Mercoid MPC Operating Manual

Series MPC Pump Controller

Installation and Operating Manual

Bulletin L-20

MERCOID A Division of Dwyer Instruments, Inc.

P.O. BOX 258 • MICHIGAN CITY, INDIANA 46361, U.S.A.

Phone: 219/879-8000 • Fax: 219/872-9057

www.dwyer-inst.com • e-mail: lit@dwyer-inst.com

FR # M1-443247-00 Rev. 4

CONTENTS

3.596

(91.3 mm)

Panel Thickness

0.250 (6.53 mm) Max.

Panel cut-out: 3.620 x 3.620 in, +0.032/-0.000

(92 x 92 mm, +0.8/-0.0).

Allow for 0.5 in (13 mm) clearance

at the rear of the instrument.

Meets IP66 (UL Type 4X)

3.774 (95.9)

4.500

(114.3)

0.530

(13.5)

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Front Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Home Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Security Level Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lead/Lag Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Seal Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Over Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Analog Retransmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Pump Run Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Serial Communication Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Menu Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Secondary Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Secure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23

Alarm Type and Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22

Diagnostic Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Programming Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-28

Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-31

DIMENSIONS

SPECIFICATIONS Inputs: 4 to 20 mA DC or 2.0 to 10.0 V DC selectable. Input Impedance: Current input: 10 ohms, Voltage input: 100K ohms. Output Ratings:

Control Relays: SPDT, rated 10A @ 240 VAC res., 1/4 hp @120 VAC,

1/3 hp @ 240 VAC.

Alarm Relays: SPST, 3A @ 240 VAC res., 1/10 hp @ 120 VAC. Control Type: on/off, reverse or direct acting. Power Requirements: 100 to 240 VAC nominal, +10%-15%, 50 to 400 Hz, single phase;

132 to 240 VDC nominal, +10%-15%.

Power Consumption: 7.5 VA maximum. Accuracy: 0.25% of span, 1 least significant digit. Display: Two 4 digit, 7 segment 0.56” high LED’s. Display Resolution: 1 count. Memory Backup: Nonvolatile memory (no batteries required). Serial Communications: Optional RS-232 or RS-485 with Modbus

protocol.

Ambient Operating Temperature / RH: 14 to 131° F (-10 to 55° C) / 0 to 90% up to 104° F (40° C) non-condensing, 10 to 50% at 131° F (55° C) non-condensing.

Weight: 16 oz. (454 g). Front Panel Rating: Meets UL Type 4X (IP66). Loop Power Supply (isolated): 24 VDC @ 50 mA, regulated. Seal Failure (Moisture Sensor):

Power Supply to Moisture Sensor: 2.5 VDC.

Search Current: 3 micro amps.

Resistance Sensitivity: 10K to 500K ohms.

Resistance Resolution: 10K ohm steps. Over Temperature:

Input: Dry contact on Transistor switch (NPN open collector type).

Current: 1 mADC.

Isolation: Shares common ground with transmitter input. Alarm On-Off Differential: 1 count. Set Point Range: Selectable. Power Voltage Stability: 0.05% over the power voltage range. Temperature Stability: 100 ppm / °C typical, 200 ppm / °C maximum. Common Mode Rejection: 140 db minimum at 60 Hz. Normal Mode Rejection: 65 db typical, 60 db at 60 Hz. Isolation:

Relay: 1500 VAC to all other inputs and outputs.

24 VDC Loop Power: 500 VAC to other inputs and outputs.

Process Output: 500 VAC to other inputs and outputs.

Seal Failure Input: 500 VAC to other inputs and outputs. Storage Temperature: -40 to 176° F (-40 to 80° C). Agency Approvals: UL 508, CE.

Modbus®is a registered trademark of Schnieder Automation.

GETTING STARTED

1. Install the control as described on page 4.

2. Wire the control following the instructions on pages 5 through 7. Page 5 contains basic wiring for the control. If using the Series MPC’s transmitter power supply follow the additional directions on page 6. Wiring instructions for the 232 and 485 series communication options is included on page 7.

3. Familiarize yourself with the front key pad functions and read the menu structure prior to starting the programming process. A programming chart with the menu structure and spaces to write your programming values is included on pages 26 through 28. This chart can be a helpful tool to save time in programming. For further assistance programming examples are included on pages 28 through 31.

MODEL IDENTIFICATION

Model MPC -

Options

Options:

RS-232 Modus®-RTU Serial Communications. Allows remote

232

computer to read and write all control parameters.

RS-485 Modbus®-RTU Serial Communications. Allows remote

485

computer to read and write all control parameters.

RV Analog retransmission of input, 2 to 10 VDC.

Input Ranges Process Input Types

The 0 to 20 mADC, 4 to 20 mADC, 0 to 10 VDC, and 2 to 10 VDC inputs are fully scalable from a minimum of 100 count span placed anywhere within the range of

-1999 to +9999. Decimal point position is adjustable from the zero place (9999), tenths (999.9), hundredths (99.99), or thousandths (9.999).

INSTALLATION

Mount the instrument in a location that will not be subject to excessive temperature, shock, or vibration (see Specifications for specific tolerances). All models are designed for mounting in an enclosed panel.

Select the position desired for the instrument on the panel. Prepare the panel by cutting and deburring the required opening.

From the front of the panel, slide the housing through the cut out. The housing gasket should be against the housing flange before installing.

From the rear of the panel slide the mounting collar over the housing. Hold the housing with one hand and using the other hand, push the collar evenly against the panel until the springs are compressed. The ratchets will hold the mounting collar and housing in place.

Figure 1 – Panel Cut Out Dimensions

Panel cut-out:

3.620 x 3.620 in, +0.032/-0.000 (92 x 92 mm,

+0.8/-0.0)

CAUTION: It is not necessary to remove the instrument chassis from the housing for installation. If the instrument chassis is removed from the housing, you must follow industry standard practice for control and protection against Electro-Static Discharge (ESD). Failure to exercise good ESD practices may cause damage to the instrument.

WIRING

Do not run transmitter wiring or other class 2 wiring in the same conduit as power leads. Use only the probe or transmitter for which the control has been programmed. Maintain separation between wiring of sensor, auxiliary in or out, and other wiring. See the ˝Secure Menu˝ for input selection.

Supply connections should be made in accordance with the National Electrical Code per Article 300, and local regulations. All line voltage output circuits must have a common disconnect and be connected to the same pole of the disconnect. Input wiring for probe or transmitter is rated CLASS 2. Control wiring is as shown in Figure 2 below.

Figure 2 - Wiring

Pump 1 Over Temp

Analog Retransmission

Pump 2 Over Temp

24 VDC

Voltage Current

Seal

Pump 1

Sensor

Inputs

Pump 2

Alarm 1 Contacts

Alarm 2 Contacts

NOTES:

1. For supply connections use No. 16 AWG or larger wires rated for at least 167˚F (75˚C) or, in accordance with an equivalent national standard.

2. Maximum ambient temperature rating 131˚F (55˚C).

3. Use copper conductors only.

4. Terminals 1-6, 11, 12, 21-32 are class 2 "SELV".

N.O. COM.

Line Input 100 to 240 VAC 50400 Hz. Single PH.

132 to 240 VDC 5VA. Max. Output Ratings:

Relay: 10A @ 240 VAC Res.

1/4 HP @ 120 VAC 1/3 HP @ 240 VAC

Alarm: 3A @ 240 VAC Res.

1/10 HP, 120 VAC

50 mA

Isolated

Pump 1

Output

Pump 2

Output

290-3120

If not using pump over temperature inputs then jumper terminals 22 to 23 and 22 to 24.

WIRING FOR TRANSMITTER INPUTS USING INTEGRAL POWER SUPPLY

Wire power and outputs as shown on previous page. Wiring for two-wire transmitters shown below in Figure 3. All wiring shown in Figure 3 is Class 2.

Figure 3 - Transmitter Wiring

Connect Jumper between terminals 2 and 12 Connect Transmitter Plus (+) to terminal 11

Connect Transmitter minus (-) to terminal 3

Level Transmitter

For three or four wire transmitters follow the wiring instructions provided with your transmitter.

DO NOT wire the 24 Volt Power Supply across the input of the control. Damage to the control input circuitry will result.

WIRING FOR 485 AND 232 SERIAL COMMUNICATION OPTIONS

Wire power and outputs as shown on page 5. Wiring for options is shown in Figure 4 below. All wiring shown below is Class 2. Shielded twisted pair is recommended for Option 485.

DO NOT run signal wiring in the same conduit or chase as the power wiring. Erratic operation or damage to the control circuitry will result.

Figure 4 – Wiring for Options

DB-25 WIRING

Option 485 DIP Switch Positions*

Half Duplex* Full Duplex

1 2 3 4 5 6

27 28

OFF

1 2 3 4 5 6

Terminal 29 30 31 32

Option 485 Y (receive -) Z (receive +) A (transmit -)* B (transmit +)*

Option 232 not used data out data ground data in

*For half-duplex operation wire only A and B. Do not connect to Y and Z.

(VIEWED FROM WIRE SIDE)

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25

PIN DESCRIPTION 1 SHIELD 2 TRANSMIT 3 RECEIVE 4 RTS 5 CTS

RS-232 DB-9 WIRING

(VIEWED FROM WIRE SIDE)

1 2 3 4 5

6 7 8 9

DATA IN 30 DATA OUT 32 DATA GROUND 31

PIN DESCRIPTION 6 DSR 7 GROUND 8 DCD 20 DTR

DATA OUT 32 DATA IN 30 DATA GROUND 31

PIN DESCRIPTION 1 DCD 2 RECEIVE 3 TRANSMIT 4 DTR 5 GROUND 6 DSR 7 RTS 8 CTS

FRONT PANEL FUNCTIONS

Key functions are as follows:

INDEX: Pressing the INDEX key for 2 seconds will bring up the Secondary

menu starting at the Secure menu starting with the menu item

SP1H menu item. Holding the key for 5 seconds will bring up the

SECr. Once in the menus, pressing the

INDEX key advances the display to the next menu item. May also be used in conjunction with other keys as noted below.

SYSTEM TEST: When Test menu item is ˝On˝ depressing this key for three seconds will make the MPC Pump Controller go through a system test. See page 18 for explanation of system test function.

UP ARROW: Increments a value, changes a menu item, or selects the item to ON. The maximum value obtainable is 9999 regardless of decimal point placement.

DOWN ARROW: Decrements a value, changes a menu item, or selects the item to OFF. The minimum value obtainable is -1999 regardless of decimal point placement.

ENTER: The ENTER key is used to store the value of menu items once they are changed to a new value. If the ENTER key is not pressed after changing the value the item will revert to the previously stored value.

PUMP RUN TIME: Pressing this key will cause the MPC Pump Controller to display the total run time (in hours) that the pump(s) have been on since the last reset.

INDEX & DOWN ARROW: Pressing these keys simultaneously will allow backing up one menu item, or if at the first menu item they will cause the display to return to the primary menu. If an alarm condition has occurred, these keys may be used to reset the alarm.

INDEX & ENTER: Pressing these keys simultaneously and holding them for 5 seconds allows recovery from the various error messages. The following menu items will be reset:

ALiH : Alarm inhibit CHEC CAL : Check calibration error

Correct the problems associated with the above conditions before using these reset keys. More than one error could be present. Caution is advised since several items are reset at one time.

THE HOME DISPLAY

The home display is the normal display while the control is operating. If no errors or functions are active, the HOME display will indicate the Process Variable (the level that is being measured) on the top display and the

SP1H value, Pump 1 On Set Point, on the

bottom display.

Error messages may over-ride the HOME display. See ERROR MESSAGES on pages 24 and 25.

While in the Secondary Menu, if no key is pressed for a period of 30 seconds, the display will return to the HOME position displaying the process value. While in the Secure Menu, if no key is pressed for a period of 60 seconds, the display will return to the HOME position displaying the process value. Outputs are disabled (turned off) when the Secure Menu is active.

+ 22 hidden pages