Pulsafeeder DLC XP RC User Manual

Installation, Operation & Maintenance Instruction

Bulletin No. PR- IOM - XPRC-0301-C

Manufacturers 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-XP/RC™ FACTORY SERVICE POLICY

Your DLC–XP/RC™ is a state of the art microprocessor-based stroke length control device for use with PULSAR experiencing a problem with your DLC–XP/RC, 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 Pulsafeeder Sales Representative or our Technical Service Department at (585) 292-8000 for further assistance.

Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include purchasing a replacement unit or returning the DLC–XP/RC 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–XP/RC by Pulsafeeder personnel.

Certain components may be purchased for replacement in the field. Parts purchased to correct a warranty issue may be credited after examination of the original parts by Pulsafeeder. Parts returned for warranty consideration that are good will be sent back freight collect.

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

This document describes product features controlled by ATEX requirements. Those features, and this document, can not be changed without notification or approval of the appropriate agency.

Diaphragm Metering Pumps. It includes extensive on-board diagnostics. If you are

Revision History

Rev C (09-27-2007)

• Started revision history

• Added ATEX statement above

• Other minor text changes throughout

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.

Table of Contents

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

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

1.1.1 Standard Features........................................................................................................... 2

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

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

2.2 Explosive Atmosphere Safety............................................................................................... 3

2.3 Electrical Safety...................................................................................................................... 3

2.4 Mechanical Safety................................................................................................................... 3

2.5 Hydraulic Safety...................................................................................................................... 3

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

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

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

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

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

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

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

5.2.1 Electrical Wiring.............................................................................................................. 6

5.3 Getting Started........................................................................................................................ 7

5.3.1 Finding your way around the DLC-XP and DLC-RC Field Wiring Boards................. 8

5.4 Control Connections .............................................................................................................. 9

5.4.1 Control.............................................................................................................................. 9

5.5 High Voltage Connections..................................................................................................... 10

5.5.1 Supply Power................................................................................................................... 11

5.5.2 PULSAR Motor Starter Relay (DLC-RC)........................................................................ 11

5.5.3 Alarm Relay (DLC-RC) .................................................................................................... 12

5.6 Low Voltage Input Connections............................................................................................ 12

5.6.1 Analog Input (DLC-RC)................................................................................................... 13

5.6.2 Leak Detection Input (DLC-RC)...................................................................................... 13

5.6.3 Drum Level Input (DLC-RC)............................................................................................ 13

5.6.4 Second Analog Input (DLC-RC)..................................................................................... 13

5.7 Low Voltage Output Connections......................................................................................... 14

5.7.1 Analog Output (DLC-RC)................................................................................................ 14

5.7.2 Alarm and Motor Status Outputs (DLC-RC) ................................................................. 15

5.8 Fuse Replacement.................................................................................................................. 16

6. START UP INSTRUCTIONS..................................................................................................................... 17

6.1 Overview.................................................................................................................................. 17

6.1.1 User Interface Familiarization........................................................................................ 18

6.1.2 Check Wiring and Close Covers.................................................................................... 19

6.1.3 Confirm Correct Incoming Power.................................................................................. 20

6.1.4 Confirm the display and keypad are functioning properly......................................... 20

6.1.5 Performing a Factory Re-initialization. ......................................................................... 21

6.1.6 Start-up Factory Re-initialization:.................................................................................. 21

6.1.7 Menu Factory Re-Initialization:...................................................................................... 22

6.1.8 Test Pump Motor............................................................................................................. 22

6.1.9 Confirm Proper DLC-XP Operation. .............................................................................. 23

6.1.10 Set Time and Date........................................................................................................... 23

6.1.11 Calibration (1-point)........................................................................................................ 24

iii

6.1.12 Wrapping up.....................................................................................................................24

7. GENERAL OPERATION ..........................................................................................................................25

7.1 Calibration................................................................................................................................25

7.1.1 Pump Flow Calibration....................................................................................................25

7.1.2 Analog Input Signal Calibration.....................................................................................27

7.1.3 Reverse Acting Analog Input Signal Calibration..........................................................29

7.1.4 Analog Output Signal Calibration..................................................................................29

7.2 Menu.........................................................................................................................................30

7.2.1 Diagnostics ......................................................................................................................30

7.2.2 Set Time and Date............................................................................................................33

7.2.3 Analog Signal Failure Set Up .........................................................................................34

7.2.4 Leak Detection Failure Set Up........................................................................................35

7.2.5 Level Switch Failure Set Up............................................................................................36

7.2.6 Digital Output Set Up.......................................................................................................37

7.2.7 Motor Thermostat Set Up................................................................................................37

7.2.8 Over Temperature Set Up...............................................................................................37

7.2.9 Power Failure Set Up.......................................................................................................38

7.2.10 Alarm Relay......................................................................................................................38

7.2.11 Analog Mode....................................................................................................................39

7.2.12 Security.............................................................................................................................39

7.2.13 Number Format................................................................................................................40

7.2.14 Contrast Adjust................................................................................................................41

7.2.15 Serial Communications...................................................................................................41

7.2.16 Language..........................................................................................................................41

7.2.17 Factory Default.................................................................................................................42

7.3 Units .........................................................................................................................................42

7.4 Varying The Flow Rate - Manually.........................................................................................42

7.5 Mode.........................................................................................................................................42

7.6 Batch ........................................................................................................................................43

7.6.1 One Time Only .................................................................................................................43

7.6.2 Repeating .........................................................................................................................43

7.6.3 Overlapped.......................................................................................................................43

8. DIAGRAMS: INSTALLATION / COMPONENT..............................................................................................46

9. SPECIFICATIONS...................................................................................................................................49

10. FACTORY DEFAULT VALUES .................................................................................................................51

11. TROUBLE SHOOTING GUIDE..................................................................................................................52

11.1 System Diagnostics................................................................................................................52

11.2 Encoder Diagnostics ..............................................................................................................57

12. CONVERSION (MANUAL TO DLC-XP/RC) .............................................................................................58

13. SYSTEM REPAIRS.................................................................................................................................59

13.1 Emergency Manual Pulsar Operation. ..................................................................................59

13.2 DLC-XP Replacement .............................................................................................................59

APPENDIX A – QUICK START GUIDE ............................................................................................................61

Preparing..............................................................................................................................................61

Installation:..........................................................................................................................................61

Wiring Connections ............................................................................................................................62

1. Introduction

The DLC–XP/RC is a microprocessor based stroke length control device for use with the PULSAR diaphragm metering pump. It has been designed with many advanced features that allow the PULSAR to operate in a wide variety of industrial environments.

This instruction manual covers the DLC–XP/RC - Digital Stroke Length Controller for NEMA 7 installations. Refer to Table 1 for the specific standard features and options for your model. All standard features are covered in this manual and most options have instructions where applicable.

For information specific to the metering pump itself, please consult the appropriate IOM. This document contains information on the electronic controller only.

1.1 Description

The DLC–XP/RC is an electromechanical servo controller dedicated to the PULSAR diaphragm metering pump series. The stroke control mechanism is physically attached and integrated into the pump's design. The control and user interface is located remotely to the pump -- in a safe environment. The purpose of the DLC–XP/RC is to precisely adjust output flow of a process media by means of stroke length positioning.

The DLC-XP/RC 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-XP/RC responds immediately to user commands. Pump output is displayed as a percentage of stroke length position or in units of calibrated flow: GPH, LPH, CCH, GPM, LPM, CCM. In addition, the DLC-XP/RC display supports any one of four standard languages: English, French, German, or Spanish.

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

The DLC-XP/RC 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-XP/RC readily accepts PULSAlarm® leak detection and drum level inputs. These may be configured to stop the pump and/or activate an alarm relay. Alarms 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.

1.1.1 Standard Features

• Digital stroke length control for PULSAR and SHADOW model pumps

• User keypad

• Back-lit 2 x 16 LCD display

• Solid state PULSAR motor control relay

• 4-20mA input and output

• 10-Year battery backed clock and configuration memory

• Solid state digital outputs

• Drum level / Remote start input

• PULSAlarm® Leak Detection interface

• Diagnostics built into software

Security states may be activated to prevent unwanted tampering. All settings and diagnostics are battery backed up to 10 years in absence of power.

The DLC-XP/RC is available in any combination of 120/240 VAC, 50/60 Hz, this configuration must be specified at time of order.

2. Safety Considerations

The DLC-XP/RC 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, the user should be mindful of this relative to his/her safety, that of co-workers and of the process environment. Please consider the following prior to the installation and operation of a DLC-XP/RC controlled PULSAR metering pump:

2.1 General Safety

The DLC-XP/RC 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 warrantees.

2.2 Explosive Atmosphere Safety

WARNING -- EXPLOSION HAZARD -- DO NOT PERFORM INSTALLATION/MAINTENANCE OF ANY

KIND ON THIS DEVICE WHILE CIRCUIT IS LIVE AND

With the proper marking, the DLC-XP/RC is suitable for use in Class I, Division 1, Group C & D and Class I, Zone 1, Group IIB or non-hazardous locations only. The DLC-XP/RC will be marked for use Div. 2 / 2 one 2 or non-hazardous locations only.

/OR THE AREA IS KNOWN TO BE HAZARDOUS.

The control chassis of the DLC-XP/RC is not suitable for use in a hazardous environment and must be remotely located in a safe area. Wiring between the two units must conform to local, state, and national codes and requirements.

2.3 Electrical Safety

The DLC-XP/RC can be considered an industrial controller with an integrated single phase motor starter. Improper application and use can be hazardous. The user is solely responsible for its use.

Electrical installation must conform to all location 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-XP/RC emits electro-magnetic energy and generates radio frequency interference. Its use is restricted to industrial applications. The user bears all responsibility for shielding this energy/interference.

2.4 Mechanical Safety

When properly installed, the device has no external moving parts. The DLC-XP/RC should not be operated without its cover installed. When under power, the DLC-XP/RC is under computer control and as such may actuate without warning to the user.

2.5 Hydraulic Safety

Thoroughly review and adhere to the contents of the appropriate pump IOM for installation of your PULSAR metering pump. As a microprocessor controlled device, the DLC-XP/RC may activate the pump motor without warning to the user -- generating hydraulic pressure and fluid flow. Care should be taken to protect both users and system from such conditions.

3. Equipment Inspection

Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported within 30 days of receipt of this equipment to the freight carrier and your PULSAFEEDER Representative.

4. Storage Instructions

The DLC-XP/RC can be successfully stored for extended periods. The key to this success is control of temperature and humidity.

4.1 Short Term (0 - 12 months)

The DLC-XP/RC 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 by hand one full revolution every six months.

If the DLC-XP/RC 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-XP/RC is removed from the pump, it should be stored in the same pump mounted orientation. After removal, seal the eccentric box opening with a dust and moisture proof material. If the DLC-XP/RC was shipped in its own carton, it should be stored in that carton.

4.2 Long Term (12 months or more)

Storage of the DLC-XP/RC for periods of longer than twelve months is not recommended. If extended storage is un-avoidable the DLC-XP/RC 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

IMPORTANT! Review the Safety section prior to installing the DLC-XP/RC. This

section contains important information required to properly install and operate the equipment in an industrial environment.

The site selected for the installation of your DLC-XP/RC is largely dependent on that of the PULSAR metering pump. Review the PULSAR Installation Operation Maintenance Instruction Manual provided with your PULSAR metering pump. It details system related issues that are important to proper operation of the PULSAR metering pump.

Your DLC-XP/RC with the NEMA-7 option consists of 2 main components: the DLC-XP is a pump mounted actuator for installation in hazardous environments, the DLC-RC is the controller that supervises the actuator (DLC-XP). The DLC-RC 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. It must be mounted within 305m (1000ft) of the DLC-XP. Avoid locations where both the DLC-XP/RC would be subjected to extreme cold or heat. Note the following warning statement. The installation of this device should comply with national, state and local codes.

Figure 1. Typical Installation.

AVOID LOCATIONS WHERE THE DLC-XP/RC WOULD BE SUBJECTED TO EXTREME COLD OR

[LESS THAN -18° CELSIUS (0° FAHRENHEIT) OR GREATER THAN 40° CELSIUS (104°

HEAT

FAHRENHEIT)] OR DIRECT SUNLIGHT. FAILURE TO OBSERVE THIS WARNING COULD DAMAGE

DLC-XP/RC AND VOID ITS WARRANTY.

THE

5.2 Installation Notes

1. The DLC-RC is a microprocessor based controller that uses static sensitive CMOS components. Do

not make any electrical connections (high or low voltage) without adequately grounding the DLC-RC 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-RC enclosure is adequate to satisfy this requirement.

2. Calibration is an important element of successful DLC-XP/RC operation, the permanent installation

of a calibration column as shown in Figure 1 is strongly recommended.

3. Conduit connections can carry fluids and vapors into the DLC-XP/RC causing damage and void of

warranty. Care should be taken when installing conduit to protect against fluid/vapor entry. Sealed fittings within 18 inches are required for all connections to the DLC-XP.

4. The upper enclosure cover of the DLC-XP pump-mounted control unit must be securely and

properly fastened to ensure compliance with hazardous area regulations. See Section 6.1.2 for the proper procedure.

5.2.1 Electrical Wiring

The DLC-XP/RC has many advanced features that may make wiring the unit appear complicated. Wiring is actually very simple -- a minimum of three high voltage and 14 low voltages connections are all that is required to take advantage of a majority of the DLC-XP/RC’s features. It is highly recommended that you take a step-by-step approach to wiring and confirming proper DLC-XP/RC operation:

1. Make the (10) low voltage control connections. These allow the DLC-RC to communicate with the

DLC-XP.

2. Make the high voltage connections. These will allow you to operate the DLC-XP/RC and attached

PULSAR pump. Power-up and test the DLC-XP/RC to confirm the connections and check for proper operation.

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

power-up and test these connections.

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

Again, perform the power-up and test cycle. Refer to Section 6 – Start Up Instructions for details on how to perform the power-up tests.

5.3 Getting Started

The field wiring terminals of the DLC-XP are accessed by removing the its cover. Remove the 13 retaining screws (Phillips head screw driver required). Refer to Figure 2. The field wiring terminals of the DLC-RC are openly visible on the chassis.

Figure 2 – Accessing the Field Wiring board

The DLC-XP cover has the Serial Number Tag on it. Please keep the cover with the DLC-XP from which it was removed. The DLC-XP is marked internally with the Serial Number. The internal marking will be used for warranty claims.

The DLC-XP and DLC-RC Field Wiring Boards (see Figure 3) contains wiring blocks for making all of the electrical connections.

Keep careful track of the hardware and o-ring used to secure and seal the upper cover of the control unit. The upper enclosure cover of the DLC-XP pump-mounted control unit must be securely and properly fastened to ensure compliance with hazardous area regulations. See Section 6.1.2 for the proper procedure.

5.3.1 Finding your way around the DLC-XP and DLC-RC Field Wiring Boards.

The electrical connections are segregated on the Field Wiring Boards. On the DLC-XP, the High Voltage connections are near the conduit ports, the low voltage connections are furthest away from them. On the DLC-RC, the high voltage connections are on the right half of the board while the low voltage connections are on the left. Refer to the Field Wiring Board map in Figure 3 for specific connection and fuse locations.

Figure 3. Field Wiring Board Map.

5.4 Control Connections

The DLC-RC is attached to the DLC-XP through one 10 conductor shielded cable. This cable transmits the encoder information from the DLC-XP to the DLC-RC -- allowing the DLC-RC to know the position of the stroke adjustment shaft at all times. Additionally this cable transmits the synchronous motor control and power signals from the DLC-RC to the DLC-XP. This allows the DLC-RC to change the position of the stroke adjustment shaft. Care should be taken to ensure that the control connections are made properly. Failure to do so will result in unpredictable operation.

The DLC-XP to DLC-RC separation distance should be no more than 1220m (4000 ft). The control wiring must not be routed in a conduit that also contains power conductors, as this will cause electrical interference and result in erratic operation. Separate conduits must be used for high voltage and low voltage circuits.

5.4.1 Control

Use Belden 1422A (5 Pair), 24 AWG, 7X32 strand, NEC CM, UL 2919, 30V, 80C, shielded or equivalent.

1. Connect the 4 encoder lines from the DLC-RC J17 terminal block to the DLC-XP J2 terminal block.

2. Connect the 6 control lines from the DLC-RC J18 terminal block to the DLC-XP J5 terminal block.

The shields for both cables should be terminated at the DLC-RC J19 only. The wiring is straight through -- connect position 1 on J17 to position 1 on J2 and position 1 on J18 to position 1 on J5. Refer to Figure 4.

TERMINATE THE CONTROL SHIELD AT THE DLC-RC END ONLY! TERMINATING THE SHIELD AT

BOTH THE UNPREDICTABLE OPERATION AND

WARRANTY.

Wire the control connection carefully. Double check wire order (color codes) before proceeding. 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.

DLC-RC AND DLC-XP WILL POTENTIALLY CAUSE A GROUND LOOP RESULTING IN

/OR FAILURE OF THE UNIT THAT IS NOT COVERED BY THE

Figure 4. Control Connections

5.5 High Voltage Connections

There is only one high voltage connection to be made on the DLC-XP: the supply power (J1). On the DLC-RC, there are only three high voltage connections: the supply power (J1), the PULSAR motor starter relay load (J3), and the Alarm Relay Load (J2). Only the supply power and PULSAR motor starter relay load connections are required. Refer to Figure 5 for connection location.

Figure 5. High Voltage Connections

5.5.1 Supply Power

The DLC-RC requires one connection to an external power source. It uses this same connection to power its own supply, the motor starter relay (external) and the alarm relay output. The user must be mindful of these external loads when sizing the branch circuit.

The DLC-RC power supply and attached PULSAR motor starter relay (external) are not fuse protected. The user is responsible for correctly sizing the protection element (i.e., fuse or circuit breaker at the distribution panel). Use the work sheet in Table 2 for correctly sizing the branch protection element.

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

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

DLC-RC 1A (1A Max.) DLC-RC .5A (.5A Max.) Motor Relay* + (8A Max.) Motor Relay* + (4A Max.) Alarm Relay* + (1A Max.) Alarm Relay* + (1A Max.)

Total DLC-RC**

Total DLC-XP**

1A (1A Max.)

Total-DLC-RC **

Total DLC-XP**

.5A (.5A Max.) * 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.

Table 2: Branch Circuit Protective Element Sizing Worksheet.

The DLC-RC with an attached pump motor relay 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.

The DLC-XP should also 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.

The operating voltage and frequency of the DLC-XP are factory configured -- an internal motor/capacitor and power supply are sized according to voltage and frequency. Attempting to operate DLC-XP outside of rating will result in damage to the unit that is not covered by the warranty.

The operating voltage and frequency of the DLC-RC are also factory configured. If the power supplied to the DLC-RC does not match the factory configuration, it will display an {OVER 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 DLC-XP, 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 28VDC) lines in a common conduit!

5.5.2 PULSAR Motor Starter Relay (DLC-RC)

Connect the pump motor starter relay to the J3 terminal block on the DLC-RC labeled PUMP 'MOTOR OUT AC/DC.' Use 14 AWG, 105° C insulation wire size or larger. The pump motor starter relay must be wired to operate at the DLC-RC supply voltage (i.e., if the power supplied to J1 is 115VAC 60Hz, then the motor must operate on 115VAC at 60Hz).

THE DLC-RC USES SOLID-STATE RELAYS FOR IT'S HIGH VOLTAGE OUTPUTS (I.E., MOTOR AND

ALARM THE SUPPLY VOLTAGE WORKING ON ELECTRICAL CONNECTIONS

). IN THE 'OFF' STATE, THESE DEVICES TYPICALLY LEAK 20-30MA OF CURRENT AT

! THE SUPPLY POWER MUST BE DISCONNECTED AT THE MAIN BEFORE

Wire the PULSAR motor to the motor starter in accordance with the starter manufacturer's instructions. Alternately, the three-phase logic output may be used for most solid-state relay control devices. See the Low Voltage Output, Three-Phase Solid State Relay sub-title in this Section for more information. 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.

5.5.3 Alarm Relay (DLC-RC)

The Alarm Relay is an output that is configured by the user. Please refer to the section 7-General Operation for specific instructions on how to activate the Alarm Relay. The Alarm Relay Load must not exceed 1Amp at rated voltage. Connect the Alarm load to the J2 terminal block labeled 'ALARM RELAY OUT.' Use 22 AWG wire size or larger. Make three connections: Neutral, Earth (ground) and Hot as labeled.

5.6 Low Voltage Input Connections

There are two types of Low Voltage inputs: Analog (e.g., 4-20mA) and Dry Contact. The Low Voltage Input connection block is labeled J4 'INPUT' (see Figure 6). It contains four-pairs of inputs: Analog Input, Alarm, Drum and Second Analog Input.

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

CLOSURE TO ACTIVATE

. DO NOT ATTACH EXTERNALLY POWERED CIRCUITRY.

Figure 6. Low Voltage Input.

5.6.1 Analog Input (DLC-RC)

The Analog Input is used for remote control of the PULSAR flow. The input accepts current inputs anywhere in the range of 0-25mA (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. No hardware adjustments are required. The channel is surge protected and fused for over-current protection. The device is designed to avoid damage in the event high voltage is inadvertently applied.

Attach the analog signal generated by an external device (e.g., PLC) to the connection points labeled '1-CURRENT1(+)' and '2-CURRENT1(-)' on the J4 terminal block labeled 'INPUT' (refer to Figure 6). 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-RC 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 the Section 7 – General Operation for Analog Input software set-up.

5.6.2 Leak Detection Input (DLC-RC)

The Leak Detection Dry Contact Input is designed to operate with the PULSAlarm leak detection option. It is software configurable to generate an alarm, activate the alarm relay and/or shut down the PULSAR motor. The input is internally powered -- only a mechanical switch closure is required for activation. 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 (see Figure 6). A resistance of 15K ohms or less is required across the two connections for proper detection. Follow the instructions in the section 7-General Operation for Alarm Input (Leak Detection) software set-up.

5.6.3 Drum Level Input (DLC-RC)

The Drum Level Dry Contact Input is designed to monitor a single-point drum level sensor and 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. Attach one side of the switching device to the position labeled '5-LEVEL(+)' and the other side to the position labeled '6LEVEL(-) of connector J4-INPUT (see Figure 6). A resistance of 15K ohms or less across the two terminals is required for proper detection.

This input is also commonly used as a “RUN/STOP” input and can be connected to any appropriate switching device or PLC output. Follow the instructions in the Section 7-General Operation for Drum Level Input software set-up.

5.6.4 Second Analog Input (DLC-RC)

The Second Analog Input is reserved for future use. Make no connection here.

5.7 Low Voltage Output Connections

The DLC-XP control offers one Analog (e.g., 4-20mA) output, and two Transistor-based digital ouputs. The Low Voltage Output connection block is labeled J5 'OUTPUT' (refer to Figure 7). It contains three-pairs of outputs: Analog, Alarm and Motor Control Signal.

The Transistor based Dry Contact output is optically isolated. It is not self-powered to achieve total isolation. The external device must supply and detect a return voltage level. The maximum voltage capability of these outputs is 24 VDC.

5.7.1 Analog Output (DLC-RC)

The Analog Output Channel follows the actual stroke length position. It is calibrated to source current in the 0 to 20mA range (e.g., 4-20mA). Refer to the Section 7 – General Operation: Calibration for further details.

The Analog 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 '2-CURRENT(-)' on connector J5-OUTPUT (see Figure 7) to the external device. 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. The Analog Output is isolated from all other inputs, outputs. and earth ground. Refer to the instructions in Section 7 – General Operation: Calibration for Analog Output Calibration.

Figure 7. Low Voltage Output.

5.7.2 Alarm and Motor Status Outputs (DLC-RC)

The Alarm and Status outputs are solid state transistor type. Logic HIGH indicates an ON condition while logic LOW indicates an OFF condition. They are commonly used to indicate an alarm status and run status to external control equipment (i.e., PLC, PC or other digital controllers). These outputs are limited to switching a maximum of 24 VDC. Refer to Figures 7 and 8.

Figure 8. Schematic, Transistor based Alarm Output.

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 output is activated. 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 device. As such, the external control equipment must generate the supply on the positive output and detect the return of that signal when the output is activated by the DLC. In a typical application, attach the terminal labeled '3ALARM(+)' -- the collector terminal -- to the external equipment's logic supply (refer to Figure 8). 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 a sinking current (e.g., a photo-diode of an opto-isolator). The Alarm output cannot be directly configured in software. It follows the Alarm Relay output. Similarly, the status output is available at terminals 5 (+) and 6 (-) and it’s status will follow the operation of the pump motor.

5.8 Fuse Replacement

Although Fuse replacement is not a part of normal installation, it is often likely that fuse failure will result from improper wiring. The DLC-RC uses a total of 7 user replaceable fuses: 1 for the alarm relay output, 2 for each of the Analog Input and Output Channels. Table 3 details fuse replacement information:

Designator Function Rating Manufacture P/N Pulsafeeder P/N F1 Alarm Relay 1A@250VAC WK4048-ND NP5300026-000 F2-7 Analog Current I/O 50mA @ 250VAC WK3022-ND NP5300027-000

Table 3: Replacement Fuse Information

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

Figure 11. Fuse Location.

The Internal DLC-RC power supply is fused at 2Amps. This fuse is not user serviceable. The DLC-XP power supply is not fuse protected. The user is responsible for supplying this element in an nonhazardous location. The DLC-XP Stroke Length Adjustment Shaft Synchronous Motor is inherently protected. It can operate continuously in a locked rotor state. The DLC-RC also monitors this motor's duty cycle to maintain a 50% balance between ON and OFF times. The isolation elements of the Current Inputs and Outputs, and the Motor Transistor 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-XP/RC is ready for Start-up. This can be completed in 9 simple steps.

WHEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT ON THE FIELD WIRING BOARDS OF BOTH THE DLC-XP AND DLC-RC EVEN WHEN THE MOTOR IS OFF.

Display

Keypad

DLC-RC

Pump Motor

Serial Number Tag

Wiring Cover

DLC-XP

Conduit Adaptor

Figure 12 – Key DLC–XP/RC start-up elements

DURING START-UP, IT IS NECESSARY TO START THE PUMP MOTOR. THIS WILL CAUSE FLUID TO

DISCHARGE FROM THE PUMP THE PUMP DURING START

. THE USER IS RESPONSIBLE FOR SAFELY DIVERTING FLOW FROM

-UP AND CALIBRATION.

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