Troubleshooting guide

1
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. For information specific to the metering pump or any other
accessories, please refer to the appropriate IOM.
1.1 Description
The MPC is an advanced pump controller that is physically attached and integrated into the pump's
enclosure. Its purpose is to precisely adjust output flow of a process media by means of pump motor
speed control.
The MPC is designed for a wide variety of control applications. The device is factory configured and
calibrated for the attached pump. The human/machine interface is user friendly. Local setup and
control is achieved through the keypad and a backlit two-line liquid crystal display. Basic operation is
simple with dedicated function keys eliminating the need for a sophisticated menu system. The MPC
responds immediately to user commands. Pump output is displayed as Gallons per Hour (GPH), Liters
per Hour (LPH), Strokes per Minute (SPM), Percent Speed, or Percent Flow (% of total pump capacity).
Digital and analog inputs will support a variety of industry standard signals to offer flexible remote
control.
The MPC is designed to simplify and automate the calibration of pump flow and analog signals. Flow
calibration uses on-screen prompting and automated pump operation to eliminate stopwatches,
calculators and human inaccuracies. Analog signal calibration is also accomplished by simple keypad
entry. It includes a real-time display of signal level. This eliminates the need for external meters.
The MPC readily accepts PULSAlarm
®
leak detection and tank level inputs. These may be configured
to stop the pump and/or activate an alarm relay.
The MPC will accept, and automatically adjust to, either 60 Hz or 50 Hz input. No special
modifications, settings, or adjustments are required. All MPC controllers are supplied with a motor
rated at 60 Hz, regardless of the supply frequency. The controller/motor combination allows for full
pump speed and flow even when operating from a 50 Hz input. Users in locations with 50 Hz AC
supply do not have to de-rate pump flow with this controller.
The motor used with the MPC is a three-phase motor, however the three-phase power is generated
internally by the MPC itself. Do not be confused by the motor nameplate. Input power to the MPC is
single-phase AC only, either 115 or 230 volts (see Section 11, Specifications for acceptable voltage
range). The nameplate on the rear of your MPC controller will list the appropriate supply requirements
for your controller.
At lower stroke frequencies (below 3:1 turndown), the MPC employs intermittent motor actuation
technology. This allows the user to achieve reliable low-end performance not usually associated with
variable speed controllers. By completing a full pump stroke at constant speed, and varying the interval
between strokes, hydraulic stability and process consistency is maintained.
The AC drive used in the MPC maintains tight control over voltage and current supplied to the pump
motor. This results in lower motor operating temperatures and less stress on motor windings, resulting
in longer motor life and more reliable overall operation. This holds true even when metering in the
lower flow ranges where the MPC uses intermittent operation.