Installation, Operation & Maintenance Manual MPC® IOM-CTL-2000-Rev.
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 INSTALLATION, OPERATION & M AINTENANCE M ANUAL ................................................................................. I MPC™ FACTORY SERVICE POLICY ..................................................................................................... I TABLE OF CONTENTS .................................................................................................................................. III FOR THE REMAINDER OF THIS BULLETIN, THE FOLLOWING CONVENTIONS ARE IN EFFECT. .
10.2 10.3 10.4 10.5 10.6 10.7. 10.8 10.9 11. 12. 12.1 12.2 13. 14. 15. 16. 17. 18. 19. 19.1 19.2 19.3 Digital Input Setup ................................................................................................................. 26 Analog Output Setup............................................................................................................. 26 Digital Output Setup ..............................................................................................................
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. THIS MANUAL MUST BE CONSULTED IN ALL CASES WHERE THE WARNING SYMBOL IS MARKED IN ORDER TO FIND OUT THE NATURE OF THE POTENTIAL HAZARDS AND ANY ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM.
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.
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 is factory configured to operate at 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.
3.2 Options • Variable hand-held controller cable length, up to 1,000 feet from pump • Alternate motor selections available for outdoor, washdown, chemical duty, and other special applications 4. Safety Considerations • Read and understand all related instructions and documentation before attempting to install or maintain this equipment • Observe all special instructions, notes, and cautions.
have a numerical rating. The C classification means the extinguishing agent is non-conductive. Geometric symbol (blue circle) 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. 4.4 Mechanical Safety Users should note that the pump motor is always under the control of the MPC, and as such may actuate without warning.
Pulsafeeder, Inc. is considered released from any liability in the following cases: - improper installation; - improper use of the equipment by non-professional or inadequately trained operators; - use not in compliance with regulations in the Country of use; - lack of maintenance or improperly performed; - use of non-original spare parts or incorrect parts for the model in question; - total or partial failure to observe the instructions; - exceptional environmental events.
6. Transport and Storage 6.1 Consignment receipt and unpackaging Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation. Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment. Each product has a unique serial number.
Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current regulations at all times.
7. Storage Instructions The MPC can be successfully stored for extended periods. The key to this success is temperature and humidity control. 7.1 Short Term (0 - 12 months) The MPC should be stored in a temperature and humidity controlled environment. It is preferable to keep the temperature constant in the range of -18° to 60° Celsius (0° to 140° Fahrenheit). The relative humidity should be 0 to 90% non-condensing.
8. Installation and Wiring 8.1 Location Review the Safety section 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. 8.2 Installation Notes The MPC is a microprocessor-based controller that uses electro-static sensitive CMOS components.
8.4 Electrical Wiring The MPC has many advanced features that may make wiring the unit appear complicated. Wiring is actually very simple – one high voltage connection is all that is required to take advantage of the majority of the MPC's features. If you will be mounting your handheld controller in a remote location, refer to the Section Extending your Hand-Held Controller at this time.
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 MAY BECOME UNPLUGGED AND/OR DAMAGED. THIS CAN RESULT IN IMPROPER OPERATION.
FIGURE 2 – CONDUIT CONNECTION LAYOUT
8.4.6 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 low voltage and extra-low voltage conductors. • Applicable national and local electrical codes take precedence over recommendations in the table below. • A circuit breaker or fuse must be provided as noted below.
the branch circuit (see Table 1). A circuit breaker or disconnect switch with fuses must be wired in series with terminals L1 and L2/N in accordance with all applicable local and national electrical codes and regulations. The circuit breaker or disconnect switch shall be located in close proximity to the MPC controller. It must be positioned such that it is not difficult to operate and must be marked or labeled to identify it as the power disconnect for the MPC.
To ensure proper operation, the MPC should remain powered at all times. A dry contact input provides the MPC with motor status (on vs. off). See Section 13 (Digital In #1 & Digital In #2) Input Power must be run in separate conduit. Do not combine Power and Control wires in a common conduit! Field Wiring conductors shall be copper conductors only! Figure 3 – AC Drive Power Connections Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor.
Find the proper AC input voltage for your MPC controller on the nameplate at the rear of the unit. MPC input is always single phase, and can be either 115 VAC or 230 VAC, determined at time of order.
8.4.8 Control 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 within the enclosure in a manner that maintains separation between low voltage and extra-low voltage conductors.
Figure 4 – Signal Connections
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 the Specifications Section, for more information). Figure 5 – Sample Digital Output Connections 8.5 Check Wiring and Close Access Cover Double-check all of your electrical connections.
with a voltmeter. If the voltage is not correct, return to 5.3.2 - Power Wiring Information. Otherwise, proceed with the next step.
9. Start Up and Operation 9.1 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. WARNING: DO NOT attempt to remove the cover of the MPC and set up the MPC in a very wet or rainy environment.
9.2 Key Keypad/Lamp Operation Function Motor On/Off Press to start pump motor, press again to stop pump motor Auto/Manual Press to toggle between automatic operation and manual control of the pump Menu Press to adjust controller settings, to exit the menu system, to move cursor back when entering values, or to step back to higher level menus Enter Press to accept changes in menus, to move cursor forward when entering values, and to access lower level menus.
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 : 00.00/00.00 The first four digits displayed are the software revision for the MPC base unit, and the second four indicate the software revision for the handheld display/keypad module. The keypad can be tested by depressing each key separately.
Factory Re-initialization is typically not required. When reinitializing 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.
10. Input/Output Setup Use the “DIGITAL I/O” menu to activate the functions required for the intended application. Users may also reference Section 14 – Menu Maps for additional configuration assistance 10.1 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. 10.
Each can be set as normally OPEN or normally CLOSED. For example, if an output is set to ON/OFF INDICATION and NORMALLY CLOSED, this means that when the motor is running (indicator lamp is ON) the output will be CLOSED. A NORMALLY OPEN setup will give the opposite response. Digital output circuits are transistor based and limited to 40 VDC maximum, see Section 8.4.8 - Control Input/Output Signal Wiring, and Specifications Section, for more information. 10.
the pump to run for calibration. This calibration is also faster to complete if the flow values are already known. The MPC display will guide the user through the steps for calibration. The nameplate flow rating of the pump can be used to complete the flow calibration routine; however there will always be some variance in the actual flow rate of a pump due to system conditions and product characteristics.
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.
ENTER VOLUME VOL = XX.XXX 13. Use the UP and DOWN arrow keys and the ENTER key to input the volume pumped from the calibration column (in gallons or liters, dependent on MPC setup). 14. Press ENTER to proceed PUMP FLOW CALIBRATED 15. Pump flow calibration is complete 16. Press the MENU key three times to exit back to the main operating screen. 10.5.2 Flow Method SET STROKE 50% FLOW = 0.0000 GPH 1. You do not have to adjust the actual stroke setting of the pump 2.
10.6 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 the Control Input/Output Signal Wiring Section (8.4.8). 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.
(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) 8. Press the ENTER key three times to step through the speed setting value, most users will leave this at 000.0 %, however you an change it if you wish using the UP and DOWN arrows. 9. Press the ENTER key once more to accept the calibration value APPLY MAX MA ENTER TO START 10. Apply your desired maximum mA control signal to the MPC (usually 20 mA) 11.
The analog input signal calibration procedure should be performed again, ensuring that a minimum of 3 mA difference exists between the MIN and MAX signal levels.
10.7. 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.
If you receive the following message: CURRENT DELTA OUT OF RANGE This indicates that the output current for 0% flow has been set greater than or equal to the output current setting for 100% flow. Repeat the process and ensure that the 0% calibrated signal is set to a value lower than the 100% calibrated signal. 10.8 Display Contrast Adjustment Should adjustment of the contrast level of the display become necessary, use the following procedure while in the normal operating mode.
4. Scroll UP to display the default password “001” 5. Press MODE to enter the password 6. Scroll UP to the base frequency parameter which is “27” display will show “P 27” 7. Press MODE to display the current setting (will be either 50 or 60) 8. Use the UP or DOWN keys to change the setting to the new value (either 50 or 60) 9. Press MODE to store the new value 10.
COMMUNICATION ERROR Communication error exists between the MPC controller and the handheld keypad/display module 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.
12. Extending your Hand-Held Controller The hand-held controller for your MPC can be placed as far as 1000 feet from the pump with optional cable. 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 12.
7. Wrap the end of the cable with electrical tape to insulate any remaining shield so that it will not contact the circuit board, equipment case, or any other parts. 8. Referring to the notes taken earlier, connect each lead of the new cable to the proper position of the terminal block; tighten the screw terminal to hold lead. NOTE: It is recommended that you insert and secure one lead at a time. 9. Tighten the dome nut of the liquid tight to secure/seal cable. 10. Replace cover and tighten screws.
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
Figure 6 – Handheld Remote
13.
Digital In #2 J11 pins 2-3 User to provide dry-contact input * *All digital inputs require a dry contact input (maximum of 2K Ohm contact resistance to register as “active”). Do not apply power to these terminals. * Digital input functions: 1. Remote on/off control of metering pump 2. Level input from supply tank 3. Leak detection of the metering pump 4.
Standard selection is rated for indoor, dry environment, other options available Keypad: Can be mounted on the pump or up to 1000’ away from the pump Standard cable length 6 feet Display: Backlit 2 line extended temperature 16 character LCD Enclosure: NEMA 4X and IP56 ratings Altitude: 3300 Ft (1000 M) above sea level (de-rate 5% per additional 3300 Ft).
14. 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: 0.00SPM SPEED: 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
15. 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) 16.
18. Troubleshooting Guide Problem Potential Cause Solution No Display No power supplied. Backlighting Supply power wired incorrectly. Check power source. plug & circuit breaker Check wiring. Supply power outside of specification. Check voltage/frequency against specification. No Text on Display Contrast out of adjustment. Software did not initiate properly. Adjust as per section 10.8 Remove and re-apply Ac power No power No power supplied. Indicators Supply power wired incorrectly.
19. Maintenance & Spare Parts All maintenance work must be carried out only when the MPC and connected equipment is stopped and disconnected from mains supply (including auxiliary circuits). Maintaining original characteristics over time must be ensured by an efficient maintenance and inspection plan, developed and managed by qualified technicians, taking into account the service and the actual environmental conditions in which it operates. 19.
The MPC enclosure may be cleaned with water and mild detergent. Decontamination shall occur when the MPC is exposed to a release of process chemicals. Follow the SDS for clean-up in the event of a chemical spill. 19.
MPC® IOM-CTL-2000-Rev.I A unit of IDEX Corporation 2883 Brighton Henrietta Town Line Road Rochester NY 14623 +1 (585) 292-8000 pulsa.com pulsa@idexcorp.