Eaton DPCT Handbuch

DPCT IOM Instruction Operation Manual

Installation manual

ii DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN Jaunary 2023 www.eaton.com

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY

The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s

(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales

office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in

appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES

OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY

EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE

CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.

In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or

other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to

damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the

use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the

information, recommendations and descriptions contained herein. The information contained in this manual is subject to

change without notice.

iiiDPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

1. Index

1. Introduction .......................................................................................................................................................1

1.1 Safety ............................................................................................................................................................................... 1

1.2 Warranty........................................................................................................................................................................... 1

1.3 Safety precautions............................................................................................................................................................ 1

1.4 Product overview ............................................................................................................................................................. 1

2. Installation and electrical connections ...........................................................................................................2

2.1 Mounting.......................................................................................................................................................................... 2

2.2 Pressure sensor connections........................................................................................................................................... 2

2.3 Electrical connections ...................................................................................................................................................... 2

2.3.1 Field Conductor Sizes ............................................................................................................................................ 2

2.3.2 Electrical Checkout Instructions............................................................................................................................. 3

2.4 System pressure connection............................................................................................................................................ 3

3. Hardware description........................................................................................................................................4

3.1 General............................................................................................................................................................................. 4

3.1.1 Battery chargers..................................................................................................................................................... 4

3.1.2 Three-step charge .................................................................................................................................................. 4

3.1.2.1 Bulk ...........................................................................................................................................................4

3.2.1.2 Overcharge ................................................................................................................................................4

3.2.1.3 Float ..........................................................................................................................................................4

3.1.3 Charger shut down ................................................................................................................................................ 4

3.1.4 AC input fuse protection........................................................................................................................................ 4

3.1.5 Battery charger display........................................................................................................................................... 4

3.1.6 Battery charger setup: lead acid / NiCad................................................................................................................ 4

3.1.6.1 Lead acid ...................................................................................................................................................4

3.1.6.2 NiCad.........................................................................................................................................................5

3.1.7 Forced charging...................................................................................................................................................... 5

3.1.8 Battery charger specifications................................................................................................................................ 5

3.2 User interface touch screen............................................................................................................................................. 5

3.2.1 Memory ................................................................................................................................................................. 5

3.2.2 Battery backup ....................................................................................................................................................... 5

3.2.3 Color touchscreen specifications ........................................................................................................................... 5

3.2.4 USB port ................................................................................................................................................................ 5

3.3 Power I/O board ............................................................................................................................................................... 6

3.4 External pushbuttons ...................................................................................................................................................... 6

4. Operation ...........................................................................................................................................................7

4.1 General............................................................................................................................................................................. 7

4.2 Welcome screen .............................................................................................................................................................. 7

4.2.1 Welcome screen and home screen graphics ....................................................................................................... 7

4.2.1.1. Welcome screen ........................................................................................................................................7

4.2.1.2. Home tab .................................................................................................................................................8

4.3 Start sequence ................................................................................................................................................................. 8

iv DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

4.3.1 Manual start sequence .......................................................................................................................................... 8

4.3.2 Automatic start sequence...................................................................................................................................... 9

4.3.2.1 OFF mode.................................................................................................................................................9

4.3.2.2 MANUAL mode ........................................................................................................................................9

4.3.2.3 AUTO mode ..............................................................................................................................................9

4.3.2.4 STOP modes.............................................................................................................................................9

4.3.2.4.1 Manual stop mode.................................................................................................................................9

4.3.2.4.2 Automatic shutdown..............................................................................................................................9

4.3.2.4.3 Weekly test timer ..................................................................................................................................9

4.3.2.4.4 Test engine pushbutton..........................................................................................................................9

4.3.3 Minimum run time (MRT) ...................................................................................................................................... 9

4.3.4 Sequential start timer (SST)................................................................................................................................. 10

4.3.5 Control Inputs ...................................................................................................................................................... 10

4.3.5.1 Control input descriptions.......................................................................................................................10

4.3.5.1.1 Remote manual start ...........................................................................................................................10

4.3.5.1.2 Remote manual stop............................................................................................................................10

4.3.5.1.3 Remote manual start/stop ...................................................................................................................10

4.3.5.1.4 Remote auto start ................................................................................................................................10

4.3.5.1.5 Deluge valve start ................................................................................................................................10

4.3.5.1.6 Low suction..........................................................................................................................................10

4.3.5.1.7 Low foam level..................................................................................................................................... 11

4.3.5.1.8 Proof pressure switch .......................................................................................................................... 11

4.3.5.1.9 Low room temperature ........................................................................................................................ 11

4.3.5.1.10 High room temperature...................................................................................................................... 11

4.3.5.1.11 Interlock .............................................................................................................................................. 11

4.3.5.1.12 Low reservoir ..................................................................................................................................... 11

4.3.5.1.13 High reservoir..................................................................................................................................... 11

4.3.5.1.14 Reservoir empty................................................................................................................................. 11

4.3.5.1.15 Low fuel ............................................................................................................................................. 11

4.3.5.1.16 High fuel............................................................................................................................................. 11

4.3.5.1.17 Fuel spill.............................................................................................................................................. 11

4.3.5.1.18 Dump valve ........................................................................................................................................ 11

4.3.5.2.19 Enable sequential start ...................................................................................................................... 11

4.3.5.1.20 Relief valve discharge......................................................................................................................... 11

4.3.5.1.21 Custom input...................................................................................................................................... 11

4.3.5.1.22 Undefined...........................................................................................................................................12

4.3.5.3 Loss of DC power...................................................................................................................................12

4.3.5.4 Speed switch malfunction ......................................................................................................................12

4.3.5.5 Engine starter coil failure........................................................................................................................12

4.3.5.6 Audible alarm silencing...........................................................................................................................12

4.4 Output relays.................................................................................................................................................................. 12

4.4.1 Engine run (1CR).................................................................................................................................................. 12

4.4.2 Low fuel (2CR) ..................................................................................................................................................... 12

4.4.3 Auto mode (3CR) ................................................................................................................................................. 12

4.4.4 Common alarm (4CR) .......................................................................................................................................... 12

vDPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

4.5 Engine Alarm Functions ................................................................................................................................................. 12

4.5.1 Engine overspeed ................................................................................................................................................ 12

4.5.2 Fail to start ........................................................................................................................................................... 12

4.5.3 High engine temperature..................................................................................................................................... 12

4.5.4 Low oil pressure .................................................................................................................................................. 12

5. Programming ...................................................................................................................................................13

5.1 Introduction .................................................................................................................................................................... 13

5.2 Navigation ................................................................................................................................................................... 13

5.3 Startup tab...................................................................................................................................................................... 14

5.3.1 Quick setup.......................................................................................................................................................... 14

5.3.2 Manual/automatic start ........................................................................................................................................ 14

5.3.3 Test alarm ............................................................................................................................................................ 14

5.3.4 USB download ..................................................................................................................................................... 14

5.4 Panel setup tab .............................................................................................................................................................. 15

5.4.1 Language ............................................................................................................................................................. 15

5.4.2 Set time ............................................................................................................................................................... 15

5.4.3 Set date ............................................................................................................................................................... 15

5.4.4 Set day of the week............................................................................................................................................. 15

5.4.5 Auto shutdown .................................................................................................................................................... 15

5.4.6 Source voltage ..................................................................................................................................................... 15

5.4.7 Battery voltage..................................................................................................................................................... 15

5.4.8 Battery type ......................................................................................................................................................... 15

5.4.9 Common alarm settings....................................................................................................................................... 15

5.4.10 Notification area settings ..................................................................................................................................... 15

5.4.11 Foam controller .................................................................................................................................................... 15

5.4.12 Menu password................................................................................................................................................... 15

5.4.13 Controller serial number ...................................................................................................................................... 15

5.4.14 Pump serial number............................................................................................................................................. 15

5.4.15 Save configuration to USB................................................................................................................................... 15

5.4.16 Load configuration to usb .................................................................................................................................... 15

5.4.17 Save settings as factory default .......................................................................................................................... 15

5.4.18 Restore factory default settings........................................................................................................................... 15

5.4.19 Screen brightness................................................................................................................................................ 16

5.4.20 Welcome screen.................................................................................................................................................. 16

5.4.21 Screen lock .......................................................................................................................................................... 16

5.4.22 Customer service contact.................................................................................................................................... 16

5.4.22.1 Save configuration ................................................................................................................................16

5.4.22.2 Load configuration ................................................................................................................................16

5.4.23 Update firmware.................................................................................................................................................. 16

5.4.24 Update languages ................................................................................................................................................ 16

5.5 Help tab.......................................................................................................................................................................... 16

5.5.1 Product manual.................................................................................................................................................... 16

5.5.2 Service contact information................................................................................................................................. 16

5.5.3 Factory contact information................................................................................................................................. 16

vi DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

5.6 Pressure settings tab ..................................................................................................................................................... 16

5.6.1 Start pressure ...................................................................................................................................................... 16

5.6.2 Stop pressure ...................................................................................................................................................... 16

5.6.3 Stop mode ........................................................................................................................................................... 16

5.6.4 Start above pressure............................................................................................................................................ 16

5.6.5 Pressure variance recording................................................................................................................................. 16

5.6.6 Hourly pressure recording ................................................................................................................................... 17

5.6.7 Low suction shutdown ........................................................................................................................................ 17

5.6.8 Low foam shutdown............................................................................................................................................ 17

5.6.9 Proof pressure switch.......................................................................................................................................... 17

5.6.10 Pressure units...................................................................................................................................................... 17

5.6.11 Pressure transducer............................................................................................................................................. 17

5.6.12 Calibrate transducer............................................................................................................................................. 17

5.7 Timer values tab............................................................................................................................................................. 17

5.7.1 Minimum run time (MRT) .................................................................................................................................... 17

5.7.2 Sequential start time............................................................................................................................................ 17

5.7.3 AC power failure alarm ........................................................................................................................................ 18

5.7.4 AC power failure start .......................................................................................................................................... 18

5.7.5 Weekly engine test timer .................................................................................................................................... 18

5.8 Alarm setpoints tab ........................................................................................................................................................ 18

5.8.1 Source voltage alarm setpoint ............................................................................................................................. 18

5.8.2 Battery voltage alarm setpoint............................................................................................................................. 18

5.8.3 Transducer fail pump start ................................................................................................................................... 18

5.8.4 Abort engine test ................................................................................................................................................. 18

5.9 Inputs/outputs tab .......................................................................................................................................................... 18

5.9.1 Inputs................................................................................................................................................................... 18

5.9.2 Outputs................................................................................................................................................................ 18

5.10 History stats diag. Tab (history/statistics/diagnostics) .................................................................................................. 19

5.10.1 Message History.................................................................................................................................................. 19

5.10.2 Controller Statistics.............................................................................................................................................. 19

5.10.3 Controller diagnostics .......................................................................................................................................... 20

5.10.4 Start up information............................................................................................................................................. 20

5.10.5 Save to USB......................................................................................................................................................... 20

6. Optional add-on boards..................................................................................................................................21

6.1 Relay output board ......................................................................................................................................................... 21

6.1.1 Programming ...................................................................................................................................................... 21

6.2 Secondary 4-20 mA device ............................................................................................................................................ 21

6.2.1 Programming: ...................................................................................................................................................... 21

6.3 Modbus board ............................................................................................................................................................... 21

6.3.1 Programming: ...................................................................................................................................................... 21

6.3.2 Modbus dip switch settings ................................................................................................................................ 21

viiDPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

Appendix A: Menu structure.................................................................................................................................22

Appendix B: Startup tab menu structure............................................................................................................23

Appendix C (a): Panel setup tab menu structure ...............................................................................................24

Appendix C (b): Panel setup tab menu structure continued.............................................................................25

Appendix C (c): Panel setup tab menu structure continued .............................................................................26

Appendix C (d): Panel setup tab menu structure continued ............................................................................27

Appendix D: Help tab menu structure.................................................................................................................28

Appendix E (a): Pressure settings tab menu structure .....................................................................................29

Appendix E (b): Pressure settings tab menu structure continued ..................................................................30

Appendix E (c): Pressure settings tab menu structure continued....................................................................31

Appendix F: Timer values tab menu structure ...................................................................................................32

Appendix G: Alarm settings tab menu structure................................................................................................33

Appendix H (a): Inputs/outputs settings tab menu structure ..........................................................................34

Appendix H (b): Inputs/outputs settings tab menu structure continued........................................................35

Appendix I: History stats diag. Tab menu structure ..........................................................................................36

Appendix J: Relay option board– tab menu structure.......................................................................................37

Appendix K (a): 4-20 mA device – tab menu structure......................................................................................38

Appendix K (b): 4-20 mA device – tab menu structure continued ..................................................................39

Appendix L: Modbus board – tab menu structure .............................................................................................40

Appendix M: Alarm/status messages ................................................................................................................41

Appendix N: I/O board error codes ....................................................................................................................43

Appendix O: Assembly information.....................................................................................................................44

Appendix P: End user license agreement (EULA) .............................................................................................45

1. Information about us...................................................................................................................................................... 45

2. Definitions ...................................................................................................................................................................... 45

3. Grant and scope of license ............................................................................................................................................ 46

4. Location data.................................................................................................................................................................. 47

5. Necessary equipment .................................................................................................................................................... 47

6. Updates.......................................................................................................................................................................... 47

7. Transfer and assignment restrictions ............................................................................................................................ 47

8. Restricted uses ............................................................................................................................................................. 47

9. Third party software ...................................................................................................................................................... 49

10. Open-source software ................................................................................................................................................... 49

viii DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

Index

11. Fees................................................................................................................................................................................ 49

12. Support services ............................................................................................................................................................ 49

13. Disclaimer of warranty ................................................................................................................................................... 49

14. Limitation of liability ...................................................................................................................................................... 49

15. Indemnification .............................................................................................................................................................. 50

16. Amendments to this agreement ................................................................................................................................... 50

17. For authorized parties in california ................................................................................................................................. 50

18. Enforcement rights ....................................................................................................................................................... 50

19. Data protection ............................................................................................................................................................. 51

20. Confidential information ................................................................................................................................................ 51

21. Intellectual property ownership...................................................................................................................................... 51

22. Termination or suspension ............................................................................................................................................ 52

23. Links .............................................................................................................................................................................. 52

24. Representations, warranties, covenants and disclaimers ............................................................................................. 52

25. Force majeure ................................................................................................................................................................ 53

26. Miscellaneous .............................................................................................................................................................. 53

27. Regulatory matters......................................................................................................................................................... 53

28. Governing law and jurisdiction ....................................................................................................................................... 54

29. Cybersecurity ................................................................................................................................................................. 54

30. Agreement ..................................................................................................................................................................... 54

Introduction

DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

1. Introduction

1.1 Safety

This technical document is intended to cover most aspects

associated with the installation, application, operation,

and maintenance of the DPCT Fire Pump Controller. It is

provided as a guide for authorized and qualified personnel

only in the selection and application of the DPCT Controller.

If further information is required by the purchaser regarding

particular installation, application, or maintenance activity,

please contact an authorized EATON sales agent or the

installing contractor.

1.2 Warranty

No warranties, expressed or implied, including warranties

of fitness for a particular purpose of merchantability, or

warranties arising from course of dealing or usage of trade,

are made regarding the information, recommendations

and descriptions contained herein. In no event will EATON

be responsible to the purchaser or user in contract, in tort

(including negligence), strict liability or otherwise for any

special, indirect, incidental or consequential damage or loss

whatsoever, including but not limited to damage or loss of

use of equipment, plant or power system, cost of capital,

loss of power, additional expenses in the use of existing

power facilities, or claims against the purchaser of user by

its customers resulting from the use of the information and

descriptions contained herein.

1.3 Safety precautions

All safety codes, safety standards, and/or regulations must

be strictly observed in the installation, operation, and

maintenance of this device.

CAUTION

COMPLETELY READ AND UNDERSTAND THE MATERIAL

PRESENTED IN THIS DOCUMENT BEFORE ATTEMPTING

INSTALLATION, OPERATION, OR APPLICATION OF THE

EQUIPMENT. IN ADDITION, ONLY QUALIFIED PERSONS

SHOULD BE PERMITTED TO PERFORM ANY WORK

ASSOCIATED WITH THIS EQUIPMENT. ANY WIRING

INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST

BE FOLLOWED PRECISELY. FAILURE TO DO SO COULD

CAUSE PERMANENT EQUIPMENT DAMAGE.

1.4 Product overview

The DPCT Controller is a comprehensive, multi-function

microprocessor-based Diesel Fire Pump Controller.

Designed to meet the needs of markets worldwide, the

DPCT controller meets the requirement of and is certified

by the following authorities: Underwrites Laboratories (UL),

Underwriters Laboratories of Canada (ULC), Complies with

UL 218, Factory Mutual 1321/1323 (FM), ANSI/NFPA 20,

National Electrical Code (NEC), and meets the requirements

for U.S.B. / C.B.C Seismic approvals.

Refer to Appendix O for additional assembly information.

Installation and electrical connections

DPCT IOM INSTRUCTION OPERATION MANUAL MN124018EN January 2023 www.eaton.com

2. Installation and electrical connections

2.1 Mounting

Carefully unpack the controller and inspect it thoroughly.

The controller should be located as close as is practical

to the engine it controls and shall be within sight of the

engine, preferably ten feet or less.

The DPCT controller is designed for wall mounting and

it is recommended to use ½” Grade 5 hardware. For

dimensional and weight data please refer to the respective

data sheet for the Diesel Fire Pump Controller.

The Occupational Health and Safety Administration (OSHA)

recommends that the weight limit for individual lifting be 50

pounds (22.7kg). The final assembled weight of the DPCT

controller depending on selected options could exceed this

value. Therefore, Eaton recommends a two-person lift when

lifting or transferring the controller assembly.

If the assembly is mounted outdoors, it should not be

mounted in direct sunlight. Direct sunlight exposure will risk

damaging the user interface touchscreen.

2.2 Pressure sensor connections

The DPCT is equipped with a pressure sensor to monitor

the fire suppression system water pressure. The controller

is provided with a ½” NPT female system pressure

connection. It is located external to the enclosure on

the right-hand side. The connection should be installed

as per the direction given in the latest revision of NFPA

20, Standard for the Installation of Stationary Pumps for

Fire Protection.

NOTE

Water supply lines to the pressure sensor or pressure

switch must be free of dirt and contamination.

The measured system pressure is displayed on the

user interface touch screen. Specific START and STOP

pressure set points are programmable through the

user interface touchscreen. Refer to Section 5 for

programming instructions.

The maximum operating pressure of the pressure sensor

and internal plumbing components is listed on the

controller nameplate.

2.3 Electrical connections

NOTICE

ALL CONDUIT CONNECTIONS TO THE CONTROLLER

ARE RECOMMENDED TO ENTER THROUGH THE

BOTTOM OR LOWER RIGHT SIDE OF THE ENCLOSURE.

THE ENCLOSURE IS SUPPLIED WITH LABELLING THAT

DIRECTS THE INSTALLER TO THE ENTRY/EXIT LOCATIONS

REQUIRED TO MAINTAIN WARRANTY. REFER TO THE

ASSOICATED DIMENSIONAL DRAWING FOR REFERENCE.

DRILLING HOLES OR INSTALLING CONDUIT ABOVE

THE LEVEL OF THE MICROPROCESSOR BOARD MAY

VOID WARRANTY.

All electrical connections should meet all relevant national

and local electrical codes and standards and follow the wire

sizing guidance supplied inside the controller enclosure.

The controller shall be located or protected in such a

manner so that it will not be damaged by water escaping

from pumps or pump connections.

Current carrying parts of controllers shall be a minimum of

12 inches (305mm) above the floor.

Prior to starting, verify all data on the nameplate such as:

catalog number, AC line voltage and DC battery voltage.

Inspect all electrical connections, components, and wiring

for any visible damage and correct as necessary. Ensure

that all electrical connections are properly tightened before

energizing the controller.

Refer to the appropriate field connection drawing affixed

to the enclosure door, for all wiring information pertaining

to the incoming AC power supply, batteries, and diesel

engine wiring.

Install required conduit using industry standard methods

and tools.

The incoming 120-240V 50-60Hz AC line voltage connection

is clearly marked L (Line), N (Neutral) and G (Ground), and is

located on the DPCT I/O (Input/Output) Board (port P11).

Terminals 1 through 12, 301 through 304, and 310 through

312 (ports P13, P14, P15, P16, P17 and P18) located on the

DPCT I/O board are for connections to the corresponding

terminals in the diesel engine controller.

Terminals 39 through 49 (port P1) located on the DPCT I/O

board are for connecting a variety of external I/O devices to

the DPCT. These I/O are designed to be used with dry type

contacts (voltage free).

CAUTION

DO NOT APPLY AC VOLTAGE TO TERMINALS 39

THROUGH 49.

Terminals 50 through 73 (ports P2, P3, P4, and P5) located on

the DPCT I/O board are for connection of all the output relay

functions. Terminals 50 through 55 (port P2) can carry 240VAC

maximum at 10 Amperes. Terminals 56 through 73 (ports P3,

P4 and P5) can carry 240VAC maximum at 8 Amperes.

NOTE

All field connections and AC wiring must enter the

enclosure through the lower right sidewall or right side of

the bottom end wall ONLY OTHERWISE WARRANTY IS

VOID. (Refer to the labels affixed inside of the enclosure)

2.3.1 Field Conductor Sizes

Refer to the recommended wire size table supplied inside

of the controller enclosure.

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