Installation, Operation & Maintenance Manual BULLETIN No.
MPC™ FACTORY SERVICE POLICY Your MPC is a state of the art microprocessor based motor speed control for use with Pulsafeeder Diaphragm Metering Pumps. It includes extensive on-board diagnostics. If you are experiencing a problem with your MPC, first review the on-screen information, then consult the troubleshooting guide. If the problem is not covered or cannot be solved, please contact your local authorized Sales Representative or our Technical Service Department at (585) 292-8000 for further assistance.
Table of Contents 1. INTRODUCTION ..................................................................................................................................... 1 1.1 Description ............................................................................................................................... 1 1.2 MPC Standard Features .......................................................................................................... 2 1.3 Options .................................................
Conventions For the remainder of this bulletin, the following Conventions are in effect. A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT. PAY CLOSE ATTENTION TO ANY WARNING. Notes are general information meant to make operating the equipment easier. Tips have been included within this bulletin to help the operator run the equipment in the most efficient manner possible.
1. Introduction The Metering Pump Controller (MPC) is a microprocessor based motor speed control device, for use with Pulsafeeder mechanical and hydraulic diaphragm metering pumps. It has been designed for simplicity, yet still has many advanced features that allow the MPC to operate in a wide variety of environments and applications. This instruction manual covers the MPC only. All standard features are covered in this manual and most options have instructions where applicable.
1.2 1.
2. Safety Considerations 2.1 Read and understand all related instructions and documentation before attempting to install or maintain this equipment Observe all special instructions, notes, and cautions. Act with care and exercise good common sense and judgment during all installation, adjustment, and maintenance procedures.
3. Equipment Inspection When you receive your order, check all equipment for: Completeness against the shipping document / purchase order For any evidence of shipping damage. Shortages or damage should be reported immediately to the carrier and your Pulsafeeder Representative. 4. Storage Instructions The MPC can be successfully stored for extended periods. The key to this success is temperature and humidity control. 4.
5. Installation and Wiring 5.1 Location Review the Safety section (pg 3) prior to installing the MPC. It contains information required to properly install and operate the MPC in an industrial environment. The site selected for the installation of your MPC is largely dependent on that of the metering pump. Review the Installation, Operation, and Maintenance manual provided with your metering pump. It details system related issues that are important to proper operation of the pump.
AVOID LOCATIONS WHERE THE MPC WOULD BE SUBJECTED TO EXTREME COLD OR HEAT [LESS THAN 0 CELSIUS (32 FAHRENHEIT) OR GREATER THAN 40 CELSIUS (104 FAHRENHEIT)] OR DIRECT SUNLIGHT. FAILURE TO OBSERVE THIS WARNING COULD DAMAGE THE MPC AND VOID ITS WARRANTY. 5.2 Installation Notes The MPC is a microprocessor-based controller that uses electro-static sensitive CMOS components.
5.3.1 Controller Layout The design of the MPC incorporates all control circuitry onto one easily accessed circuit board. This board is located on the inside of the main controller cover. Gain access to this board by removing the 10 bolts and gently allowing the cover to hinge downwards. USE CARE NOT TO PULL ON OR ATTEMPT TO COMPLETELY SEPARATE THE COVER FROM THE MPC UNIT, AS THE ELECTRICAL CONNECTIONS CAN BE DAMAGED.
5.3.2 Power Wiring Information Verify the correct supply voltage (115VAC or 230VAC) with the nameplate affixed to your MPC. Ensure that your supply voltage matches the MPC configuration. Wires should be routed within the enclosure in a manner that maintains separation between high voltage and low voltage conductors. Incoming power wiring should adhere to all applicable local and national electrical codes and regulations. A circuit breaker or fuse must be provided as noted below.
5.3.3 Power Wiring Diagram MPC Drive Terminal L1 L2 / N Earth 120 V operation Line Neutral Ground 240 V operation Line Line Ground Table 2 – AC Drive Terminals L1 L2/N LINE1 LINE2 / NEUTRAL PE EARTH GROUND Figure 3 – AC Power Connections Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor. Capacitors retain a charge even after power is removed from the controller.
5.3.4 Input/Output Signal Wiring Signal wiring is routed through the two unused conduit openings at the side of the MPC. All input/output signals are connected to the terminal strips at the edge of the MPC circuit board. Use caution to observe proper wire location and signal polarity. Always cap or plug unused openings. Wires should be routed with in the enclosure in a manner that maintains separation between high voltage and low voltage conductors.
Digital output signals can drive devices such as relays or indicator lamps. 24 VDC power must be supplied from an external source. Each output has a maximum current capability of 500 mA. Maximum voltage capability of these circuits is 40 VDC (see Section 11, Specifications, for more information). Figure 5 – Sample Digital Output Connections 5.4 Check Wiring and Close Access Cover Double-check all of your electrical connections.
6. Start Up and Operation 6.1 Overview Once all electrical connections have been made, your MPC is ready for Start-up. The following sections detail the procedures required to complete the MPC start up. WHEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT WITHIN THE MPC ENCLOSURE EVEN WHEN THE MOTOR IS OFF. DURING START-UP, IT IS NECESSARY TO RUN THE PUMP MOTOR. THIS WILL CAUSE FLUID TO DISCHARGE FROM THE PUMP.
6.3 Confirm Display and Keypad Functionality The example display messages are shown in English for demonstration purposes. If an alternate language has been set, the text is displayed as a translation of the English version. Now that you have confirmed that the MPC is receiving power, it is necessary to confirm that the display and keypad are functioning properly. On normal power-up, the display appears for approximately 2 seconds. PULSAFEEDER INC. FW: 00.00/00.
6.6 Factory Re-Initialization Factory Re-initialization is typically not required. When re-initializing your MPC, all of the system settings and calibration information will be overwritten by the original factory default settings. The controller must be re-configured and re-calibrated to your specifications. A Factory Re-initialization should be performed only if there is reason to believe that the internal MPC memory has become corrupted.
7. Input/Output Setup Use the “DIGITAL I/O” menu to activate the functions required for the intended application. Users may also reference Section 12 – Menu Maps for additional configuration assistance 7.1 Analog Input Setup Use the “ANALOG I/O” menu to activate the analog input signal function. The menu can be used to set the analog input to either ACTIVE or INACTIVE. Note that Analog Input #2 is not yet available for use, the MPC accepts only one incoming analog signal at this time. 7.
8. Calibrations 8.1 Pump Flow Calibration Your MPC is factory calibrated at rated flow and pressure. Nevertheless, you should always perform a calibration with the MPC installed in your system. This will provide the most accurate flow display. The only item required to calibrate your MPC is a means to measure the flow of the pump (i.e., calibration column, graduated cylinder, etc.). The most accurate calibration will be obtained by using a measurement device installed on the suction side of the pump.
8.1.1 To Start Calibration 1. The starting display will be: SETPT FLOW XX.XXX XX.XXX 2. Press the MENU key -MENUCALIBRATION 3. Press the ENTER key CALIBRATION PUMP FLOW 4. Press the ENTER key CALIBRATION “VOLUME” 5. To perform the Volume Method, press the ENTER key and go to Section 8.1.2 6. To perform the Flow Method, press the UP arrow key CALIBRATION “FLOW” 7. Press the ENTER key and go to Section 8.1.
8.1.2 Volume Method SET STROKE TO 50% ENTER TO START 1. Manually adjust the stroke length of the pump to 50% 2. ** Fill your calibration column to the zero or starting point 3. Press the ENTER key TIMER XX SEC ENTER TO STOP 4. Allow the pump to run for any length of time you choose, dependent on flow rate, calibration column size, process conditions, etc. The system will time out at a maximum of 300 seconds. 5. Press the ENTER key to stop the pump ENTER VOLUME VOL = XX.XXX 6.
8.1.3 Flow Method SET STROKE 50% FLOW = 0.0000 GPH 1. You do not have to adjust the actual stroke setting of the pump 2. Use the UP and DOWN arrow keys and the ENTER key to input the desired flow rate (in gallons or liters per hour, dependent on MPC setup). This should be the flow rate expected when the pump is set to 50% stroke length setting. 3. Press ENTER to proceed SET STROKE 100% FLOW = 000.00 GPH 4. You do not have to adjust the actual stroke setting of the pump 5.
8.2 Analog Input Calibration If you are not using the 4-20mA input to the MPC for control, skip this section. To calibrate the Input Current you must first correctly wire an external signal source. Refer to Section 5 – Installation: Low Voltage Input Connections, Analog Input. To perform a calibration, the signal-generating device must be active and capable of generating the full range (low to high) of potential input signals. 1. The starting display will be: SETPT FLOW XX.XXX XX.XXX 2.
11. Press the ENTER key MAX SETPT SPEED X.XX MA 100.0% (The mA value will be equal to your input signal level) (The speed value is the setting the MPC will use for this signal value) 12. Press the ENTER key three times to step through the speed setting value, most users will leave this at 100.0 %, however you an change it if you wish using the UP and DOWN arrows. 13. Press the ENTER key once more to accept the calibration value ANALOG INPUT CALIBRATED 14. Analog input signal calibration is complete 15.
8.3 Analog Output Calibration 1. The starting display will be: SETPT FLOW XX.XXX XX.XXX 2. Press the MENU key -MENUCALIBRATION 3. Press the ENTER key CALIBRATION PUMP FLOW 4. Press the UP ARROW key to access the analog output calibration CALIBRATED ANALOG OUTPUT 5. Press the ENTER key SET 0% FLOW TO 04.0 MA 6. Use the UP and DOWN arrow keys to adjust the output signal as required. The actual output signal will vary and can be monitored with a meter or your facility control system.
8.4 Display Contrast Adjustment Should adjustment of the contrast level of the display become necessary, use the following procedure while in the normal operating mode. 8.5 To increase contrast, press and hold at the same time. To decrease contrast, press and hold at the same time. Changing the Motor Base Frequency This procedure will not be necessary during normal operation of the MPC controller.
9. Alarm and Error Messages If a fatal error has occurred while in Operational Mode, the error will flash on the screen and the Red LED lamp will also flash. The menus can still be accessed by holding down the menu key. This allows the user to try and fix the source of the error if possible. The following table gives an example of these messages and when you can expect them to be displayed.
NON-FATAL ERRORS: The pump and controller can still be run while these conditions exist. The Red LED will flash, however no message will flash on the screen. The Red LED will stop flashing once the error condition has been corrected.
10. Extending your Hand-Held Controller The hand-held controller for your MPC can be placed as far as 1000 feet from the pump. It is recommended that all calibrations be completed before the cable is lengthened, as these tasks are easier when the pump and hand-held controller are close to each other. To replace the cable for the hand-held unit: POWER TO THE UNIT MUST BE OFF! A GROUNDING WRIST STRAP SHOULD BE WORN WHEN MAKING CONNECTIONS TO ANY PCB 10.
10.3 Removal and Connection of the Cable from the Base Unit: Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor. Capacitors retain a charge even after power is removed from the controller. 1. Remove the 10 screws that are securing the cover to the side of the main unit. 2. CAUTION: The cover is wired and should be folded down gently being sure not to pull any of the wires that are connected to it. 3.
RED BLACK/RED GREEN BLACK/GREEN WHITE BLACK/WHITE Figure 5a – Handheld Remote Wiring TAPE END CUT BLK/GRN TAPE SHIELD AN00446-006 Figure 5b – Wire Preparation Detail, Base Unit End 28
Figure 6 – Handheld Remote 29
11.
Control Outputs Analog Out #1 Wiring J23 pins 5-6 Digital Out #1 Digital Out #2 Digital Out #3 J23 pins 1-4 J23 pins 2-4 J23 pins 3-4 Specification / Description 4-20mA output for pump flow indication Max voltage out 12 Volts; Max current out 30mA; Max load resistance 300 Ohm Internally protected with resetable fuse Transistor-based output, various functions * Transistor-based output, various functions * Transistor-based output, various functions * All digital outputs maximum 40 VDC, maximum 500 mA NOTE
12. Menu Maps Pulsafeeder, Inc. FW XX.XX/XX.XX Pump Serial Num: SN: XXXXX MPC Part Number: MPCXXXXXXX-XXXX SETPT: 0.00GPH FLOW: 0.00GPH & -MENUCALIBRATION SETPT: FLOW: 0.0 % 0.0 % SETPT: SPEED: 0.00SPM 0.00SPM SETPT: SPEED: 0.0 % 0.0 % STROKE SET TO XXX.X% CALIBRATION PUMP FLOW CALIBRATION ANALOG OUTPUT CALIBRATION ANALOG INPUT CALIBRATION VOLUME CALIBRATION FLOW SET 0% FLOW TO 04.0 mA APPLY MIN mA ENTER TO START SET STROKE 50% ENTER TO START SET STROKE 50% FLOW: 000.
-MENUANALOG I/O -MENUDIGITAL I/O ANALOG I/O ANALOG INPUT #1 ANALOG INPUT #1 INACTIVE ANALOG INPUT #1 ANALOG INPUT #1 ANALOG INPUT #1 INACTIVE ANALOG INPUT #1 ACTIVE DIGITAL I/O DIGITAL INPUT #1 SIGNAL PURPOSE INACTIVE DIGITAL I/O DIGITAL INPUT #2 SIGNAL PURPOSE SIGNAL PURPOSE SIGNAL PURPOSE SIGNAL PURPOSE SIGNAL PURPOSE SWITCH STATE INACTIVE SWITCH STATE SWITCH STATE SWITCH STATE SWITCH STATE FLO
13. Factory Default Values Parameter Digital Input #1 Digital Input #2 Factory Set Value INACTIVE, normally closed INACTIVE, normally closed Analog Input #1 INACTIVE Analog Input #2 NOT AVAILABLE this revision Digital Output #1 Digital Output #2 Digital Output #3 STROKE Indication, normally closed AUTO/MANUAL Indication, normally closed Alarm Indication, normally closed Security Code Default = 0000 Language ENGLISH MODE Local (Manual) UNITS GPH (gallons per hour) 14.
16. Troubleshooting Guide Problem Potential Cause Solution No Display Back-lighting No power supplied. Supply power wired incorrectly. Supply power outside of specification. Check power source. plug & circuit breaker Check wiring. Check voltage/frequency against specification. No Text on Display Contrast out of adjustment. Software did not initiate properly. Adjust as per section 8.4 Remove and re-apply Ac power No power Indicators No power supplied. Supply power wired incorrectly.
17. Spare Parts User replaceable parts for the MPC.
BULLETIN No.
