Pulsafeeder DLC User Manual
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
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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.
Copyright
Copyright © 2001 Pulsafeeder, Inc. All rights reserved.
Information in this document is subject to change without notice. No part of this publication may be
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
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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
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Conventions
For the remainder of this bulletin, the following Conventions are in effect.
v
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 -
- 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 -
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