Installation, Operation & Maintenance Manual BULLETIN No. IOM-PS-DLC-1101-G Manufacturer’s of Quality Pumps, Controls and Systems Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623 Telephone: (585) 292-8000 Fax: (585) 424-5619 www.pulsa.com pulsa@idexcorp.
DLC™ FACTORY SERVICE POLICY Your DLC is a state of the art microprocessor based stroke length/motor speed control for use with PULSAR Diaphragm Metering Pumps. It includes extensive on-board diagnostics. If you are experiencing a problem with your DLC, first review the diagnostic menu, then consult the trouble shooting guide.
Table of Contents 1. INTRODUCTION................................................................................................................................ 1 1.1 Description ......................................................................................................................... 1 1.2 DLC Standard Features...................................................................................................... 2 1.3 Options ..................................................................
7.2 Menu ................................................................................................................................... 39 7.2.1 Alarm, and Error messages........................................................................................ 40 7.2.2 Diagnostics ................................................................................................................. 41 7.2.3 Set Time & Date.........................................................................................
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 DLC is a microprocessor based stroke length control device for use with the PULSAR diaphragm metering pump. It has been designed with many advanced features that allow the DLC to operate in a wide variety of industrial environments. This instruction manual covers the DLC -- Digital Stroke Length Controller. All standard features are covered in this manual and most options have instructions where applicable. 1.
1.2 DLC Standard Features • • • • • • • • • • • • 1.
2. Safety Considerations The DLC is a sophisticated microprocessor based controller for use only with PULSAR diaphragm metering pumps. It yields tremendous control capacity – electrical, mechanical and (in conjunction with the PULSAR pump) hydraulic in nature. In consideration of SAFETY, you should be mindful of this relative to your safety, that of co-workers and of the process environment. Consider the following prior to the installation and operation of a DLC controlled PULSAR metering pump. 2.
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 DLC can be successfully stored for extended periods. The key to this success is temperature and humidity control. 4.1 Storage Length 4.1.
5. Installation 5.1 Location Review the Safety section prior to installing the DLC. It contains information required to properly install and operate the DLC in an industrial environment. The site selected for the installation of your DLC is largely dependent on that of the PULSAR metering pump. Review the PULSAR Installation Operation Maintenance Instruction Manual (Bulletin No. PMPIOM-96) provided with your PULSAR metering pump.
AVOID LOCATIONS WHERE THE DLC WOULD BE SUBJECTED TO EXTREME COLD OR HEAT [LESS THAN –18° CELSIUS (0° FAHRENHEIT) OR GREATER THAN 40 ° CELSIUS (104 ° FAHRENHEIT)] OR DIRECT SUNLIGHT. FAILURE TO OBSERVE THIS WARNING COULD DAMAGE THE DLC AND VOID ITS WARRANTY. 5.2 Installation Notes 1. The DLC is a microprocessor based controller that uses electro-static sensitive CMOS components.
5.3.1 Getting Started The field wiring of the DLC is accomplished through a rear access cover at the back of the unit – near the PULSAR gearbox and motor. The access panel is opened by removing the 4 retaining screws (Phillips head screw driver required). Removal reveals the Field Wiring Board (refer to Figure 2). Figure 2 – Accessing the Field Wiring Board The Field Wiring Access Cover has the Serial Number Tag on it. Keep the cover with the DLC it was removed from.
5.3.2 Finding your way around the Field Wiring Board The electrical connections are segregated on the Field Wiring Board. The high voltage connections are on the right-half side while the low voltage connections are on the left. Refer to Figure 3, Field Wiring Board for specific connection and fuse locations. Figure 3.
5.4 High Voltage Connections There are only three high voltage connections to be made on the DLC: supply power (J1), PULSAR motor load (J3), and Alarm Relay Load (J2). Only the supply power and PULSAR motor load connections are required. Refer to Figure 4 for connection location. Figure 4 – High Voltage Connections 5.4.1 Supply Power THE DLC REQUIRES ONE CONNECTION TO AN EXTERNAL POWER SOURCE.
The DLC with an attached pump motor and alarm load, should be connected to its own branch circuit. Size the supply wire and protective element according to local code requirements. Use 14 AWG, 105° C insulation wire or better. Attach the supply to the J1 terminal block labeled 'LINE POWER IN'. Make 3 connections: Neutral, Earth (ground) and Hot as labeled. Device 115VAC +/- 10% 50/60Hz Current Requirement (Amp) Device 230VAC +/- 10% 50/60Hz Current Requirement (Amp) DLC 1A (1A Max.) DLC .5A (.5A Max.
5.4.2 PULSAR Motor Connect the pump motor to the J3 terminal block labeled 'PUMP MOTOR OUT AC/DC.' (Use 14 AWG (2.1mm2), 105ø C insulation wire size or larger.) The pump motor must be wired to operate at the DLC supply voltage (i.e., if the power supplied to J1 is 115VAC 60Hz, then the motor must operate on 115VAC at 60Hz). THE DLC USES SOLID-STATE RELAYS FOR IT'S HIGH VOLTAGE OUTPUTS (I.E., MOTOR AND ALARM).
5.4.3 Alarm Relay The Alarm Relay is an output that is configured by the operator. Refer to Section 7 – General Operation for specific instructions on how to activate the Alarm Relay. The Alarm Relay Load must not exceed 1 Amp at rated voltage. Connect the Alarm load to the J2 terminal block labeled 'ALARM RELAY OUT.' Use 22 AWG wire size. Make three connections: Neutral, Earth (ground) and Hot as labeled. 5.5 Low Voltage Input Connections There are two types of Low Voltage inputs: Current (e.g.
5.5.1 Analog Inputs The DLC can accept one analog input signal. This signal controls the pump’s flow. The Analog Input is used to control pump stroke. The Analog input accepts current inputs in the range of 0 to 25mA (e.g., 4-20mA) provided the 'span,' (the difference between the High and Low value), is greater than 2mA. Voltage signals in the 0-5 volt range are accepted but displayed as current during Analog Input calibration.
5.5.2 Alarm Input The Alarm Dry Contact Input is designed to operate with the PULSAlarm leak detection option. It is software configurable to generate an alarm, activate the alarm relay and/or shut down the PULSAR motor. The input is internally powered – only a mechanical switch closure is required for activation. Use 0.32mm2 – 0.52mm2 (22-20 AWG) wire.
5.6 Low Voltage Output Connections There are two types of Low Voltage outputs: Analog (e.g., 4-20mA) and Transistor based Dry Contact. The Low Voltage Output connection block is labeled J5 'OUTPUT' (refer to Figure 6). It contains threepairs of outputs: Current, Alarm and Motor Status/Stroke or mode indication. The Transistor based Dry Contact outputs are optically isolated. To achieve total isolation, they are not self powered. The external device must supply and detect a return voltage level (32VDC max).
5.6.1 Current Output Current Output is calibrated to source current in the 0 to 20mA range (e.g., 4-20mA). The output can be calibrated for reverse acting and split ranging and control. Refer to Section 7 – General Operation: Calibration for further details. Current Output is used to control slave devices (e.g., DLC's, ELMA's, PULSAMATICs, etc.) or to fulfill closed loop system requirements.
5.6.3 Digital Output The Digital Output can be configured through software to indicate one of the following: a) Pump Motor status – (on or off). b) Pump stroke (generates a pulse with every pump stroke for use with an external stroke counter). The Stroke output is not in phase with the pump stroke but has a 50% duty cycle (e.g., the output is ON for half of the stroke and OFF for the other half).
(Optional) (Optional) Figure 8 – Tachometer and Pump Motor Thermostat Connections To connect the Tachometer Input, connect the wire labeled VDC (typically brown) to the connection point labeled 1–TACH [+] on connector J-10 CONTROL. Connect the wire labeled TACH (typically blue) to the connection point labeled 2–TACH [-] on connector J-10 CONTROL. Make these connections using the 22 AWG wire provided with the Tachometer Sensor (refer to Figure 8).
5.8 Motor Thermostat The motor thermostat has been supplied as an equipment safety measure. This allows the DLC pump motor to operate without the danger of overheating the motor windings. In the event that the internal temperature of the motor exceeds the motor manufacturer’s specification, the DLC can be configured to: a) Turn the motor off. b) Sound an alarm. c) Restart the motor when the temperature lowers to a safe level.
Important Wiring Detail Slave to Slave When connecting two Slaves, the wiring is straight through. For example: Connect the transmit lines to the transmit lines and the receive lines to the receive lines (refer to the drawing below). Master to Slave When wiring between a Master and a Slave, the Transmit and Receive lines must be crossed. For example: Connect the transmit lines to the receive lines (refer to the drawing below).
5.10 Fuse Replacement Although Fuse replacement is not a part of normal installation, it is possible that fuse failure will result from improper wiring. The DLC uses a total of 7 user replaceable fuses: 1 for the alarm relay output, 2 for each of the Current Input and Output Channels.
6. Start Up Instructions 6.1 Overview Once all electrical connections have been made, your DLC is ready for Start-up. The following 9 sections detail the procedures required to complete a DLC start up. WHEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT ON THE FIELD WIRING BOARD LOCATED AT THE BACK OF THE UNIT 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.
6.1.1.1 Display: This is a 2 line by 16 character alpha-numeric Liquid Crystal Display (LCD) located above the keypad. It is back-lit with a yellow-green light source for easy viewing in dark areas. Its contrast can be adjusted by using the keypad. 6.1.1.2 Keypad: The Keypad is a sealed 9-button membrane style input device. It is easy to use and will guide you quickly to specific functions. Refer to Figure 13 to familiarize yourself with the function of each key before starting.
6.1.1.3 Manual Adjustment Knob: The manual adjustment knob is mechanically attached to the PULSAR stroke length adjustment mechanism. The DLC uses the shaft attached to this knob to make its automatic adjustments. Visually, the knob is a good indication of what the DLC is doing. For example, if the DLC is increasing the pump stroke length – moving from 0 to 100% -- the knob will turn counter-clockwise until the desired position is achieved.
6.1.3 Confirm Correct Incoming Power Double check that the wiring access cover is on and tightened down. Whenever power is supplied to the DLC, the display's back-lighting will 'glow' with a yellow-green light. The presence of this backlighting is an excellent indication that the DLC's incoming power has been wired successfully and voltage is present. Characters may or may not appear on the display. This is normal and will be covered in the next section.
The keypad can be tested by depressing each key separately. Most, but not all keys will cause the text on the display to change. Do not be alarmed if a single key does not invoke a change to the display. This is normal. Different keys become active/inactive depending on the current operating mode . There are a number of functions that the DLC performs (e.g., zero calibration) where the keypad has no effect.
v Menu Factory Re-initialization: Use this procedure if the display and key pad appear to be functioning properly, but you suspect other problems with data corruption, erratic operation, etc. Factory Re-initialization can be found in the Configure Menu. Perform the following steps: 1. Apply power to the unit. Wait for the {SELF-TEST} display to disappear. The unit should display a standard power on screen. 2. Press [MENU]. The display will show the first menu item {DIAGNOSTICS}. 3. Press [DOWN].
6.1.7 Set Time & Date The clock on your DLC has been activated at the factory, but you should set it to the local time and date of the installation site. Time and Date are set in the Configuration Menu. Below is an example that accepts some software default values: 1. From the Current Operating Mode Display, press [MENU]. The {–MENU– / DIAGNOSTICS-0} screen is displayed (refer to illustrations below). 2. Press [UP] one time. The {–MENU– / SET TIME & DATE} screen is displayed. 3. Press [ENTER].
6.1.8 Flow Calibration (1-point). Your DLC is factory calibrated at rated flow and pressure (1-point). Nevertheless, you should always perform a calibration with the PULSAR DLC installed in your system. The only item required to calibrate your DLC is a means to measure the output of the pump (i.e., calibration column, graduated cylinder, etc.). The following is a minimal procedure for performing a 1-point calibration. 1. Press [MOTOR] to start the motor (if the motor is not currently running). 2.
6.1.9 Analog Input Calibration. If you are not using the 0-20mA input to the DLC 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 (e.g., PLC) must be powered up and capable of altering its output from minimum to maximum signal. 6.1.9.
7. General Operation This section covers the General Operation of the DLC as it relates to software. It includes detailed instructions and example screens. The default values of the DLC have been set at the factory. You can over-ride these settings to tune the DLC to your particular needs. 7.1 General Operation Instructions 7.1.1 Pump Flow Calibration Pulsafeeder recommends performing at minimum a Two-Point flow calibration on every PULSAR DLC installed.
CALIBRATE ZERO? YES Press [ENTER] If you are confident with the quality of your zero calibration, press [UP] and the {CALIBRATE ZERO? / NO} screen is displayed. Press [ENTER] and continue with step 8. 5. Press [ENTER]. The {TURN MOTOR ON / TESTING ENCODER} screen is displayed, or if the pump motor was ON when you started the calibration process, the {PLEASE WAIT / TESTING ENCODER} screen is displayed. TURN MOTOR ON TESTING ENCODER – or – PLEASE WAIT TESTING ENCODER 6.
11. At the end of 60 seconds, the pump motor will automatically turn off. The display will automatically change to prompt you to enter the new measured flow rate. ENTER VALUE 100% 2.641718 G Read the new measured flow from the calibration column. Enter the new value one position at a time using [UP] or [DOWN]. Press [ENTER] to accept each digit setting and move the cursor to the next position. Continue to use the arrow keys and press [ENTER] on the last position to accept your setting.
v Change Constants Procedure 1. Navigate to the Change Constants menu by pressing [CAL]. The {CALIBRATE / PUMP FLOW} menu is displayed. Press [ENTER] twice. The {FLOW CALIBRATION / 1 POINT} menu is displayed. 2. Press [UP] until {FLOW CALIBRATION / CHANGE CONSTANTS} is displayed. FLOW CALIBRATION CHANGE CONSTANTS This option is used to set the slope and y-intercept in the equation that describes the linear calibration curve: y = ax + b. Where 'a' is the slope and 'b' is the y-intercept.
2. Navigate to the Change Constants menu by pressing [CAL]. The {CALIBRATE / PUMP FLOW} menu is displayed. Press [ENTER] twice. The {FLOW CALIBRATION / 1 POINT} menu is displayed. Press [UP] until {CALIBRATION / TUNE} is displayed. Press [ENTER] to accept and continue with the {CALIBRATION / TUNE} menu. The following screen is displayed: TUNE FLOW 60.0% 0.1000 G Using [UP] or [DOWN] enter the volume displaced for 1 minute of pump flow at the current stroke length.
Send the low analog signal to the DLC (i.e., 0mA, 1mA, 4mA or 1 volt input to the J4 Current 1 terminals) from the signal generating device (e.g., PLC). Refer to Section 5-Installation: Low Voltage Input and Figure 5 for the wiring instructions. It is highly recommended that you use the actual signal the DLC will be receiving during operation. The DLC will display its interpretation of the received signal. Do not be alarmed if the signal does not match the instrument.
7.1.3 Reverse Acting Analog Input Signal Calibration To set up a reverse acting application, follow the above Analog Input Calibration procedure with the following changes to step 4 and step 5. 1. In step 4, when the display requests the minimum analog signal value (0% flow), you should send the DLC the high analog signal value (i.e., 10mA, 20mA or 5 volts). INPUT ANALOG MIN 0% = XX.XmA Send High (20mA) Signal The DLC will store this as the 0% analog input signal value.
7.1.4 Analog Output Signal Calibration The DLC will generate an analog output signal proportional to the current stroke setting. The signal can be in the range of 0-20 mA, 4-20 mA, 1-5 mA, or 1-5 volts. It should be calibrated to the attached system. For more information on configuring the Analog Output Signal refer to Section 7.2.5 – Analog Output Set up. The value that the DLC displays is not precisely calibrated to its output. The value that is displayed (e.g., 4.0mA) is for reference only.
7.2 Menu The default values of the DLC Controller have been factory set, but you may want to configure the DLC to meet your specific application. The [MENU] key activates the Configuration Menu system. This consists of 20 different sub-menus as shown below. Press [UP] or [DOWN] to scroll through the sub-menus. –MENU– DIAGNOSTICS–0 Press [UP] –MENU– SET TIME & DATE Press [UP] –MENU– ANALOG SIG FAIL Press [UP] –MENU– MODBUS SIG.
7.2.1 Alarm, and Error messages When an error occurs, the DLC flashes Alarm and Error messages alternately with the standard display. If the error is catastrophic (e.g.; Tachometer Failure), the catastrophic error message will remain displayed until the problem is repaired. The following table gives an example of these messages and when you can expect them to be displayed.
7.2.2 Diagnostics The DLC is supplied with a complete diagnostic menu. It will alert you if something has failed, the time and date of the failure, and allows you to clear the failure. v Diagnostics procedure 1. Press [MENU]. In a normal condition, the display reads {–MENU– / DIAGNOSTICS-0}. -MENUDIAGNOSTICS-0 If a diagnostic failure was detected, the "DIAGNOSTICS - #" would appear. The '#' indicates the number of items that have failed. 2. Press [ENTER] and the first diagnostic sub-menu is displayed.
8. Press [UP] to scroll to the next sub-menu. The DLC is equipped with a thermistor to monitor internal enclosure temperatures. If the temperature approaches its operating limit, (70°Celsius or 158°Fahrenheit) the DLC will show a warning in this diagnostic sub-menu. DIAG MENU 7/11 DRIVE TEMP: OK - or - DIAG MENU 7/11 DRIVE TEMP: FAIL 9. Press [UP] to scroll to the next sub-menu. The DLC is equipped with a clock that is backed by a 10year lithium battery.
12. Press [UP] to scroll to the next sub-menu. The total Stroke count of the pump is displayed here. To reset the Stroke count, press [ENTER] and you are prompted to {RESET COUNT?} or continue with the original count. DIAG MENU 11/11 STROKES: xxxxx Press [ENTER] RESET COUNT? YES The Stroke count is available only with the Tachometer option installed. In steps 11 and 12, if you select YES to either {RESET RUN TIME?} or {RESET COUNT?}, an {ARE YOU SURE?} prompt is displayed.
3. The time will now be flashing with the cursor located under the hour position. Press [UP] or [DOWN] to adjust the time to your local time. 12 HR 2:31a MM/DD/YY 1/22/01 The cursor located under the digit in the time, indicates the character being changed. Once the hour is set, press [ENTER] and the cursor will move to the first digit in the minute setting. Press [UP] or [DOWN] to set the correct tens of minutes digit, then press [ENTER]. 12 HR 2:31a MM/DD/YY 1/22/01 4.
9. If "AUTO CHANGE" was selected in the previous step, the DLC prompts you for the current day of the week. Press [UP] to scroll through the days of the week. Press [ENTER] to accept the current day of the week. DAY OF WEEK WEDNESDAY 10. The DLC prompts you to accept the time and date programmed in the above referenced steps {CONFIRM CHANGE? / YES}. Press [ENTER] to accept. If you do not want to accept the new inputs, press [UP] to scroll to {NO} and press [ENTER]. CONFIRM CHANGE? YES 11.
2. The menu for having the DLC freeze at the last signal is displayed. ANALOG SIG FAIL FREEZE @LAST SIG To accept this action, press [ENTER]. Go to step 3. If you desire a different action, press [UP]. a) The menu for having the DLC shut the motor off is displayed. ANALOG SIG FAIL MOTOR OFF To accept this action, press [ENTER]. Go to step 3. If you desire a different action, press [UP]. b) The menu for having the DLC go to a default signal (e.g.: 10%) is displayed.
7.2.5 MODBUS Signal Failure Setup This sub-menu allows you to set up the DLC response if the MODBUS Signal fails. You can program the DLC to have one of the following responses: − − − Freeze at the last digital input signal, Shut the motor off, Go to a default setting. A MODBUS Signal failure is detected if the DLC does not receive a valid message sent to its address within the timeout setting. v Setting up the DLC response. 1.
4. The menu that selects the MODBUS Signal failure action is displayed. There are three available options: e) Freeze at last signal, f) Motor off, g) Go To Default Press [UP] or [DOWN] to select the desired option. MODBUS SIG. FAIL FREEZE @LAST SIG Press [UP] MODBUS SIG. FAIL MOTOR OFF Press [UP] MODBUS SIG. FAIL GO TO DEFAULT Press [ENTER] to accept your setting. 5. If you selected {FREEZE @LAST SIG} or {MOTOR OFF} in step 4, proceed to step 6.
v Leak Detection Failure Set Up Procedure 1. Press [MENU] to enter the { –MENU– } sub-system. Press [UP] or [DOWN] until {–MENU– / LEAK DETECTION} is displayed. -MENULEAK DETECTION Press [ENTER] to continue to program the Leak Detection options. 2. The Leak Detection Input can be configured as {INACTIVE}. If the pump is not supplied with a PULSAlarm Leak Detection Diaphragm, it should be set as {INACTIVE}. LEAK DET INPUT INACTIVE Press [ENTER] to accept your selection.
v Level/Start-Stop Set Up Procedure 1. Press [MENU] to enter the { –MENU – } sub-system. Press [UP] or [DOWN] until { –MENU– / LEVEL SWITCH} screen is displayed. -MENULEVEL SWITCH Press [ENTER] to continue to program the Level Switch sub-menu. 2. The level input can be configured as {INACTIVE}, if it will not be used. LEVEL SWITCH INACTIVE Pressing [ENTER] when {LEVEL SWITCH / INACTIVE} is displayed will cause the screen to return to the { –MENU– / LEVEL SWITCH} screen. 3.
10. If you want the PULSAR motor to stay on when a Drum Level is sensed, press [UP] to scroll to {NO}.and press [ENTER]. LEVEL SWITCH MOTOR OFF? NO 11. The display prompts you for the alarm relay status should the Drum Level Input trigger the alarm relay. LEVEL SWITCH ALARM RELAY? YES Press [ENTER] if you want the Alarm Relay to activate with the Drum Level Input. The display returns to the {–MENU– / LEVEL SWITCH} screen. 12.
7.2.8 Digital Output Set Up This sub-menu allows you to determine if the Digital Output is to be used as a counter for pump strokes, as a remote motor on/off indicator, or for Mode indication. For example: If the Digital Output is set up as {RUN/STOP STATUS}, and {DIGITAL OUTPUT / NORMALLY OPEN} it will activate when the motor is on and deactivate when the motor is off.
v Digital Output Set Up Procedure 1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– / DIGITAL OUTPUT}. –MENU– DIGITAL OUTPUT 2. Press [DOWN]. The {DIGITAL OUTPUT / RUN/STOP STATUS} screen is displayed. DIGITAL OUTPUT RUN/STOP STATUS To use the DIGITAL OUTPUT function as a remote On/Off indication, press [ENTER]. 3. Press [ENTER] to continue to program the Digital Output sub-menu. The {DIGITAL OUTPUT / PUMP STROKE} screen is displayed.
7.2.9 Motor Thermostat Set Up This sub-menu allows you to configure the DLC to interact with the pump motor thermostat. The motor must be equipped with the optional thermostat for this to work.
MOTOR THERMOSTAT ALARM RELAY? NO Press [ENTER] to accept the desired configuration. 6. If {MOTOR THERMOSTAT / MOTOR OFF? YES} is selected in step 4, the {RESTORE TO: / MOTOR ON} screen is displayed. RESTORE TO: MOTOR ON If you want the DLC to turn the motor back on when the thermostat deactivates, set {RESTORE TO:} to {MOTOR ON}. Press [UP] to select between {MOTOR ON} and {MOTOR OFF}. Press [ENTER] to accept your setting. RESTORE TO: MOTOR OFF 7.
7.2.11 Power Failure Set Up This sub-menu allows you to configure the way the DLC reacts when power is restored after a power outage. Additionally this sub-menu allows setting the action to take if improper voltage is applied. During the power up stage, the DLC can either: − − Return to settings that were active when the pump lost power. Shut the motor off. A power outage is defined as the loss of power whenever the DLC is not in the {MOTOR OFF} state. v Power Failure Set Up Procedure 1.
7.2.12 Alarm Relay This sub-menu sets up the alarm relay outputs as normally open or normally closed. These screens configure both the high voltage output and low voltage switch (transistor). v Alarm Relay Set Up Procedure 1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / ALARM RELAY} is displayed. Press [ENTER] to continue to program the Alarm Relay sub-menu. –MENU– ALARM RELAY 2. The alarm relay can be configured as {NORMALLY OPEN}.
v Analog Mode Set Up Procedure 1. Press [MENU] once and then [UP] or [DOWN] until the screen {–MENU– / ANALOG MODE} is displayed. -MENUANALOG MODE Press [ENTER] to continue to program the Analog Mode sub-menu. 2. The {ANALOG MODE / ACTIVE} screen is displayed. ANALOG MODE ACTIVE Press [ENTER] to accept the default value. If you want the analog mode to be inactive and {ACTIVE} is displayed, press [UP] to change the display to {INACTIVE}. Press [ENTER] to accept your selection. Go to step 12. 3.
v MODBUS mode setup procedure: O To access the {MODBUS MODE} menu you must have Serial Comm enabled and the class set to Slave. Refer to the Serial Communications section later in this chapter. 1. Press [MENU]. Press [UP] or [DOWN] until the {–MENU– / MODBUS MODE} screen is displayed. –MENUMODBUS MODE Press [ENTER] to continue to program the MODBUS mode. The {MODBUS MODE / INACTIVE} screen is displayed.
7.2.15 Security The DLC has three modes of security: − − − None (OFF) Tamper Proof Calibration With Tamper Proof security active, the DLC will lockout all of the front panel keys with the exception of [MOTOR]. To use any other key you will be prompted to enter a four digit Personal Identification Number (PIN). Successful entry of a PIN allows you to access all DLC functions without PIN re-entry.
7. If the pin number is not correct or you don’t want the selected security level, press [UP] to change the display to {CONFIRM CHANGE? / NO} CONFIRM CHANGE? NO Press [ENTER] to reject the security changes. 8. The menu display returns to {–MENU– / SECURITY} screen. Remembering the PIN # you set, is probably one of the most important functions of setting security. 7.2.
If a display unit was specified (e.g., GPH), each time any of the Flow displays are accessed, only the specified unit is displayed. To return the system back to the default setting of ALL, return to step 6, press [UP] or [DOWN] to cycle through the units options until ALL is displayed and the press [ENTER]. 7.2.17 Contrast Adjust The DLC display contrast can be adjusted to a desired setting. v Contrast Adjustment Procedure 1. Press [MENU].
If you are installing this DLC into an existing network, retrieve the following parameters (bold indicates default DLC values not network defaults). Communication Parameters Worksheet MODBUS Type: ¨ RTU ¨ ASCII Baud Rate: Data Parity: ¨ 300 ¨ Even Slave Address(es): ¨1 ¨ 13 ¨ 25 ¨ 600 ¨ Odd ¨2 ¨ 14 ¨ 26 ¨ 1200 ¨ None ¨3 ¨ 15 ¨ 27 ¨4 ¨ 16 ¨ 28 ¨ 2400 ¨5 ¨ 17 ¨ 29 ¨ 4800 ¨6 ¨ 18 ¨ 30 ¨7 ¨ 19 ¨ 31 ¨ 9600 ¨8 ¨ 20 ¨ 32 ¨ 19,200 ¨ 38,400 ¨9 ¨ 10 ¨ 11 ¨ 21 ¨ 22 ¨ 23 (Mark one or more.
Press [UP] or [DOWN] to set the parity type. DATA PARITY EVEN Press [UP] DATA PARITY ODD Press [UP] DATA PARITY NONE Press [ENTER] to accept. 6. The Class setting defines how the DLC will operate in the network. If Class is set to Master, then the DLC tells other equipment (e.g., other DLC’s) that are configured as slaves what to do (e.g., adjust stroke percent to 50%). If the Class setting is set for Slave, then the DLC is expecting a command from a Master unit.
To set or view Slaves manually, press [UP] or [DOWN]. As you do so, the display will show the address followed by the status, Address IDENTIFY SLAVES 1 NO Status In the example above, the device at address 1 is not identified as a Slave. Press [UP] or [DOWN] to scroll through the 32 addresses. To manually identify a Slave, press [UP] or [DOWN] to display the address of the Slave device. Press [ENTER]. Now press [UP] or [DOWN] to change the status of this device to {YES}.
7.2.19.1 Loopback Test Procedure The Loopback test is helpful in the identification of wiring errors. While this menu is displayed the DLC transmits and expects to receive characters back. The display shows the percent (%) of successful characters exchanged. The Loopback test requires the installation of a Loopback device at the end of the cable segment under test.
7.2.20 Language All displayed text can be displayed in English, Spanish, French or German. v Language Set Up Procedure 1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / LANGUAGE} is displayed. -MENULANGUAGE Press [ENTER] to continue through the language sub-menu. 2. The language type appears on the display. Press [UP] to scroll through the available languages.
Press [UP] to change the value to {YES}. Press [ENTER] to accept your selection. The following message is displayed: PLEASE WAIT 5. The first screen displayed during the Re-Set procedure prompts you to turn the motor on. TURN MOTOR ON TESTING ENCODER 6. Press [MOTOR].
7.4 Varying the Flow Rate - Manually When the DLC is in Manual Mode, pump flow rate can be increased by pressing [UP]. The flow rate is decreased by pressing [DOWN]. The DLC will display the corresponding value of the flow adjustment. Do not adjust the DLC's hand-wheel while the power is off. This will cause the DLC to lose its zero point and force a {ZERO CALIBRATION } at startup. 7.5 Mode Pressing [MODE], switches the DLC’s operating mode.
7.6.2 Repeating A Repeating Batch will start at a specified time and run for a specified duration. It will stop for a specified period of time and then repeat the run time. This will continue indefinitely (refer to Figure 19). Any of the three batches can be specified as one time only or repeating. Figure 19. Repeating Batch. 7.6.3 Overlapped The batches can also be overlapped (refer to Figure 20 below). Figure 20 – Overlapping Batch. When the batches are overlapped, the flow rates are NOT additive.
v Batching system Set Up procedure: 1. Press [BATCH], to enter the batch set-up menu. 2. The display will come up as {BATCHES / ACTIVE} or {BATCHES / INACTIVE}. Press [UP] to change the batch system to {ACTIVE}. Setting the batch system to ACTIVE will cause any pre-configured batches that are scheduled to start at this time, to start immediately, so you might want to do this last. Press [UP] BATCHES ACTIVE BATCHES INACTIVE Press [ENTER] to continue on to the batch sub-menu. 3.
7. The cursor then moves to minutes field. Use [UP] or [DOWN] to scroll through the numbers 0-5. Set the first digit of the minute value one position at a time and press [ENTER] to accept it. BATCH #1 DURATION 12 HRS 30 MIN 8. The cursor then moves to the second digit of the minutes field. Use [UP] or [DOWN] to scroll through the numbers 0-9. Set the second digit of the minute value.
16. When the batch has operated for the specified time period, it will automatically shut off the pump's motor. 17. If this a One Time Only batch, the display will show the batch completed message and the operating mode will be set to manual. BATCH #1 COMPLETED PRESS ANY KEY Press any key to clear the display. MOTOR OFF 18. If this was a repeating batch, the display will return to {BATCH #X PENDING / HH:MM MM/DD/YY} and the DLC will wait until its internal clock matches the displayed Time/Date.
8.
Diagram 2 – Motor Wiring Diagram 75
Diagram 3 – Serial Communications – RS 485 Connections 76
9. Specifications STROKE LENGTH CONTROL: 0-100% control range 0.1% resolution 10:1 turndown for accuracy specification. Combined Calibrated Flow: 6 significant digits for displayed units of flow. Pump Accuracy: Accuracy Standard Diaphragm Diaphragm With Leak Detection Single Solid Teflon Diaphragm Capacity Reference ±0.5% ±0.5% ±1.0% ±0.5% ±1.0% ±3.0% ±0.5% ±1.0% ±3.
Low Voltage Outputs Outputs Analog Output Channel Field Wiring Location J5 Pin 1 is + J5 Pin 2 is – Alarm Status J5 Pin 3 is + J5 Pin 4 is – Digital Output J5 Pin 5 is + J5 Pin 6 is – Programmable as Remote Run Status Or Stroke Counter Or Mode Indication Specification / Description Any signal within the range of 0 – 20mA (e.g.: 4-20). Minimum span of 2mA. Maximum load: 700 ohms. Reverse Acting standard on all units, which is accessible via calibration. Fused at 50mA protected against mis-wiring.
High Voltage Inputs Inputs Field Wiring Location J1 Line Power: Specification / Description Factory configured to one of the following: 115VAC ±10%, 50/60 Hz, 10 Amp max 230VAC ±10%, 50/60 Hz, 5 Amp max Surge Protection: 7.4 Joules Software protected against Over/Under voltage. (user selectable) High Voltage Outputs Inputs Alarm Relay Field Wiring Location J2 Specification / Description Fused at 1 amp at rated Line voltage. May be software configured as Normally Open or Normally Closed.
10.
LANGUAGE English MODE Manual – Motor Off UNITS Percent (%) BATCH Batch #n Rate Batch #n Duration Batch #n Type Batch #n Start FLOW RATE Stroke Position Inactive 0% 0 H 00 M One Time Only Current Date and Time for first setting 0% 0% FACTORY DECIMAL POSITION SETTINGS RATED CAPACITY RANGE UNITS –MENU – / DECIMAL POSITION 5.99999 1,585.03 5,999.99 5,999,990 0.0999999 26.4172 99.9999 99,999.9 to to to to to to to to 59.9999 15,850.3 59,999.9 59,999,900 0.999999 264.172 999.
FACTORY DECIMAL POSITION SETTINGS (cont.) RATED CAPACITY RANGE UNITS –MENU – / DECIMAL POSITION 0.00599999 1.58503 5.99999 5,999.99 0.0000999999 0.0264172 0.0999999 99.9999 to to to to to to to to 0.0599999 15.8503 59.9999 59,999.9 0.000999999 0.264172 0.999999 999.999 CMH GPH LPH CCH CMM GPM LPM CCM 0.999999 0.999999 0.999999 0.999999 0.999999 0.999999 0.999999 0.999999 0.000000001 0.000001 0.000001 0.001 0.00000000001 0.00000001 0.00000001 0.00001 to to to to to to to to 0.00599999 1.58503 5.
11. Trouble Shooting Guide 11.1 System Diagnostics Your DLC contains extensive diagnostics that allow it to determine the source of common problems. If your DLC is not operating properly, your first course of action should be to review the {DIAGNOSTICS} sub-menu. To access this menu from the standard operating mode follow this procedure (provided your user interface – keypad and display – is functioning): 1. Press [MOTOR] repeatedly until the display reads {MOTOR OFF}. 2.
Symptom DIAG 7/11 DRIVE TEMP: FAIL DIAG 8/11 BATTERY: FAIL DIAG 9/11 CIRCUIT: FAIL *RAM* DIAG 9/11 CIRCUIT: FAIL *EEPROM* DIAG 9/11 CIRCUIT: FAIL *MOTOR* MENU (DIAGNOSTICS) [cont] Probable Cause Possible Solution The DLC internal temperature has exceeded the rating. The DLC clock is backed by a Lithium Battery with a 10 year life. The Random Access Memory (RAM) on the mother board cannot be reliably read and/or written to.
PULSAR MOTOR (1-Phase) Probable Cause Possible Solution Symptom Motor will not start. . Motor will not stop. No power supplied. Motor wired incorrectly. Supply power outside of specification. Motor key not pressed. Keypad problem. Remote Motor Switch is off Software did not initiate properly. Alarm or Level input set with option MOTOR OFF? set to YES. PULSAR mechanicals locked. Motor Thermostat not connected or programmed. Solid-state relay failed. MODBUS in control. Motor wired incorrectly.
PULSAlarm Symptom Probable Cause Possible Solution Not Responding to PULSAlarm Input Input wired incorrectly. Input not configured properly. Check wiring. Review Section 7-General Operation: Menu, Leak Detection Failure Set-up. Remove and replace with dry contact. If no change, contact Technical Services. Symptom Probable Cause Possible Solution Not Responding to Level Input Input wired incorrectly. Input not configured properly. Check wiring.
Symptom MANUAL ADJUSTMENT KNOB / DLC INTERNAL DRIVE MOTOR Probable Cause Possible Solution Knob will not turn under DLC control or by hand. Knob will not turn under DLC control. Display shows {DUTY CYCLE}. PULSAR Stroke Adjustment jammed on mechanical stop at 0%. PULSAR Stroke Adjustment jammed on mechanical stop at 100%. DLC gearing worn. Internal DLC Synchronous motor has achieved its duty cycle limit of 50% ON time (based on a 20 minute interval).
CALIBRATION Possible Solution Symptom Probable Cause Message: {Terminated / Press any key} appears during Calibration. Manual Knob adjusted while Calibration session was active. Symptom Probable Cause Possible Solution Units do not increment with change in %. Displayed units read - 000000 Unit not properly calibrated. Calibration beyond display resolution. Re-calibrate to value within display range. Change number format to give additional precision. Display is normal.
ENCODER ERROR Possible Solution Symptom Probable Cause Message: {ENCODER ERROR / PRESS ENTER} displays during encoder test. Encoder defective. Internal Motor unable to turn adjustment knob. 11.1.1 Contact Technical Services Broken or jammed gears – contact Technical Services. Defective motor – contact Technical Services. Defective Drive circuits – contact Technical Services.
11.1.2 Tachometer Troubleshooting The DLC may utilize a tachometer sensor installed in the gear box (optional). This sensor detects the passage of 24 gear teeth per motor shaft revolution. Required Tools: − − − Phillips head screw driver Adjustable Wrench Multi-meter 1. Turn off and lock out the power to the DLC at the main panel. 2. Remove the Wiring Access cover (refer to Figure 2: Accessing the Field Wiring Board). 3.
18. The Tachometer or Target gear may be damaged. Rotate the pump motor 360 degrees and count the number of transitions from high to low that you observe on your multi-meter. 19. If you do not count exactly 24 high interspersed with 24 low levels, the Tachometer target gear is damaged. . 20. Test your settings. Turn off and lock-out the power to the DLC at the main panel. 21. Reconnect all conduit fittings to the Tachometer if removed in a previous step. 22. Remove the multi-meter 23.
12. Conversion (Manual to DLC) Your PULSAR can be easily converted from a Manual Stroke Adjustment Mechanism to the DLC. The DLC effectively replaces the Manual Cover Assembly. Use the following procedure for conversion: 1. While running the pump motor, adjust the stroke setting to approximately 50%. 2. Disconnect the power supply going to the PULSAR drive motor. 3. Remove the six Phillips Head screws that hold the Manual Cover Assembly to the Eccentric Box (refer to Figure 21).
Figure 22 – DLC/Eccentric mating components 7. Locate the face on the bottom of the DLC that mates with the face of the lip of the eccentric box. The DLC is oriented such that the control pad and display sit to the left of the pump's reagent head (as viewed standing in front of the reagent head looking at the motor). The conduit connections and access panel (with Serial Tag) reside at the rear of the pump near the gear box. 8.
13. General Repairs The DLC contains no user-serviceable components within its main enclosure. In the un-likely event that your DLC needs to be repaired, PULSAFEEDER has implemented a replacement program. Fill out the Diagnostic form included in the back of this manual, then contact PULSAFEEDER Customer Service at (585) 292-8000 to enter a replacement order Within 24-hours a DLC will be shipped to you in a returnable container.
13.2 DLC Replacement v The following procedure assumes that you have received your replacement DLC and are ready to perform the replacement. 1. If possible, activate the PULSAR motor and adjust the stroke setting in the range of 10 to 90%. Avoid 0 and 100% stroke settings on the PULSAR when replacing a DLC. If necessary, use the Manual Adjustment knob. It should be easier to adjust the stroke manually in the (+) counter clockwise direction.
O Perform steps 5 and 6 only if there is a Tachometer installed. If there is no Tachometer installed, go to step 7 on the next page. 5. Remove the Tachometer Sensor Input Cable on the Field Wiring Board. a) Disconnect the wire (typically brown) connected to Pin 1 of J10. b) Disconnect the wire (typically blue) connected to Pin 2 of J10 6.
7. Remove the four screws and Teflon Gaskets that retain the conduit adapter(refer to Figure 25). Figure 25 – Conduit Adapter Screw Removal When removing the DLC in Step 8, the conduit adapter will stay with the wire and conduit. It plugs into the bottom of the DLC. When lifting the DLC off the Conduit Adapter, it may be necessary to have a second person hold the Adapter and associated conduit while the DLC is 'un-plugged' from it. 8.
12. Note the position of the PULSAR adjustment shaft 'flats'. They mate with a slot in the DLC drive coupling of the output shaft. The output shaft is connected to the adjustment knob. Familiarize yourself with these mating components prior to installation (refer to Figure 27). Figure 27 – DLC/Eccentric Mating Components 13. Locate the face on the bottom of the DLC that mates with the face of the lip of the gear box.
14. Orient the DLC properly at a comfortable height above the pump and align the slot in the DLC coupling with the 'flats' on the adjustment shaft by turning the Manual Control knob on the DLC. Do not turn the PULSAR gear box adjustment shaft! 15. Lower the DLC onto the gear box. Figure 29 – Positioning the DLC It may be necessary to tip the DLC slightly towards the motor to clear the Motor adapter.
Figure 30 – Shaft Alignment 100
16. Align the Conduit Adapter with the mating surface on the DLC. A card edge in the DLC housing will mate with an edge connector on the Conduit Adapter. Once properly aligned, the units will mate with moderate force (approximately 20 Newtons or 5 pounds of force). a) Install the four screws and Teflon Gaskets that hold the Conduit Adapter to the DLC (refer to Figure 28). FAILURE TO INSTALL THE TEFLON GASKETS WILL CAUSE YOU TO LOSE THE NEMA-4X RATING ON YOUR ENCLOSURE, AND WILL VOID THE PRODUCT WARRANTY.
14. PulsaNet Specification For simplicity, the DLC, DLCM, MLC, MLCM, NEMA-4X and NEMA-7 variations will ALL be referred to as the DLC unless otherwise noted. 14.1 Introduction The DLC PulsaNet communication system is an implementation of the industry standard MODBUS® protocol. The physical layer uses an RS-485 four-wire multi-drop scheme. Up to 32 slave units can be connected to a single master on the same set of wires.
14.3 MODBUS Messaging The MODBUS protocol was written for use with PLC’s. Programmable Logic Controllers typically have relay outputs, digital inputs, analog inputs, analog outputs and general system settings (e.g., setpoints, alarm points, etc.).
14.5 Coils Coils are discrete, single bit outputs like the ALARM OUTPUT and DIGITAL OUTPUT. Notes: • • • • Read only. The coil information is packed as 8 coils per byte. Coils are accessible through Function Code 0x01. The requested value is returned in the least most significant bit. Function Read (0x01) Read (0x01) Address 0x0000 0x0001 DDE Ref. 000001 000002 Purpose Alarm Output Digital Output Data Format Bit(0x01 = On) Bit(0x01 = On) 14.
14.7 Input Registers These 16-bit input registers contain Analog (4-20mA) and Thermistor input readings. Notes: i The input information is returned as 16-bit integers. i Input Registers are accessible through Function Code 0x04. Function DDE Ref.
Function Address DDE Ref.
Function Address DDE Ref. Purpose Data Format Read (0x03) Read (0x03) Read (0x03) Read (0x03) Read (0x03) Read (0x03) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Write (0x06) Write Mult. (0x10) Read (0x03) Read (0x03) Read (0x03) Write (0x06) Write Mult.
Notes: 1. There is one character per 16-bit value, which resides in the least significant byte. 2. The most significant byte contains the cursor status (0 = cursor off, 1 = cursor on). The least significant byte contains the cursor position offset (0-15 for the first line and 16-31 for the second). 3. Used to invoke Key-presses. The key value must be sent in the least significant byte (the most significant byte is unused). THIS REGISTER (0X0041 – KEY PRESS) MUST NOT BE USED FOR AUTOMATION PURPOSES.
13. This is provided because you can only write items while in MODBUS MODE. 0=MANUAL MODE, 1=ANALOG MODE, 2=MODBUS MODE, 3=BATCH MODE. 14. Reading determines if we are currently performing a Find Zero Calibration. (0=no, 1=in progress) This register can be written with a ‘1’ to force a Find Zero Calibration to occur.
SUPPORTED FUNCTION CODES and SUB-FUNCTION CODES 0x01 0x02 READ COIL STATUS (bits) READ INPUT STATUS (bits).
Notes: 1. Function codes that are NOT SUPPORTED or NOT ASSIGNED return an ILLEGAL FUNCTION CODE response 2. Unsupported SUB-FUNCTION CODES under DIAGNOSTIC FUNCTIONS return INVALID DATA 15. MODBUS Mode 15.1 Introduction The serial communications supplied with the DLC/M is similar in operation to that with the 4-20mA signal. The [MODE] key controls the current operating mode: MANUAL, ANALOG (4-20mA) or MODBUS. Serial communications can occur with the DLC/M regardless of the mode setting.
16. Spare Parts User replaceable parts for the DLC.
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EC Declaration of Conformity Manufacturer: Pulsafeeder, Inc. 2883 Brighton Henrietta Townline Rd. Rochester, NY 14623 USA Pulsafeeder Inc.
BULLETIN No. IOM-PS-DLC-1101-G Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623 Telephone: (585) 292-8000 Fax: (585) 424-5619 www.pulsa.com pulsa@idexcorp.
