher than the adjusted one, Example:

Using Height Operating pressure adjustment Minimum Pump Pressure
20m 2.2 bar 3 bar
25m 2.7 bar 3.5 bar

This operation only adjusts the starting pressure, not the working pressure which only depends on the pump feature.  It is easier to proceed with the adjustment if a tap of the installation is opened, that will reduce the internal pressure of the control.

Possible problems
1. Pump doesn’t stop:
A)  Water leakage higher than 1.2 L/min at some point…check the system, the tap.etc.
B) Manual start switch (RESET) is blocked…press it several times.  Consult your dealer if the problem persists.
C) Breakdown on the electronic board…proceeds to its substitution.
D) Incorrect electric connection on electronic board 2…checks the connections according to fig.3.
2. Pump doesn’t start
A) Not enough water supply, the security system has been activated and LED (FAILURE) is on…check the water supply and restart the pump through the reset switch (RESET).
B) Pump is blocked:
LED (FAILURE) is on and the security system is activated. When we act on the manual start switch (RESET) the LED (ON) is activated but the pump doesn’t work…consult your dealer.
C) Failure in the electronic circuit…switches off power supply, wait a few seconds and turn it on again.  If the pump doesn’t start immediately then replace the circuit.
D) No electrical supply…check the proper electric feeding.  The tension LED (POWER) should be on.
E) Not enough pump pressure…the security system has been activated and the corresponding LED (FAILURE) is on.  Check that the pump pressure is 0.8 bar higher than the starting pressure of the controller.
F) Air in the pump aspiration…the pressure gauge will indicate a pressure lower than the nominal or constant oscillations. The security system will act by stopping the pump and the LED (FAILURE) will be on.  Check the sealing of the connections and O-ring of the aspiration conducts.
3. The pump starts and stops repeatedly:
A) Small leakage in some point of the installation…Verify possible tap of tank leakage and repair them.
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