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09-18-2013 MANUAL-APX-V1

ADVANCED DUPLEX PUMP CONTROL PANEL

APX PACKAGE

Table of Contents
1. Safety precautions ............................................................................................................................. .............................. 2
2. Introduction .............................................................................................................................. ........................................ 3
3. Installation and wiring .............................................................................................................................. ....................... 3
4. Startup and control features .............................................................................................................................. .............. 4
5. Internal timers adjustments .............................................................................................................................. .............. 5

6. Enabling, disabling and reset features .......................................................................................................................... 6

7. Principle of operation .............................................................................................................................. ........................ 6

8. Specifications .............................................................................................................................. ..................................... 8

Warranty .............................................................................................................................. ................................................. 8

Four-Float Switches Control schematic ............................................................................................................................. 9

Two-Pressure Switches Control .............................................................................................................................. .......... 10

Power Schematic .............................................................................................................................. ................................. 10

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1. SAFETY PRECAUTIONS

To prevent injury and property damage, follow these instructions. Failure to adhere to installation/operation
procedures and all applicable codes may result in hazards as indicated by warning codes below:

The meaning of each symbol in this manual, and on your equipment, is as follows.

This is the safety alert symbol. Read and follow instructions carefully to avoid a dangerous situation.

This symbol alerts the user to the presence of dangerous voltage inside the product that might cause bodily
harm or electric shock.

This manual should be placed in a location where it can be accessed by users.


This manual should be given to the person who actually operating the control panel and is responsible for its
maintenance.

As with all electrical products, read manual thoroughly. Only qualified, expert personnel should
perform installation and maintenance. Do not disassemble or repair unit unless described in this manual; death or injury to
electrical shock or fire hazard may result. Specifications and manual data are subject to change. Consult factory for
additional information.

2. INTRODUCTION
The advanced pump control package is designed to meet UL-508 requirements and provide different alternating modes
and Lead-Lag control based on input signals from float switches (FSW) or pressure switches (PSW).
All float switch inputs are fed from PLC internal 24VDC power supply and they should be Form-A N.O. contacts for
Emptying application and Form-B N.C. contacts for Filling applications. See picture below for float switches
arrangements. The control panel has four main inputs and one redundant Enable input. The control system monitors status
of all float switch inputs and generates an alarm output when
abnormal sequence is detected. The common alarm light will
indicate a faulty float switch number by number of flashes.
The standard advanced pump control panel consists of an
industrial UL Type 4 enclosure (other types are optional), two
combination motor starters with electronic overload relays,
PLC based control system, two Hand-Off-Auto (HOA)
switches, two run pilot lights & one common system fault
light on the door of the enclosure.
The options for standard package include main disconnect
switch with handle lockout provision in OFF position, two
pump fault lights, two motor seal failure relays, two digital hour meters, Horn or Buzzer with silence push button, and a
Beacon light.

3. INSTALLATION AND WIRING


The advanced pump control panel should be installed in environment suitable for the enclosure UL type rating. The gauge
of the field power, motor and control wiring shell be selected based on the NEC and local law requirements. The power
wiring and grounding shell be done by a licensed electrician at the points shown as dashed lines on the provided electrical
diagrams.
Check if supply voltage matches the voltage rating on the provided drawing & manufacturers panel label
before powering up the pump control panel!
The APX package is ready from the factory for 3, 4, 5 and 6 float switches control configuration.

3-Float switches control


Wire Low Level/Stop float switch SSW between EN1 and P0 terminals, Lead start
float switch LSW1 between 24+ and P1 terminals, and Lag Start float switch LSW2
between 24+ and P2 terminals. There is no High Level alarm in this configuration. If
system should provide alarm when lag pump starts, install a jumper between P2 and
P3 terminals. If system should not provide a motor fault alarm, remove JFA jumper
between P3 and P3A.

4-Float switches control


Wire Low Level/Stop, Lead Start and Lag Start float switches as for 3-Float
configuration. The High Level float switch HSW should be wired between 24+ and
P3 terminals. The alarm output will be provided at High level and any motor fault.

5 and 6-Float switches control


Wire Low Level/Stop, Lead Start, Lag Start and High Level float switches
as for 4-Float configuration. The Low-Low Level/Shutdown float switch
ESW should be wired between 24+ and EN1 terminals. This switch is a
redundant Stop/Shutdown float switch which provides additional
protection for critical application. The redundant High-High float switch
should be wired in parallel with High Level float switch between terminals
24+ and P3. It provides more reliable alarm output in case of high level.

2-Float Switches control


If there only two float switches in the system, one should be used to start Lead
pump and stop both pumps and another one to start Lag pump. Install a jumper
JES between P0 and P1 terminals to provide Lead Start/System Stop control with
float switch LSW1. The alarm output will be activated only at motor fault.

4. STARTUP AND CONTROL FEATURES


Before applying power to the panel, adjust each overload protection to actual motor FLA (for submersible motor set SFA).
Apply power to the panel and check if voltage is in specified range. Turn both MMSs (manual motor starters) on and check
if PLC module POWER and RUN LED lights are lit. The alarm light will flash twice indicating the TMR1 and TMR2
positions (the default position #1 for both).
Check every float switch input by flipping a float switch and monitoring corresponding PLC input LED light.
Example: Lag Start float is wired to terminal P2 and will activate PLC P02 LED.
When all the switch inputs are checked, activate Enable/Stop SSW switch and put HOA
(Hand-Off-Auto) switch #1 in hand position. Check the rotation of the motor #1 which should start after 2-second delay. Put
HOA1 switch in OFF position and HOA2 switch in HAND position. Check the rotation of the motor #2 then put HOA2 in
OFF position. If rotation of any pump motor was incorrect, turn the power off and swap any two motor wires of
corresponding pump motor. Turn the power on and check the pump motor rotation again. If motor rotation is correct, the
system is ready for normal operation.
By default the hand mode is protected by Enable/Stop float switch and pump alternation will occur at every start.
The APX panel provides the following control features:
1. Feature #1- Alarm Activation by Stop switch SSW in open state. Default is Disabled.
Note: This feature will be automatically disabled when Feature #6 is enabled.
2. Feature #2- Alternating at Every Start when alternator TMR-2 is in OFF position. Default is Enabled.
Note: This feature will be automatically disabled when TMR2 is not in position #1 (OFF).
3. Feature #3- Latched Pump Start. When it is enabled, lead and lag pumps start by corresponding float switch and stop
when SSW is open. When it is disabled, Lead and Lag Pumps will start and stop at corresponding Switch state
change. Default is Enabled.
Note: This feature will be automatically disabled when Feature #6 is enabled. Disabling this feature will disable feature #5.
4. Feature #4- Hand Mode Protection. When it is enabled, any pump starts in Hand mode only when stop switch SSW is
closed. When it is disabled, any pump can run in Hand mode without enable signal from SSW. Default is Enabled.
5. Feature #5- Float Switch Fault Alarm. When it is enabled, PLC monitors proper float switches operation sequencing.
If it detects an abnormal sequence, an alarm relay will be activated and alarm light will flash faulty float switch number.

The float switch alarm will be deactivated when fault condition is cleared. When it is disabled, the PLC does not
monitor float switches sequencing. Default is Enabled.
Note: This feature will be automatically disabled when Feature #3 is disabled or feature #6 is enabled.
6. Feature #6- Proof of Flow. When it is enabled, the PLC input wiring configuration should be as it is shown on the
drawing to the left. The PLC monitors flow switch FLSW
input P1 after lead pump start. If flow switch FLSW is not
closed within 15 sec. non-adjustable time delay when lead
pump started or opens at any time after that, the system will
stop a lead pump, initiate an alarm and assign a lead status
to another pump and start it. The alarm can be cleared by
putting the corresponding HOA switch in OFF position.
When Feature #6 is disabled, the PLC monitors all inputs in
4-float switch configuration. Default is Disabled.
Note: Enabling Feature #6 will automatically disable features #1,
#3, #4 and #5. This feature will be automatically disabled when
Feature #7 is enabled.
7. Feature #7- High level run latched. When it is enabled and alarm level switch ASW is closed, both pumps will run
until Stop switch SSW is open even if Feature #3 is disabled. Default is Disabled.
Note: This feature will be automatically disabled when Feature #6 is enabled. When this feature is enabled, feature #6 will be disabled.

5. INTERNAL TIMERS ADJUSTMENTS


The two internal potentiometers TMR1 and TMR2 are located in the
PLCs top left corner under terminal block cover and converted by
PLC programming into five-position switches for easy adjustments.
The factory default position for each timer is #1 (Max. CCW). After
panel is powered up, the alarm light flashes a code for TMR1 and TMR2 positions.
Example: When position of TMR1 is #1 (3sec.) and position of TMR2 is #5 (7 days) at power
up, the alarm light will provide one 1-second flash, 2-second pause then five 1-second
flashes corresponding to TMR1 and TMR2 positions. If TMR1 position is changed, the alarm
light will flash the pulse code for TMR1 new position and current position of TMR2. If TMR2
position is changed, the alarm light will only flash the pulse code for TMR2 new position.
The Lag pump start delay time is adjustable by potentiometer TMR1 with 3, 6, 10, 30 and 60 seconds settings (Default
setting is 3 seconds). The little control screwdriver should be used for the timer adjustment. Apply a very low force at
mechanical limits preventing a damage of the potentiometer. For a 3 sec. setting (default) insert a screwdriver and turn
the potentiometer CCW to the mechanical limit. For a 6 sec. setting insert a screwdriver and turn the potentiometer CCW
to the mechanical limit then turn it 30 degrees CW. For a 10 sec. setting insert a screwdriver and turn the potentiometer
CCW to the mechanical limit then turn it 120 degrees CW. For a 30 sec. setting insert a screwdriver and turn the
potentiometer CW to the mechanical limit then turn it 30 degrees CCW. For a 60 sec. setting insert a screwdriver and turn
the potentiometer CW to the mechanical limit.
The alternation timer is adjustable by PLC internal potentiometer TMR2 with OFF, 12h, 24h, 3 days and 7days settings
(Default setting is OFF). The alternating timer counts lead pump run time and will stop counting when lead pump stops
and continue counting when it starts again. The timer will be reset if pumps were alternated by hand or lead pump failed.
The little control screwdriver should be used for the timer adjustment. Apply very low force at mechanical limits preventing
a damage of the potentiometer. For an OFF setting (alternating by clock is disabled and alternating at every start is
enabled) insert a screwdriver and turn the potentiometer CCW to the mechanical limit and alarm LED flashes once. For a
12 hours setting insert a screwdriver and turn the potentiometer CCW to the mechanical limit then turn it 30 degrees CW
and alarm LED flashes twice. For a 24 hours setting insert a screwdriver and turn the potentiometer CCW to the
mechanical limit then turn it about 120 degrees CW (mid position) and alarm LED flashes 3 times. For a 3 days setting

insert a screwdriver and turn the potentiometer CW to the mechanical limit then turn it 30 degrees CCW and alarm LED
flashes 4 times. For 7 days setting insert a screwdriver and turn the potentiometer CW to the mechanical limit and alarm
LED flashes 5 times. Call FCS factory if different setting for the timers are required.

6. ENABLING, DISABLING AND RESET FEATURES #1- #7


Programming mode. In order to enable or disable the desired feature, the system must be in programming mode. Before
changing to programming mode, turn the power off and install a wire jumper between terminals [+24] and [S2H] and put
HOA1 in OFF and HOA2 in AUTO positions. After power is turned on, the PLC input LEDs P04 and P05 should be off, P06
and P07 should be on and alarm light will flash a pulse code. Right down position codes for TMR1 and TMR2 showed by
alarm light.
Example: when position of TMR1 is 2 (6sec.) and position of TMR2 is 4 (3 days) at power up, the alarm light will provide
two 1-second pulses, 2-second pause then four 1-second pulses corresponding to TMR1 and TMR2 positions. The PLC is
ready for programming of the control features.
In order to check current setting (enabled or disabled) of any feature, put TMR1 or TMR2 in proper position. When position
of the TMR is changed, the alarm light will flash the pulse code for its current position and after 2-second pause the stored
selection for corresponding to its position feature. The LED indication for enabled feature is a solid light for 2 seconds and
for disabled feature 2-second burst of fast flashes.
Example: If feature #6 is disabled and TMR2 is moved to position #1 (CCW to the limit), the
alarm light will create six 1-second flashes and after 2-second pause a burst of fast flashes.
If TMR2 was already in position #1, change its position to any # and wait until alarm light
flashes a code then return it back to position #1. The indication mode is activated every time
when any TMR position # is changed. The TMR1 is inactive if TMR2 is in position #1
(feature #6) of position #2 (feature #7). In order to use TMR1, put TMR2 in position #5 (CW
to the limit).
Example: If feature #2 is enabled and TMR1 is moved to position #2 (feature #2) when
TMR2 is in position #5 (CW to the limit), the alarm light will create two 1-second flashes and
after 2-second pause a 2-second flash.
Enabling or disabling feature. In order to change the feature setting, move proper TMR to feature # position and after it
indicates the feature setting, switch HOA1 to AUTO position 3 times to enable (solid 2-second LED flash) and 4 times to
disable (burst of fast flashes) selected feature. The switching should be done in 3 seconds.
Example: If feature #3 needs to be enabled, move TMR1 to position #3 when TMR2 is in
position #5 (CW to the limit) and switch HOA1 to AUTO position 3 times. The alarm light will
be on for 3 seconds indicating that feature was enabled.
Note: If PLC does not accept a feature enable selection, some other enabled feature
automatically disables it. Check feature description for details.
Reset to factory default. The PLC can be reset to factory default features settings by
switching HOA1 to HAND position 5 times in 4 seconds. When reset is done, the alarm light will be on for 3 seconds.
When programming of the features is finished, put both HOA switches in OFF position and turn power off. Remove the
jumper from [+24] and [S2H] and turn power on. Put both timers TMR in original positions (from your notes) and after LED
indication mode put HOA switches in desired mode and system will be ready to operate.

7. PRINCIPLE OF OPERATION
When power is applied, both MMSs are in on position and HOA switches are in OFF position, both pumps will be in stop
mode and alarm light will indicate positions of TMR1 and TMR2 for 10 seconds. The control mode is set to 4-float switches
by default. When Stop float switch SSW on input P0 is closed and other floats on inputs P1-P3 are open, the system is
ready for operation but pumps are still in Stop mode.
Hand Mode. Any pump will start if corresponding HOA switch is in Hand position and stop if either its HOA is in OFF
position or SSW float is open (low level protection). The low level protection for Hand mode can be disabled by

programming feature #4. The status of Lead Start and Lag Start float switches are not monitored in Hand mode. With
factory installed jumper JFA the alarm output will be activated by closed high level float switch ASW or fault relays FR1 and
FR2. In order to exclude a pump fault from alarm, remove JFA jumper. If system was power up with both HOAs in Hand
position, pumps will sequentially start with 4-second delay to decrease starting inrush.
Auto Mode with float switches. The control system assigns Lead and Lag status to pumps and alternates them based on
selected features. The default setting for alternation is at every start. When both HOA switches are in Auto position and
Stop and Lead Start float switches are closed, lead pump will start. The lead pump will run until Stop float switch is open
provided by enabled by default Feature #3 (Latched Pump Start).
Example: If Lead Start float switch is closed with closed Stop float switch, lead pump starts after 4-second time delay.
When Lead Start float is open, lead pump stops even if Stop float is still closed. If Lag Start float switch is closed with
closed Stop float switch, lead pump starts after 4-second time delay. When Lead Start float is open, lead pump stops even
if Stop float is still closed.
If Feature #3 is disabled, the control system starts and stops pumps independently by corresponding float switch. The Stop
float still disables both pumps. The alternation will occur at next start and the lag pump will become a lead pump. The lag
pump will start after adjustable by TMR1 time delay when Stop, Lead Start and Lag Start float switches are closed and
run until the Stop float switch is open. The lead pump will be replaced with the lag pump automatically with both HOA
switches in Auto position when its motor protection is tripped or lead pump HOA is set to OFF position. If both HOA
switches where in Auto position and one is put In Hand position, the corresponding to this switch pump will become a
lead pump.
Auto Mode with pressure switches. In order to change control mode to Two-Pressure switches
with Proof of Flow, change feature #6 setting to Enabled. The PSW1 Pressure switch on terminal
P0 will start and stop a Lead pump. The 2nd Pressure switch on terminal P2 will start and stop a
Lag pump. The N.O. Flow Switch contact should be wired to 24+ and P1 terminals and if it is not
closed in 15 seconds when any pump starts, the system will stop this pump and initiate an alarm. If
No Flow alarm occurs when lead pump is running, the system will initiate an alarm and stop
current Lead pump and replace it with Lag pump. If this configuration does not require a Proof of
Flow, install a jumper between 24+ and P1 terminals.
Alarm Output and Light. The alarm light works as an indicator for TMR1 and TMR2 positions, faulty float switch number
and system alarm. The control system provides three form C fault relay outputs and one common red alarm light. The FR1
fault relay contact is for Pump #1 fault activated by EOL1 or MMS1, FR2 fault relay contact is for Pump #2 fault activated
by EOL2 or MMS2 and AR is a common alarm relay contact activated by all applicable faults and alarms. With factory
installed JFA jumper, the alarm level float switch or one of the motor fault relays will activate an alarm relay and alarm pilot
light and deactivate them when level drops or fault is cleared. In order to clear a motor fault, the corresponding HOA switch
should be put in OFF position. If the horn option DPX-Q is installed, the horn will sound during alarm condition and can
be turned off by Silence pushbutton. If APX-STR seal failure option is installed, the system will monitor resistance
between pump case and internal electrode and trip when there is a moisture and resistance is less than a relay set value.
The system will stop a faulty pump and provide alarm light and relay output.

This manual is applicable to all Franklin Control Systems (former Cerus) standard APX duplex starter panels built after
September 18, 2013.

8. SPECIFICATIONS

General Power Voltage 208-230-480VAC


Outputs Relay Contacts 6A 480VAC Max.
Motor Starters Rated to specified motor horse power
Inputs All external Rated for 24VDC 10mA
switches inputs
TMR1 Lag Start Five settings: 3sec., 6sec., 10sec., 30sec., and 60sec.
Delay Timer
Adjustments TMR2 Alternator Five settings: OFF, 12h, 24h, 3 days, and 7 days.
Timer
EOL Electronic Must be set to motor rated FLA and Time dial set to class 10
Overload Relays
Indicators Alarm Light Indicates TMR1 & TMR2 positions, alarm level, motors and float
switches faults
Storage 12F to 132F (-10C to 55C)
Environmental Operating 32F to 122F (0C to 50C) Non-direct sun installation

Disconnect and lock out all power before installing or servicing equipment.
This equipment may require locking out multiple power sources prior to service.

Warranty Information
Franklin Control Systems provides 5-year warranty for all Franklin Control Systems brand electrical components excluding
thermal protection devices. All other brand name devices installed in Franklin Control Systems control panels will carry
original manufacturer warranties.

Warranty period is 60 months after date of invoice. Detailed warranty terms and conditions are available from
Franklin Control Systems Industrial or can be found at www.Franklin-Controls.com

Warranty service information

o If the APX panel does not operate properly because of any defective component under normal and proper use within
the warranty term, contact an authorized FRANKLIN CONTROL SYSTEMS distributor or FRANKLIN CONTROL
SYSTEMS technical support.

Warranty is void if damage to the unit was caused by any of the following:

o Misuse, negligence or accident.


o Abnormal supplied power voltage.
o Improper repair or altering by other than a FRANKLIN CONTROL SYSTEMS authorized distributor or service center.
o Earthquake, fire, flooding, lighting, or other natural calamities
o When the warranty period has expired

APX Float Switches Control Wiring Schematic

APX 2-Pressure Switches with Proof of Flow Control Wiring Schematic

APX Power Wiring Schematic

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