AES EPIC 3D Electronic Triple Pump Control Panel

Introduction

1.1 Presentation

This manual provides essential information for the proper installation, use, and maintenance of the EPIC 3D control panel. Users must read this manual before operation. Improper use may lead to machine damage and void the warranty. Always provide the model identification code and construction number when requesting technical information or spare parts. Instructions and warnings apply to the standard version; consult sale contract documentation for modifications. For situations not covered, contact customer service. Units must be installed in sheltered, well-ventilated, non-hazardous environments, with an operating temperature range of -5°C to +40°C.

1.2 Description

These control panels are designed to manage up to 3 motors or electric pumps in pressurization systems, well emptying, or water tank applications. The reserve pump starts automatically if the main pump fails.

Atlantic S.r.l.s. is not liable for any damage caused by unauthorized or improper use.

Technical Features:

• Self-learning of motor data.
• Min-max amperage protection (A).
• Dry running protection (via cosφ and min Amperage).
• Min and max voltage protection (V).
• Phase failure protection.
• Start and stop delay.
• Delay network restore.
• Protection delay.
• Frequency: 50-60Hz.

Output Alarms and Protections:

• Acoustic alarm.
• Light alarm.
• Alarm output Relais 220V AC.
• Alarm output Relais 12V DC.
• Alarm output with Buzzer 12V.
• Min-max water level.
• Min-max Voltage.
• Phase failure.
• Frequency failure alarm.
• Min-max motor Amperage.
• Min cosφ.
• Motor klixon alarm.
• Water in oil chamber alarm.

1.3 Handling

Handle the control panel with care to prevent damage from falls or knocks, which may not be externally visible.

Preliminary Inspection:

After unpacking, visually inspect the control panel for shipping damage. Report any visible damage to an Atlantic dealer within five days of delivery.

Stored:

If the unit is not installed immediately, store it in its original packaging, protected from weather (especially freezing temperatures) and physical impact.

Safety Information

2.1 Safety Information

⚠️ Risk of Electric Shock: Failure to follow instructions may result in electric shock.

⚠️ Risk for People and Property: Failure to follow prescriptions may cause damage to persons and/or property.

⚠️ Warning: Failure to observe prescriptions may damage the pump, unit, or system.

2.2 Caution

Attention: Pumps

• Ensure pumps are fully primed before starting.
• Verify pumps are running with correct rotation.
• Electric pumps or motors may start automatically.

Attention: Electrical Connection

• Connection must be made by a qualified electrician, adhering to current electrical regulations.
• Ensure an efficient grounding system is connected to the pumps, motors, and panel, complying with local regulations.
• Ground the unit before any other operation.

Attention: Service

Always disconnect the power supply before performing any operations on electrical or mechanical components.

Line of Supply Current:

Connect the unit to ground before any other operation. The input voltage must match the data on the panel and pump: (400V ± 10% 50/60Hz for EPIC 3D -400/...) or (230V ± 10% 50/60Hz for EPIC 3D -230).

Ensure the power supply cable can bear the nominal current and connect it to the control panel's general switch terminals. Exposed cables must be protected. The line must be protected with an Earth leakage and magnetic switch according to local regulations.

Line of Motor Power Supply:

The input voltage must match the data on the motor: (400V±10% 50/60Hz three-phase) or (230V±10% 50/60Hz single-phase).

During startup, ensure the motor rotation direction is correct, usually indicated by an arrow on the motor.

Installation

3.1 Assembling

Fix the control panel securely to a stable support using screws and anchors through the holes in the box. Use a correctly sized tool to fix cables to terminals, avoiding damage to screws or their seats. Be cautious with electric screwdrivers to prevent stripping threads. After fixing, remove any plastic or metallic surplus inside the box before applying power.

Diagram Description: This section includes diagrams showing the external dimensions and mounting hole locations of the control panel enclosure. Dimensions are provided in millimeters for front, side, and rear views.

3.2 Electrical Connections

Detailed wiring diagrams are provided for the EPIC 3D 230 and EPIC 3D 400 models, illustrating connections for power supply, pumps (P1, P2, P3), float switches (G1-G5), klixon sensors (K1-K3), alarms, sensors (4-20mA), and dip-switches across two electronic boards (A and B).

3.3 Adjustments and Settings (Initialization)

Control Panel Turn On:

After making electrical connections, switch on the control panel and wait for the initial message.

Language Setting (Obligatory):

Select the display language using the arrow buttons (Down Arrow ▼, Up Arrow ▲). Press the Confirm button ■ to confirm the selection.

Pumps Trigger:

To proceed with the self-learning procedure, pumps must be triggered. Press and hold the MAN button for 3 seconds for each pump (P1, P2, P3). Do NOT press the Confirm button ■ at this stage.

Autotuning (Obligatory):

Follow the on-screen prompts to start the self-learning of pump data. Press ■ to confirm data. If prompted, select YES to proceed to the next pump or NO to return to the previous step.

⚠️ Important: Before starting autotuning, verify with a tester that the mains voltage matches the nominal voltage.

⚠️ Important: After final confirmation for each pump, self-learning cannot be undone. Access the advanced menu (3.4) to perform it again.

Control Panel Operativity:

Once self-learning is complete, the panel displays learned data. Pressing the AUT button for P1/P2/P3 makes the panel operational.

Preset Parameters:

3.4 Adjustments and Settings (Advanced Menu)

Access to Advanced Menu:

The control panel is set to access the "ADVANCED MENU" by setting DIP-SWITCH 2 to the "ON" position. Switch off the panel, set the dip-switch, then turn the panel back on. The "ADVANCED MENU" message will appear.

Setting Parameters:

Navigate the menu using the arrow buttons (▼, ▲) and confirm selections with the ■ button. The available functions include:

• M01 UTILITY
• M02 GENERAL
• M03 NET CONTROL
• M04 PUMP 1
• M05 PUMP 2
• M06 PROGRAM
• M07 SENSOR
• M08 TIMER
• M09 PUMP 3
• EXIT

Confirm Modifications and Exit from Advanced Menu (Example):

Follow the on-screen prompts using arrow buttons and the confirm button ■ to change parameters like Language. To exit the "ADVANCED MENU", set DIP-SWITCH 2 back to the "OFF" position after confirming modifications.

M01 UTILITY:

Modified Parameters:

• LANGUAGE: Language selection.
• START DELAY: Control panel switch-on delay after restart (in sec.).
• MANUAL KEYPAD: Option to operate the "MAN" button in stable or unstable mode (ON: stable / OFF: unstable).
• MAX LEVEL ALARM DELAY: A 15-minute delay for the maximum level alarm. The display shows the alarm, and pumps start (if available), but the alarm relay and buzzer are delayed.

Change Language:

Navigate through language options using arrow buttons and confirm with ■.

Change Start Delay:

Adjust the start delay value using arrow buttons and confirm with ■.

Change "MAN" Button (Stable/Unstable):

Select between stable or unstable mode for the "MAN" button using arrow buttons and confirm with ■.

Change Max Level Alarm Delay:

Enable or disable the max level alarm delay using arrow buttons and confirm with ■.

M02 GENERAL:

Modified Parameters:

• PUMP START DELAY: Set the pump start delay.
• PUMP STOP DELAY: Set the pump stop delay.
• PUMPS ALTERNATION: Set the pumps alternation.
• TIME ON MAX: Maximum continuous pump operation time (in min.). This parameter is not active if set to 0 min.

Change Start Delay:

Adjust the start delay value using arrow buttons and confirm with ■.

Change Stop Delay:

Adjust the stop delay value using arrow buttons and confirm with ■.

Change Pumps Alternation:

Enable or disable pump alternation using arrow buttons and confirm with ■.

Change Time on Max:

Set the "TIME ON MAX" parameter using arrow buttons and confirm with ■.

"Time on Max" Procedure: For correct functioning, set pump alternation to "ON", then set "STARTING FOR HOURS" from M04, M05, and M09 menus, entering the maximum allowed starts per pump.

Attention: Refer to chapter 4.2 ALARMS for alarm management.

M03 NET CONTROL:

Modified Parameters:

• NOMINAL VOLTAGE: Set the nominal voltage.
• MINIMUM VOLTAGE: Set the minimum voltage.
• MAXIMUM VOLTAGE: Set the maximum voltage.
• NOMINAL FREQUENCY: Set the nominal frequency.
• FREQUENCY RANGE: Set the frequency range.

Change Nominal Voltage:

Adjust the nominal voltage using arrow buttons and confirm with ■.

Change Minimum Voltage:

Adjust the minimum voltage using arrow buttons and confirm with ■.

Change Maximum Voltage:

Adjust the maximum voltage using arrow buttons and confirm with ■.

Change Nominal Frequency:

Adjust the nominal frequency using arrow buttons and confirm with ■.

Change Frequency Range:

Adjust the frequency range using arrow buttons and confirm with ■.

M04 PUMP 1 / M05 PUMP 2 / M09 PUMP 3:

Modified Parameters:

• AUTOTUNING: Allows self-learning of data to be redone.
• NOMINAL CURRENT: Set nominal/operating current of the pump.
• MINIMUM AMPERAGE: Minimum setting for dry running protection.
• MAXIMUM AMPERAGE: Maximum setting for overcurrent protection.
• START PER HOUR: Set max number of pump starts per hour.
• MIN COSφ: Minimum cosφ for dry running protection (default 75% of autotuning value).

Note: Amperage and cosφ values displayed may differ by ±5% from nominal values due to the panel not being a measuring instrument.

Autotuning:

Follow prompts to initiate autotuning. Confirm data with ■.

Change Nominal Current:

Adjust nominal current using arrow buttons and confirm with ■.

Change Minimum Amperage:

Adjust minimum amperage using arrow buttons and confirm with ■.

Change Maximum Amperage:

Adjust maximum amperage using arrow buttons and confirm with ■.

Change Start Per Hour:

Adjust "Start Per Hour" value using arrow buttons and confirm with ■.

Change Min COSφ:

Adjust "Min COSφ" value using arrow buttons and confirm with ■.

M06 PROGRAM:

Modified Parameters:

• OPERATION: Select "EMPTY" (emptying) or "FILL" (filling).
• TYPE: Select "POTABLE" or "WASTE" water type.
• SELF HOLDING: Primarily for wastewater applications. Uses float switches for pump control.
• BMS (Remote Emergency Start/Stop): Allows remote control via a button connected to the G4 input.
• MULTI TANK: For use with 2 pumps in separate tanks (P1 and P2 only).

Operation (Empty/Fill):

Select operation mode using arrow buttons and confirm with ■.

Type (Potable/Waste Water):

Select water type using arrow buttons and confirm with ■.

Self Holding:

Configure self-holding operation using arrow buttons and confirm with ■.

BMS Setting:

Configure BMS remote control using arrow buttons and confirm with ■.

Multi Tank Setting:

Configure multi-tank operation using arrow buttons and confirm with ■.

M07 SENSOR (Sensor/Transducer 4÷20 mA):

Modified Parameters:

• PARAMETERS: Setting unit of measure (mt/bar/celsius).
• FULL SCALE: Set the full scale value specified by the sensor manufacturer (default 160.0).
• MINIMUM LEVEL: Parameter active only with unit of measure in mt.
• MAXIMUM LEVEL: Parameter active only with unit of measure in mt.
• START P1 and STOP P1, START P2 and STOP P2, START P3 and STOP P3: Pump start/stop points.

Attention: Switch off the control panel before connecting the sensor. For level sensors, autotuning (page 17) is required to set level 0mt with the sensor out of water.

Set Parameters:

Configure measurement units and other parameters using arrow buttons and confirm with ■.

Set Full Scale:

Set the full scale value using arrow buttons and confirm with ■.

Set Minimum Level:

Set the minimum level value using arrow buttons and confirm with ■.

Set Maximum Level:

Set the maximum level value using arrow buttons and confirm with ■.

Pump 1 Start:

Set the start point for Pump 1 using arrow buttons and confirm with ■.

Pump 1 Stop:

Set the stop point for Pump 1 using arrow buttons and confirm with ■.

Pump Start / Stop Pumps 2, 3: The same procedure applies for setting "START PUMP 2 / PUMP3" and "STOP PUMP 2 / PUMP3" parameters.

For mt and celsius parameters, FILL and EMPTY programs are possible: FILL: START value < STOP value; EMPTY: START value > STOP value. For bar parameters, only EMPTY is possible: EMPTY: START value < STOP value.

M08 TIMER:

Modified Parameters:

• ENGAGE TIMER T1/T2/T3: Set working (ON) and pause (OFF) minutes for each pump.

Set Duty/Stand-By:

Configure timer settings using arrow buttons and confirm with ■.

Timer T1 ON:

Set the "TIMER T1 ON" value using arrow buttons and confirm with ■.

Timer T1 OFF:

Set the "TIMER T1 OFF" value using arrow buttons and confirm with ■.

Timer Setting T2/T3 ON / Timer T2/T3 OFF: The same procedure applies for setting "TIMER T2/T3 ON" and "TIMER T2/T3 OFF" parameters.

3.5 Trimmer Settings

To manually change threshold protections, interrupt power to the control panel and adjust the trimmers.

Trimmer 1: Probe Sensitivity Change:

Adjusts sensitivity for CLC probes and the water sensor in the oil chamber. Interrupt power and turn trimmer 1 clockwise to increase sensitivity, counterclockwise to decrease.

⏰ Protection Delay: The pump protection switching delay is set at 5 seconds.

3.6 Alarm Contact Outputs

Single Phase Version:

• Alarm outputs: L-OUT / N = 230 V a.c. +/- 10%
• + -12 / NO = 12V c.c. or contact NO

Tree Phase Version:

• Alarm outputs: L-OUT / N = 400 V a.c. +/- 10%
• + -12 / NO = 12V c.c. or contact NO

Diagram Description: Images show the alarm output terminals on the electronic boards, illustrating connections for 12V c.c. output and free contact NO.

General Use

4.1 Keypad and Lights Indications

Control Panel Indicators:

• PW: Blue light indicating power network presence and that the panel is powered.
• ALARM: Red light indicating a general alarm and pump stop (e.g., min/max Amp, min/max V, min/max level, motor klixon, water in oil chamber, phase failure).
• START: Green light indicating pump start. Solid ON means pump running; flashing indicates auto-setting mode.
• AUT: Activates auto-setting mode and automatic pump operation (if the green START light is on).
• 0: Pump stop button and alarm reset; turns off sound alarm.
• MAN: Activates manual pump operation. Holding it down bypasses protections.

4.2 Alarms

The control panel signals alarms that may occur during operation. Some stop pumps, others are only displayed. All alarms are shown on the panel with a flashing red LED, and the display shows the code/description until cleared by the operator.

⚠️ The alarm "AL 11" starts all available pumps.

Alarm with Stop Pump:

Following an alarm and pump blocking, the control panel offers these operations:

• Attempt first restart after 5 minutes.
• If unsuccessful, try again after 30 minutes, followed by 3 more attempts at 60-minute intervals.
• After 5 unsuccessful attempts, the panel permanently blocks the pump, and the alarm remains active until user intervention.

Delete Alarm:

To delete an alarm (e.g., dry run), press the pump button "0" (P1, P2, or P3) twice:

• First press: Mutes the buzzer.
• Second press: Resets the alarm.

If the alarm is not reset (by pressing "0" twice), the panel will remain in "mute" mode for the next alarm signal.

⚠️ Important: If an alarm recurs after being canceled, the cause must be addressed.

4.3 Typical Installations

Diagram Description: This section provides several diagrams illustrating typical installation and wiring configurations for the EPIC 3D control panel. These diagrams show connections for pumps, various sensors (4-20mA, level probes, water-in-oil chamber, klixon), float switches (clear and waste water), and pressure transducers. A legend explains the symbols used for each component and connection type.

Maintenance

5.1 Pumps Stop

5.2 Service

The EPIC 3D requires no routine maintenance, provided its operating limits are observed. Any maintenance operations must be performed by qualified and experienced personnel in compliance with safety regulations.

⚠️ Danger: Ensure EPIC 3D is disconnected from the power supply before performing any maintenance.

5.3 Spare Parts

Always state the exact model identification number and construction number when requesting technical information or spare parts. Use only original spare parts; unsuitable parts can cause malfunctions, injury, and damage.

5.4 Waste Disposal

Customers are responsible for the appropriate disposal of waste materials according to local legislation. If the control panel or its parts are decommissioned, follow local regulations for sorted waste disposal and refer to recycling centers.

⚠️ Caution: Contamination with hazardous substances can cause serious environmental damage and endanger health.

Certifications

6.1 Certificate of Conformity

Manufacturer: Atlantic Power Control S.r.l.s, Via E. Fermi, 10 - 35020 Polverara (PD) - ITALIA

Declares that the control panels EPIC 3D -230 and EPIC 3D -400 are in conformity with Community Directives regarding:

• European directive 2006/95/CE
• Electromagnetic compatibility directive 2004/108/CE

And as applicable to harmonized standards:

• EN 61439-1, EN 61439-2, EN 60204-1, EN 55014-1
• EN 55014-2, EN 61000-3-2, EN 61000-3-3

Mr. Giuseppe Franchin, as legal representative, is authorized to compile the technical documentation file.

Polverara - Italy, 10/01/2018

Technical Manager (Giuseppe Franchin)

CE Mark is present.