Pulsafeeder DLC User Manual

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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.com

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. If the problem is not covered or cannot be solved, please contact your local PULSA Series Sales Organization or our Technical Service Department at (585) 292-8000 for further assistance. Do not open or tamper with your DLC enclosure as this will void the warranty.

Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include purchasing a replacement unit or returning the DLC to the factory for inspection and repair. All returns require a Return Material Authorization (R.M.A.) number to be issued by Pulsafeeder. Replacements purchased under a possible warranty situation may be credited after an examination of the original DLC by Pulsafeeder personnel.

Certain components may be purchased for replacement. Refer to Section 15 – Spare Parts for more information and part numbers. Parts purchased to correct a warranty issue may be credited after examination of the original parts by Pulsafeeder personnel. Parts returned for warranty consideration that test satisfactorily, will be sent back to the originator freight collect.

Any field modifications will void the Pulsafeeder DLC warranty. Out-of-warranty repairs will be subject to Pulsafeeder's standard bench fees and testing costs associated with replacement components.

DLC LIMITED WARRANTY

The manufacturer warrants the DLC, microprocessor -based controller against defects in materials or workmanship for a period of one year under normal use from date of shipment. The manufacturer's liability is limited to the repair or replacement of any failed component which is proven defective in material or workmanship upon manufacturer's examination. This warranty does not include removal or installation costs and in no event shall the manufacturer's liability exceed the selling price of such equipment.

This warranty does not extend to damage by corrosion, erosion, mishandling, any force of nature or any other conditions beyond the seller's reasonable control.

The manufacturer disclaims all liability for damage to its products through improper installation, maintenance, use or attempts to operate such products beyond their functional capacity, intentionally or otherwise or any unauthorized repair. The manufacturer is not responsible for consequential or other damages, injuries or expenses incurred through the use of its products.

The above warranty is in lieu of any other guarantee, either expressed or implied. The manufacturer makes no warranty of fitness or merchantability. No agent of ours is authorized to make any warranty other than the above.

FCC Warning

This equipment generates and uses radio frequency energy. If not installed and used properly, in strict accordance with the manufacturer’s instructions, it may cause interference to radio communications. Operation of this equipment in a residential area is likely to cause interference in which case the user, at his own expense, will be required to take whatever measures necessary to correct the interference.

reproduced, stored in a retrieval system or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser’s personal use without the written permission of Pulsafeeder, Inc.

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Table of Contents

1. INTRODUCTION................................................................................................................................1

1.1 Description.........................................................................................................................1

1.2 DLC Standard Features......................................................................................................2

1.3 Options...............................................................................................................................2

1.4 Accessories........................................................................................................................2

2. SAFETY CONSIDERATIONS ...............................................................................................................3

2.1 General Safety....................................................................................................................3

2.1.1 Explosive Atmosphere Safety....................................................................................3

2.1.2 Electrical Safety..........................................................................................................3

2.1.3 Mechanical Safety.......................................................................................................3

2.1.4 Hydraulic Safety .......................................................................................................... 3

3. EQUIPMENT INSPECTION ..................................................................................................................4

4. STORAGE INSTRUCTIONS .................................................................................................................4

4.1 Storage Length...................................................................................................................4

4.1.1 Short Term (0 - 12 months).........................................................................................4

4.1.2 Long Term (12 months or more).................................................................................4

5. INSTALLATION ................................................................................................................................5

5.1 Location..............................................................................................................................5

5.2 Installation Notes ...............................................................................................................6

5.3 Electrical Wiring.................................................................................................................6

5.3.1 Getting Started............................................................................................................7

5.3.2 Finding your way around the Field Wiring Board......................................................8

5.4 High Voltage Connections.................................................................................................9

5.4.1 Supply Power..............................................................................................................9

5.4.2 PULSAR Motor............................................................................................................11

5.4.3 Alarm Relay.................................................................................................................12

5.5 Low Voltage Input Connections ........................................................................................12

5.5.1 Analog Inputs..............................................................................................................13

5.5.2 Alarm Input .................................................................................................................. 14

5.5.3 Level Input (Remote Start/Stop).................................................................................14

5.6 Low Voltage Output Connections......................................................................................15

5.6.1 Current Output............................................................................................................16

5.6.2 Alarm Dry Contact Output..........................................................................................16

5.6.3 Digital Output..............................................................................................................17

5.7 Tachometer Input (optional) ..............................................................................................17

5.8 Motor Thermostat...............................................................................................................19

5.9 Serial Communications Input............................................................................................19

5.10 Fuse Replacement..............................................................................................................21

6. START UP INSTRUCTIONS ................................................................................................................22

6.1 Overview.............................................................................................................................22

6.1.1 User Interface Familiarization.....................................................................................22

6.1.2 Check Wiring and Close Access cover......................................................................24

6.1.3 Confirm Correct Incoming Power...............................................................................25

6.1.4 Confirm Display and Keypad functionality................................................................25

6.1.5 Performing a Factory Re-initialization........................................................................26

6.1.6 Test Pump Motor.........................................................................................................27

6.1.7 Set Time & Date...........................................................................................................28

6.1.8 Flow Calibration (1-point)...........................................................................................29

6.1.9 Analog Input Calibration.............................................................................................30

6.2 Wrapping up.......................................................................................................................30

7. GENERAL OPERATION .....................................................................................................................31

7.1 General Operation Instructions.........................................................................................31

7.1.1 Pump Flow Calibration ...............................................................................................31

7.1.2 Analog Input Signal Calibration .................................................................................35

7.1.3 Reverse Acting Analog Input Signal Calibration.......................................................37

7.1.4 Analog Output Signal Calibration ..............................................................................38

7.2 Menu...................................................................................................................................39

7.2.1 Alarm, and Error messages........................................................................................40

7.2.2 Diagnostics .................................................................................................................41

7.2.3 Set Time & Date...........................................................................................................43

7.2.4 Analog Signal Failure Set Up......................................................................................45

7.2.5 MODBUS Signal Failure Setup ...................................................................................47

7.2.6 Leak Detection Failure Set Up....................................................................................48

7.2.7 Level / Remote / Start – Stop Set Up ..........................................................................49

7.2.8 Digital Output Set Up..................................................................................................52

7.2.9 Motor Thermostat Set Up............................................................................................54

7.2.10 Over Temperature Set Up ...........................................................................................55

7.2.11 Power Failure Set Up ..................................................................................................56

7.2.12 Alarm Relay.................................................................................................................57

7.2.13 Analog Mode...............................................................................................................57

7.2.14 MODBUS Mode............................................................................................................58

7.2.15 Security .......................................................................................................................60

7.2.16 Number Format...........................................................................................................61

7.2.17 Contrast Adjust...........................................................................................................62

7.2.18 Serial Communications ..............................................................................................62

7.2.19 Serial Diagnostics.......................................................................................................65

7.2.20 Language.....................................................................................................................67

7.2.21 Factory Default Settings.............................................................................................67

7.3 Units....................................................................................................................................68

7.4 Varying the Flow Rate - Manually......................................................................................69

7.5 Mode...................................................................................................................................69

7.6 Batch...................................................................................................................................69

7.6.1 One Time Only.............................................................................................................69

7.6.2 Repeating ....................................................................................................................70

7.6.3 Overlapped..................................................................................................................70

8. DIAGRAMS: INSTALLATION / COMPONENT .........................................................................................74

9. SPECIFICATIONS .............................................................................................................................77

10. FACTORY DEFAULT VALUES ............................................................................................................80

11. T ROUBLE SHOOTING GUIDE .............................................................................................................83

11.1 System Diagnostics...........................................................................................................83

11.1.1 Encoder Diagnostics...................................................................................................89

11.1.2 Tachometer Troubleshooting.....................................................................................90

11.1.3 Tachometer Upgrade Adjustment Instructions .........................................................91

12. CONVERSION (MANUAL TO DLC)......................................................................................................92

13. GENERAL REPAIRS .........................................................................................................................94

13.1 Emergency Manual Pulsar Operation................................................................................94

13.2 DLC Replacement...............................................................................................................95

14. PULSANET SPECIFICATION ..............................................................................................................102

14.1 Introduction........................................................................................................................102

14.2 Operational Overview.........................................................................................................102

14.3 MODBUS Messaging..........................................................................................................103

14.4 PulsaNet DDE Server Messaging ......................................................................................103

14.5 Coils....................................................................................................................................104

14.6 Input Bits (1x references)...................................................................................................104

14.7 Input Registers...................................................................................................................105

14.8 Holding Registers...............................................................................................................105

15. MODBUS MODE............................................................................................................................111

15.1 Introduction........................................................................................................................111

15.2 General Discussion ............................................................................................................ 111

16. SPARE PARTS ................................................................................................................................112

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. These “Tips” are drawn from the knowledge and experience of our staff engineers, and input from the field.

This is a procedure heading. A Procedure Heading indicates the starting

point for a procedure within a specific section of this manual.

1. Introduction

The DLC is a microprocessor based stroke lengt h 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 Description

The DLC is an electromechanical servo controller dedicated to the PULSAR diaphragm metering pump series. The unit is physically attached and integrated into the pump's design. It's purpose is to precisely adjust output flow of a process media by means of stroke length positioning.

The DLC is designed for the international industrial market. The device is factory configured and calibrated for the attached pump. The man/machine interface is user friendly. Local setup and control is achieved through the nine button keypad and a back-lit two-line liquid crystal display. Basic operation is simple with dedicated function keys eliminating the need for a sophisticated menu system. The DLC responds immediately to user commands. Pump output is displayed as a percentage of stroke length position or in units of calibrated flow: CMH, GPH, LPH, CCH, CMM, GPM, LPM, CCM. In addition, the DLC display supports any one of four languages : English, French, German, or Spanish.

Analog signals and MODBUS™ serial communications offer flexible remote control. They are fully isolated -- from each other as well as earth ground -- for improved protection and reliability. A Batch feature, with up to three independent programs, supplements the control features and allows for greater flow turndown.

The DLC is designed to simplify and automate the calibration of pump flow and analog signals. Flow calibration uses on-screen prompting, automated pump operation, and automatic curve fitting to eliminate stop-watches, calculators and human inaccuracies. Analog signal calibration is also accomplished by simple key-pad entry. It includes a real-time display of signal level. This eliminates the need for external meters.

The DLC readily accepts PULSAlarm® leak detection and drum level inputs. These may be configured to stop the pump and/or activate an alarm relay. Failures are time and date stamped into memory for later retrieval. Other diagnostics include analog signal failure and line power failure. These are time and date stamped as well and may be preset to control stroke position or motor status upon detection of a failure.

1.2 DLC Standard Features

• Manual Stroke Length Control

• Keypad

• Back-lit 2 line 16 character LCD display

• NEMA 4X Enclosure

• 4-20mA input for stroke length control

• 4-20mA output

• MODBUS RS-485 Serial Communications

• 10-Year Battery Backed Clock

• Solid State Alarm Relay

• Level Input/Remote Start-Stop Inputs

• PULSAlarm Leak Detection Interface

• Diagnostics

1.3 Options

− NEMA 7 Enclosure

− Operating Voltage/Frequency

− DC Motor Speed Control

Security password protection may be activated to prevent unwanted tampering. All settings and diagnostics have a battery back up for up to 10 years in the absence of power.

The DLC is available in any combination of 120/240 VAC, 50/60 Hz. Protection exists to prevent damage against over or under voltage conditions in the event the wrong line source is used.

1.4 Accessories

PulsaNet MODBUS DDE Server

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.

2.1 General Safety

The DLC was designed as a stroke length position actuator for operation solely with the PULSAR metering pump. Use for any other application is considered un-safe and voids all certification markings and warranties.

2.1.1 Explosive Atmosphere Safety

Explosion Hazard -- Do not perform installation or maintenance of any kind on this device while circuit is live and/or the area is known to be hazardous.

With the proper marking, this equipment is suitable for use in Class I, Division 2, Groups C & D; Zone 2, Groups IIA and IIB or non-hazardous locations only.

2.1.2 Electrical Safety

The DLC can be considered an industrial stroke length. Improper application and use can be hazardous. You are solely responsible for its use.

The DLC's electrical installation must conform to all relevant electrical codes. Installation and electrical maintenance must be performed by a qualified electrician. Before installing or servicing this device, all power must be disconnected from the source at the main distribution panel.

The DLC emits electro-magnetic energy and generates radio frequency interference. Its use is restricted to industrial applications. You are responsible for shielding this energy/interference.

2.1.3 Mechanical Safety

When properly installed, the device has only one externally accessible moving part – the hand adjustment knob. This component is under computer control and as such may actuate without warning. Care should be taken to keep loose clothing away from this component. Hands and fingers should be kept clear while the knob is turning under DLC control.

The DLC was designed to be service free. It contains no user-maintainable components. Removal of the entire DLC as an assembly from the pump is permissible. Do not disassemble the DLC enclosure unless instructed to do so in Section 13 of this manual. Evidence of unauthorized disassembly shall void the warranty.

2.1.4 Hydraulic Safety

Thoroughly review and adhere to the contents of the PULSAR Installation, Operation, Maintenance and Instruction manual (Bulletin No. PMP-IOM-96) for hydraulic installation of your PULSAR metering pump. As a microprocessor controlled device, the DLC may activate the pump motor without warning – generating hydraulic pressure and fluid flow. Care should be taken to protect both users and systems should the pump activate.

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

4.1.1 Short Term (0 - 12 months)

The DLC 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.

The adjustment knob should be rotated in alternate directions by hand one full revolution every six months.

If the DLC is installed on the pump, it should not be removed during this period – provided the above conditions can be applied to the pump as well. If the DLC is removed from the pump, it should be stored in the same pump mounted orientation. After removal of the DLC from the PULSAR metering pump, seal the eccentric box opening with a dust and moisture proof material. If the DLC was shipped in its own carton, it should be stored in that carton.

4.1.2 Long Term (12 months or more)

Storage of the DLC for periods of longer than twelve months is not recommended. If extended storage is unavoidable the DLC should be stored in accordance with those conditions stipulated for Short Term Storage. In addition, a porous bag of 85g (3 oz) silica gel or similar desiccant should be placed beneath the wiring access cover. The cover should be re-installed to seal the desiccant within the enclosure. The three conduit connections must be tightly capped.

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. It details system related issues that are important to proper operation of the PULSAR metering pump. Consider the following DLC related issues when selecting a site. The DLC should be mounted in an area where the operator has access to the front of the unit and a clear view of the display panel and keyboard. Avoid locations where the DLC would be subjected to extreme cold or heat. Note the warning statement on the next page. The installation of this device must comply with national, state and local codes.

Figure 1 – Typical Installation.

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. Do not make any electrical connections (high or low voltage) without adequately grounding the DLC and the worker to eliminate an electro-static charge between the two. A conductive wrist strap worn by the worker and attached to the DLC enclosure is adequate to satisfy this requirement.

2. Calibration is an important element of successful DLC operation. Permanent installation of a calibration column as depicted in Figure 1 is strongly recommended.

3. Conduit connections can carry fluids and vapors into the DLC causing damage and void the warranty. Care should be taken when installing conduit to protect against fluid/vapor entry. If necessary, provide sealed entries or conduit drains near the point of entry.

5.3 Electrical Wiring

The DLC 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 a majority of the DLC's features. It is highly recommended that you take a step-by-step approach to wiring and confirming proper DLC operation:

1. Make the high voltage connection. These will allow you to operate the DLC and attached PULSAR pump.

2. Power-up and test the DLC to confirm the connections and check for proper operation.

3. Power-down the DLC.

4. Decide which low voltage Inputs (e.g., 4-20mA in) will be used and make those connections.

5. Power-up and test the DLC to confirm the connections and check for proper operation.

6. Power-down the DLC.

7. Decide which low voltage Outputs (e.g., 4-20mA out) will be used and make those connections.

8. Conduct a final power-up and test the DLC to confirm the connections and check for proper operation.

9. Go to the Section 6 – Start Up Instructions for details on how to perform the power-up tests.

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. The DLC is marked internally with the Serial Number. The internal marking will be used for warranty claims.

The Field Wiring Board (refer to Figure 2) contains wiring blocks for making all of the electrical connections. It is mechanically attached to the Conduit Adapter. The adapter in conjunction with the Field Wiring Board form a modular connector or plug. This allows the DLC to be removed from the PULSAR unit without disturbing the conduit connections.

REMOVE THE CONDUIT ADAPTER AND FIELD WIRING BOARD FOR DLC REPAIR/REPLACEMENT

PURPOSES ONLY (REFER TO SECTION 12 – BASIC REPAIRS) FOR FURTHER INFORMATION.

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. Field Wiring Board

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.

5.4.1 Supply Power

THE DLC REQUIRES ONE CONNECTION TO AN EXTERNAL POWER SOURCE. IT USES THIS SAME

CONNECTION TO POWER ITS OWN SUPPLY, THE SINGLE PHASE PUMP MOTOR (OR MOTOR STARTER RELAY) AND THE ALARM RELAY OUTPUT. YOU MUST TAKE THESE EXTERNAL LOADS INTO CONSIDERATION WHEN SIZING THE BRANCH CIRCUIT.

The DLC power supply and attached PULSAR motor are not fuse protected. You are responsible for correctly sizing the protection element (i.e., fuse or circuit breaker at the distribution panel). Use the work sheet on the next page for correctly sizing the branch protection element.

Figure 4 – High Voltage Connections

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.

115VAC +/- 10% 50/60Hz 230VAC +/- 10% 50/60Hz

Device Current Requirement (Amp) Device Current Requirement (Amp)

DLC 1A (1A Max.) DLC .5A (.5A Max.) Pump Motor* + (8A Max.) Pump Motor* + (4A Max.) Alarm Relay* + (1A Max.) Alarm Relay* + (1A Max.) Total ** = Total ** = * In-rush current requirements should be considered. All values RMS. ** Calculation is for guideline purposes only. User must consult local electrical codes when sizing branch

circuits. Protection must not exceed 10Amps RMS at 115VAC or 5.5Amps RMS at 230VAC.

Branch Circuit Protective Element Sizing Worksheet.

The operating voltage and frequency of the DLC are factory configured – an internal motor and capacitor are sized according to voltage and frequency. If the power supplied to the unit does not match the factory configuration, the DLC will display either an {OVER VOLTAGE} or {UNDER VOLTAGE} diagnostic message on power-up. This is possible because the microprocessor and display are powered by a switching power supply. It detects the incoming power and self-regulates its output. This power supply is protected by a 7.4 Joule surge suppression device. The microprocessor will not operate the internal stroke adjustment motor, potentially causing damage, until the voltage problem is corrected.

HIGH VOLTAGE CIRCUITS (E.G., BRANCH) SHOULD BE RUN IN SEPARATE CONDUIT. DO NOT

COMBINE HIGH VOLTAGE (I.E., GREATER THAN 100VAC) LINES AND LOW VOLTAGE (I.E.,

LESS THAN 32VDC) LINES IN A COMMON CONDUIT! FAILURE TO COMPLY WILL RESULT IN ELECTRICAL INTERFERENCE THAT MAY RESULT IN IMPROPER (AND POSSIBLY UNSAFE) OPERATION.

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). IN THE 'OFF' STATE, THESE DEVICES TYPICALLY LEAK 20-30MA OF CURRENT AT THE SUPPLY VOLTAGE TO THE ATTACHED DEVICE (OR TERMINAL BLOCK)! THE SUPPLY POWER MUST BE DISCONNECTED AT THE MAIN BEFORE WORKING ON ELECTRICAL CONNECTI ONS OR ANY MOVING PUMP COMPONENTS (E.G., MOTOR, GEAR TRAIN, ETC.).

DOUBLE CHECK ALL CONNECTIONS TO CONFIRM GOOD ELECTRICAL CONTACT BETWEEN THE

TERMINAL BLOCK CLAMP AND BARE WIRE. MAKE SURE THE CLAMP IS ON THE WIRE, NOT THE INSULATION. INSURE THAT BARE WIRE IS NOT FRAYED AND DOES NOT RISE ABOVE DIVIDERS.

If the PULSAR pump motor is controlled by a Variable Speed Drive (e.g., DC Drive), the Variable Speed Drive must be powered by the DLC. Wire the Variable Speed Drive to J3. Wire the PULSAR motor to the Variable Speed Drive in accordance with the Variable Speed Drive manufacturer's instructions. Refer to Section 8 – Diagrams: Diagram 2 for recommended wiring.

If the PULSAR pump motor or Variable Speed Drive operates at a voltage different than that supplied to the DLC or is a three-phase motor, then a motor starter must be used. Wire the motor starter relay to J3. Wire the PULSAR motor or Variable Speed Drive to the motor starter in accordance with the starter manufacturer's instructions. Refer to Section 8 – Diagrams: Diagram 2 for recommended wiring.

DAMAGE MAY OCCUR TO THE DLC IF THE PULSAR PUMP MOTOR IS NOT WIRED AND

COMMUNICATING WITH THE DLC.

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., 4-20mA) and Dry Contact. The Low Voltage Input connection block is labeled J4 'INPUT' (refer to Figure 5). It contains three pairs of inputs: Current 1, Alarm and Level.

Figure 5 – Low Voltage Input

THE DRY CONTACT INPUTS ARE SELF-POWERED. SUPPLY ONLY A MECHANICAL SWITCH

CLOSURE TO ACTIVATE. DO NOT ATTACH EXTERNALLY POWERED CIRCUITRY.

THE WIRE USED TO CONNECT LOW VOLTAGE INPUTS, AND SERIAL COMMUNICATIONS SHOULD

BE RUN IN A CONDUIT SEPARATE FROM THE HIGH VOLTAGE POWER. DO NOT COMBINE HIGH

VOLTAGE (I.E., GREATER THAN 100VAC) LINES AND LOW VOLTAGE (I.E., LESS THAN 32VDC)

LINES IN A COMMON CONDUIT! FAILURE TO COMPLY WILL RESULT IN ELECTRICAL INTERFERENCE THAT MAY RESULT IN IMPROPER (AND POSSIBLY UNSAFE) OPERATION.

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.

Split-ranging, reverse acting, and ratio control are accomplished in the calibration routine in Section 7 – General Operation. No hardware adjustments are required. The channel is electrically isolated, surge protected and fused for protection. The input is designed to avoid damage in the event high voltage is inadvertently applied.

To make the Analog Signal connection, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire for hookup. Attach the analog signal generated by an external device (e.g., PLC) to the connection points labeled '1CURRENT1(+)' and '2-CURRENT1(-)' on the J4 terminal block labeled 'INPUT' (refer to Figure 5). Attach the Positive lead to position 1 and the Negative lead to position 2.

Position indicators are printed on the circuit board above the terminal. The DLC will provide approximately 200 ohms of resistance to a current loop. The Analog Input is isolated from all other inputs, outputs and earth ground. Follow the instructions in Section 7 – General Operation for Analog Input signal calibration and set-up.

5.5.2 Alarm Input

The Alarm Dry Contact Input is designed to op erate 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. Attach one side of the switching device to the position labeled '3-ALARM(+)' and the other side to the position labeled '4-ALARM(-)' of connector J4-INPUT (refer to Figure 5). A resistance of 15K ohms or less is required across the two connections for proper detection. Follow the instructions in Section 7 – General Operation for Alarm Input (Leak Detection) software set-up.

5.5.3 Level Input (Remote Start/Stop)

The Level Dry Contact Input is designed to monitor a single-point Level Input sensor and generate an alarm, activate the alarm relay and/or shut down the PULSAR motor. It can also be used with a Remote Start/Stop station (Dry Contact switch) to start and stop the pump’s motor. The input is internally powered, only a mechanical switch closure is required for activation. Use 0.32mm2 –

0.52mm2 (22-20 AWG) wire. Attach one side of the switching device to the position labeled '5LEVEL(+)' and the other side to the position labeled '6-LEVEL(-) of connector J4-INPUT (refer to Figure 5). A resistance of 15K ohms or less across the two terminals is required for proper detection. Follow the instructions in Section 7 – General Operation for Level / Start-Stop set-up.

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).

THE WIRE USED TO CONNECT LOW VOLTAGE INPUTS, OUTPUTS AND SERIAL COMMUNICATIONS

SHOULD BE RUN IN A CONDUIT SEPARATE FROM THE HIGH VOLTAGE POWER. DO NOT COMBINE HIGH VOLTAGE (I.E., GREATER THAN 100VAC) LINES AND LOW VOLTAGE (I.E., LESS

THAN 32VDC) LINES IN A COMMON CONDUIT! FAILURE TO COMPLY WILL RESULT IN ELECTRICAL INTERFERENCE THAT MAY RESULT IN IMPROPER (AND POSSIBLY UNSAFE) OPERATION.

Figure 6 – Low Voltage Output

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. Attach the connection points labeled '1-CURRENT(+) and '2CURRENT(-)' on connector J5-OUTPUT (refer to Figure 6) to the external device. Use 0.32mm2 –

0.52mm2 (22-20 AWG) wire. Attach the Positive lead to position 1 and the Negative lead to position 2. The analog output will drive against a maximum load of approximately 700 ohms. Thus, a single DLC Analog Output could be used to drive two slave DLC's. They, in turn, could each drive two additional slaves. The Analog Output is isolated from all other inputs, outputs and earth ground. Follow the instructions in Section 7 – General Operation: Analog Output Signal Calibration.

5.6.2 Alarm Dry Contact Output

The Alarm output is a solid state transistor closure. It indicates the present state of the alarm relay output. If the Alarm Relay is on, the Alarm Dry Contact will be closed. If the Alarm Relay is off, the Alarm Dry Contact will be open. It is commonly used to indicate an alarm status to external control equipment (i.e., PLC, PC or other Manual controllers). Refer to Figure 6.

VCC (+5VDC) and Ground are provided on terminals 7 and 8 of connector J5. A 250 ohm resistor from terminal '7-VCC' to terminal '3-ALARM(+)' will cause a +5VDC signal to appear between

terminals '4-ALARM(-)' and '8-DCGND' when the Alarm Relay is on. This technique is only recommended if the input on the external device is isolated from all other inputs, outputs and grounds.

An opto-coupler is used to achieve total isolation of this output. As such, the external control equipment must generate the supply on the positive output and detect the return of that signal from the DLC. In a typical application, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire to attach the terminal labeled '3-ALARM(+)' – the collector terminal – to the external equipment's logic supply. Connect the terminal labeled '4-ALARM(-)' – the emitter terminal – to the positive input of the equipment. The negative input of the equipment should be connected to its isolated ground. A series resistance of 400 ohms is recommended – especially when sinking current (e.g., a photo-diode of an opto-isolator). The Alarm output cannot be separately configured in the software, it follows the Alarm Relay output.

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).

c) Mode Indication (Manual, Analog, or MODBUS) An opto-coupler is used to achieve total isolation of this output. As such, the external control

equipment must generate the supply on the positive output and detect the return of that signal from the DLC. In a typical application, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire to attach the terminal labeled '5-STATUS(+)' – the collector terminal – to the external equipment's logic supply. Connect the terminal labeled '6-STATUS(-)' – the emitter terminal – to the positive input of the equipment. The negative input of the equipment should be connected to its isolated ground. A series resistance of 400 ohms is recommended – especially when sinking current (e.g., a photo-diode of an opto-isolator).

There is also an internal stroke counter that is re-settable. Refer to Section 7.2 - Menu – Diagnostics – Diag. Menu 11/11.

5.7 Tachometer Input (optional)

The Tachometer Sensor is connected to the Tachometer Input. It senses motor rotation. This input allows the DLC to count pump strokes if so equipped.

Figure 7 – Tachometer Sensor Conduit Assembly

(

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).

For additional information relating to the Tachometer Sensor, refer to Section 13 – Repairs: DLC Replacement.

The Tach input is designed for use with the supplied sensor only. Do not attempt to use any other device (e.g.: motor based tachometer outputs).

It is permissible to run the pump motor thermostat in the same conduit as the pump motor power. The signal is conditioned to prevent erroneous operation due to cross-talk.

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.

For more information about the Motor Thermostat settings, refer to Section 7 – General Operation: Motor Thermostat Setup .

To connect the Motor Thermostat to the DLC, connect the two thermostat wires (typically these wires are a smaller gauge wire) coming from the pump motor to the connection point labeled ‘3–THERM [+]’ and ‘4–THERM [-]’ on connector J–10 CONTROL (refer to Figure 8).

5.9 Serial Communications Input

The Serial Communications input is used to communicate digitally with the DLC. It allows remote control and, if so configured, can be used to replace the analog input and output to allow one or more DLC’s to be slaved to a single DLC, DLCM, PLC, or PC master.

Figure 9 – Typical Serial Communications Connections

Use Belden™ Type 1590A data twist cable or equivalent. RJ-11 connectors (not supplied) are used to plug into jacks J7 & J8 (refer to Figure 9).

The DLC uses a 4-wire RS-485 network. This uses two wires for transmit and two wires for receive. The RS-485 specification limits the total network length to 1200M (4000 ft). It also requires termination resistors at both the first and last device.

Line Terminators can be constructed according to the drawing above.

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).

Figure 10 – Wiring Detail

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. The table below details fuse replacement information:

Designator Function Rating Wickman P/N Pulsafeeder P/N

F1 Alarm Relay 1A @ 250VAC WK4048-ND NP5300026-000 F2-7 Current I/O 50mA @ 250VAC WK3022-ND NP5300027-000

Figure 11 details the location of these fuses on the Field Wiring Board.

Replacement Fuse Information

Figure 11. – Fuse Location.

The Internal DLC power supply is fused at 2 Amps. This fuse is not user serviceable. The DLC Stroke Length Adjustment Synchronous Motor is inherently protected. It can operate continuously in a locked rotor state. The DLC also monitors this motor's duty cycle to maintain a 50% balance between ON and OFF times. The serial ports and the Remote Run Status Output are protected by self-resetting current limit devices. These components are not user serviceable.

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. YOU ARE RESPONSIBLE FOR SAFELY DIVERTING FLOW FROM THE PUMP DURING START-UP AND CALIBRATION.

6.1.1 User Interface Familiarization.

There are four key elements that will be useful in starting-up the DLC: a) Display

b) Keypad c) Manual Adjustment Knob d) Pump Motor. Refer to Figure 12 to familiarize yourself with the location of these items before proceeding.

Figure 12. – Key DLC start-up elements.

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.

MOTOR MENU

UNITS

ARROWS

ENTER

BATCH

CAL

MODE

Figure 13 – Key Pad

Press this key to Start the PULSAR motor or place it in stand-by. Press this key to access the Configuration Menu. Press the ARROW keys to scroll

through the Configuration Menu Items. Press [MENU] a second time to exit the Configuration menu to the current operating mode (e.g., MANUAL MODE).

Press this key to cycle to the next flow unit type whenever a flow unit is displayed at

the operating mode (e.g., MANUAL MODE).

These keys are used to change values currently displayed on screen. Use [DOWN]

to decrease the value and [UP] to increase it. Pressing both [UP] and [DOWN] simultaneously performs special editing and by-pass functions. This is described further in Section 7 – General Operation.

Use this key to accept a flashing value or parameter and proceed to the next sub-

menu screen.

This key is used to activate the [BATCH] processing menu. Press [BATCH] a second

time to exit the Batch Setup function.

Press [CAL] to activate the Calibration menu for Flow and Analog Signals. Press

[CAL] a second time to exit the Calibration function.

The [MODE] key is used to change the operating mode of the DLC. For example,

press once to change from MANUAL to ANALOG. Press a second time to change from ANALOG to MODBUS. Press a third time to change from MODBUS back to MANUAL.

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.

If you manually adjust the knob while performing a pump calibration, the calibration session will be terminated.

While in the Analog Signal, MODBUS Mode or while under Batch Control– any attempts you make to change the stroke setting using the Manual Control Knob to a value other than that specified by the remote signal will cause the DLC to make a correction.

The Manual Adjustment Knob should not be adjusted while power is removed from the DLC. If the knob is moved while the DLC power is out, upon re-starting, the DLC will detect the movement and perform a Zero Calibration .

WHEN THE DLC IS PERFORMING A ZERO CALIBRATION (THE DISPLAY WILL READ {CALIBRATING ZERO}), DO NOT TO TOUCH THE MANUAL ADJUSTMENT KNOB. DURING A ZERO CALIBRATION THE DLC IS SEARCHING FOR A HARD MECHANICAL STOP. ANY MANUAL

INTERVENTION COULD CAUSE THE DLC TO INCORRECTLY DETECT THIS STOP. THIS WILL RESULT IN AN IMPROPER CALIBRATION.

You may notice that when adjusting from a lower to a higher value (e.g., 10% to 20%) the DLC appears to 'over-shoot' its destination and reverse direction for approximately 1/16 of a revolution. This behavior is normal. The DLC always approaches a new position from the same direction to

eliminate backlash in the stroke adjustment mechanism.

6.1.2 Check Wiring and Close Access cover

Double check all of your electrical connections. Pay attention to polarity of all inputs and outputs – both low and high voltage. Additionally, insure that all clamp style terminals are clamping onto the bare conductor, not on its insulation.

Replace the wiring access cover and its 4 retaining screws with associated washers.

Use a screwdriver to tighten the retaining screws evenly. Failure to do so may cause the cover to leak and void the Warranty. The supplied teflon washers are required to properly seal this cover. Failure to replace these components will void the warranty.

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.

WITHOUT PRIOR OPERATING KNOWLEDGE, IT IS IMPOSSIBLE TO TELL IF THE PULSAR MOTOR

WILL RUN WHEN POWER IS APPLIED TO THE DLC. YOU ARE RESPONSIBLE FOR TAKING THE NECESSARY STEPS TO ENSURE THAT ALL ASPECTS OF SAFETY HAVE BEEN CONSIDERED (E.G., ELECTRICAL, HYDRAULIC, ETC.). IF IN DOUBT, DISCONNECT THE MOTOR FROM J3 PRIOR TO APPLYING POWER.

The DLC detects any adjustments made to manual adjustment knob while its power is off. If it detects that the knob position has been changed, it will perform a zero calibration when the motor is started. This action is normal.

Turn on power at the main. If the DLC's incoming power is connected correctly, the back-lighting on the DLC's display will illuminate (depending on lighting conditions, it may be necessary to shade the display to confirm illumination). If the display is not illuminated, first check the line voltage with a volt meter. If the voltage is not correct, return to Section 5 – Installation: High Voltage Connections. Otherwise, proceed with the next step.

6.1.4 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 DLC is receiving power, it is necessary to confirm that the display and keypad are functioning properly. On normal power-up, the {SELF-TEST} display appears for approximately 5 seconds.

SELF-TEST

B123 1.24

After that time, the display will change the message to one of the following:

TURN MOTOR ON

CALIBRATING ZERO

BATCH#1 RUNNING

10.0%

- or -

At this time, the actual message is not important, the characters should be visible and form a reasonable message.

If the display is blank (no-characters) then the display contrast must be adjusted. This is accomplished by pressing and holding [MENU] while simultaneously pressing [UP]. This will darken the display. Be patient! You may have to hold both keys down for as long as 30 seconds before the characters will become visible. If the display is too dark, press [MENU] and [DOWN] simultaneously to decrease (lighten) the contrast. Once the contrast is properly adjusted, check the message displayed. If it does not look similar to one of those shown above, proceed directly to the next section to perform a Factory Re-initialization on your DLC.

PLEASE WAIT

CALIBRATING ZERO

MOTOR STOPPED

- or -

10.0%

MANUAL MODE

- or -

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. If the stroke adjustment knob is not moving, at least one key on the key pad should cause the text on the display to change. Go to Section 6.1.6. If this is not the case, refer to Section 11 – Trouble Shooting.

6.1.5 Performing a Factory Re-initialization

When Re-initializing your DLC, all of the system settings will be overwritten by the original factory default settings. The controller must be re-configured to your specifications (e.g., re-calibrated).

If your DLC appears to be functioning properly – the display is similar to one of those shown on the previous page – skip to Section 6.1.6.

A Factory Re-initialization restores all factory defaults to the DLC's memory, and typically is not required.

A Factory Re-initialization should be performed only if there is reason to believe that the internal DLC memory has become corrupted. A number of factors could cause this including: long-term storage, disregard of electrostatic precautions (refer to Section 2 – Safety) during installation, improper wiring, voltage surges, etc. The condition usually manifests itself with inconsistent or erratic operation – often associated with characters on the display. Depending on the state of your DLC, use one of the following procedures:

v Start-up Factory Re-Initialization:

Use this procedure when you cannot read the display, or if the DLC does not seem to be responding to your key presses:

1. Cycle power to the unit (turn it OFF then ON).

2. Within the first 5 seconds of power on, depress and hold the [UNITS], [MODE], and [ENTER] keys simultaneously for approximately 1 second.

3. The display will continue to display the version number while the DLC’s memory is restored. The display will then show {TURN MOTOR ON / CALIBRATING ZERO}. Return to Section 6.1.4. Confirm the display and keypad are functioning properly.

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]. The {FACTORY DEFAULTS} menu item should be displayed. If not, repeatedly press [DOWN] until it does.

4. Press [ENTER]. The prompt {FACTORY RESET? / NO} is displayed.

5. Press [UP]. The prompt will read {FACTORY RESET? / YES}.

6. Press [ENTER] to accept the {YES} prompt. The prompt {ARE YOU SURE? / NO} is displayed.

7. Press [UP]. The prompt will read {ARE YOU SURE? / YES}.

8. Press [ENTER] to accept the {YES} prompt.

9. The display will read {PLEASE WAIT} for approximately 5 seconds while the DLC’s memory is restored. The display should then display {TURN MOTOR ON / TESTING ENCODER}. Return to Section 6.1.4. Confirm the display and keypad are functioning properly.

6.1.6 Test Pump Motor

The Level Input, PULSAlarm and Signal Loss inputs can be configured to shut the motor down if they are enabled. If this is the case, a message is displayed on the screen indicating the failure. You cannot re-start the motor until these inputs have been corrected or the {Motor Off} option has been

disabled. Refer to Section 7 – General Operation for further information on configuring these options.

To test the PULSAR motor connection, press [MOTOR]. If the motor is running it should stop and the display should read {MOTOR STOPPED} or {TURN MOTOR ON / CALIBRATING ZERO} or {TURN MOTOR ON / TESTING ENCODER} as shown below.

MOTOR STOPPED

If the motor is stopped, press [MOTOR] to start it and set the unit in Operating Mode. The display should then read {MANUAL MODE} or {BATCH#X RUNNING} or {PLEASE WAIT / CALIBRATING ZERO} as shown below.

10.0%

MANUAL MODE

If the display appears as shown above, but the PULSAR motor does not start, return to Section 5 – Installation: High Voltage Connections and check your wiring. If the wiring is correct, refer to Section 11 – Trouble Shooting.

- or -

TURN MOTOR ON

CALIBRATING ZERO

BATCH#1 RUNNING

10.0%

- or -

TURN MOTOR ON

TESTING ENCODER

PLEASE WAIT

CALIBRATING ZERO

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]. The date and time screen is displayed.

4. Press [ENTER] to accept the 24 Hour time setting.

5. Press [UP] or [DOWN] to adjust the hour value displayed to the local time. Press [ENTER].

6. Press [UP] or [DOWN] to adjust the 10 minute value displayed to the local time. Press [ENTER].

7. Press [UP] or [DOWN] to adjust the minute value displayed to the local time. Press [ENTER] twice (to accept the default MM/DD/YY format setting).

8. Press [UP] or [DOWN] to adjust the month value displayed to the current month. Press [ENTER].

9. Press [UP] or [DOWN] to adjust the day value displayed to the current day. Press [ENTER].

10. Press [UP] or [DOWN] to adjust the year value displayed to the current year. Press [ENTER] twice (accepting the default Daylight Savings NO setting).

The time and date information has now been set.

-MENU-

DIAGNOSTICS – 0

Press [UP]

-MENU-

SET TIME & DATE

Press [ENTER]

24 HR MM/DD/YY 21:07 1/22/01

Refer to Section 7 – General Operation: Set Time & Date for more detailed instructions on how to set the Time and Date information.

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. Press [UNITS] repeatedly until a unit that is consistent with your flow measurement device (i.e., calibration column) appears. For example, if your column reads in Gallons then set the display to GPM or GPH. Gallons will be used in this example.

3. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.

4. Press [ENTER]. The {LAST FLOW CAL / 11:32 1/22/01} screen is displayed.

5. Press [ENTER]. The {FLOW CALIBRATION / 1-POINT} screen is displayed.

6. Press [ENTER]. The {CALIBRATE ZERO? / YES} screen is displayed.

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 10.

7. 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.

8. Turn the pump motor on if necessary and the encoder performs its self test. When the self test is completed, the{PLEASE WAIT / CALIBRATING ZERO} screen is displayed. The DLC will adjust the stroke to the 0% position.

9. The {PLEASE WAIT / XX% 100%} screen is displayed. The DLC will adjust the stroke to the 100% position. The PULSAR motor will shut off.

PLEASE WAIT

XX% 100%

10. The {ENTER TO START/ 100% 2.641718 G} screen is displayed. The value '2.641718' represents the amount of fluid discharged over 60 seconds the last time a calibration was performed at the 100% stroke setting. Record the fluid base reading from your calibration column.

11. Press [ENTER]. The PULSAR motor will start to run. A timer is displayed counting down from 60 seconds. After 60 seconds the motor will stop automatically.

TIMER: XX SEC

2.641718 G

12. The {ENTER VALUE 100% / 2.641718 G} screen is displayed. Calculate the measured volume displaced from the calibration column and enter the new value one position at a time using [UP] and [DOWN] to change an individual position. Press [ENTER] to move the cursor to the next position.

13. Pressing [ENTER] on the last position will cause the {CONFIRM CHANGE? / YES} screen to be displayed. Press [ENTER] to accept. Your 1-point calibration is now complete.

Refer to Section7 – General Operation: Calibration, Pump Flow for more detailed instructions on how to perform DLC calibration.

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.

6.1.9.1 Analog Input Calibration

v The following is a minimal procedure for calibrating the Analog Input if the 1 – Signal option is to be

used.

1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.

2. Press [UP]. The {CALIBRATE / ANALOG IN} screen is displayed.

3. Press [ENTER]. The {0% = 4.0mA / 100% = 20.0mA} screen is displayed. These values repres ent the previous calibration.

4. Press [ENTER]. The {INPUT ANALOG MIN / 0% = XXmA} screen is displayed. Adjust your PLC to output a minimum signal (i.e., 4.0mA). The DLC display will update as the incoming signal changes.

5. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT ANALOG MAX / 100% = XXmA} screen is displayed. Adjust your PLC to output a maximum signal (i.e., 20.0mA). Again, the DLC display will update with the changing signal.

6. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT RATIO / 100% = XX.XmA} screen is displayed.

7. Press [ENTER] to accept the 100% Ratio setting. The {CONFIRM CHANGE? / YES} screen is displayed.

8. Press [ENTER]. Analog input calibration is now complete. Refer to Section 7-General Operation: Analog Input Signal Calibration for more detailed instructions

on how to perform Analog Input calibration.

6.2 Wrapping up

Your PULSAR DLC is now commissioned for use. Refer to Section 7 – General Operation for specific instructions on how to access your DLC's advanced features. Please don't be intimidated by your DLC, take time to explore and experiment with its features. Remember, you cannot configure the software in a way that would damage the DLC. Typically, whenever you are about to set a critical value (e.g., Calibrate Flow), you are always prompted to confirm your change before it takes effect. If you are ever dissatisfied with the configuration of your DLC, you can always return to the Factory Defaults by repeating Section 6.1.5.

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. Maintenance re-calibration should be performed periodically – at least every three to four months – to account for component wear. Re-calibration of the pump is also recommended whenever wet-end components are replaced.

The DLC does not automatically compensate for changing system conditions (e.g., discharge pressure, fluid viscosity, etc.). You should re-calibrate whenever the application conditions change.

v Multi-point Calibration Procedure

1. Press [CAL] to enter the Calibration Menu. Press [ENTER] to go to the calibrate pump flow submenu:

CALIBRATE PUMP FLOW

Press

[ENTER]

2. The DLC displays the last time the pump was calibrated. Press [ENTER] to continue with pump flow calibration.

LAST FLOW CAL

3:25 1/22/01

3. The display shows {FLOW CALIBRATION / 1 POINT}. The '1 POINT' text will be flashing.

FLOW CALIBRATION

1 POINT

Press [UP] to change flow calibration to 2 points, 3 points, 4 points or 5 points. The calibration points correspond to the following stroke length values:

1 point: 100% 4 points: 10, 25, 50 and 100% 2 points: 10 and 100 % 5 points: 10, 25, 50, 75 and 100% 3 points: 10, 50 and 100%

A 1 – point calibration should be avoided in applications where the displayed flow rate is critical. For discharge pressures less than 500 psi (34.5 Bar), a minimum 2 – point calibration is recommended. For discharge pressures above 500psi (34.5 Bar) a minimum 3 – point calibration is recommended.

These percentage values correspond to the API standards. If you continue to press [UP] you will also see the following options: {CHANGE CONSTANTS} and {TUNE}. These options are for use after a multi-point calibration has been performed. For a standard multi-point calibration, set the number of calibration points to use and press [ENTER] to continue.

You can "skip" a calibration point by entering a flow value of 0.0000. “Skipping” a point means that it will

be omitted from the mathematical regression to establish the flow curve. Values which are less than 10% of the pumps’ rated output flow should be skipped.

Press

[ENTER]

Press

[UP]

4. Press [ENTER]. The {CALIBRATE ZERO? / YES} screen is displayed.

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. Turn the pump motor on if necessary and the encoder performs its self test. When the self test is completed, the{PLEASE WAIT / CALIBRATING ZERO} screen is displayed.

PLEASE WAIT

CALIBRATING ZERO

7. The DLC will now perform a ZERO CALIBRATION. First, it will turn on its motor. Then it will test the encoder's position by increasing the stroke adjustment mechanism 2%. Then the DLC will adjust in the opposite direction until it reaches the mechanical zero stop (0% stroke setting). This ensures that the positioning mechanism is working properly and calibrations will be accurate. The screen will display one of three messages:

PLEASE WAIT

CALIBRATING ZERO

- or -

TURN MOTOR ON

TESTING ENCODER

- or -

ENCODER ERROR

PRESS ENTER

If the {TURN MOTOR ON…} screen is displayed, start the PULSAR motor by pressing [MOTOR]. The DLC will adjust to the 100% position. If you get the {ENCODER ERROR..} screen, refer to

Section 11 – Trouble Shooting Guide.

8. The following screen is displayed.

PLEASE WAIT

XXX.X% 100%

If you get the {PRESS ENTER / TO START MOTOR} screen, start the PULSAR motor by pressing [ENTER] or [MOTOR].

The XXX.X% represents the current stroke length adjustment setting and 100% is the stroke length destination.

9. Once the destination setting has been reached, the PULSAR motor will shut down and the display will show:

ENTER TO START

2.641718 G

The display is showing the amount of fluid discharged from the pump the last time this operation was performed (e.g., 2.641718 Gallons). This flow rate is based on 60 seconds of pump operation. Fill the calibration column in the system to the proper level to avoid running the pump dry during

calibration.

10. When you are ready, press [ENTER], which will start the pump motor for a period of 60 seconds. The screen will show a 60 second timer and display its count down toward 0 seconds. During this time, the pump is operating at the designated stroke length setting.

TIMER: 60SEC

2.641718 G

If you already know the displaced volume, you can bypass the 60 second timer by pressing [UP] and [DOWN] simultaneously.

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.

If you make a mistake entering the measured flow rate and realize it before pressing [ENTER] on the last position, press [UP] and [DOWN] simultaneously and the cursor is returned to the first digit.

If you would like to "skip" a calibration point, enter a value of 0.

Any measured volume which translates to less than 10% of the maximum rated flow of the pump should be disregarded from the calibration routine. To do this, enter a value of 0.0000.

12. If a 2 through 5 point calibration was selected, the DLC will automatically proceed to the next stroke length setting and repeat steps 9, 10, 11, and 12 as described above. After the DLC has completed the above referenced process for all stroke length settings, it prompts you to accept the data collected in the above referenced steps:

CONFIRM CHANGE?

YES

13. Press [ENTER] to accept the calibration. The DLC will display a {PLEASE WAIT} message while it performs the Least Squares curve fit to the data points and calculates the new flow curve. Any point entered with a value of 0.0000 will be ignored by the curve fitting routine.

If you do not want to accept the new calibration, press [UP] to scroll to {NO} and press [ENTER]. The display is then returned to its original operating mode.

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. The input to this equation (i.e., x) is given in flow (GPM). The output (i.e., y) represents stroke position in percent (%). The units for the constants are given on screen. Values can be calculated from two or more flow readings and associated stroke settings.

3. Press [ENTER] and the display prompts you to enter the slope value:

SLOPE %/GPM

0.3785415569416

You edit the calculated slope value in the displayed units (%/GPM in the example above) value one position at a time. Press [UP] or [DOWN] to set the digit. Press [ENTER] to move to the next digit.

It is possible for the CHANGE CONSTANTS display of numbers to be larger than the 16 character screen. If you have a number that overflows the screen in one direction or the other, a greater than (>) or less than (<) symbol is displayed to indicate this (e.g., <0.37854155694>). Pressing [ENTER] as you edit the number string, moves the cursor one position to the right. Pressing [ENTER] on the last displayed number will shift the display one position to the left. This pattern will continue until the last digit in the string is reached. Press [ENTER] on the last digit to accept your change.

4. The display prompts you to enter the y-intercept.

y-INTERCEPT

0.00%

Use [UP] and [DOWN] to enter the calculated y-intercept value. The value can be positive or negative (typically the value will be positive). Press [ENTER]. The {CONFIRM CHANGE? / YES} menu is displayed. Press [ENTER] to accept your changes. The DLC will convert the constants to the other display units automatically.

The display is then returned to its original operating mode.

v Calibration / Tune Flow procedure.

1. In this sub-menu the flow curve can be shifted to 'tune' the flow to one given point. The reason you might perform this procedure is the process you are currently running is too critical to be shut down to complete a full calibration. The Tune Flow procedure is a quick fix. Before entering the TUNE submenu, you should measure the actual flow rate at a specific stroke setting. For example, the DLC is currently set at 60.0% stroke and it displays a calibrated flow rate of 6.0 GPH. An actual flow measurement is taken and found to be 5.775 GPH. Leaving the stroke setting at 60%, tune the flow rate to 5.775 GPH.

Since the {TUNE FLOW} screen displays flow per minute, the flow per hour will have to be converted:

6.0 GPH / 60 minutes per hour = 0.1 GPM.

5.775 GPH / 60 minutes per hour = 0.09625 GPM

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. The percentage value displayed represents the net pump output. Press [ENTER]. The pump will now display the 5.775 GPH value at the 60.0% stroke setting. Internally, the DLC has retained the slope calculated at the last calibration and has off-set the flow curve to satisfy the current reading requirement.

7.1.2 Analog Input Signal Calibration

The DLC will accept analog input signals of 0-20mA, 4-20mA, 1-5mA, or 1-5 volts. The analog input signal should be calibrated to the system. To perform a calibration, the signal generating device (e.g., PLC) must be powered up, wired to the DLC and capable of altering its output from minimum to maximum signal.

You are calibrating the Analog Input Signal to the percentage of calibrated flow. The 0% and 100% values displayed in this section refer to a percentage of Flow not Stroke Position. For example: In a high pressure application, the PULSAR begins discharging fluid at 10% stroke length. Thus it has

0% flow at 10% stroke. If you calibrate 0% = 4.0mA, and then input a 4.0mA signal the DLC will adjust the stroke length to 10%.

7.1.2.1 Analog Input Calibration

v Use the following procedure to calibrate the Analog Input:

The Analog Input controls the DLC Calibrated Stroke Length. For more information about the Analog Input signal, refer to Section 7.2.15 Analog Mode.

1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.

CALIBRATE PUMP FLOW

2. Press [UP] to scroll to the {CALIBRATE / ANALOG IN}.

CALIBRATE ANALOG IN

Press [ENTER] to go to the calibrate analog input sub-menu.

3. The display shows the previous 0% and 100% flow analog signal calibration values:

0% = 4.0mA

100% = 19.8mA

If you would like to skip the calibration and change only the Signal Ratio, press both [UP] and [DOWN] simultaneously. Skip to step 6. Pressing both [UP] and [DOWN] can also skip either the min. or the max. calibration.

Press [ENTER] to continue with Analog Input Calibration..

4. The display prompts you to input the minimum analog signal value, 0% flow.

INPUT ANALOG MIN

0% = XX.XmA

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.

For example, your instrument is generating 4.0mA but the DLC display reads 3.6mA. The DLC also accepts voltage inputs (0-5VDC), but displays only mA. It is only important that the DLC detects the full range of the instruments output. The DLC will store this value as the 0% analog signal value. As the analog signal varies, the DLC will display the fluctuating values. Wait approximately 10 seconds until the value displayed stabilizes and press [ENTER] to accept it as the 0% flow analog signal value.

5. The display prompts you to input the maximum analog signal value, 100% flow. Send the maximum analog signal to the DLC (i.e., 10mA, 20mA or 5 volts).

INPUT ANALOG MAX

100% = XX.XmA

As the signal varies, the DLC will display the fluctuating values. Wait approximately 10 seconds until the value stabilizes and press [ENTER]. The DLC stores this value as the 100% flow analog signal value.

If the range between the minimum and maximum analog signal values is less than or equal to 2mA, the DLC will display the following:

RANGE TOO SMALL

RE-ENTER

Press [ENTER] to return to step 4 to input the analog signal values again.

6. You are now ready to set the Signal Ratio. This option allows you to scale the Analog signal input to the pump output. Use this option only if you want to limit the range of operation of the pump (e.g., you want to limit the pump's output from 0 to 50% flow over the 4-20mA range). The display reads as follows:

INPUT RATIO

50% = 19.8mA

To use the ratio option, Press [UP] or [DOWN] to set the ratio value. Press [ENTER] to accept the setting.

If you do not want to use the Input Ratio Option, enter a value of 100%.

7. The DLC prompts you to accept the analog signal calibration programmed in the above referenced steps.

CONFIRM CHANGE?

YES

Press [ENTER] to accept. If you do not want to accept the new analog signal calibration, press [UP] to scroll to {NO} and press [ENTER].

The display will then return to its original operating mode.

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

The DLC will store this as the 0% analog input signal value. As the analog signal varies, the DLC will display the fluctuating values. Wait approximately 10 seconds for the signal to stabilize. Press [ENTER] to accept this as the 0% analog signal value.

2. In step 5, when the display requests the maximum analog signal value (100%), you send the DLC the low analog signal value (i.e., 0mA, 1mA, 4mA or 1 volt).

INPUT ANALOG MAX

100% = XX.XmA

The DLC will store this as the 100% analog input signal value. As the signal varies, the DLC will display the fluctuating values. Wait approximately 10 seconds for the signal to stabilize. Press [ENTER] to accept this signal as the 100% analog signal value.

You can confirm the reverse acting input signal calibration by re-entering the Analog Input Calibration menu. The first screen summarizes your calibration.

0% = 20.0mA 100% = 4.0mA

Send High

(20mA) Signal

Send Low

(4mA) Signal

3. Press [CAL] again to cancel the calibration at this point.

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. In many cases, the displayed value will not exactly match the value read by the attached equipment.

The Analog Output reflects the calibrated output (e.g., Flow) not the Mechanical output (e.g., Stroke position).

If the pump motor is off, the output will represent the minimum value (0%) regardless of the Stroke Position.

1. Press [CAL] to enter the {CALIBRAT E} sub-menu. Press [UP] twice to scroll to the {ANALOG OUTPUT} selection:

CALIBRATE

ANALOG OUTPUT

2. Press [ENTER]. The screen that allows you to set the output at 0% is displayed.

OUTPUT AT 0%

4.0mA

Using [UP] or [DOWN], set the value for the desired output. Note, the value that you set is for reference only. If you need a true 4.0mA's at the remote equipment, you should read the actual value from the remote equipment and set the value here at whatever is required by that equipment. For example, say a remote PLC needs exactly 4.0mA's at 0% stroke. The PLC currently reads its input as

3.8mA and the DLC reads its output as 4.0mA. Increase the DLC output (e.g., 4.2mA) until the PLC reads correctly.

3. Once you have set the 0% value press [ENTER] to accept it. The screen that allows you to set the output at 100% is displayed.

OUTPUT AT 100%

20.0mA

As described in step 2, set the output using [UP] or [DOWN]. When you are satisfied with your settings press [ENTER] to accept it.

4. The DLC will prompt you to accept the analog output calibrated values.

CONFIRM CHANGE?

YES

Press [ENTER] to accept the calibration. If you do not want to accept, press [UP] to display {NO}and then press [ENTER].

The display will return to the last operating mode.

You can set the Analog Output to reverse acting by simply setting the output at 0% to be 20.0mA and the output at 100% to be 4.0mA.

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

–MENU–

MODBUS SIG. FAIL

–MENU–

DIGITAL OUTPUT

–MENU–

POWER FAILURE

–MENU–

MODBUS MODE

–MENU–

CONTRAST ADJUST

–MENU–

LANGUAGE

Press [UP]

–MENU–

SET TIME & DATE

–MENU–

LEAK DETECTION

–MENU–

MOTOR THERMOSTAT

–MENU–

ALARM RELAY

–MENU–

SECURITY

–MENU–

SERIAL COMM

–MENU–

FACTORY DEFAULTS

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

–MENU–

ANALOG SIG FAIL

–MENU–

LEVEL SWITCH

–MENU–

OVER TEMPERATURE

–MENU–

ANALOG MODE

–MENU–

NUMBER FORMAT

–MENU–

SERIAL DIAG.

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

Press

[UP]

Pressing the [UP] key takes you back to the –MENU– DIAGNOSTICS-0 screen.

As you go through this section of the manual, the screens are displayed as defined in the Factory Default settings. If any of the settings are changed, (e.g., during initial set up or modifying operating parameters) the availability of screens displayed within a Sub-Menu item sub-set may change.

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.

Message Displayed When:

ANALOG SIG FAIL

LEAK DETECTION The PULSAlarm leak detection diaphragm has failed.* LEVEL SWITCH The Drum Level switch has been activated.*

The Analog signal has fallen below its calibrated range or has fallen rapidly (indicating an open circuit).

POWER FAILURE

OVER TEMPERATURE

ALARM RELAY

*DUTY CYCLE*

MOTOR THERMOSTAT

REMOTE ON/OFF

TERMINATED / PRESS ANY KEY

POSITION ERROR

MODBUS SIG FAIL

The input power to the DLC was interrupted while the pump motor was running.*

The internal temperature of the DLC has exceeded its operating limit.*

If configured, this message is displayed when the alarm relay activates.

When displayed, indicates that the stroke adjustment motor has run continuously for more than 20 minutes and is now in a cool down phase.

The temperature of the DLC Pump Motor has reached its operating limit.*

If configured, displays when the remote On/Off switch is in the Off position.

The Manual Control Knob moved during calibration.

Motion has not been detected when expected for a fairly long period of time.

The digital command was not received within the timeout

limit. OVER VOLTAGE The incoming power exceeds the specified range. UNDER VOLTAGE The incoming power is below the specified range.

* Refer to the Diagnostics Section (next section) for information on each of these messages.

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}.

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. If the incoming power supply to the DLC was interrupted while the pump motor was running, a failure will be detected and logged.

DIAG MENU 1/11

POWER IN: OK

3. Press [UP] to scroll to the next sub-menu. If the analog signal fails, a failure will be detected and logged. An analog input failure is detected if one of the following conditions occur. First, the signal falls below the calibrated range by 0.3mA (if the DLC is calibrated with a range of 4-20mA and the signal falls to 3.6mA then a failure will be logged). Second, if the analog signal falls below 0.3mA and is changing at a rate of 8.8 mA per second or more a failure will be logged. This second condition is primarily for the situation where the input is calibrated down to 0 (0.0mA). Refer to Section 7.2.4 Analog Signal Failure Setup for further information.

DIAG MENU 2/11

ANALOG IN: OK

-MENU-

DIAGNOSTICS-0

- or -

DIAG MENU 1/11 POWER IN: FAIL

DIAG MENU 2/11

ANALOG IN: FAIL

4. Press [UP] to scroll to the next sub-menu. If the MODBUS communications fails, a failure will be detected and logged. A MODBUS signal failure is logged when the DLC is in the MODBUS mode and the DLC has not received a valid command within the timeout limit.

DIAG MENU 3/11

MODBUS: OK

- or -

DIAG MENU 3/11

MODBUS: FAIL

5. Press [UP] to scroll to the next sub-menu. If a PULSAlarm leak detection diaphragm rupture is detected, the DLC will show a failure in this diagnostic sub-menu.

DIAG MENU 4/11

LEAK DET.: OK

- or -

DIAG MENU 4/11

LEAK DET.: FAIL

6. Press [UP] to scroll to the next sub-menu. If the Level switch is configured as a {DRUM LEVEL} type and the switch is activated, the DLC will show a failure in this diagnostic sub-menu. If the Level Input is configured as {START/STOP}, a failure will not be logged.

DIAG MENU 5/11 LEVEL SW.: OK

- or -

DIAG MENU 5/11

LEVEL SW.: FAIL

7. Press [UP] to scroll to the next sub-menu. The DLC can be equipped with a pump motor thermostat to monitor pump motor temperatures. If the temperature has exceeded its operating limit, the DLC will show a warning in this diagnostic sub-menu.

DIAG MENU 6/11 MOTOR TEMP: OK

- or -

DIAG MENU 6/11

MOTOR TEMP: FAIL

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. If the battery fails, the DLC will show a failure in this diagnostic sub-menu. The error is automatically cleared when the new battery is installed.

DIAG MENU 8/11

BATTERY: OK

- or -

DIAG MENU 8/11

BATTERY: FAIL

If the battery fails, the clock will continue to operate from line power, however, the clock and battery backed RAM will not function when the line power source is interrupted.

10. Press [UP] to scroll to the next sub-menu. If error’s are detected with the RAM, EEPROM or internal synchronous stroke adjustment motor, the FAIL message will flash in this diagnostic sub-menu. The error is automatically cleared when the component is replaced and power is applied to the DLC.

The Motor: FAIL is only an indication that we shut down (Duty Cycle) the stroke adjustment motor to keep from overheating it.

DIAG MENU 9/11

CIRCUIT: OK

- or -

DIAG MENU 9/11

CIRCUIT: FAIL

If a failure occurs, you can access a sub-menu from the {DIAG MENU / CIRCUIT: FAIL} screen by pressing [ENTER]. The lower level menus show more descriptive circuit information.

Press [UP] to scroll between sub-menus. The DLC tests its RAM at power-up. The results are shown as follows..

CIRCUIT FAILURE

RAM: OK

-or-

CIRCUIT FAILURE

RAM: FAIL

The DLC tests EEPROM whenever it writes information to long term memory

CIRCUIT FAILURE

EEPROM: OK

-or-

CIRCUIT FAILURE

EEPROM: FAIL

The {MOTOR: FAIL} message only indicates that the Stroke Adjustment motor has exceeded its Duty Cycle limit.

CIRCUIT FAILURE

MOTOR: OK

-or-

CIRCUIT FAILURE

MOTOR: FAIL

Circuit failures can only be cleared by cycling the power to the DLC.

11. Press [UP] to scroll to the next sub-menu. The run time on the pump motor is displayed in this diagnostic sub-menu. To reset the run time, press [ENTER] and you are prompted to reset the total run time or continue counting the total operating hours.

DIAG MENU 10/11 RUN XXX HRS

Press

[ENTER]

RESET RUN TIME?

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. Press [UP] and [ENTER] to confirm the change.

13. Press [ENTER] on any of the ‘Fail’ diagnostic screens (with the exception of BATTERY: FAIL and CIRCUIT FAIL) depicted above to display the time and date of the failure or more descriptive information.

Only the first occurrence of an error will be logged. The error must be cleared to log future occurrences.

DIAG MENU 1/11 POWER IN: FAIL

Press

[ENTER]

POWER FAILURE

13:27 1/22/01

14. Press [ENTER] again, and you are prompted to clear the failure. Depending upon the type of failure diagnosed, you may want to take other steps before clearing the failure and restarting the pump. If so, press [ENTER] to keep the error date and time stamp. Otherwise, press [UP] to scroll to {YES} and press [ENTER]. The DLC will return to the first menu screen depicted in step 1.

POWER FAILURE

CLEAR? NO

7.2.3 Set Time & Date

The clock/calendar is essential to the proper operation of the batch system and proper error time stamping. The clock should be set during installation. It can be configured to operate without any additional maintenance in most time zones.

1. Press [MENU], then [UP] to display the menu:

Press [ENTER] to access the Set Time & Date sub-menu.

2. Flashing in the upper left hand corner of the display should be "24 HR", which denotes a 24 hour clock. By pressing [UP], you can change this to a 12 hour ("12 HR") clock.

The 12 hour clock selection will add an 'a' or 'p' after the time.

Press [ENTER] to accept the desired time format..

-MENU-

SET TIME & DATE

12 HR MM/DD/YY 2:31a 1/22/01

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 MM/DD/YY 2:31a 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 MM/DD/YY 2:31a 1/22/01

4. The cursor moves to the second digit of the minute setting. Press [UP] or [DOWN] to set the correct second minute digit, then press [ENTER].

12 HR MM/DD/YY 2:31a 1/22/01

5. If you selected the 12 hour format, the cursor moves under the a.m./p.m. character. Press [UP] or [DOWN] to set the correct a.m./p.m. character ( a or p), then press [ENTER].

12 HR MM/DD/YY 2:31a 1/22/01

6. The date format will now be flashing on the display. The date can be expressed in one of three formats:

Month, Day, Year MM/DD/YY Day, Month, Year DD/MM/YY

Year, Month, Day YY/MM/DD Press [UP] or [DOWN] to scroll through the above referenced formats. When the format you desire is displayed, press [ENTER] to accept this format and continue.

7. The date is now flashing on the display. Press [UP] or [DOWN] to change this to the current date. Press [ENTER] to accept this value and the cursor moves to the next date position. Continue to press [UP] or [DOWN]. Press [ENTER] on the last date field to accept your setting.

12 HR MM/DD/YY 2:31a 1/22/01

You are not allowed to exit the date field if the date does not exist like June 31st or Feb 29th in a nonleap year.

8. The DLC prompts you to change the time and date for {DAYLIGHT SAVINGS / NO}. Press [UP] to scroll to {AUTO CHANGE}. The auto-change option complies with daylight savings time changes as mandated by United States legislation. Press [ENTER] to accept the correct configuration based on the location of the DLC.

DAYLIGHT SAVINGS

AUTO CHANGE

The times change over on the first Sunday in April and on the last Sunday in October.

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. The display will return to the {–MENU– / SET TIME & DATE} screen.

7.2.4 Analog Signal Failure Set Up

This sub-menu allows you to set up the DLC response if the analog signal fails. You can program the DLC to have one of the following responses:

− Freeze at the last good analog input signal,

− Shut the motor off,

− Go to a default signal.

An analog input failure is detected if one of the following conditions occur. First, the signal falls below the lower calibrated range by 0.3mA. For example, if the DLC is calibrated with a range of 4-20mA and the signal falls to 3.6mA, then a failure is recognized. Second, if the analog signal falls below

0.3mA and is changing at a rate of 8.8mA per second or more, a failure will be logged. This second condition is primarily for the situation where the input is calibrated down to 0 (0.0mA).

When an Analog Input is calibrated in the 0-5mA or 0-20mA range and you are operating down near the lower end (<2.5mA) the detection of a failed signal may not occur because the slew rate (rate of change) is too low to be detected. If you are calibrated down to 0mA, operation after a failure will be restored immediately because 0mA is an in-range signal.

If Analog Input Signal Failure is important to operation, avoid calibrating to 0mA.

v Setting up the DLC response

1. Press [MENU] and press [UP] or [DOWN] until {–MENU– / ANALOG SIG FAIL} is displayed.

Press [ENTER] to continue to the Analog Signal Fail setup screens. The first entry in the Analog Signal Failure menu determines how the DLC recovers from a failed

analog input. You can select from two {RESTORE TO:} modes: Analog or Manual. If {ANALOG MODE} is selected, the DLC will resume automatically following the 4-20mA input. If {MANUAL MODE} is selected, the DLC will enter the manual mode as soon as the signal loss is detected. It will remain in Manual Mode until it is changed manually (press [MODE] on the front panel). The benefit of using a {RESTORE TO: / ANALOG MODE} is that it's totally automatic. If so programmed, the DLC can shut itself down, wait for a signal to return, and then start itself back up.

Press [ENTER] to accept the factory default of {RESTORE TO: / ANALOG MODE} or press [UP] and then press [ENTER] to select the {RESTORE TO: / MANUAL MODE}.

RESTORE TO: ANALOG MODE

-MENU-

ANALOG SIG FAIL

Press

[UP]

RESTORE TO: MANUAL MODE

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.

ANALOG SIG FAIL

GO TO DEFAULT

To accept this action, press [ENTER]. c) The next display prompts for the uncalibrated percent of flow to be the default setting. Enter the

value using [UP] or [DOWN].

SIGNAL DEFAULT

10.0%

To accept this value, press [ENTER].

3. The {ERROR MESSAGE / ENABLED} screen is displayed.

ERROR MESSAGE

ENABLED

To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is displayed. If you desire a different action, press either [UP] or [DOWN] to display the {ERROR MESSAGE /

DISABLED} screen.

ERROR MESSAGE

DISABLED

To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is displayed.

The error will still be logged with the time and date, but the flashing error message on the screen is suppressed. This is for applications that intentionally interrupt the analog signal in the normal course of operations, stopping and re-starting the pump.

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. Press [MENU] and press [UP] or [DOWN] until the display reads {–MENU– / MODBUS SIG. FAIL}.

–MENU–

MODBUS SIG. FAIL

Press [ENTER] to continue to the MODBUS Signal Fail sub-menus.

2. The {RESTORE TO:} menu is displayed. This setting determines how the DLC will recover from a failed MODBUS Signal. You can select from two {RESTORE TO:} modes – MODBUS or Manual.

If {MODBUS MODE} is selected the DLC will resume following the MODBUS signal automatically when the signal is restored.

If {MANUAL MODE} is selected, the DLC will enter manual mode as soon as the signal loss is detected. The DLC will remain in Manual Mode until it is changed manually (press [MODE] on the front panel).

The benefit of using {RESTORE TO: / MODBUS MODE} is that it’s totally automatic. If so programmed, the DLC can shut itself down, wait for the signal to return and then start itself back up.

Press [ENTER] to accept the factory default of {RESTORE TO: / MODBUS MODE} or press [UP] and then press [ENTER] to select the {RESTORE TO: / MANUAL MODE}.

RESTORE TO: MODBUS MODE

Press [UP]

RESTORE TO: MANUAL MODE

3. The next entry in the MODBUS SIG. FAIL sub-menu allows you to set the timeout value in seconds. This defines the maximum interval between messages addressed to this node. If a message is not received within this period, a MODBUS Signal failure will be detected. A number of factors influence the value you should set here:

a) Number of nodes on the network. b) Type of master. c) Baud rate. d) Electrical environment. Here are some general guide lines:

− Increase this value as you increase the number of nodes on the network.

− Increase this value as you decrease the communications baud rate.

− Increase this value if the DLC is a slave connected to a heavily loaded PC/PLC master.

− Increase this value if you are in an electrically noisy environment.

− Decrease this value if the DLC is mission critical on a small (2-3 node) network.

Always use the default setting (2.5 seconds) as a starting point. To adjust the value, press [UP] or [DOWN]. Press [ENTER] to accept the value.

TIMEOUT

2.5 SECONDS

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. If you selected {GO TO DEFAULT}, you must set the default value.

Press [UP] or [DOWN] to set the default signal in percent.

SIGNAL DEFAULT

10.0%

Press [ENTER] to accept your setting.

6. The {ERROR MESSAGE} screen is displayed. Press [UP] or [DOWN] to select between {ENABLED} or {DISABLED}

ERROR MESSAGE

ENABLED

Press [UP]

ERROR MESSAGE

DISABLED

Press [ENTER] to accept your setting.

When the DISABLED setting is selected, the error will still be logged with the date and time, but the flashing error message on the screen will be suppressed. This option is for applications that intentionally interrupt the MODBUS Signal in the normal course of operations, stopping and restarting the pump.

7.2.6 Leak Detection Failure Set Up

This sub-menu allows you to configure the DLC to interact with a PULSAlarm Leak Detection Diaphragm. You can modify the way the DLC responds to a diaphragm rupture. The following responses are available:

− Shut the motor off,

− Trigger an alarm relay,

− Shut the motor off and trigger an alarm relay,

− Have no interaction with the Pump Motor or Alarm Relay other than log the diaphragm failure

and display a message on the LCD display (this message is displayed until a key on the keypad is pressed).

The leak sensor switch must be a dry contacting type. Refer to Section 5-Installation: Low Voltage Inputs for wiring information.

If you select the 'motor off' option, the motor will have to be manually re-started if a Leak Detection Failure is detected (i.e., press [MOTOR] to start the pump motor).

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.

-MENU-

LEAK 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. The {–MENU– / LEAK DETECTION} screen is displayed.

3. If your pump is supplied with a PULSAlarm Leak Detection Diaphragm, press [UP] to select the type of switch. The Leak Detection Input switch can be configured as {NORMALLY OPEN},

LEAK DET INPUT

NORMALLY OPEN

or press [UP] to configure the switch as {NORMALLY CLOSED}.

LEAK DET INPUT

NORMALLY CLOSED

Press [ENTER] to accept the desired configuration.

4. The display prompts you to configure the motor state (ON/OFF) should a diaphragm rupture occur (i.e., a leak is detected).

LEAK DETECTION

MOTOR OFF? NO

If you do not want the pump's motor to turn off when a leak is detected, press [ENTER] to accept the default value. If you want the motor to shut off if a leak is detected, press [UP] to scroll to {YES} and press [ENTER].

5. The display prompts you to configure the alarm relay status (triggered or not triggered).

LEAK DETECTION

ALARM RELAY? NO

If you do not want the Alarm Relay activated when a leak is detected, press [ENTER] to accept the default of {NO}. If you want the alarm relay to be active if a leak is detected, press [UP] to scroll to {YES} and press [ENTER]. The display returns to the { –MENU– / LEAK DETECTION} screen.

7.2.7 Level / Remote / Start – Stop Set Up

This sub-menu allows you to configure the DLC to interact with a level input. You can program the DLC to have one of the following responses:

− Shut the motor off,

− Trigger the alarm relay,

− Shut the motor off and trigger the alarm relay,

− Shut the motor OFF when the level input is in one state (e.g. CLOSED) and turn the motor ON

when the level input is in the other state (e.g. OPEN).

The level sensor or Start/Stop switch must be a dry contacting type. Refer to Section 5-Installation: Low Voltage Input Connections.

If you select the 'motor off' option, the motor will have to be manually re-started when a Level Failure is detected (i.e., press [MOTOR] to start the pump motor).

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.

LEVEL 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

Pressing [ENTER] when {LEVEL SWITCH / INACTIVE} is displayed will cause the screen to return to the { –MENU– / LEVEL SWITCH} screen.

3. Press [UP] to scroll to the next option {LEVEL SWITCH / ACTIVE}.

LEVEL SWITCH

4. Press [ENTER] when {LEVEL SWITCH / ACTIVE} is displayed and the following screen is displayed.

LEVEL SWITCH

Select this option if the level input is to be connected to a drum level switch. Press [ENTER] to select. Go to step 7.

5. Pressing [UP] when the {LEVEL SWITCH / DRUM LEVEL} screen is displayed will open the{LEVEL SWITCH / START/STOP} screen.

LEVEL SWITCH

6. Pressing [ENTER] from {LEVEL SWITCH / START/STOP} screen to configure the LEVEL SWITCH input for use with a remote motor On/Off switch.

7. The Level Switch Configuration screen is displayed:

LEVEL SWITCH

NORMALLY CLOSED

8. Press [ENTER] to configure the switching device as {NORMALLY CLOSED}, or press [UP] and then press [ENTER] to configure the switching device as {NORMALLY OPEN}.

LEVEL SWITCH

NORMALLY OPEN

When {LEVEL SWITCH / START/STOP} has been selected, you are returned to the {–MENU– / LEVEL SWITCH} screen. This setting uses the default settings of {MOTOR OFF? / YES} and {ALARM RELAY? / NO}. These settings cannot be modified.

-MENU-

INACTIVE

ACTIVE

DRUM LEVEL

START/STOP

9. The display prompts for the motor status when the Level Input trips:

LEVEL SWITCH

MOTOR OFF? YES

Press [ENTER] if you want the PULSAR motor to turn off when the Drum Level input is sensed. Go to step 11.

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. If you do not want the Alarm Relay to activate with the Level Switch Input, press [UP] to scroll to {NO}.

LEVEL SWITCH

ALARM RELAY? NO

Press [ENTER] to accept the setting. The display returns to the {–MENU– / LEVEL SWITCH} screen.

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.

If the Digital Output is set up as {PUMP STROKE}, it will activate for 50% of each stroke and deactivate for 50% of each stroke.

The Tachometer option is required for this to work.

Figure 14 – Run/Stop Status

Figure 15 – Pump Stroke Status

If the Digital Output is set up as {MODE INDICATION / ANALOG MODE}, and {DIGITAL OUTPUT / NORMALLY OPEN} it will activate when the mode is set to {ANALOG} and deactivate in any other (e.g., {MANUAL MODE}) mode.

Figure 16 – Mode Indication

v Digital Output Set Up Procedure

1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– / DIGITAL OUTPUT}.

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.

DIGITAL OUTPUT

To use the DIGITAL OUTPUT to indicate pump strokes, press [ENTER]. Go to step 6.

4. Press [DOWN]. The {DIGITAL OUTPUT / MODE INDICATION} screen is displayed.

DIGITAL OUTPUT

MODE INDICATION

To use the DIGITAL OUTPUT function as a Mode Indicator press [ENTER]. The following screens are displayed:

MODE INDICATION

MANUAL MODE

Press [UP]

–MENU–

PUMP STROKE

MODE INDICATION

ANALOG MODE

Press [UP]

MODE INDICATION

MODBUS MODE

Press [UP] or [DOWN] to scroll through the screens shown above. Press [ENTER] to select the desired option

5. The {DIGITAL OUTPUT / NORMALLY OPEN} screen is displayed. In this mode, the output is open (non-conducting) when the motor is off or the Mode is wrong

DIGITAL OUTPUT

NORMALLY OPEN

The output is closed (conducting) when the motor is on or the Mode is correct. Configure the output as {NORMALLY OPEN} by pressing [ENTER]. Go to step 7.

6. Press [UP] to open the {DIGITAL OUTPUT / NORMALLY CLOSED} screen. In this mode, the output is open (non-conducting) when the motor is on or the Mode is correct.

DIGITAL OUTPUT

NORMALLY CLOSED

The output is closed (conducting) when the motor is off or the Mode is wrong. Press [ENTER] to configure the output as {NORMALLY CLOSED}.

7. The {–MENU– / DIGITAL OUTPUT} 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.

For equipment safety, the DLC can be programmed to have one of the following responses if the Motor Thermostat activates:

− Shut the motor off, (no alarm) (no restart)

− Trigger the alarm relay, (motor stays on)

− Shut the motor off and trigger the alarm relay, (no restart)

− Shut the motor off, trigger the alarm relay, and then restart the motor when the Motor Thermostat

resets,

− Shut the motor off and then restart the motor when the Motor Thermostat resets (No alarm),

− Ignore the thermostat input.

v Motor Thermostat Set Up Procedure

1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– / MOTOR THERMOSTAT}.

MOTOR THERMOSTAT

2. Press [ENTER] and the {MOTOR THERMOSTAT / NORMALLY CLOSED} screen is displayed.

MOTOR THERMOSTAT

NORMALLY CLOSED

Press [ENTER] to accept the {NORMALLY CLOSED} configuration. Go to step 4. or Press [UP] and the {MOTOR THERMOSTAT / INACTIVE} screen is displayed.

MOTOR THERMOSTAT

INACTIVE

If the {MOTOR THERMOSTAT} is to be configured as {INACTIVE}, (this is the factory default setting) press [ENTER] and you are returned to the {–MENU– / MOTOR THERMOSTAT} screen.

IF YOU SET {MOTOR THERMOSTAT} TO {INACTIVE} OR SET {MOTOR OFF?} TO {NO},

IT IS POSSIBLE FOR THE MOTOR WINDINGS TO OVERHEAT LEADING TO PREMATURE MOTOR FAILURE AND POSSIBLE HAZARDOUS CONDITIONS (E.G., FIRE).

3. Pressing [UP] from the {MOTOR THERMOSTAT / INACTIVE} screen will display the {MOTOR THERMOSTAT / NORMALLY OPEN} screen.

MOTOR THERMOSTAT

NORMALLY OPEN

–MENU–

Press [ENTER] to accept the {NORMALLY OPEN} configuration.

4. The {MOTOR THERMOSTAT / MOTOR OFF? YES} screen is displayed.

MOTOR THERMOSTAT

MOTOR OFF? YES

Press [UP] to select between {YES} or {NO}. If you want the motor to turn off when the thermostat activates, (recommended), set {MOTOR OFF?}

to {YES}. Press [ENTER] to accept the desired configuration.

5. The {MOTOR THERMOSTAT / ALARM RELAY? YES} screen is displayed.

MOTOR THERMOSTAT

ALARM RELAY? YES

Press [UP] to select between {YES} and {NO}.

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. The display will return to the {–MENU– / MOTOR THERMOSTAT} screen.

7.2.10 Over Temperature Set Up

This sub-menu allows you to disable the warning message when the DLC’s internal temperature approaches it’s operating limit of 70°C / 158°F. The error condition will not reset until the temperature drops below 65°C / 149°F. The difference between the trip and release point is 5°C / 9°F.

RUNNING THE DLC AT ELEVATED TEMPERATURES COULD RESULT IN IMPROPER AND

DANGEROUS OPERATION.

This warning does not affect the operation of the DLC, it is for your information only. Disabling this flashing warning message does not inhibit the logging of the Diagnostic Time and Date of the event.

v Over Temperature Set Up Procedure

1. Press [MENU] once and then [UP] or [DOWN] until the display reads {–MENU– / OVER TEMPERATURE}.

–MENU–

OVER TEMPERATURE

Press [ENTER] to go to the Over Temperature response sub-menu.

2. The {OVER TEMPERATURE / ENABLED} (system default) screen is displayed.

OVER TEMPERATURE

ENABLED

3. Press [ENTER} to accept the {ENABLED} setting and you are returned to the {–MENU– / OVER TEMPERATURE} screen.

or Press [UP] to display the {OVER TEMPERATURE / DISABLED} screen.

OVER TEMPERATURE

DISABLED

Press [ENTER} to accept the {DISABLED} setting. The display will return to the {–MENU– / OVER TEMPERATURE} screen.

–MENU–

OVER TEMPERATURE

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. Press [MENU] once and then [UP] or [DOWN] until the display reads {–MENU– / POWER FAILURE}.

POWER FAILURE

Press [ENTER] to go the power failure response sub-menu.

2. The display prompts you for the Power-up status. To shut the motor off when the power is returned to the unit (after a power failure), select the {MOTOR OFF} option (factory default).

DURING POWER UP

Press [ENTER] to accept. Go to step 4.

3. If you want to return to the prior settings, press [UP] and scroll to {DURING POWER UP / PRIOR SETTINGS}.

DURING POWER UP

PRIOR SETTINGS

Press [ENTER] to accept.

4. The display prompts you for an action to take when the wrong voltage is detected.

WRONG VOLTAGE

HARD SHUT DOWN

-MENU-

MOTOR OFF

The following options are available:

Selection Action

Hard Shutdown

Message Only Display under/over voltage message. Ignore Error None

Press [UP] or [DOWN] to make your selection. Press [ENTER] to accept your selection.

5. The display will return to the {–MENU– / POWER FAILURE} screen.

Display under/over voltage message. Turn motor off. Inhibit motor operation. (Motor Key Disabled) Voltage correction and power cycle required to reset alarm. Display under/over voltage message. Motor Off Turn motor off.

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.

2. The alarm relay can be configured as {NORMALLY OPEN}. With this setting the relay will CLOSE when the alarm output is activated.

If you would rather have the relay OPEN when the output is activated, press [UP] to change the configuration to {NORMALLY CLOSED}.

When you have finished making your selection, press [ENTER] to accept.

3. The display returns to the {–MENU– / ALARM RELAY} screen.

7.2.13 Analog Mode

–MENU–

ALARM RELAY

RELAY OUTPUT

NORMALLY OPEN

RELAY OUTPUT

NORMALLY CLOSED

Use the Analog Mode setting to activate or de-activate the analog mode and set the number of active signals. If deactivated, the analog mode will not appear when the [MODE] key is pressed. If you are not using the analog input (i.e., you have made no connections to J4-1, J4-2, and J4-7, J4-8) but have the Analog Mode set to ACTIVE then any time you press [MODE], by default the DLC will generate an {ANALOG SIG FAIL} alarm. De-activating Analog Mode prevents this.

You can modify the way the DLC responds to a signal. You can set the number of samples to be averaged (within a range of 1 to 100 samples), and you can set the interval, in number of samples, that the DLC should adjust the stroke setting to the specified average (within a range of 1 to 100 samples). The DLC samples the Analog Input every 0.25 seconds. The default value for the number of samples is 20 and the default value for the sample interval is 20. Therefore, the DLC will average the last 20 samples and make an adjustment every 5 seconds (20*.25=5.0). Here are some general guidelines to assist you when adjusting these values:

− Increase the {SAMPLE SIZE} value to reduce the effect of electrical noise on the Analog Input.

− Decrease the {SAMPLE SIZE} value to increase sensitivity to changes in the Analog Input.

− Increase the {UPDATE EVERY / XX SAMPLES} value if the DLC is constantly adjusting the

stroke setting (often resulting in a {DUTY CYCLE} alarm).

− Decrease the {UPDATE EVERY / XX SAMPLES} value to increase tracking response.

In most situations, the default values will be adequate.

v Analog Mode Set Up Procedure

1. Press [MENU] once and then [UP] or [DOWN] until the screen {–MENU– / ANALOG MODE} is displayed.

Press [ENTER] to continue to program the Analog Mode sub-menu.

2. The {ANALOG MODE / ACTIVE} screen is displayed.

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. The {SAMPLE SIZE / XXX} screen is displayed.

Press [UP] or [DOWN] to set the number of samples taken from the 4-20mA input to average. The DLC will adjust its output in accordance with the average of the number of samples you set here. Enter a value in the range of 1 to 100 samples using the [UP] or [DOWN] key(s).

Press [ENTER] to accept the entry.

Increase the number of samples to smooth out a noisy input. Decrease the number of samples to cause the DLC to track a rapidly changing signal more closely.

-MENU-

ANALOG MODE

ACTIVE

SAMPLE SIZE

XXX

4. The {UPDATE EVERY / XXX SAMPLES} screen is displayed. Press [UP] or [DOWN] to set how often the DLC will adjust to the current average value. The default value (20) causes the DLC to adjust every 20 samples or every 5 seconds (20 * 0.25 = 5). You may enter a value in the range of 1 to 100 using the [UP] or [DOWN] key(s).

Decrease the value to better follow a rapidly changing signal.

5. Press [ENTER] to accept your selection.

6. The {–MENU– / ANALOG MODE} screen is displayed.

7.2.14 MODBUS Mode

Use the MODBUS mode setting to activate or de-activate the DLC’s ability to support a MODBUS serial signal. If deactivated, the MODBUS mode will not appear when [MODE] is pressed. If you are not using the serial input (i.e., you have made no connections to J7 or J8) but have the MODBUS mode set to active, then any time you mistakenly press [MODE], by default the DLC will generate a {MODBUS SIGNAL FAILURE} alarm. De-activating MODBUS mode prevents this.

The [MODE] key allows you to select an operating mode. It acts as a master switch allowing you to select what signal controls the DLC. It does not inhibit MODBUS communications. It only inhibits MODBUS commands that pertain to the operation (e.g., you cannot turn the pump motor on using MODBUS unless the mode is set to MODBUS).

UPDATE EVERY

XXX SAMPLES

v MODBUS mode setup procedure:

To access the {MODBUS MODE} menu you must have

Serial Comm

enabled and the

class set to

Slave

. Refer to the

section later in this chapter.

1. Press [MENU]. Press [UP] or [DOWN] until the {–MENU– / MODBUS MODE} screen is displayed.

Press [ENTER] to continue to program the MODBUS mode. The {MODBUS MODE / INACTIVE} screen is displayed.

{MODBUS MODE / INACTIVE} would be selected if you do not intend to control the DLC using the MODBUS protocol. Pressing [ENTER] when {INACTIVE} is displayed will cause the screen to return to the {–MENU– / MODBUS MODE} menu.

2. {MODBUS MODE / ACTIVE} would be selected if you are going to control the DLC using the MODBUS protocol.

With the {MODBUS MODE / INACTIVE} screen displayed, press [UP] to display the {MODBUS MODE / ACTIVE} screen.

MODBUS MODE

INACTIVE

Press [ENTER] to accept the setting.

3. The {INPUT RATIO / 100%} screen is displayed.

4. Use the {INPUT RATIO} setting to scale the serial input value to meet your needs. Press [UP] or [DOWN] to set the ratio value between 20% and 100%.

Press [ENTER] to accept your changes. The {ACTION / FORWARD} screen is displayed.

5. You can also instruct the DLC to act on the MODBUS signal in a forward or reverse direction. When {ACTION / FORWARD} is selected, the DLC “acts” in the same direction as the signal. If the signal changes from 25% to 75%, the DLC will adjust its output from 25% to 75% (assuming the ratio is set to 100%). When {ACTION / REVERSE} is selected the DLC will “act” in the opposite direction. If the signal changes from 25% to 75% the DLC will adjust its output from 75% to 25% (assuming the ratio is set to 100%).

Press [UP] or [DOWN] to switch between {ACTION / FORWARD} and {ACTION / REVERSE}.

ACTION

FORWARD

Press [ENTER] to accept your selection.

6. The {–MENU– / MODBUS MODE} screen is displayed.

Serial Communications

–MENU-

MODBUS MODE

INACTIVE

Press [UP]

INPUT RATIO

100%

Press [UP]

MODBUS MODE

ACTIVE

ACTION

REVERSE

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. With Calibration security set, the DLC will lockout access to the [CAL] sub-menu, Pin Setup and Factory Reset Ability. To use [CAL] you must first enter your PIN. Successful entry of a PIN allows you to access the {CALIBRATE} menu.

The security mode re-sets after 5-minutes of keypad in-activity.

v Security Set Up Procedure

1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / SECURITY} is displayed. Press [ENTER] to continue to program the Security sub-menu.

2. The type of security available appears flashing on the display. If no password security protection is desired, press [ENTER] and go to step 8.

3. Press [UP] and the {TAMPER PROOF} option is displayed. If complete tamper proof security of all settings is required, press [ENTER] and go to step 5.

4. Press [UP] and the {CAL SETTINGS} option is displayed. If security protection of only the calibration settings is desired, press [ENTER].

5. The display prompts you to enter a four digit pin number. A line under the first digit indicates the character to be changed. Press [UP] and [DOWN] to scroll through the numbers 0-9. Press [ENTER] to accept the desired number. The line then moves to beneath the second digit. Continue to press [UP], [DOWN] and [ENTER] to set the four digit password.

The values you enter are visible to both yourself and anyone else who may be watching you. Safe guard the security of your password.

-MENU-

SECURITY

SECURITY TYPE

OFF

SECURITY TYPE

TAMPER PROOF

SECURITY TYPE

CAL SETTINGS

NEW PIN #

0000

6. After the four digit PIN has been entered, the display prompts you to confirm the new number:

CONFIRM CHANGE?

YES

Press [ENTER] to accept the pin number and go to step 8.

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?

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.

7.2.16 Number Format

Accessing {–MENU – / NUMBER FORMAT} allows the modification of three system variables: a) The meaning of the comma and decimal point can be interchanged between English and European

format (step 2). b) Change the decimal position (step 3). c) Change the preferred unit of flow to be displayed when the [UNITS] key is pressed (step 4).

v Number Format Set Up Procedure

1. Press [MENU]. Press [UP] or [DOWN] until the display reads {–MENU– / NUMBER FORMAT}. Press [ENTER] to continue into the number format sub-menu.

2. The display shows the English numerical format of 9,999.99. Press [UP] to change to the European format of 9.999,99.

e.g.: 9,999.99

DECIMAL OR COMMA

Press [ENTER] to accept the displayed format.

3. The decimal position screen is displayed. Press [DOWN] to move the decimal position one place to the left. Press [UP] to move the decimal position one place to the right. For example, the screen displays

9.99999, pressing [DOWN] causes the display to change to 0.999999. The valid range is 999.999 to

0.0999999.

Refer to the table in Section 10 – Factory Defaults for factory decimal position settings.

Press

[UP]

e.g.: 9.999,99

DECIMAL OR COMMA

e.g.: 9.99999

DECIMAL POSITION

Press

[DOWN]

e.g.: 0.999999

DECIMAL POSITION

Press [ENTER] to accept the decimal position.

You should perform a pump flow calibration if you change the decimal position.

4. The Display Units screen is displayed.

ALL

DISPLAY UNITS

5. To accept the default setting of ALL, press [ENTER].

6. To specify the desired Display Unit, press [UP] or [DOWN] to cycle through the units options: CMH, GPH, LPH, CCH. CMM, GPM, LPM, and CCM, until the desired unit is displayed.

Press [ENTER] to accept your selection.

7. The display returns to {–MENU– / NUMBER FORMAT} screen.

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]. Press [UP] or [DOWN] until the display reads {–MENU– / CONTRAST ADJUST}. Press [ENTER] to continue in the contrast adjust sub-menu.

CONTRAST ADJUST

2. Press and hold [UP] to darken the characters on the display. Press and hold [DOWN] to lighten the characters.

ADJUST CONTRAST

By going too far in either direction the screen can be extremely difficult to read. Press and hold the opposite arrow to correct the display or you can return to the factory setting by pressing [UP] and

[DOWN] simultaneously while in this menu.

-MENU-

USE ARROWS TO

3. Press [ENTER] to accept the desired contrast setting.

4. The display returns to {–MENU– / CONTRAST ADJUST} screen.

You can adjust the contrast at any time by pressing and holding [MENU] and [UP] or [MENU] and [DOWN] simultaneously.

7.2.18 Serial Communications

Use {–MENU– / SERIAL COMM} to configure the serial communications port for operation using the MODBUS protocol (refer to the PULSAnet Specification section at the back of this manual for further information).

By using the serial communications port you can communicate digitally with your DLC. This allows a PC/PLC or another DLC or DLCM to send and receive exact values. This eliminates inaccuracies typically associated with analog signal conversion.

In order for two or more devices to communicate using serial communications they must:

− Be electrically connected (refer to Section 5.3: Electrical Wiring).

− Enabled.

− Speak the same language (protocol).

− Speak at the same speed (baud rate).

− Use the same error detection protocol.

− Have unique addressing in the network..

− Have only one master on a given network.

The {SERIAL COMM} menu allows the setting of these communication parameters.

If you are installing this DLC into an existing network, retrieve the following parameters (bold indicates default DLC values not network defaults).

MODBUS Type: ¨ RTU ¨ ASCII

Baud Rate: Data Parity:

Slave Address(es):

¨ 300 ¨ 600 ¨ 1200 ¨ 2400 ¨ 4800 ¨ 9600 ¨ 19,200 ¨ 38,400 ¨ Even ¨ Odd ¨ None

¨ 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 ¨ 26 ¨ 27 ¨ 28 ¨ 29 ¨ 30 ¨ 31 ¨ 32 (Mark one or more.)

Communications settings for DLC’s operating in a multiplexed environment (i.e., one motor driving one or more pump heads) are pre-configured.

v Communications Setup Procedure

1. To access the Serial Communications menu press [MENU] and then press [UP] or [DOWN] until the {–MENU– / SERIAL COMM} screen is displayed.

Press [ENTER] to view/modify the settings.

2. The display prompts you to enable or disable the DLC’s communications function.

SERIAL COMM

DISABLED

Communication Parameters Worksheet

-MENU-

SERIAL COMM

Press [UP]

SERIAL COMM

ENABLED

Press [UP] or [DOWN] to reveal your selection. Press [ENTER] to accept your setting.

3. The display prompts you for the type of communications. The DLC supports the standard MODBUS protocol. This standard defines two ways for devices to format the data they exchange:

− “RTU” is a binary format that offers improved data throughput.

− “ASCII” is a format based on the ANSI character standard. It has larger message blocks that

yield reduced data throughput. If you are installing a DLC into an existing network, you must match the setting you marked on the worksheet.

If this is a new DLC/DLCM only installation, choose “RTU”. Press [UP] or [DOWN] to select your choice.

TYPE

RTU

Press [UP]

TYPE

ASCII

Press [ENTER] to accept.

4. The display prompts you to set the baud rate. The baud rate must be common for the network (i.e., all devices must be set at the same baud rate).

Set this value to that recorded on your worksheet previously or use the default setting of 9600.

BAUD RATE

9600

Press [UP] or [DOWN] to select your choice. Press [ENTER] to accept.

5. The data parity display instructs the DLC on the use of the parity bit for error checking transferred data. This setting must match that of the existing network (refer to the selection you made on the work sheet). Otherwise, select the default value of EVEN.

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.

You can only have one Master in a network. Thus, the Class setting will typically be Slave.

Press [UP] or [DOWN] to set the Class setting.

CLASS SLAVE

Press [UP]

CLASS

MASTER

Press [ENTER] to accept your setting.

The Master does not have a network address. Skip to Step 8.

7. Every slave attached to a MODBUS network must have a unique address. Use the {NET ADDRESS} menu to set the address for this DLC.

If this is a new installation, check your worksheet for an available address.

NET ADDRESS

Press [UP] or [DOWN] to set the address. Press [ENTER] to accept your setting.

8. If you selected Master in step 6, you must also set the amount of time the DLC should wait for a response from a Slave. If the Slave fails to respond within this time period, the Master will attempt to communicate with the next Slave on its list.

RESPONSE TIME

1.5 SECONDS

Press [UP] or [DOWN] to set the response time value (refer to the beginning of this section for tips on making this setting).

9. If you selected Master in step 6, then you will be presented with a menu that allows you to identify Slaves. Otherwise go to step 10.

You can use the {IDENTIFY SLAVES} menu in one of two ways: a) Set the Slave addresses manually b) Use the Auto Detect feature To use the Auto Detect feature, press [UP] or [DOWN] to change the setting to Auto Detect. Press

[ENTER] to accept your selection.

IDENTIFY SLAVES

AUTO DETECT

The DLC will then display a status screen as it scans the 32 addresses for slave devices. The address under test is indicated to the right of AUTO DETECT.

PLEASE WAIT

AUTO DETECT #

You can use the AUTO DETECT feature to validate communications between a master DLC and one or more slaves. You can also use the Serial Diagnostic Menu (refer to the next section).

After the AUTO DETECT completes, you are returned to the {–MENU– / SERIAL COMM} screen.

Repeat steps 1 through 9a or b without selecting AUTO DETECT to return to this menu.

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

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}. Press [ENTER] to accept your selection for this address.

When you have completed your settings press [UP] or [DOWN] to select {DONE ENTRY}.

Press [ENTER] to accept your settings.

10. The {–MENU– / SERIAL COMM} screen is displayed.

7.2.19 Serial Diagnostics

The Serial Diagnostics menus are designed to assist you in the trouble shooting of the communications system.

v Serial Diagnostic

1. To access the Serial Diagnostics menu press [UP] or [DOWN] until the {–MENU– / SERIAL DIAG.} is displayed.

IDENTIFY SLAVES

1 NO

IDENTIFY SLAVES

DONE ENTRY

–MENU–

SERIAL DIAG.

Status

Press [ENTER]

2. The first menu shows the number of MODBUS messages exchanged by this node while the menu is displayed.

RECEIVE: 640 TRANSMIT: 640

Press either [UP] or [DOWN] to reset the count value. Press [ENTER] to proceed to the next screen.

LOOPBACK TEST

Selecting {YES} will start the test (go to – Loopback Test Procedure – on the next page), or if {NO} is selected you are sent to the {ECHO TEST / NO} screen.

3. The {ECHO TEST / NO} screen is displayed.

The Echo test causes the DLC to echo back all characters it received, much like the Loopback Device. You can then use another piece of equipment (e.g., PC) to originate characters.

4. Press [ENTER] to skip the echo test or press [UP] and then [ENTER] to set {ECHO TEST / NO} to {ECHO TEST / YES} and initiate the test. The following screen is displayed:

ECHO CHARACTERS

TEST IN PROGRESS

When the Echo Test is complete, the following screen is displayed:

GOOD XXXX BAD XXXX

5. Press [ENTER] to exit the Echo Test and return to the {–MENU– / SERIAL COMM} screen.

- or -

ECHO TEST

LOOPBACK TEST

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. This can be constructed according to Figure 17 below:

Figure 17 – Loopback Device Wiring Diagram

– – Loopback Test Procedure – –

a) Install the line terminator in one port of the

DLC. (J7 or J8)

b) Install the cable under test in the second port.

(J7 or J8)

c) Install the loop back device at the far end of the

cable under test.

d) With the {LOOPBACK TEST YES} screen displayed, press [ENTER].

LOOPBACK TEST

YES

e) While the LOOPBACK test is being conducted, the following screen is displayed:

PLEASE WAIT

TEST IN PROGRESS

When the test is completed, a result screen is displayed:

100.0% SUCCESS RETRY YES

- or -

f) If the indicated percent of success is 0%, the cable segment is bad. If the indicated percent of

success is 100%, the segment is good. If the success rate is less than 100%, but greater than zero you may want to lower the baud rate on the network.

6. To exit the diagnostic menu press [UP] and then press [ENTER]. The {–MENU– / SERIAL COMM} screen is displayed.

100.0% SUCCESS RETRY NO

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.

-MENU-

LANGUAGE

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.

LANGUAGE TYPE

ENGLISH

LANGUAGE TYPE

DEUTSCH

When the correct language is displayed, press [ENTER] to activate. All text will be displayed in the selected language.

3. The display returns to {–MENU– / LANGUAGE}.

7.2.21 Factory Default Settings

Press

[UP]

Press

[UP]

LANGUAGE TYPE

FRANCAIS

LANGUAGE TYPE

ESPANOL

Press

[UP]

All of the DLC settings can be returned to factory defaults.

v Procedure for resetting the factory defaults

1. Press [MENU] and [UP] or [DOWN] until the {–MENU– / FACTORY DEFAULTS} screen is displayed.

-MENU-

FACTORY DEFAULTS

Press [ENTER] to continue through the factory defaults sub-menu.

2. The display prompts you to not reset all the settings to the factory defaults.

FACTORY RESET?

If a Factory Reset is not desired, press [ENTER] to go back to the {–MENU– / FACTORY DEFAULTS} screen.

3. If the DLC is to be reset to the factory defaults, press [UP] to scroll the value to {YES}.

FACTORY RESET?

YES

Press [ENTER] to accept your selection.

4. The display prompts you to verify your action.

Re-setting Factory Defaults will destroy all user calibration information.

ARE YOU SURE?

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]. You will hear the pump motor spin up, and the DLC will perform an Encoder test (displaying the

following message:)

PLEASE WAIT

TESTING ENCODER

When the Encoder test is complete, (usually takes about 2 or 3 seconds) the DLC performs a Zero Calibration (displaying the following message:)

PLEASE WAIT

CALIBRATING ZERO

When the Zero Calibration is complete, you are returned to the {–MENU– / FACTORY DEFAULTS} screen.

Press [MENU] and the next screen displayed is:

MOTOR STOPPED

Re-establish any Menu and Calibration settings that are non-standard at this time..

7.3 Units

By pressing [UNITS] with the motor on, the display will scroll through the CMH, GPH, LPH, CCH, CMM, GPM, LPM, CCM, % flow, % stroke length or % motor speed. The DLC will automatically convert the motor and stroke settings based on the calibrated flow, to the above referenced units.

If the {MENU / NUMBER FORMAT} was setup to show only one specific calibrated unit of flow, then you will have only that unit displayed alternately with the % flow display.

The accuracy of the flow rate display is dependent on the pump flow calibration accuracy.

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. If the ANALOG MODE is set to ACTIVE, then pressing [MODE] will switch between {MANUAL MODE} and {ANALOG MODE}. When MODBUS MODE is set to ACTIVE, pressing [MODE] will switch between {MANUAL MODE} and {MODBUS MODE}. If both ANALOG and MODBUS modes are active the mode key switches between all three. In essence, this key acts like a local auto/manual switch.

7.6 Batch

The DLC is capable of following up to three (3) different batch programs. The batches operate in two modes: One Time Only and Repeating.

When Daylight Savings is set to Auto Change, use caution when setting up batches that run through or start or stop in the time change over periods where one full hour either doesn’t exist at all or occurs twice consecutively. If you are in doubt, set the {DAYLIGHT SAVINGS} option to [NO].

(Refer to Section 7.2.3 – Set Time & Date)

7.6.1 One Time Only

The One Time Only batch will start at a specified time and run for a specified duration at a specified flow rate that you define (refer to Figure 18).

Figure 18 – One Time Only Batch.

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. The highest of the two or three flow rates is used.

The DLC can make a 1% per second adjustment of pump stroke length. Remember that when a batch starts, the DLC will require some amount of time to achieve the new stroke setting. The adjustment time is taken as a portion of the batch running time. This will cause the output of the pump to be skewed.

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.

BATCHES

ACTIVE

Press [ENTER] to continue on to the batch sub-menu.

3. The display shows {EDIT / BATCH #1}. Press [UP] to {EDIT / BATCH #2} and [UP] again to {EDIT / BATCH #3}.

EDIT

BATCH #1

The DLC is supplied with three user programmable batches. Press [ENTER] to select the desired batch to edit.

4. The display shows {BATCH #1 RATE / 92.5%} (the value and unit of flow will depend on previous programming). The {RATE} text will be flashing. You can press [UP] or [DOWN] to view/change the other menu items related to this batch (e.g., RATE / DURATION / TYPE / START, etc.). Pressing [ENTER] causes the {RATE} value to stop flashing and allows you to program the batch flow rate. Press [UP] or [DOWN] to set the value.

If a value has been set previously it will be used as a starting point for the new setting.

Press

[UP]

Press

[UP]

BATCHES

INACTIVE

EDIT

BATCH #2

Press

[UP]

EDIT

BATCH #3

You can change the display units at any time by pressing [UNITS].

BATCH #1 RATE

92.5%

Press [ENTER] to accept your setting.

5. The display shows {BATCH #1 DURATION / XX HRS, XX MIN} with the word DURATION flashing. Press [ENTER] to set the duration (i.e., pump on time) of the batch.

BATCH #1 DURATION

12 HRS 30 MIN

6. The hours value should now be flashing on the display. A line (cursor) under the second digit indicates the field to be changed. Press [UP] or [DOWN] to scroll through the numbers 0-99. Press [ENTER] to accept the desired hour setting.

BATCH #1 DURATION

12 HRS 30 MIN

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. Press [ENTER] to accept the desired second digit of the minute setting which completes the batch duration entry and exits the Batch duration screen.

BATCH #1 DURATION

12 HRS 30 MIN

9. The display shows {BATCH #1 TYPE / ONE TIME ONLY}. Press [ENTER] to program the type of batch.

BATCH #1 TYPE ONE TIME ONLY

10. You can select from one of two types of batches: either a one time only batch or a repeating batch. A one time only batch executes the batch only once. A repeating batch repeats an on/off cycle indefinitely. Press [UP] to scroll between the different batch types.

BATCH #1 TYPE ONE TIME ONLY

Press

[UP]

BATCH #1 TYPE

REPEATING

Press [ENTER] to select the type of batch desired. If you select {ONE TIME ONLY} skip to step 12.

11. If a Repeating batch is selected, the display prompts you to enter the off duration time of the batch.

BATCH #1 OFF TIME

10 HRS 23 MIN

Follow the procedure outlined in steps 5 through 8. Press [ENTER] to accept the time setting.

12. The display shows {BATCH #1 START TIME / XX:XX XX/XX/XX}. Press [ENTER] to edit the batch start time. Press [UP] or [DOWN] to set the time and date value one character at a time. Press [ENTER] to accept your setting.

BATCH #1 START

8:01a 2/3/01

13. The display shows {BATCH #1 CONFIRM? / YES}. Press [ENTER] to confirm the batch or press [UP] to scroll to the {NO} value and then press [ENTER] to disregard the changes to the batch.

BATCH #1 CONFIRM?

YES

14. If the batch was made active, the display changes to let you know the batch is now pending and displays the time and date the batch will begin.

BATCH #1 PENDING

8:01a 2/3/01

15. When the clock reaches the start time and date for the batch, the display automatically changes to indicate that the batch is running. The pump will then operate at the specified rate, for the specified time.

You can press [UNITS] to change the displayed units while the batch is running.

BATCH #1 RUNNING

92.5%

While a batch is running you can display the time left in HH:MM:SS format by pressing either [UP], [DOWN] or [ENTER].

BATCH #1 RUNNING

REMAIN 11:59:58

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.

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. At that time, the batch will recycle.

BATCH #1 PENDING 6:54a 2/4/01

7.6.3.1 Inactivating The Batches

If the batch operation is not required to operate over a certain period of time, for instance the weekend, the batches should be inactivated.

v Batch Inactivation

1. Press [BATCH]. The screen will show the batch status: {BATCHES / ACTIVE}. Press [UP] to change the display to {BATCH / INACTIVE}. Press [BATCH] to accept and inactivate the batches and return to Manual Mode.

MOTOR OFF

8. Diagrams: Installation / Component

Diagram 1 – DLC Wiring Diagram

Diagram 2 – Motor Wiring Diagram

Diagram 3 – Serial Communications – RS 485 Connections

9. Specifications

STROKE LENGTH CONTROL: 0-100% control range

0.1% resolution 10:1 turndown for accuracy specification.

Combined Calibrated Flow:

Pump Accuracy:

Diaphragm

Steady State

Repeatability

Linearity

±0.5% ±0.5% ±0.5% ±0.5% ±1.0% ±1.0% ±1.0% ±3.0% ±3.0%

Adjustment Response:

Temperature:

Low Voltage Inputs

Inputs Field Wiring

Analog Input

J4 Pin 1 is + J4 Pin 2 is –

6 significant digits for displayed units of flow.

Diaphragm

With Leak

Detection

1% per second on stroke length. 1% per second on steady state speed.

–18°C to 40°C (0°F to 104°F) Operation. –18°C to 60°C (0°F to 140°F) Storage.

Location

Single Solid

Teflon

Diaphragm

Any signal within the range of 0 to 25mA (e.g.: 4-20) or 0 to 5 volts (e.g.: 1-5) Minimum span of 2mA or 0.4 volts. Note: No jumpers used. Displayed in mA.

Capacity

Reference

Set Point 10:1 20:1 50:1 Full Rating 10:1 20:1 50:1 Full Rating 10:1 20:1 50:1

Specification / Description

Stroke

Length

Turndown Range Accuracy Standard

Motor

Speed

Combined Turndown

PULSAlarm (Leak Detection)

Digital Input

Programmable as

Level Input

Remote Run / Stop

J4 Pin 3 is + J4 Pin 4 is –

J4 Pin 5 is + J4 Pin 6 is –

Split Ranging, Reverse Acting and Ratio Control standard on all units; accessible via calibration.

Fused at 50mA. Protected against mis-wiring. Surge Protection: 7.4 Joules Isolation: 500 volts from all other inputs, outputs, and ground.

Dry Contact. (Optically Isolated) – Do not apply powered signal. Isolation: Not isolated from Digital Input or Motor Thermostat, 500

volts from all other inputs, outputs and ground.

May be software configured as Normally Open or Normally Closed. May be software configured to operate the Alarm Relay. May be configured to turn the Pump Motor off.

Dry Contact. (Optically Isolated) – Do not apply powered signal. Isolation: Not isolated from PULSAlarm or Motor Thermostat, 500 volts

from all other inputs, outputs and ground. May be software configured as Normally Open or Normally Closed. May be software configured to operate the Alarm Relay (Level Input Only). May be configured to turn the Pump Motor off. (Level Input Only)

Low Voltage Outputs

Outputs Field Wiring

Analog Output Channel

Alarm Status

Digital Output

Programmable as

Remote Run Status

Stroke Counter

Mode Indication

Location

J5 Pin 1 is + J5 Pin 2 is –

J5 Pin 3 is + J5 Pin 4 is –

J5 Pin 5 is + J5 Pin 6 is –

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. Surge Protection: 7.4 Joules Isolation: 500 volts from all inputs and outputs. Dry Contact (Transistor Type) VCE (SAT): 0.3 volts Max forward current: 50mA Maximum 32VDC On-state resistance: 100 ohms Isolation: 5000 volts from all inputs, outputs and ground. Follows the state of High Voltage Alarm Output, which may be software configured as Normally Open or Normally Closed. Dry Contact (Transistor Type) VCE (SAT): 0.3 volts Max forward current: 50mA Maximum 32VDC On-state resistance: 100 ohms Isolation: 5000 volts from all inputs, outputs and ground. May be software configured as Normally Open or Normally Closed. (Remote Run Status and Mode Indication only).

High Voltage Inputs

Inputs Field Wiring

Line Power:

High Voltage Outputs

Inputs Field Wiring

Alarm Relay

Serial Communications

Inputs Field Wiring

RS–485

Control Inputs

Control Inputs Field Wiring

Location

Tachometer

Sensor

Motor

Thermostat

J10 Pin 1 is VDC J10 Pin 2 is Tach

J10 Pin 3 is + J10 Pin 4 is –

Specification / Description

Location

J1 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)

Specification / Description

Location

J2 Fused at 1 amp at rated Line voltage.

May be software configured as Normally Open or Normally Closed.

Specification / Description

Location

J7 & J8 Max Cable length: 1219 meters (4000 feet)

Max Address sites: 32 Use 120 ohm terminating resistors at both ends of network.

Isolation: 500 volts from ground and all other inputs and outputs.

Specification / Description

Connection point for TURCK Sensor..

Dry Contact (Optically Isolated) – Do not apply powered signal. Isolation: Not isolated from PULSAlarm or Digital Input, 500 volts from all other inputs, outputs, and ground. May be software configured as Normally Open or Normally Closed (default). May be software configured to operate the Alarm Relay (default is YES). May be software configured to turn the Pump Motor OFF If MOTOR OFF is selected may optionally restart the Pump Motor when the thermostat resets (default).

10. Factory Default Values

CALIBRATION

Pump Flow 1-Point Calibration on PULSAR at Rated Flow and Pressure. Analog Input 4.0 - 20.0mA @ 100% Ratio Analog Output 4.0 - 20.0mA @ 100% Ratio

DIAGNOSTICS

Alarms Cleared

DATE/TIME

Date Format MM/DD/YY Time Format 24:00 Daylight Savings Time No

ANALOG INPUT

Failure Mode Freeze at last signal / Restore to Analog Mode/ Error message enabled Sample Average 20 Samples Sample Update 20 Samples (5.0 Seconds)

LEAK DETECTION

Failure Mode Inactive

LEVEL INPUT

Failure Mode Inactive

DIGITAL OUTPUT

Run/Stop Normally Open

MOTOR THERMOSTAT

Input Enabled Switch Normally Closed Motor Off Alarm Restore to:

OVER TEMPERATURE

Error Message Enabled

POWER FAILURE

Failure Mode During power up – Motor Off Wrong Voltage Hard Shutdown

ALARM RELAY

Relay Output Normally Open

SECURITY Remains as previously set

NUMBER FORMAT

Separators X , XXX . XX (Comma / Decimal) Position PULSAR dependent (e.g., 9.99999, 0.999999, etc.)

Enabled – Number of input channels enabled is one.

Motor On

Factory set to match pumphead size. Refer to Factory Decimal Position Settings below.

All units are dispalyed.

CONTRAST Restored to initial Factory setting SERIAL COMM

Net Address Disabled

LANGUAGE English MODE Manual – Motor Off UNITS Percent (%) BATCH Inactive

Batch #n Rate 0% Batch #n Duration 0 H 00 M Batch #n Type One Time Only Batch #n Start Current Date and Time for first setting

FLOW RATE 0% Stroke Position 0%

FACTORY DECIMAL POSITION SETTINGS

RATED CAPACITY RANGE UNITS –MENU – / DECIMAL POSITION

5.99999 to 59.9999 CMH 999.999

1,585.03 to 15,850.3 GPH 999.999 5,999.99 to 59,999.9 LPH 999.999

5,999,990 to 59,999,900 CCH 999.999

0.0999999 to 0.999999 CMM 999.999

26.4172 to 264.172 GPM 999.999

99.9999 to 999.999 LPM 999.999

99,999.9 to 999,999 CCM 999.999

0.599999 to 5.99999 CMH 99.9999

158.503 to 1,585.03 GPH 99.9999

599.999 to 5,999.99 LPH 99.9999 599,999 to 5,999,990 CCH 99.9999

0.00999999 to 0.0999999 CMM 99.9999

2.64172 to 26.4172 GPM 99.9999

9.99999 to 99.9999 LPM 99.9999

9,999.99 to 99,999.9 CCM 99.9999

0.0599999 to 0.599999 CMH 9.99999 (default size)

15.8503 to 158.503 GPH 9.99999 (default size)

59.9999 to 599.999 LPH 9.99999 (default size)

59,999.9 to 599,999 CCH 9.99999 (default size)

0.000999999 to 0.00999999 CMM 9.99999 (default size)

0.264172 to 2.64172 GPM 9.99999 (default size)

0.999999 to 9.99999 LPM 9.99999 (default size)

999.999 to 9,999.99 CCM 9.99999 (default size)

Actual Flow is usually slightly larger than the

rated flow.

FACTORY DECIMAL POSITION SETTINGS (cont.)

RATED CAPACITY RANGE UNITS –MENU – / DECIMAL POSITION

0.00599999 to 0.0599999 CMH 0.999999

1.58503 to 15.8503 GPH 0.999999

5.99999 to 59.9999 LPH 0.999999

5,999.99 to 59,999.9 CCH 0.999999

0.0000999999 to 0.000999999 CMM 0.999999

0.0264172 to 0.264172 GPM 0.999999

0.0999999 to 0.999999 LPM 0.999999

99.9999 to 999.999 CCM 0.999999

0.000000001 to 0.00599999 CMH 0.0999999

0.000001 to 1.58503 GPH 0.0999999

0.000001 to 5.99999 LPH 0.0999999

0.001 to 5,999.99 CCH 0.0999999

0.00000000001 to 0.0000999999 CMM 0.0999999

0.00000001 to 0.0264172 GPM 0.0999999

0.00000001 to 0.0999999 LPM 0.0999999

0.00001 to 99.9999 CCM 0.0999999

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. Cycle power to the DLC (turn the main OFF then ON). This will cause the self-test routine to reexecute.

3. Press [MENU]. The screen {–MENU– / DIAGNOSTICS-1} is displayed. The value, in this case '1' indicates how many failures were detected.

4. Press [ENTER] to enter the Diagnostics Menu. The screen {DIAG MENU 1/11 / POWER IN: OK} is displayed.

5. Repeatedly press [UP] to cycle through all nine Diagnostic screens.

6. If a screen displays a FAIL message, press [ENTER] to display the time and date the failure occurred. Press [ENTER] again to display the clear screen. Press [UP] and then [ENTER] to clear the message. (This paragraph does not apply should you encounter a Battery Fail or Circuit Fail situation).

Make a note of any failures reported in the Diagnostics Menu. Using this information, proceed with the troubleshooting instructions below:

Other actions may be necessary to bring the process back to normal conditions before clearing a failure.

MENU (DIAGNOSTICS)

Symptom Probable Cause Possible Solution

DIAG 1/11 POWER IN: FAIL

DIAG 2/11 ANALOG IN: FAIL

DIAG 3/11 MODBUS FAIL

DIAG 4/11 LEAK DET: FAIL

DIAG 5/11 LEVEL INPUT: FAIL

DIAG 6/11 MOTOR TEMP

The power to the DLC failed while the pump motor was running.

The Analog Input signal fell under the calibrated range, or fell to 0 within 0.25 seconds (i.e., the signal was changing by more than 8.8mA per second and was less than 0.3mA).

A properly formatted and addressed MODBUS message was not received in the allotted time.

The Leak Detection Switch closure activated according to its configuration.

The Level Input Switch closure activated according to its configuration.

The motor exceeded its maximum internal temperature.

Place DLC in {MOTOR OFF} operating mode before disconnecting power. Refer to POWER trouble shooting.

Place DLC in {MANUAL MODE} or OFF before the signal loss occurs. Re-calibrate Analog Input. Condition Analog Input Signal. Refer to ANALOG INPUT trouble shooting.

Increase the Response Time setting.

Review Section 7-General Operation: Leak

Detection Failure Set-up. Refer to LEAK DETECTION trouble shooting.

Review Section 7-General Operation:

Level Input Failure Set-up. Refer to

LEVEL INPUT trouble shooting. Relocate to a cooler area.

MENU (DIAGNOSTICS) [cont]

Symptom Probable Cause Possible Solution

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* The DLC's internal motor has achieved its

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.

The Electrically Erasable Programmable Read Only Memory (EEPROM) on the mother board cannot be reliably read and/or written to.

The DLC's internal motor failed to respond when given a command to do so.

Duty Cycle limit: 50% over a 20 minute interval.

Re-locate the DLC to a environment with lower ambient temperatures. Refer to Section 9-Specifications.

The life expectancy is over. Contact Technical Services.

Cycle Power on unit to double check error. Contact Technical Services.

Cycle Power on unit to double check error. Review MANUAL KNOB / DLC INTERNAL DRIVE MOTOR trouble shooting. Contact Technical Services. Cycle Power to clear. Reduce motor run time by changing batch or conditioning analog input or Averaging Parameters.

DISPLAY

Symptom Probable Cause Possible Solution

No Display No power supplied. Check power source. plug & circuit breaker Back-lighting Supply power wired incorrectly. Check wiring. Supply power outside of specification. Check voltage/frequency against specification. Low voltage I/O wired incorrectly. Check wiring. Display ribbon cable loose. Contact Technical Services. Low voltage power supply failed. Contact Te chnical Services.

No Text on Display

Memory corrupted. Cycle power. Perform Factory Re-Initialize.

Environment exceeds 40°C (104°F).

Contrast out of adjustment. Adjust with [MENU] – [UP] or [MENU] –

[DOWN]

Software did not initiate properly. Cycle power.

Relocate to another area.

POWER

Symptom Probable Cause Possible Solution

No power No power supplied. Check power source. Plug & Circuit Breaker Indicators Supply power wired incorrectly. Check wiring. Supply power outside of specification. Check voltage/frequency against specification. Low voltage I/O wired incorrectly. Check wiring. Low voltage power supply failed. Contact Technical Services.

PULSAR MOTOR (1-Phase)

Symptom Probable Cause Possible Solution

Motor will not start. No power supplied. Check power source to DLC. . Motor wired incorrectly. Check wiring. Supply power outside of

specification.

Motor key not pressed. Keypad

problem. Remote Motor Switch is off Turn switch on. Software did not initiate properly. Cycle power. Alarm or Level input set with option

MOTOR OFF? set to YES. PULSAR mechanicals locked. Check PULSAR, reference PULSAR IOM. Motor Thermostat not connected or

programmed. Solid-state relay failed. Contact Technical Services. MODBUS in control. Check MODBUS control application

Motor will not stop. Motor wired incorrectly. Check wiring. Software did not initiate properly. Cycle power. Motor key not pressed. Keypad

problem. Solid-state relay failed. Contact Technical Services.

Check voltage/frequency against name plate.

Press [MOTOR}to start motor. Refer to the Keypad trouble shooting section.

Correct Alarm or Level condition. Set MOTOR OFF? to NO.

Connect or program the Motor Thermostat.

Press [MOTOR] to stop motor. Refer to the Keypad trouble shooting section.

ALARM RELAY

Symptom Probable Cause Possible Solution

Alarm Relay Relay wired incorrectly. Check wiring. will not Relay fuse blown.

Activate Software not configured properly. Refer to Section 7 – General Operation:

Replace with 1A@250VAC fuse.

Menu.

ANALOG INPUT

Symptom Probable Cause Possible Solution

Not Responding to Analog (mA) Input

Signal Failure Message Displayed with no signal loss

Lo Analog Input point (e.g., 4.0mA) does not equate to 0% unit reading

Input wired incorrectly. Check wiring. Input not wired to correct channel. Refer to Section 5 – Installation: Analog

Input for wiring instructions.

Input fuse(s) blown.

Not in Analog Operation Mode. Press [MODE] or configure Active. Input not calibrated properly. Review Section 7-General Operation:

Break in wiring. Check wiring. Input outside of specification. Boost/Condition Signal. Process fluctuates too rapidly: < 0.3mA and changing by more than 8.8mA/s

Miss-Calibrated. Re-Calibrate. 0% calibration value mis-interpreted. The "0% = 4.0mA" calibration screen refers to

Jitters or slow response. Change Averaging Parameters.

Replace F4 & F5 w/ 50mA@250VAC for channel #1 and F6 & F7 for Channel #2.

Calibration.

Condition Signal. Change Failure Mode. Recalibrate.

0% flow. Not 0% stroke.

PULSAlarm

Symptom Probable Cause Possible Solution

Not Input wired incorrectly. Check wiring. Responding to PULSAlarm Input Powered contact used. Remove and replace with dry contact . If no

Input not configured properly. Review Section 7-General Operation: Menu,

Leak Detection Failure Set-up.

change, contact Technical Services.

LEVEL

Symptom Probable Cause Possible Solution

Input wired incorrectly. Check wiring. Not Responding to Level Input Powered contact used. Remove and replace with dry contact . If no

Input not configured properly. Review Section 7-General Operation: Menu,

Level Input Set-up.

change, contact Technical Services.

ANALOG OUTPUT

Symptom Probable Cause Possible Solution

No Analog (mA) Signal Present.

Not tracking Output not calibrated properly. Review Section 7-General Operation:

Output wired incorrectly. Check wiring.

Output fuse(s) blown.

Replace F2 & F3 w/ 50mA@250VAC.

Calibration.

ALARM RELAY OUTPUT

Symptom Probable Cause Possible Solution

No Output Output wired incorrectly. Check wiring. External Device not powering output. Refer to Section 8 – Diagram 1 – DLC Wiring

Diagram. External device must supply voltage to dry contact.

Alarm Options not set. Review Section 7-General Operation: Leak

Detection/Level Input Set-up/Alarm Relay.

MANUAL ADJUSTMENT KNOB / DLC INTERNAL DRIVE MOTOR

Symptom 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}.

Know will not turn under DLC control. Display shows {POSITION ERROR}. The DLC has attempted to move the stroke adjustment for at leat 10 minutes with no movement determined.

Knob turns at power-up.

PULSAR Stroke Adjustment jammed on

mechanical stop at 0%.

PULSAR Stroke Adjustment jammed on

mechanical stop at 100%.

DLC gearing worn. Contact Technical Services.

Internal DLC Synchronous motor has

achieved its duty cycle limit of 50% ON

time (based on a 20 minute interval).

Rapidly cycling batches and wildly

swinging analog inputs will cause this

motor to run continuously.

Motor Starter wired incorrectly. Motor starter must be wired through the DLC.

The Stroke Position encoder is bad. Cycle power and attempt re-calibration. If

The Stroke Position gear train has failed. Cycle power. Use [UP] and/or [DOWN] to set

The Stroke Adjustment is jammed. Rotate adjustment in the direction opposite to

Normal Zero Calibration . Display should

read {PLEASE WAIT / CALIBRATING

ZERO}.

Remove DLC. Turn shaft counter-clockwise with crescent wrench on flats to free. Re-install DLC. Re-calibrate flow. Remove DLC. Turn shaft clockwise with crescent wrench on flats to free. Re-install DLC. Re-calibrate flow.

Eliminate batches that are cycling too rapidly (e.g., changing stroke from 0 to 100% one minute and 100 to 0% the next - the internal drive motor runs all the time). Condition analog input signal. Cycle Power. Wait for 'cool-down' period. Refer to Section 5 – Installation: High Voltage Connections, PULSAR MOTOR.

Encoder diagnostics appears, contact Technical Services.

stroke to 50% while the DLC stroke motor is running. Adjust knob by hand. Feel for smooth operation and “Catching”. Contact Technical Services.

the current position (i.e., at 100% rotate clockwise, at 0% rotate counter clockwise.

Do not turn knob by hand while DLC's power is off.

KEYPAD

Symptom Probable Cause Possible Solution

Display does Software did not initiate properly. Cycle power. Not respond Memory Corrupted. Cycle power. Perform Factory Re-Initialize. To keypad Keypad connector loose. Contact Technical Services. Entry.

BATCH OPERATION

Symptom Probable Cause Possible Solution

Activated batch appears to be running through batches rapidly.

Repeating Batch will not start.

Repeating Batch activated with Old Start

Date. For example, today is 1/22/01, You

have a repeating batch programmed to start

on 1/5/01). The display will show the 'run-

through' of all batches between the start

day and time and today.

Batch duration is set to 0 hours and 0

minutes.

Change Batch start-time/date to current or future date/time.

Duration must be greater than 0 minutes for batch to activate.

CALIBRATION

Symptom Probable Cause Possible Solution

Message: {Terminated / Press any key} appears during Calibration.

Manual Knob adjusted while Calibration

session was active.

Do not touch the Manual adjustment knob while a Calibration session is active.

UNITS

Symptom Probable Cause Possible Solution

Units do not increment with change in %.

Displayed units read - 000000

Unit not properly calibrated. Calibration

beyond display resolution.

High pressure pump. Due to

compressibility, the pump will not

discharge fluid until the Stroke Adjustment

is above a non-zero value (e.g. set the

adjustment to 3% and the pump discharges

fluid. Set the adjustment below 3% and no

fluid will be discharged.) When the stroke

is set below the zero point, the display

shows –000000.

Re-calibrate to value within display range. Change number format to give additional precision.

Display is normal. Increase the stroke setting until the unit reads properly. Re-calibrate.

SERIAL COMMUNICATIONS

Symptom Probable Cause Possible Solution

No response to Master Communications setting mis-match

Master Not Receiving. Use serial diagnostics to check receipt and

Poor Performance

Communication Settings Refer to the guidelines in Section 7 – General

Frequent Message {MODBUS SIG. FAIL}

Wiring Master / Slave wiring incorrect. Refer to

Wiring Serial Communications Input. Check Communications settings. Refer to

between Master & Slave.

Wiring/Interference Use proper wire type.

Time Out setting Refer to Section 7 – General Operation:

Section 7, General Operation: Serial Communications.

transmission of characters.

Limit total network length to 1200M (4000ft) Do not run communication wire in the same conduit with the power wire. Avoid runs near large motors.

Operation: Serial Communications.

MODBUS Signal Failure Setup for

guidelines on time out settings.

MISCELLANEOUS

Symptom Probable Cause Possible Solution

Over voltage or under voltage message displayed. DLC factory configured for operating

Power failure message displayed.

Incoming Power un-reliable.

Note: You must power off and then power

back up to clear.

voltage other than input.

PULSAR motor running at time of power

loss.

DLC should have separate branch circuit taken from main. Re-wire. Consider surgesuppression.

DLC must run under Factory configured operating voltage. Locate source of correct voltage and re-wire.

Turn PULSAR motor off before powering DLC down.

ENCODER ERROR

Symptom Probable Cause Possible Solution

Message: {ENCODER ERROR / PRESS ENTER} displays during encoder test.

Encoder defective. Contact Technical Services

Internal Motor unable to turn adjustment

knob.

Defective Drive circuits – contact Technical

Defective encoder or wiring

Broken or jammed gears – contact Technical Services.

Defective motor – contact Technical Services.

Services.

11.1.1 Encoder Diagnostics

Whenever the DLC is re-calibrated it optionally first performs a Zero Calibration . The first portion of the {CALIBRATING ZERO} routine is the encoder test. The DLC will increase the stroke adjustment one full rotation of the encoder gear train (approximately one half turn of the Manual Adjustment Knob), while monitoring the encoder output. It will then reverse direction and drive the mechanism to the 0% position. During this cycle, the DLC reads the encoder output and compares it to an expected value. If, at any time during this process the DLC detects an error the following screen is displayed:

ENCODER ERROR

PRESS ENTER

There could be internal damage to the encoder or gear train – possibly an obstruction or a broken gear.

The {ENCODER ERROR / PRESS ENTER} screen is also displayed if the DLC times out while

trying to adjust the Stroke Position and senses no detected motion.

Press [ENTER] and the following status screen is displayed

TURN MOTOR ON

TESTING ENCODER

Prior to turning the motor on, gently rotate the Manual Control Knob in both directions. If there is a minor jam in the encoder gear train, this simple action could clear it.

Press [MOTOR] and the following screen is displayed.

PLEASE WAIT

TESTING ENCODER

If the encoder error has been cleared, the DLC will continue with the {ZERO CALIBRATION} procedure.

If the encoder error is still present, the following screen is displayed:

ENCODER ERROR

PRESS ENTER

At this time the operator should remove power from the DLC, and contact Technical Services.

There is no way to bypass the Encoder Test in the {CALIBRATING ZERO} process.

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. Disconnect the motor power from J3 on the Field Wiring Board (refer to Figure 4 – High Voltage Connections).

4. Assure that the pump will not discharge fluid and will not be subject to back pressure. Take all necessary precautions.

5. To complete this procedure, you will have to manually rotate the PULSAR drive motor. If the motor type is TEFC, you can push against the fan blades through the shroud to do this. If the motor type is TENV, you must remove the protective cap from the end of the motor to access the motor shaft.

6. Turn on the power to the DLC at the main panel.

7. Check the supply voltage to the Tachometer. Set your multi-meter to read DC voltage in the range of 0-100 VDC. Connect the positive lead of the multi-meter to J10-1 (TACH[+]). Connect the negative lead of the multi-meter to J5-8 (unlabeled, it is actually DC ground). You should read a value of

12.0VDC +/- 1.0VDC. If you do not read this value, stop your test and contact Technical Services.

8. Check the output from the Tachometer. Set your multi-meter to read DC voltage in the range of 0-10 VDC. Connect the positive lead of your multi-meter to J10-2 (TACH[-]) and the negative lead to J5-8 (unlabeled, it is actually DC ground). Slowly rotate the pump motor observing the high and low multimeter readings. When the Tachometer is working properly this output will be transition from a value of approximately 1.0 VDC when a gear tooth is near the end of the sensor to a value above 5.0 VDC when it is away from it. If these readings are obtained skip to step 17.

9. If these voltage readings are not obtained, adjust the sensor as follows.

10. Remove the conduit from the sensor housing by removing the ‘C’ clip and threading the plastic coupling from the sensor. Note: the tachometer cord will prevent you from removing the conduit completely. Refer to Figure 8: Tachometer and Pump Motor Thermostat Connections.

11. Remove the lock nut from the sensor housing and carefully rotate the sensor body clockwise until the sensor bottoms against the gear, then rotate the sensor body counter clockwise 1/2 turn.

12. Slowly rotate the pump motor until the minimum multi-meter reading is obtained. If the meter does not exhibit any voltage change either the sensor or the interface circuitry is defective.

13. Slowly rotate the sensor body counter-clockwise a few degrees at a time until the minimum multimeter reading is obtained. If this reading is above 1.5 volts either the sensor or the interface circuitry is defective.

14. Slowly rotate the sensor body clockwise a few degrees at a time until the multi-meter reading rises slightly (0.01 to 0.05 volts above the minimum obtained above).

15. Replace and tighten the lock nut, while maintaining the voltage reading above by holding the sensor cable to prevent the sensor from rotating.

Slowly rotate the pump motor observing the high and low multi-meter readings. The output should now

transition from a value below 1.5 VDC when a gear tooth is near the end of the sensor to a value above

5.0 VDC when it is away from it. If the meter reads a low value above 1.5 VDC or a high value below

5.0 VDC either the sensor or the interface circuitry is defective. .

17. If you have already made adjustments to the Tachometer position at this point you may want to skip to step 20 and test your adjustments.

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. Connect the motor power to J3 on the Field Wiring Board (refer to Figure 4: High Voltage Connections).

24. Replace the Wiring Access cover (refer to Figure 2: Accessing the Field Wiring Board).

25. Turn ON the power to the DLC at the main panel.

26. Press [MOTOR] to start the motor.

27. Verify that strokes are being counted, if not contact Technical Services.

11.1.3 Tachometer Upgrade Adjustment Instructions

The new Pulsar DLC/DLCM controllers are equipped with upgraded tachometer circuitry which increases the accuracy of the unit and decreases the possibility of errors in the future. When this new circuit replaces the older tachometer circuit, there is an adjustment procedure that must be followed to insure proper operation of the tachometer circuit.

1. Install the DLC/DLCM controller on your pump as per the instructions in the Pulsar IOM

(Installation, Operation and Maintenance) Manual.

2. Secure and carefully check all wiring connections to and from the DLC/DLCM.

3. Power up the DLC/DLCM.

4. Note the following terminals: J5-8 signal ground (VDC -)

J10-1 voltage output (12 VDC +) J10-2 tachometer signal (VDC variable +)

5. Measure voltage between J5-8 and J10-1, should read 12 VDC.

6. Remove the top cover of your drive motor so that you can access the motor shaft.

7. Measure the voltage between terminals J5-8 and J10-2, and rotate the motor shaft until you have

the lowest voltage reading.

8. Loosen the locknut on the tachometer body, and adjust the position of the tachometer sensor until

the voltage reads 1.0 VDC.

9. Rotate the motor shaft again, and observe the voltage, the highest voltage observed should be 5.5 –

6.0 VDC.

10. As the motor shaft is rotated, the voltage should vary between 1.0 and 5.5 to 6.0 VDC.

11. Make necessary adjustments to achieve this range, then tighten the locknut on the tachometer body.

12. Secure all wiring, replace all covers, and prepare the pump for operation as per your normal

procedures.

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 21 – Manual Cover Assembly

4. Remove the Manual Cover vertically from the Eccentric Box.

5. Visually inspect the Cam Pocket cover. If the Cam Pocket cover is constructed out of plastic, refer to and perform the procedure defined in

Bulletin No. PMP-DLC-FCM-98 Cam Pocket Cover Replacement. If the Cam Pocket cover is constructed out of metal continue to step 6.

6. Note the position of the adjustment shaft 'flats'. They mate with a slot in the DLC output shaft. Familiarize yourself with these mating components prior to installation (refer to Figure 22).

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. 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 black hand knob on the DLC. Do not turn the adjustment shaft!

9. Lower the DLC onto the eccentric box. It may be necessary to tip the DLC slightly towards the motor to clear the motor adapter. With the DLC approximately 25mm (1 inch) above the eccentric box, make a fine adjustment to align the slot in the DLC coupling with the adjustment shaft 'flats'. Once aligned, lower the DLC to mate with the eccentric box. Do not force the cover! When the coupling is properly aligned, the DLC will seat properly under its own weight.

10. Install the 4 DLC mounting screws and washers provided.

11. Remove the 4 wiring access panel screws.

12. Follow the instructions in Section 5 – Installation: Electrical Wiring of this manual for electrical connections.

13. Perform the steps detailed in Section 6 – Start Up Instructions.

14. Review Section 7 – General Operation for detailed information on configuring your DLCM and its advanced features.

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. Remove the replacement DLC from the packaging and swap it with the DLC needing repair. Return the DLC in the same packaging within 30 days. Make sure that there are no components missing from the returned unit – you will be

charged accordingly. Upon receipt of the unit at PULSAFEEDER, an evaluation will be made within 14

days. The unit returned will be refurbished for use in the replacement program.

The DLC has been designed to allow you to replace a defective unit without disturbing the wiring and conduit The replacement unit will be shipped with the conduit adapter and attached field wiring board (refer to Figure 2). It is left to your discretion as to whether or not these components are used for the replacement. (Typically, these are left attached to the wire/conduit and form a 'plug' for the replacement unit.) When the original unit is returned to PULSAFEEDER, the unused conduit adapter (“new or “original”) must be attached to the original unit.

13.1 Emergency Manual Pulsar Operation

If your DLC is not functioning, you can operate your PULSAR manually without removing the DLC. Follow this procedure:

1. Disconnect the power to the DLC at the main.

2. Remove wires to J1 LINE POWER and J3 PUMP MOTOR. Use wire nuts or other code approved connectors to attach the LINE HOT to the MOTOR HOT, the LINE EARTH to the MOTOR EARTH, and the LINE NEUTRAL to the MOTOR NEUTRAL.

3. Re-connect the DLC power at the main.

THE PULSAR MOTOR WILL START IMMEDIATELY! TAKE ALL NECESSARY SAFETY

PRECAUTIONS.

4. Rotate the manual adjustment knob on the DLC clockwise to zero the pump. It will be difficult to rotate as you are back-driving the DLC motor. Be careful! Do not force the knob. Try turning it in both directions to get a feel for the back-drive torque. As you approach zero the knocking will diminish.

5. Once you have found zero, mark the knob and cover with a piece of tape to use as a reference.

6. You can set the stroke adjustment to a specific value by calculating the number of knob turns. To do this, divide the desired setting (%) by a factor of 4(%/rotation). For example, say your desired setting was 67%. You would divide 67 by 4 which equals 16.75. So you would turn the knob 16 and 3/4 revolutions from the zero position.

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.

Do not adjust the stroke setting beyond the 100% (25 turns from 0%) setting.

2. Disconnect the power to the DLC at the main. Power down all attached equipment (e.g., PLC's).

3. Remove the four screws and Teflon Gaskets that hold the wiring access cover to the DLC (refer to Figure 23).

Figure 23 – Wiring Cover Access

4. Remove the Wiring Access Cover

Pulsafeeder DLC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual