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Contents Introduction 5 Intended Use Specifications 6 7 Safety 9 General Safety Practices 9 Installation 15 Placement of Components Mount the BCI 15 Spacing Requirements Cabling 15 16 16 Lifting Instructions 16 AC Power Disconnect Requirements External Device Connections 16 16 Operation 17 Set HPU to Remote Operation for use with the MPCM Supervisor Setup 18 Startup and Main Screen System Unit 17 19 20 23 Status Screen Setup 27 31 Station 32 Operating the HPU Locally or Remotely H
Contents Multi-Pump Control Manager
Introduction The Multi-Pump Control Manager (MPCM) product family consists of a Basic Connection Interface (BCI) and typically the optional dedicated PC running the Supervisor software, with remote E-Stops, Station Flow Managers (SFM), and/or light stacks as options. Together, these components allow you to remotely run multiple HPUs similar to operation at the main HPU HMI panel. This manual assumes you are familiar with local operation of the HPU.
Intended Use Note MTS can provide the BCI without the Supervisor and dedicated PC. In this case, the BCI commons the signals required for the HPU(s) to work as a system controlling the cooling solenoids, bypass solenoids, and E-Stop chain (which includes external E-Stops). In this case, all control of the HPUs is accomplished at the HPU HMIs.
Specifications Specifications Parameter Specification Temperature 5ºC–40ºC (41ºF–104ºF) Humidity 5–85%, non-condensing Altitude 2000 m (6,561 ft) maximum IP rating IP40 Pollution Degree 2 Weight 41 kg (90 lb) Dimensions See illustration 29.94 MTG. KIT DIMENSION 25.56 MTG. HOLES 9.04 27.06 MTG. KIT DIMENSION 28.50 MTG. HOLES 30.00 ECLOSURE DIMENSION Multi-Pump Control Manager 24.00 ENCLOSURE DIMENSION 8.76 8.
Specifications Note Electrical connections must be made by qualified personnel and conform to local codes and regulations. Local electrical codes supersede any information found here. Parameter Specification 100–240 V AC (single phase) Input Voltage power factor corrected universal input Input Frequency 50–60 Hz 4 A at 100 V AC Input Current 2 A at 240 V AC Facility Power Requirements Provide a dedicated circuit for the chassis, computer, and monitor.
General Safety Practices Safety General Safety Practices The Multi-Pump Control Manager (MPCM) product family consists of a Basic Connection Interface (BCI) and typically the optional dedicated PC running the Supervisor software, with remote E-Stops, Station Flow Managers (SFM), and/or light stacks as options. Together, these components allow you to remotely run multiple HPUs similar to operation at the main HPU HMI panel.
General Safety Practices You should receive training on this system or a similar system to ensure a thorough knowledge of your equipment and the safety issues that are associated with its use. In addition, you should gain an understanding of system functions by studying the other manuals supplied with your test system. Contact MTS for information about the content and dates of training classes that are offered.
General Safety Practices Have first aid available Accidents can happen even when you are careful. Arrange your operator schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator. Know potential crush and pinch points Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas.
General Safety Practices Use appropriately sized fuses Whenever you replace fuses for the system or supply, ensure that you use a fuse that is appropriately sized and correctly installed. Undersized or oversized fuses can result in cables that overheat and fuses that explode. Either instance creates a fire hazard. Provide adequate lighting Ensure adequate lighting to minimize the chance of operation errors, equipment damage, and personal injury. You need to see what you are doing.
General Safety Practices Know the causes of unexpected actuator motions Do not use RF transmitters Multi-Pump Control Manager The high force and velocity capabilities of MTS actuators can be destructive and dangerous (especially if actuator motion is unexpected).
General Safety Practices 14 Safety Multi-Pump Control Manager
Placement of Components Installation The Multi-Pump Control Manager (MPCM) allows you to operate up to eight Hydraulic Power Units (HPUs) remotely. Standard installation involves placement of the components and cabling connections. Placement of Components Because all connections between components run through the Basic Connection Interface (BCI), it is usually placed in a central location; typically next to the HPUs. The dedicated PC running the Supervisor software is usually placed in the control room.
Spacing Requirements Spacing Requirements The front of the enclosure requires 65 cm (25.6 in) minimum of clearance so the door can be opened by MTS service personnel. The power entry side of the enclosure requires 16 cm (6.3 in) minimum of clearance for the power cord. The bottom of the enclosure requires 65 cm (25.6 in) minimum of clearance for the cables. The dimensions above are minimum dimensions for the BCI.
Set HPU to Remote Operation for use with the MPCM Operation This section deals with operation of the Multi-Pump Control Manager (MPCM) only. It is assumed that the hydraulic power unit (HPU) has been properly set up and you are familiar with all operating aspects of the HPU. Remote operation of up to eight HPUs can be done from the MPCM. Most operation is the same as operation of the HPU from the Human Machine Interface (HMI) panel on the HPU main electrical enclosure.
Setup Note Perform the following steps on the MPCM Supervisor. 7. If not already displayed, press the Unit button to display the Unit screen. 8. Verify that each HPU in the system is in Remote Ethernet mode and does not have a Comm alarm. Note Each HPU in the system will have to be configured on the Supervisor Setup Screen. See Setup section for more information. Setup 1. From Supervisor HMI, enter MPCM Supervisor software if not already displayed. 2. Select desired language and press Main Display. 3.
Startup and Main Screen Startup and Main Screen Note The following screen images may be from the 4 or 8 HPU version of the HMI software. Your actual display may vary slightly. Features that only exist in the 8 HPU version of the software will be listed as such. The Startup screen is displayed initially when the MPCM is powered up. The Main screen is displayed after you select the language. The push button/ indicators on the right are used to select the various screens.
System System The System screen provides an overview of the status of the entire hydraulic system. The RUN and PRESSURE buttons control application of hydraulic pressure to the system (not individual units). The following table describes the controls and indicators of the System panel.
System Item Name Description 1 System gauges: Flow/Pressure/ Temperature System gauges. The parameters of these gauges are determined by settings on the MPCM Setup screen. Flow - LPM or GPM. Gauge full scale is determined by the total number of modules present. Green range is determined by the total number of modules running in the system. Gauge reading is the current flow if a flow meter is present on all HPU(s). If a flow meter is not present, the gauge reading is the flow demand in the Auto mode.
System Item Name Description 4 Module indicators Color scheme for the module icons is: 5 Run/Pressure switch • Dashed outline - not present • Gray with black border - present but not enabled • Gray with green border - present and enabled • Green flashing - running in low pressure • Green solid - running in high pressure • Red - module fault: sequence or overload Run O/I: The O (red) switch stops all HPUs. The I (green) switch starts all enabled HPU modules in low pressure.
Unit Unit The Unit screen displays the HPU operational status. All available HPUs will be displayed in individual panes. Shown below is an example. The following table describes the controls and indicators of the Unit panes.
Unit Item Name Description 1 Faulted/Ready/Running/High Pressure/Alarm/Overtemp Bypass Indicator. Indicates the various states of the HPU. Faulted - red: Indicates when an interlock has occurred and the HPU has been shut down. Possible faults include E-Stop, watchdog timer, low level and high temperature. Ready - green: Indicates the interlocks are cleared and the HPU is ready to start. Running - green: Indicates the HPU is running in low pressure.
Unit Item Name Description 3 Run/Stop/Bypass Pushbutton/Indicator. Pushbutton used to start and stop the HPU. Run - gray. black letters: In this state, press to start the HPU. Stop - gray, red letters: In this state, press to stop the HPU. Bypass - blue, white letters: In this state, press to start the HPU in bypass mode. The Faulted state will turn to Overtemp Bypass. Bypass mode only occurs during an overtemperature condition and allows the HPU to run in low pressure to cool the hydraulic fluid.
Unit Item Name Description 8 Unit Hours Indicator/Display: Indicates total running time of the HPU. 9 Oil Pressure Indicator/Display: Indicates output pressure of the HPU. 10 Oil Temperature Indicator/Display: Indicates the temperature of the hydraulic fluid in the reservoir. 11 Oil Level Indicator/Display: Displays the level of the hydraulic fluid in the reservoir in 1/8 increments. The level is relative to the usable oil volume.
Status Screen Status Screen The Status screen is displayed by pressing the Status button on the Main screen. The following table describes the pushbuttons and indicators on the Status screen. Item Name Description 1 Indicator. Used to indicate whether the HPU’s safety relay is tripped. E- Stop E-Stop - gray - OK: Indicates the HPU’s safety relay has not tripped. E-Stop - red - Fault: Indicates the HPU’s safety relay has tripped.
Status Screen Item Name Description 3 Indicator. Used to indicate if the hydraulic fluid level is within acceptable limits. Oil Level Oil Level - gray - OK: Indicates the hydraulic fluid level is within acceptable limits. Oil Level Fault - red: Indicates the hydraulic fluid level is not within acceptable limits and an interlock is active. 4 Oil Temp Indicator. Used to indicate if the hydraulic fluid temperature is within acceptable limits.
Status Screen Item Name Description 8 Indicator: Indicates the state of the associated module. Status Status - gray: Label. Not Present - light gray: Indicates the module is not present. Ready- green: Indicates the module is present but is not enabled. Enabled - green: Indicates the module is enabled and is ready to into a run condition (replaces READY). Running Low- green: Indicates the associated pump module is running in low pressure.
Status Screen Item Name Description 14 Indicates whether the user(s) are demanding a total flow demand that is within the maximum capacity of the system. Flow Demand Indicator Flow Demand - gray - OK: Indicates that the Total Flow Demand is within the maximum capacity of the system. Flow Demand - yellow - Alarm: Indicates that the Total Flow Demand is above the maximum flow capacity of the system. 15 PLC Comm Indicator Indicates whether the Supervisor PC is able to communicate with the PLC.
Setup Setup On the Supervisor HMI, press the Setup button to display the System Setup screen. The following table describes the pushbuttons and indicators on the Setup screen. Item Name Description 1 HPU Platform Indicator. Displays the MTS model number of the HPU. 2 System Transducers Indicators. Used to indicate the presence of various sensors. Sensor not present - gray. Sensor present - black. 3 System Units Pushbutton/Indicator: Used to select the units for display.
Station Item Name Description 5 Serial Number, HMI Software Part Number, PLC Software Part Number Information fields. 6 System ROD Setup (flow sensor must be present and enabled) These pushbutton/indicators [Minimum Flow, Flow Buffer, On Delay (sec), and Off Delay (sec)] allow you to set up the Run On Demand parameters. Refer to “Setting Up System Run On Demand (ROD)” on page 35 and “Run On Demand Detailed Example” on page 36 for a detailed description.
Operating the HPU Locally or Remotely Item Description 3 Clicking this field brings up a numeric keypad that lets you enter the flow demand requirement for the associated channel. 4 Total Flow Demand indicator. This displays the total demand as defined by the Flow Demand entries (item 3) plus the flow demand available from the System screen, This indicator turns yellow if the flow demand exceeds total capacity. Refer to “Auto,” on page 22.
How to Clean the MPCM Remote operation Note Perform the following steps on the MPCM Supervisor. 1. Configure each HPU according to the “Set HPU to Remote Operation for use with the MPCM Supervisor” section. 2. If not already displayed, press the Status button to display the Status screen. 3. Verify that each Unit and System does not have any faults or alarms. If a fault or alarm exists press the Reset button to attempt to reset the fault or alarm.
Setting Up System Run On Demand (ROD) Appendix Contents Setting Up System Run On Demand (ROD) Run On Demand Detailed Example 35 36 Setting Up System Run On Demand (ROD) The ROD option automatically starts or stops pumps to meet the hydraulic flow demand from the system. The PLC monitors the hydraulic fluid flow. When the flow changes beyond a trigger point for a set period of time, one or more of the pumps are turned on or off.
Run On Demand Detailed Example 7. Check the Off Delay. If necessary, press the associated value pushbutton to change the delay time. Use the numeric keypad described above to increase or decrease the delay. 8. Press the System button to return to the System screen. 9. Press the Auto button to enable Auto. The button will turn green. 10. Press the ROD button to enable the run on demand option. The button will turn green. 11. Press I (green) to start the HPU in low pressure. 12.
Run On Demand Detailed Example 60 Hz 113 lpm 85 lpm 61 lpm 30 gpm 22 gpm 16 gpm An example is shown below. In the example Module Flow is set at 30 gpm, Minimum Flow is set at 10 gpm, Flow Buffer is set at 4 gpm (which means the total actual buffer is 10 gpm), Δton represents the on delay, and Δtoff represents off delay. The system starts out with one module running to create 30 gpm of available flow. This satisfies both the Minimum Flow requirement (10 gpm) and the Flow Buffer requirement (10 gpm).
Run On Demand Detailed Example 38 Appendix Multi-Pump Control Manager
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