Pulsafeeder MPC User Manual

Installation,
MPC®
IOM-CTL-2000-Rev.I
Operation & Maintenance Manual
SPEED CONTROLLER
ii
MPC™ FACTORY SERVICE POLICY
Your MPC is a state of the art microprocessor base d mot or spe ed c ontrol for use with Pulsafeeder Diaphragm Metering Pumps. It includes extensive on-board diagnostics. If you are experiencing a problem with your MPC, first review the on-screen information, then consult the troubleshooting guide. If the problem is not covered or cannot be solved, please contact your local authorized 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 MPC 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 MPC by Pulsafeeder personnel.
Certain components may be purchased for replacement. Refer to Section 19 – Maintenance & 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 via freight collect.
Any field modific ations will void the Pulsafeeder MPC warranty. Out-of­warranty repairs will be subject to Pulsafeeder's standard bench fees and testing costs associated with replacement components.
FCC Warning
This equipment genera tes and us es 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 such cases, the user at their own expense will be required to take whatever measures necessary to correct the interference.
Copyright
Copyright © 2007-2014 Pulsafee der , Inc . Al l rig ht s reser ved. 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.
iii
Table of Cont e nts
INSTALLATION, OPERATION & MAINTENANCE MANUAL ................................................................................. I
MPC™ FACTORY SERVICE POLICY ..................................................................................................... I
TABLE OF CONTENTS .................................................................................................................................. III
FOR THE REMAINDER OF THIS BULLETIN, THE FOLLOWING CONVENTIONS ARE IN EFFECT. ...............................V
1. INTRODUCTION ...................................................................................................................................... 1
2. FORWARD ............................................................................................................................................. 1
3. DESCRIPTION ........................................................................................................................................ 1
3.1 MPC Standard Features ........................................................................................................ 2
3.2 Options ................................................................................................................................... 3
4. SAFETY CONSIDERATIONS ..................................................................................................................... 3
4.1 General Safety ....................................................................................................................... 3
4.2 Electrical Safety ..................................................................................................................... 3
4.3 Fire Safety .............................................................................................................................. 3
4.4 Mechanical Safety ................................................................................................................. 4
4.5 Hydraulic Safety .................................................................................................................... 4
4.6 Liability Exclusion ................................................................................................................. 4
5. PUMP SUITABILITY TO SITE OF INSTALLATION ......................................................................................... 5
6. TRANSPORT AND STORAGE .................................................................................................................... 6
6.1 Consignment receipt and unpackaging .............................................................................. 6
6.2 Handling ................................................................................................................................. 6
6.3 Lifting ...................................................................................................................................... 6
6.4 Recycling and end of product life ........................................................................................ 6
7. STORAGE INSTRUCTIONS ....................................................................................................................... 8
7.1 Short Term (0 - 12 months) ................................................................................................... 8
7.2 Long Term (12 months or more) .......................................................................................... 8
8. INSTALLATION AND WIRING .................................................................................................................... 9
8.1 Location .................................................................................................................................. 9
8.2 Installation Notes ................................................................................................................... 10
8.3 Installation guidelines fo r EMC compliance ....................................................................... 10
8.3.1 The cover must be installed properly. ......................................................................... 10
8.3.2 Shielded cables used for analog inputs and outputs ................................................ 10
8.3.3 Proper Earth grounding ................................................................................................ 10
8.3.4 Ensure Power mains are properly filtered for isolation from line transients, ......... 10
8.3.5 Lightning strikes or other electrical noise sources. .................................................. 10
8.4 Electrical Wiring .................................................................................................................... 11
8.4.5 Analog input signals, so the MPC can accept a process input signal. .................... 11
8.4.6 Power Wiring Information ............................................................................................. 14
8.4.7 Power Wiring Diagram .................................................................................................. 15
8.4.8 Control Input/Output Signal Wiring ............................................................................. 18
8.5 Check Wiring and Close Access Cover .............................................................................. 20
8.6 Confirm Correct Incoming Power ........................................................................................ 20
9. START UP AND OPERATION .................................................................................................................... 22
9.1 Overview ................................................................................................................................. 22
9.2 Keypad/Lamp Operation ....................................................................................................... 23
9.3 Confirm Display and Keypad Functionality ........................................................................ 23
9.4 Flow Display ........................................................................................................................... 24
9.5 Wrapping up ........................................................................................................................... 24
10. INPUT/OUTPUT SETUP .................................................................................................................. 26
10.1 Analog Input Setup ................................................................................................................ 26
iv
10.2 Digital Input Setup ................................................................................................................. 26
10.3 Analog Output Setup ............................................................................................................. 26
10.4 Digital Output Setup .............................................................................................................. 26
10.5 Pump Flow Calibration.......................................................................................................... 27
10.6 Analog Input Calibration ....................................................................................................... 31
10.7. Analog Output Calibration .................................................................................................... 34
10.8 Display Contrast Adjustment ............................................................................................... 35
10.9 Changing the Motor Base Frequency .................................................................................. 35
11. ALARM AND ERROR MESSAGES ................................................................................................... 36
12. EXTENDING YOUR HAND-HELD CONTROLLER ................................................................................ 38
12.1 Obtain New Cable: ................................................................................................................. 38
12.2 Removal and Connection of the Cable from the Handheld: ............................................. 38
13. SPECIFICATIONS .......................................................................................................................... 42
14. MENU MAPS ................................................................................................................................ 45
15. FACTORY DEFAULT VALUES ......................................................................................................... 47
16. RETRIEVAL OF SETUP INFORMATION ............................................................................................. 47
17. SPECIAL KEYPRESS ACCESS ....................................................................................................... 47
18. TROUBLESHOOTING GUIDE........................................................................................................... 48
19. MAINTENANCE & SPARE PARTS ................................................................................................... 49
19.1 Operating Precautions .......................................................................................................... 49
19.2 Cleaning and Decontamination ............................................................................................ 49
19.3 User Replaceable Parts for the MPC ................................................................................... 50
v
Conventions
A
Notes are general information meant to make operating the
Tips have been included within this bulletin to help the operator
For the remainder of this bulletin, the following Conventions are in effect.
WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT BE CONSULTED IN ALL CASES WHERE THE IN ORDER TO FIND OUT THE NATURE OF THE P OTENTIAL ANY ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM
WARNING SYMBOL IS MARKED
. THIS MANUAL MUST
HAZARDS AND
.
CAUTION, POSSIBILITY OF ELECTRIC SHOCK AND/OR ELECTROCUTION HAZARD!
equipment easier.
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.
Revision History:
Rev E (3-25-05)
- Section 3.1 Description, added 3-phase vs. single-phase info
- Change description of digital output specification
- New figure 2 (pump mounting)
- Updated analog in, analog out, and flow calibration instructions
- Update error handling text, Section 11
- Add s pecifications for v olt ag e range and ELCB’s
- Add safety warnings about inrush current and capacitor discharge
throughout
Rev F (7-25-06)
- Added nametag diagram and note on proper input voltage selection on page 9
- Added section 8.5 on adjusting motor base frequency
- Added sample digital output diagram in section 5.3.4
Rev H (9-26-07)
- Added clarification on digital output capability, sect ions 1.2, 5.3.4, and 7.4
- Motor information added, sections 1.2, 1.3, and 11
- Added missing step in calibration instructions, section 8.1.1
Rev I (05-22-2014)
Updated to reflect requirements of UL 61010-1 3
rd
Edition

1. Introduction

The Metering Pump Controller (MPC) is a microprocessor base d m ot or sp eed control device, for use with Pulsafeeder mechanical and hy dr aulic diaphragm metering pumps. It has been designed for simplicity, yet still has many advanced features that allow the MPC to operate in a wide variety of environments and applications.
This instruction manual covers the MPC only. All stan dar d fea tur es ar e cov ered in this manual and most options hav e instructions where applicable. For information specific to the metering pump or any other accessories, please refer to the appropriate IOM.

2. Forward

The pumps to which these “instructions” refer to are designed for use in industrial areas and therefore cannot be treated as retail products. The present documentation gives instructions to be used by qualified personnel only. It must be used in compliance with the regulations, laws and technical standards in force and cannot, under any circumstances, take the place of plant standard or additional regulations, including any which are not legally enforceable, which have been issued with the scope of ensuring safety.
Equipment with special manufacturing or constructive variances may differ in details with respect to this description.
In case of any difficulty, please contact PULSAFEEDER, INC. Technical Service.
The MPC is rated for NEMA 4x locations as identified on the controller nameplate.

3. Description

The MPC is an advanced pump controller that is physically attached to the pump. Its purpose is to precisely adjust output flow of a process media by means of pump motor speed control.
The MPC is designed for a wide variety of control appl ic ati o ns . The device is factory configured and cal i br ated for the at tached pump. The human/mach ine interface is user friendly. Local setup and control is achieved through the keypad and a backlit two-line liquid crystal display. Basic operation is simple with dedicated function keys eliminating the need for a sophisticated menu system. The MPC responds immediately to user commands. Pump output is displayed as Gallons per Hour (GPH), Liters per Hour (LPH), Strokes per Minute (SPM), Percent Speed, or Percent Flow (% of total pump capacity).
Digital and analog inputs will support a variety of industry standard signals to offer flexible remote control.
The MPC is designed to simplify and automate the calibration of pump flow and analog signals. Flow calibration uses on-screen prompting and automated pump operation to eliminate stopwatches, calculators and human inaccuracies. Analog signal calibration is also accomplished by simple keypad entry. It
includes a real-time display of signal level. This eliminates the need for external meters.
The MPC readily accepts PULSAlarm® leak detection and tank lev el inputs. These may be configured to stop the pump and/or activate an alarm relay.
The MPC is factory configured to operate at either 60 Hz or 50 Hz input. No special modifications , s etti ng s , or adjustments are required. All MPC controllers are supplied with a motor rated at 60 Hz, regardless of the supply frequency. The controller/motor combination allows for full pump speed and flow even when operating from a 50 Hz input. Users in locations with 50 Hz AC supply do not have to de-rate pump flow with this controller.
The motor used with the MPC is a three-phase motor; however the three-phase power is generated internally by the MPC itself. Do not be confused by the motor nameplate. Input power to the MPC is single-phas e AC only; either 115 or 230 volts (see Section 13, Specifications for acceptable input voltage range). The nameplate on the rear of the MPC controller lists the appropriate supply requirements.
At lower stroke frequencies (below 3:1 turndown), the MPC employs intermittent motor actuation technology. This allows the user to achieve reliable low-end performance not usually associated with variable speed controllers. By completing a full pump stroke at constant speed, and varying the interval between strokes, hydraulic stability and process consistency is maintained.
The AC drive used in the MPC maintains tight control over voltage and current supplied to the pump motor. This results in lower motor operating temperatures and less stress on motor windings, resulting in longer motor life and more reliable overall operation. This holds true even when metering in the lower flow ranges where the MPC uses intermittent operation.

3.1 MPC Standard Features

Remote keypad and display for ease of operation
Display pump flow in GPH, LPH, Strokes per Minute, or % of full pump
flow
One 4-20 mA analog input signal for flow control
One 4-20 mA analog output signal for flow feedback
Two configurable digital inputs
Three configurable digital outputs
Advanced turndown capability
NEMA 4X and IP56 ratings
Available for 115 or 230 Volts, 50 or 60 Hz, single phase AC power
Security code lockout of menus
Commercial duty motor as standard for indoor, dry locations only

3.2 Options

Variable hand-held controller cable length, up to 1,000 feet from pump
Alternate motor selections available for outdoor, washdown, chemical
duty, and other special applications

4. Safety Considerations

Read and understand all related instructions and doc u m ent at ion before attempting to install or maintain this equipment
Observe all special instructions, notes, and cautions.
Act with care and exercise good common sense and judgment during
all installation, adjustment, and maint ena nc e pr oced ur es .
Ensure that all safety rules, work procedures, and standards that are applicable to your company and facility are followed during the installation, maint ena n c e, and oper a t ion of this equipment.

4.1 General Safety

The MPC was designed as a controller for operation solely with Pulsafeeder metering pum ps . Use for any other application is considered un-safe and voids all certification markings and warranties.

4.2 Electrical Safety

The MPC can be considered an industrial process controller. Improper application and use can be hazardous. You are solely responsible for its use.
The MPC'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 sour c e at the mai n dis tr i buti o n pan el .
The MPC emits electro-magnetic energy and may generate radio frequency interference. Its use is restricted to industrial applications. You are responsible for shielding this energy/interference.
Certain wiring procedures may require that the user wear a wrist strap to dissipate static charges.

4.3 Fire Safety

In case of electrical fire, use a Class C fire ex ti ng ui s her . Never use water to extinguish a Class C fire.
Class C fires involve electrical equipment, such as appliances, wiring, circuit breakers and outlets. Never use water to extinguish class C fires ­the risk of electrical shock is far too great! Class C extinguishers do not
have a numerical rating. The C classification means the extinguishing agent is non-conductive. Geometric symbol (blue circle)
Wait a minimum of 3 minutes after disconnecting power before servicing the MPC or pump motor. Capacitors retain a charg e e ven after power is removed from the controller.

4.4 Mechanical Safety

Users should note that the pump motor is always under the control of the MPC, and as such may actuate without warning. Care should be taken to keep loose clothing and other objects away from the pump motor.
The MPC was designed to be service free. It contains no user­maintainable components. Disassemble the MPC enclos ur e only for initial field wiring, or as instru c ted to do so within this manual. Evidence of unauthorized disassembly shall void the warranty.

4.5 Hydraulic Safety

Thoroughly review and adhere to the contents of the pump Installation, Operation, Maintenance and Instruction manual for installation of the Pulsafeeder metering pum p. As a microprocessor con tr ol led device, the MPC 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.

4.6 Liability Exclusion

Pulsafeeder, Inc. is unable to monitor the observance of the instructions given in this manual, nor verify the actual working conditions and installation of the equipment, the correct operation, the using and maintenance of the equipment and accessories. An incorrect installation, or misuse of the equipment, may cause serious damage and may pose a danger to persons or property. Any anomalies must be reported to the maintenance supervisor. The user is not authorized to tamper with the machine for any reason.
Attempts to disassemble, modify or tamper in general by unauthorized personnel will void the guarantee and will release Pulsafeeder, Inc. from any liability for damage caused to persons or property resulting from such actions.
Pulsafeeder, Inc. is considered released from any liability in the following cases:
- improper installation;
- improper use of the equipment by non-professional or
inadequately trained operators;
- use not in compliance with regulations in the Country of use;
- lack of maintenance or improperly performed;
- use of non-or iginal spare parts or incorrect parts for the model in
question;
-
total or partial failure to observe the instructions;
- exceptional environmental events.
DO NOT PERFORM ANY WORK ON THE PUMP, MOTOR OR MPC CONTROL UNIT WITH ELECTRICAL POWE R CONNECTED TO THE MPC CONTROL UNIT. DO NOT OPERATE MPC UNIT WITH THE COVER REMOVED. DANGER OF ELECTRONIC SHOCK AND MECHANIC AL PINCH HAZARD!
INSTALLATION AND REPAIRS SHOULD ONLY BE PERFORME D BY AUTHORIZED PERSONNEL!
FOLLOW ALL SAFETY/ LOCAL LOCK-OUT, T AG-OUT PROCEEDURES!

5. Pump Suitability to Site of Installation

Upon equipment receipt, verify that pumps have not received any damage due to transportation and are complete with every eventual accessory. In case anomalies or damages are discovered prior to installation, please contact PULSAFEEDER, INC. Technical Service.

6. Transport and Storage

6.1 Consignment receipt and unpackaging

Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation.
Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment.
Each product has a unique serial number. Check that this number corresponds with that advised and always quotes this number in correspondence as well as when ordering spare parts or further accessories.
Shortages or damage should be reported immediately to the carrier and your Pulsafeeder Representative.

6.2 Handling

Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction.

6.3 Lifting

A crane must be used for all controller/pump sets in excess of 25 kg (55 lb). Fully trained personnel must carry out lifting, in accordance with local regulations.
Slings, ropes and other lifting gear should be positioned where they cannot slip and where a balanced lift is obtained.

6.4 Recycling and end of product life

At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and local requirements. If the product contains substances that are harmful to the environment, these should be removed and disposed of in accordance with current regulations. This also i ncludes the liquids and/or gases that may be used in the "seal system" or other utilities.
Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be i n accordance with the current regulations at all times.
(Pulsar Pump arrangement shown)

7. Storage Instructions

The MPC can be successfully stored for extended periods. The key to this success is temperature and humidity control.

7.1 Short Term (0 - 12 months)

The MPC 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.
If the MPC 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.

7.2 Long Term (12 months or more)

Storage of the MPC for periods of longer than twelve months is not recommended. If extended storage is unavoidable the MPC 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 dessicant should be placed inside the enclosur e. The cover should be re­installed to seal the desiccant within the enclosure. The conduit connections must be tightly capped. . Inspect the unit carefully for any signs of damage and remove the desiccant before placing it into operation
Special note for long-term storage:
If AC input power has not been applied to the MPC for a period greater than 12 months, the controller must be prepared for operation. The MPC should have AC power applied at the input for a period of 8 hours before placing pump into normal operation. Refer to Installation and Wiring section for AC power connection instructions.

8. Installation and Wiring

8.1 Location

Review the Safety section prior to installing the MPC. It contains information required to properly install and operate the MPC i n an industrial environment.
The site selected for the installation of your MPC is largely dependent on that of the metering pump. Review the Installation, Operation, and Maintenance manual provided with your metering pump. It details system related issues that are important to proper operation of the pump. Consider the following MPC related issues when selecting a site. Avoid locations where the MPC would be subjected to extreme cold or heat. The installation of this device must comply with national, state and local codes.
Approximately 6 in (150 mm) of clearance should be maintained around all 4 sides of the MPC.
No special services (e.g. air, liquid cooling) are required. Negligible sound is emitted by the MPC - therefore, no special precautions are necessary.
The MPC controller must be secured to an appropriate support before use. Use four 3/8” (M8) bolts or anchors to secure the MPC controller and pump to a fixed base. No asse mbly is required for the MPC controller itself.
Figure 1 – Typical Installation.
°
°
AVOID LOCATIONS WHERE THE MPC WOULD BE SUBJECTED TO EXTREME
COLD OR HEAT
40
CELSIUS (104 ° FAHRENHEIT)] OR DIRECT SUNLIGHT. FAILURE TO
OBSERVE THIS WARNING COULD DAMAGE THE
[LESS THAN 0
CELSIUS (32° FAHRENHEIT) OR GREATER THAN
MPC AND VOID ITS WARRANTY.

8.2 Installation Notes

The MPC is a microprocessor-based controll e r that uses el ectr o-static sensitive CMOS components. Do not make any (low or extra-low voltage) electrical connections without adequately grounding the MPC and the worker to eliminate an electro-static charge between the two. A
conductive wrist strap worn by the worker and attached to the MPC enclosure is adequate to satisfy this requirement.
Conduit connections can carry fluids and vapors into the MPC 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. The controller comes equipped with liquid-tight connectors for signal cable entry points. The user must supply the correct connection for the power entry, as per the local codes and requirements. Any cable entrances that are not used should be appropriately sealed against moisture and vapors.
The safety of any system incorporating the MPC is the responsibility of the assembler of the system.

8.3 Installation guidelines for EMC compliance

8.3.1 The cover must be installed properly.

8.3.2 Shielded cables used for analog inputs and outputs

8.3.3 Proper Earth grounding

8.3.4 Ensure Power mains are properly filtered for isolation from line
transients,

8.3.5 Lightning strikes or other electrical noise sources.

Failure to observe the guidelines above may lead to erratic and possibly unsafe operating conditions.

8.4 Electrical Wiring

The MPC has many advanced features that may make wiring the unit appear complicated. Wiring is actually very simple – one hi g h v olt ag e connection is all that is required to take advantage of the majority of the MPC's features.
If you will be mounting your handheld controller in a remote location, refer to the Section Extending your Hand-Held Controller at this time.
WHILE THE MPC WIRING REQUIREMENTS ARE VERY SIMPLE, ALWAYS KEEP IN MIND
THAT ACCESS TO THESE CONNECTORS REQUIRES THE REMOVAL OF THE COVER AS SUCH THIS PROCEDURE SHOULD ONLY BE PERFORMED BY A TRAINED PROFESSIONAL
.
WAIT A MINIMUM OF 3 MINUTES AFTER DISCONNECTING POWER BEFORE SERVICING
MPC OR PUMP MOTOR. CAPACITORS RETAIN A CHARGE EVEN AFTER POWER IS
THE REMOVED FROM THE CONTROLLER
.
It is highly recommended that you take a step-by-step approach to wiring and confirming proper MPC operation:
, AND
8.4.1 Make the high voltage connections (ref. Section 8.4.7). These
will allow you to operate the MPC a nd attached Pulsafeeder pump.
8.4.2 Decide which low voltage Inputs and Outputs (e.g., 4-20mA in)
will be used and make those connections (ref. Section 8.4.8).
8.4.3 Power-up and test the MPC to confirm the connections and
check for proper operation.
8.4.4 Configure the software via the menu system for the desired
operational conditions. Depending on the anticipated function, users may need to enter settings for t he following:
8.4.5 Analog input signals, so the MPC can accept a proc ess input
signal.
i. Analog output settings, so the MPC can provide a process
feedback signal.
ii. Digital input s ettings, for example start/stop and/or leak
detection inputs.
iii. Digital output settings, for example status and/or alarm
outputs.
iv. Conduct a final power-up and test the MPC to confirm the
connections and check for proper operation.
v. Go to the Section 9 – Startup & Operation for details on
how to perform the power-up tests. Controller Layout
The design of the MPC incorporates all control circuitry onto one easily accessed circuit board. This board is located on the inside of the main controller cover. Gain access to this board by removing the 10 bolts and gently allowing the cover to hinge downwards.
USE CARE NOT TO PULL ON OR ATTEMPT TO COMPLETELY SEPARATE THE COVER
FROM THE
/OR DAMAGED. THIS CAN RESULT IN IMPROPER OPERATION.
AND
MPC UNIT, AS THE ELECTRICAL CONNECTIONS MAY BECOME UNPLUGGED
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