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
FIGURE 2 – CONDUIT CONNECTION LAYOUT
8.4.6 Power Wiring Information
• Verify the correct supply voltage (115VAC or 230VAC) with the
nameplate affixed to your MPC. Ensure that your supply voltage
matches the MPC configuration.
• Wi r es should be routed within the enclosure in a manner that
maintains separatio n between low voltage and extra-low voltage
conductors.
• Applicable national and local electrical codes take precedence over
recommendations in the table below.
• A circuit breaker or fuse must be provided as noted below.
• Upon initial application of AC power, a current inrush will occur to
charge the DC bus capacitors. This is normal operation, and
breakers and other circuit protection devices should be sized
accordingly.
Recommended Minimum Wiring and Circuit Breaker
Power
Requirements
MPC and 0.25
Hp motor
MPC and 0.33
Hp motor
MPC and 0.5 Hp
motor
MPC and 0.75
Hp motor
MPC and 1.0 Hp
motor
MPC and 1.5 Hp
motor
Note 1: Applicable standards are Cenelec EN61326-1, UL61010-1, and CSA
C22.2#61010-1 and EN61010-1 3
115 VAC Operation 230 VAC Operation
Actual
Draw
7.0 A 10 A 14
7.0 A 10 A 14
9.4 A 15 A 14
16.8 A 25 A 12
16.8 A 25 A 12
24.2 A 35 A 10
Circuit
Breaker
Wire
Size
AWG
AWG
AWG
AWG
AWG
AWG
Wire
Size
2.5
mm
2.5
mm
2.5
mm
4.0
mm
4.0
mm
6.0
mm
Safety
Approvals1
UL, CUL,
2
2
2
2
2
2
CE
UL, CUL,
CE
UL, CUL,
CE
UL, CUL 9.4 A 15 A 14
UL, CUL 9.4 A 15 A 14
UL, CUL 12.2 A 20 A 14
Actual
Draw
3.5 A 10 A 14
3.5 A 10 A 14
5.2 A 10 A 14
Circuit
Breaker
Wire
Size
AWG
AWG
AWG
AWG
AWG
AWG
Wire
Size
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
Table 1 – Sizing Branch Circuits
rd
edition.
The MPC requires one connection to an external power source. It uses
this same connection to power its own supply, as well as the AC pump
motor. You must take all of these loads into consideration when sizing
Safety
Approvals1
UL, CUL,
CE
UL, CUL,
CE
UL, CUL,
CE
UL, CUL
UL, CUL
UL, CUL
the branch circuit (see Tabl e 1). A circuit breaker or disconnect switch
MPC Drive
L1
Line
Line
Earth
Ground
Ground
with fuses must be wired in series with terminals L1 and L2/N in
accordance with all applicable local and national electrical codes and
regulations. The circuit breaker or disconnect switch shall be located in
close proximity to the MPC controller. It must be positioned such that it is
not difficult to operate and must be marked or labeled to identify it as the
power disconnect for the MPC.
The MPC controller is provided with a ¾ inch NPT inlet for incoming AC
power wiring at the rear (pump gearbox end) of the enclosure. Utilize the
appropriate conduit fittings to route and seal the supply wires into the
MPC enclosure.
These wires are secured to the terminal strip at the right-hand end of the
AC drive as per Table 2 and Figure 3. Remove approximately 0.20 –
0.25 inches, (6mm) of insulation from the end of each conductor. Loosen
the terminal strip screw, and insert the stripped wire end fully into the
terminal. Tighten the screw to 4.5 in-lbs. (0.5 Nm) to secure the
conductor. Make certain that the terminal grips the wire, not the
insulation. Ensure that all wiring meets applicable local and national
codes and requirements.
8.4.7 Power Wiring Diagram
Terminal
L2 / N Neutral Line/Neutral
Table 2 – AC Drive Terminals
Note: Power wiring should have a rating of at least 300 volts AC (rms) and a
temperature rating of at least 105 Degrees C.
A circuit breaker or disconnect switch with fuses, must be provided in accordance
with all applicable local and national elec tr i cal codes and reg ul ati ons. Size
external fusing/breaker for ratings for the wiring used for the unit.
115 V Operation 230 V Operation
Applicable national and local electrical codes take precedence over
recommendations made here.
To ensure proper operation, the MPC should remain powered at all times.
A dry contact input provides the MPC with motor status (on vs. off). See
Section 13 (Digital In #1 & Digital In #2)
Input Power must be run in separate conduit. Do not combine Power and
Control wires in a common conduit!
Field Wiring conductors shall be copper conductors only!
Figure 3 – AC Drive Power Connections
Wait a minimum of 3 minutes after disconnecting power before servicing the
MPC or pump motor. Capacitors retain a charge even after power is removed
from the controller.
Find the proper AC input
voltage for your MPC
controller on the
nameplate at the rear of
the unit. MPC input is
always single phase, and
can be either 115 VAC or
230 VAC, determined at
time of order.
8.4.8 Control Input/Output Si gna l Wiring
Signal wiring is routed through the two unused conduit openings at the
side of the MPC. All input/output signals are connected to the terminal
strips at the edge of the MPC circuit board. Use caution to observe
proper wire location and signal polarity. Always cap or plug unused
openings. Wires should be routed within the enclosure in a manner that
maintains separation between low voltage and extra-low voltage
conductors. Ensure all low voltage wiring is installed as per any
applicable local and national electrical codes and regulations.
Utilize 20 or 22 AWG, 250 V, shielded cable, with a 105o C insulation
rating (or better) for all signal input and output wiring. Recommended
strip length is 0.39 inches or 10 mm. Re fer to Figure 4 below for signal
connection locations.
UNUSED CONDUIT OPENINGS SHOULD BE PLUGGED AS REQUIRED TO AVOID
INGRESS OF MOISTURE AND CONTAMINANTS INTO THE
NOT REMOVE THE FACTORY PROVIDED PLUG FROM OPENINGS THAT ARE NOT
REQUIRED FOR FIELD WIRING
.
IT IS RECOMMENDED THAT A WRIST STRAP BE WORN WHEN MAKING
CONNECTIONS TO ANY PRINTED CIRCUIT BOARD
.
MPC ENCLOSURE. DO
Figure 4 – Signal Connections
Digital output signals can drive devices such as relays or indicator lamps. 24 VDC
power must be supplied from an external source. Each output has a maximum current
capability of 500 mA. Maximum voltage capability of these circuits is 40 VDC (see the
Specifications Section, for more information).
Figure 5 – Sample Digital Output Connections
8.5 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 extra-low voltage. Additionally,
insure that all terminals are clamping onto the bare conductor, not on its
insulation. Ensure that wires will not be trapped or pinched when front
cover is replaced and secur ed. Ensure that excess insulation is not
removed from the wires, as this can lead to poor connections or faulty
operation.
Replace the main access cover and secure the 10 bolts.
Use a nut driver to tighten the retaining bolts evenly to 35 in-lbs
(4.0 Nm). Failure to do so may cause the cover to leak and void the
warranty.
8.6 Confirm Correct Incoming Power
WITHOUT PRIOR OPERATING KNOWLEDGE, IT IS IMPOSSIBLE TO TELL IF THE
PUMP MOTOR WILL RUN WHEN POWER IS APPLIED TO THE
RESPONSIBLE FOR TAKING THE NECESSARY STEPS TO ENSURE THAT ALL
ASPECTS OF SAFETY HAVE BEEN CONSIDERED
.).
ETC
(E.G., ELECTRICAL, HYDRAULIC,
Clear all lockout tag out controls. Turn on power at the mains or
distribution panel. If the MPC's incoming power is connected correctly,
the backlighting on the MPC'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
MPC. YOU ARE
with a voltmeter. If the voltage is not correct, return to 5.3.2 - Power
Wiring Information. Otherwise, proceed with the next step.
9. Start Up and Operation
9.1 Overview
Once all electrical connections have been made, your MPC is ready for
Start-up. The following sections detail the procedures required to
complete the MPC start up.
WARNING: DO NOT attempt to remove the cover of the MPC and
set up the MPC in a very wet or rainy environment. While care has
been taken to insulate power connections, DANGEROUS voltages
are present and can cause electric shock, and possible
electrocution if safety procedures are not fo llowed
WHEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT WITHIN
MPC ENCLOSURE EVEN WHEN THE MOTOR IS OFF.
THE
DURING START-UP, IT IS NECESSARY TO RUN THE PUMP MOTOR. THIS WILL
CAUSE FLUID TO DISCHARGE FROM THE PUMP
SAFELY DIVERTING FLOW FROM THE PUMP DURING START
CALIBRATION
THE MPC IS DESIGNED TO RUN THE PUMP CONTINUOUSLY WITHIN ITS RATED
PRESSURE AND FLOW
INTERMITTENTLY
F THIS EQUIPMENT IS USED IN ANY MANNER NOT SPECIFIED BY PULSAFEEDER,
I
PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED
.
. OPERATION BEYOND RATED SPECIFICATIONS, EVEN
, MAY DAMAGE EQUIPMENT AND VOID THE WARRANTY.
. YOU ARE RESPONSIBLE FOR
-UP AND
.
9.2 Keypad/Lamp Opera ti on
MANUAL
ON
Key Function Description
Motor On/Off
Auto/Manual
Menu
Press to start pump motor, press again to stop
pump motor
Press to toggle between aut o matic oper a ti on and
manual control of the pump
Press to adjust controller settings, to exit the menu
system, to move cursor back when entering
values, or to step back to higher level menus
Enter
Press to accept changes in menus, to move
cursor forward when entering values, and to
access lower level menus. Also used to toggle
between pump output display options while in
operating mode (% flow, spm, gph, etc.)
Arrow Up
Arrow Down
Press to adjust values upwards, and to scroll
through menu options
Press to adjust values downwards, and to scroll
through menu options
Lamp Color Description
Green, Amber,
Red, Off
Green, Off
Table 3 – Keypad and Lamp Operation
Off = Motor off Green = Motor on
Amber = Remote standby Red (blinking) =
Error
Green = Manual Control Off = Automatic
Control
9.3 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 MPC is receiving power, it is
necessary to confirm that the display and keypad are f uncti o ni ng
properly. On normal po wer-up, the display appears for approximately 2
seconds.
PULSAFEEDER INC.
FW: 00.00/00.00
The first four digits displayed are the software revision for the MPC base
unit, and the second four indicate the software revision for the handheld
display/keypad module.
The keypad can be tested by depressing each key separately. Most, but
not all keys will cause the text on the display to change. Do not be
alarmed if a single key does not invoke a change to the display. This is
normal. Different key s become active/inactiv e depending on the current
operating mode.
Please note that it may be necessary to adjust the display contrast;
please refer to Section 10.8 if this is required.
9.4 Flow Display
The MPC will display calibrated pump flow in GPH or LPH on the dig i tal
display. The MPC is capable of very high turndown ratios, limited only by
pump configuration and system design. In some cases, the MPC display
will be unable to display very low flow rates, in these situations the
display may indicate 0.0 for flow, even though the pump is producing
measurable flow. If the pump is being operated under these conditions,
users may wish to perform extra flow calibrations to verify actual flow
rates at certain set points. Note that even after the additional calibrations
are done, the MPC will still not display the low flow that the pump is
producing.
In situations where the pump stroke length is set to 0 (zero) %, the pump
will also display 0 (zero) GPH or 0 (zero) LPH, regar dl ess of motor
speed setting. If the display registers no flow in this manner, check the
setting of the stroke length mechanism on your pump.
9.5 Wrapping up
Your MPC is now commissioned for use. Note that you cannot configure
the software in a way that would damage the MPC. Typically, whenever
you are about to set a critical value (e.g., Calibrate Flow), you are always
prompted to confirm your change before it takes effect. If you are ever
dissatisfied with the configuration of your MPC, you can always return to
the Factory Defaults by referring the next section.
Factory Re-initialization is typically not required. When re-
initializing your MPC, all of the system settings and calibration
information will be overwritten by the original factory default
settings. The controller must be re-configured and re-calibrated to
your specifications.
A Factory Re-initialization should be performed only if there is reason to
believe that the internal MPC memory has become corrupted. The
condition usually manifests itself with inconsistent or erratic operation –
often associated with meaningless characters on the display, or
exaggerated numerical values.
Factory Re-Initialization:
1. Press the MENU key to access the System Setup Menu
-MENU-
CALIBRATION
2. Press the UP arrow key to display
-MENU-
SYSTEM SETUP
3. Press the ENTER key
SYSTEM SETUP
SECURITY
4. Press the UP arrow key twice to display
SYSTEM SETUP
FACTORY INIT
5. Press the ENTER key
PRESS ENTER
TO FACTORY INIT
6. Press the ENTER key
ARE YOU SURE?
YES=ENTER NO=MENU
7. Press the ENTER key
RESETTING PUMP
TO FACTORY INIT
10. Input/Output Setup
Use the “DIGITAL I/O” menu to activate the functions required for the intended
application.
Users may also reference Section 14 – Menu Maps for additional configuration
assistance
10.1 Analog Input Setup
Use the “ANALOG I/O” menu to activate the analog input signal function.
The menu can be used to set the analog input to either ACTIVE or
INACTIVE.
10.2 Digital Input Setup
Each of the 2 Digital INPUTS can be selected as:
Inactive
Leak Detection
Tank Level Input
Remote ON/OFF Input
Flow Detection (delay time must be set)
Each can be set as normally OPEN or normally CLOSED. For example,
if an input is set to ON/OFF and NORMALLY CLOSED, this means a
CLOSED switch will activate the pump. A NORMALLY OPEN setup will
give the opposite response.
10.3 Analog Output Setup
Use the “ANALOG I/O” menu to activate the analog output signal
function.
The menu can be used to set the analog output to either ACTIVE or
INACTIVE.
10.4 Digital Output Setup
Each of the 3 Digital OUTPUTS can be selected as:
Inactive
ON/OFF Status
AUTO/MAN Status
Stroke Indicator (Pulse Output)
Alarm Indicator
Leak Detection Status
Tank Level Status
Each can be set as normally OPEN or normally CLOSED. For example,
if an output is set to ON/OFF INDICATION and NORMALLY CLOSED,
this means that when the motor is running (indicator lamp is ON) the
output will be CLOSED. A NORMALLY OPEN setup will give the
opposite response.
Digital output circuits are transistor based and limited to 40 VD C
maximum, see Section 8.4.8 - Control Input/Output Signal Wiring,
and Specifications Section, for more information.
10.5 Pump Flow Calibration
Your MPC is factory calibrated at rated flow and pressure. Nevertheless,
you should always perform a calibration with the MPC installed in your
system. This will provide the most accurate flow display.
The only item required to calibrate your MPC is a means to measure the
flow of the pump (i.e., calibration column, graduated cylinder, etc.). The
most accurate calibration will be obtained by using a measurement device
installed on the suction side of the pump. Note that calibration values for
liquid volume will be in the user’s chosen units, either gallons or liters.
There are two methods for completing the flow calibration routine, either
“Volume” or “Flow”.
Volume Method Calibration
The volume calibration is accomplished by running the pump at two
different stroke length setti ng s, 50% and 100 % . During each run a volume
of liquid will be pumped from the calibration column. This volume is then
entered into the MPC for calibration. Note that for this calibration, the
actual volume of liquid pumped is entered in gallons or liters. Do not enter
a flow rate in gallons or liters per hour, as this will not result in a valid
calibration. The MPC display will guide the user through the steps for
calibration.
Please note that it must be safe to run the pump and dispense liquid into
the system in order to complete this calibra ti o n. The pump should be fully
primed with the product in order to complete an accurate calibration.
Hydraulic diaphragm pumps must have a proper hydraulic prime as well.
10.5.1 Flow Method Calibration
The flow calibration is accomplished by entering values for flow that are
already known to the user. The MPC will request flow values in gallons or
liters per hour for each of the two calibration points, 50% and 100% stroke
length. This calibration is useful if operational circumstances do not permit
the pump to run for calibration. This calibration is also faster to complete if
the flow values are already known. The MPC display will guide the user
through the steps for calibration.
The nameplate flow rating of the pump can be used to complete the flow
calibration routine; however there will always be some variance in the
actual flow rate of a pump due to system conditions and pr oduct
characteristics. Using the pump’s nameplate rating will establish a
baseline flow rate on the MPC display; however it will not guarantee
absolute accuracy.
To Start Calibration
1. The starting display will be:
2. Press the MENU key
3. Press the ENTER key
SETPT XX.XXX
FLOW XX.XXX
-MENU-
CALIBRATION
CALIBRATION
PUMP FLOW
4. Press the ENTER key
CALIBRATION
“VOLUME”
5. To perform the Volume Method, press the ENTER key and go to the
next Section –Voume Method
6. To perform the Flow Method, press the UP arrow key
CALIBRATION
“FLOW”
7. Press the ENTER key and go to the Flow Method Section 10.5.2
If you receive the following message during the Volume calibration:
STROKE LENGTH OUT
OF RANGE
Verify that the manually set stroke length is at the correct position, either 50% or 100%.
Volume Method
SET STROKE TO 50%
ENTER TO START
1. Manually adjust the stroke length of the pump to 50%
2. ** Fill your calibration column to the zero or starting point
3. Press the ENTER key
TIMER XX SEC
ENTER TO STOP
4. Allow the pump to run for any length of time you choose, dependent on flow
rate, calibration column size, process conditions, etc. The system will time out
at a maximum of 300 seconds.
5. Press the ENTER key to stop the pump
ENTER VOLUME
VOL = XX.XXX
6. Use the UP and DOWN arrow keys and the ENTER key to input the volume
pumped from the calibration column (in gallons or liters, dependent on MPC
setup).
7. Press ENTER to proceed
SET STROKE TO 100%
ENTER TO START
8. Manually adjust the stroke length of the pump to 100%
9. ** Fill your calibration column to the zero or starting point
10. Press the ENTER key
TIMER XX SEC
ENTER TO STOP
11. Allow the pump to run for any length of time you choose, dependent on flow
rate, calibration column size, process conditions, etc. The system will time out
at a maximum of 300 seconds.
12. Press the ENTER key to stop the pu mp
ENTER VOLUME
VOL = XX.XXX
13. Use the UP and DOWN arrow keys and the ENTER key to input the volume
pumped from the calibration column (in gallons or liters, dependent on MPC
setup).
14. Press ENTER to proceed
PUMP FLOW
CALIBRATED
15. Pump flow calibration is complete
16. Pre ss t he MENU key three times to exit back to the main operating screen.
10.5.2 Flow Method
SET STROKE 50%
FLOW = 0.0000 GPH
1. You do not have to adjust the actual stroke setting of the pump
2. Use the UP and DOWN arrow keys and the ENTER key to input the
desired flow rate (in gallons or liters per hour, depend ent on MPC
setup). This should be the flow rate expected when the pump is set to
50% stroke length setting.
3. Press ENTER to proceed
SET STROKE 100%
FLOW = 000.00 GPH
4. You do not have to adjust the actual stroke setting of the pump
5. Use the UP and DOWN arrow keys and the ENTER key to input the
desired flow rate (in gallons or liters per hour, depend ent on MPC
setup). This should be the flow rate expected when the pump is set to
100% stroke length setting.
6. Press ENTER to proceed
PUMP FLOW
CALIBRATED
7. Pump flow calibration is complete
8. Press the MENU key three times to exit back to the main operating
screen.
10.6 Analog Input Calibration
If you are not using the 4-20mA input to the MPC for control, skip this
section. To calibrate the Input Current you must first correctly wire an
external signal source. Refer to the Control Input/Output Signal
Wiring Section (8.4.8). To perform a calibration, the signal-generating
device must be active and capable of generating the full range (low to
high) of potential input signals.
1. The starting display will be:
SETPT XX.XXX
FLOW XX.XXX
2. Press the MENU key
-MENU-
CALIBRATION
3. Press the ENTER key
CALIBRATION
PUMP FLOW
4. Press the UP arrow key twice, to access the analog input calibration
CALIBRATION
ANALOG INPUT
5. Press the ENTER key
APPLY MIN MA
ENTER TO START
6. Apply your desired minimum mA control signal to the MPC (usually 4
mA)
7. Press the ENTER key
MIN SETPT X.XX MA
SPEED 000.0%
(The mA value will be equal to your input signal level)
(The speed value is the setting the MPC will use for this signal value)
8. Press the ENTER key three times to step through the speed setting
value, most users will leave this at 000.0 %, however you an change it if
you wish using the UP and DOWN arrows.
9. Press the ENTER key once more to accept the calibration value
APPLY MAX MA
ENTER TO START
10. Apply your desired maximum mA control signal to the MPC (usually 20
mA)
11. Pre ss t he ENTER ke y
MAX SETPT X.XX MA
SPEED 100.0%
(The mA value will be equal to your input signal level)
(The speed value is the setting the MPC will use for this signal value)
12. Press the ENTER key three times to step through the speed setting
value, most users will leave this at 100.0 %, however you an change it if
you wish using the UP and DOWN arrows.
13. Press the ENTER key once more to accept the calibration value
ANALOG INPUT
CALIBRATED
14. Analog input signal calibration is complete
15. Press the MENU key three times to exit back to the main operating
screen.
If you receive the following message:
CURRENT DELTA
OUT OF RANGE
This indicates that there is not a wide enough range between your maximum
and minimum analog signals. The minimum signal range is 3 mA. The most
likely source of this error is the user did not change the value of the incoming
analog signal when moving from the MIN calibration to the MAX calibration.
The analog input signal calibration procedure should be performed again,
ensuring that a minimum of 3 mA difference exists between the MIN and MAX
signal levels.
10.7. Analog Output Calibration
1. The starting display will be:
SETPT XX.XXX
FLOW XX.XXX
2. Press the MENU key
-MENU-
CALIBRATION
3. Press the ENTER key
CALIBRATION
PUMP FLOW
4. Press the UP ARROW key to access the analog output calibration
CALIBRATED
ANALOG OUTPUT
5. Press the ENTER key
SET 0% FLOW TO
04.0 MA
6. Use the UP and DOWN arrow keys to adjust the output signal as
required. The actual output signal will vary and can be monitored with a
meter or your facility control system. The value displayed on the screen
may not match the actual output signal and is for visual reference only.
7. Press the ENTER key once more to accept the calibration
SET 100% FLOW TO
20.0 MA
8. Use the UP and DOWN arrow keys to adjust as in step 6 above
9. Press the ENTER key once more to accept the calibration value
CALBRATION
ANALOG OUTPUT
10. Analog output signal calibration is complete
11. Press the MENU key three times to exit back to the main operating
screen
If you receive the following message:
CURRENT DELTA
OUT OF RANGE
This indicates that the output current for 0% flow has been set greater
than or equal to the output current sett ing for 100% flow. Repeat the
process and ensure that the 0% calibrated signal is set to a value lower
than the 100% calibrated signal.
10.8 Displa y Contrast Adjustment
Should adjustment of the contrast level of the display become
necessary, use the following procedure while in the normal operating
mode.
To increase contrast, press and hold at the same
time.
To decrease contrast, press and hold at the same
time.
10.9 Changing the Motor Base Frequency
This procedure will not be necessary during normal oper a ti on o f the
MPC controller. In the event that you need to install a different drive
motor, and that motor has a different base frequency (50 Hz vs. 60 Hz)
than the original unit, please refer to this procedure. These changes are
made at the AC drive within the MPC enclosure and not at the hand-held
unit.
This procedure is performed with power applied to the MPC. Take
ALL NECESSARY precautions, keep fingers and tools clear of
energized circuits, and perform this procedure only if you are
certain it is required.
1. Open the front cover of the MPC control
2. There are three buttons on the face of the drive, MODE, UP and DOWN.
3. Press the MODE button
4. Scroll UP to display the default password “001”
FATAL ERRORS: The pump and controller will not run while one of these error
conditions exists. The Red LED will blink and the error message will flash on the
corrected.
5. Press MODE to enter the password
6. Scroll UP to the base frequency parameter which is “27” display will
show “P 27”
7. Press MODE to display the current setting (will be either 50 or 60)
8. Use the UP or DOWN keys to change the setting to the new value (either
50 or 60)
9. Press MODE to store the new value
10. Drive will exit the program mode after it stores the new value
This procedure should be us ed only if the base frequency of the pump
drive motor is changed.
11. Alarm and Error Messages
If a fatal error has occurred while in Operational Mode, the error will flash on the
screen and the Red LED lamp will also flash. The menus can still be accessed by
holding down the menu key. This allows the user to try and fix the source of the
error if possible.
The following table gives an example of these messages and when you can
expect them to be display ed.
Message Displayed When:
screen. Users can access the menu system by pressing the MENU key. The
red LED and the message will cease when the error condition has been
Analog Input #X
Out of Range
ALARM
LEAK DETECT
ALARM
LOW LEVEL
ALARM
AC DRIVE FAULT
ALARM
Motor error
The analog input is less than 2.4 mA or greater
than 24 mA
The leak detection input has triggered
The level monitoring input has triggered
Internal fault
The MPC has detected that the motor shaft is not
rotating at the expected speed
ALARM
CAM SENSOR
MPC controller is not receiving correct signals from
the cam sensor in the pump eccentric box
COMMUNICATION
Stroke length
User is trying to activate the AUTO mode, but there
the controller
ERROR
NON-FATAL ERRORS: The pump and controller can still be run while these
conditions exist. The Red LED will flash, however no message will flash on the
screen. The Red LED will stop flashing once the error condition has bee n
Communication error exists between the MPC
controller and the handheld keypad/display module
corrected.
ALARM
STROKE SENSOR
SOFTWARE Fault
Error = ####
Hardware fault
Error = ####
CONSULT fa ctory
Error = ####
USER NOTIFICATIONS: These are errors in setup or calibration. They will
display on the screen for several seconds. They can be corrected by properly
completing the procedure involved.
Cannot access
With motor on
Out of range
Current delta
Out of range
MPC does not receive valid indication from the
stroke position sensor, the flow display will not be
accurate
Software related problem, record error number and
consult factory
Hardware related problem, record error number
and consult factory
Unidentified error, record error number and consult
factory
User is trying to change a setting that cannot be
changed while the pump is running
Stroke length position is not set correctly for
current operation
Not enough difference between high and low
signals during an analog input signal calibration
(min 3 mA)
Stroke delta
Out of range
No remote
Control
For unlisted or numbered error codes, consult the factory for assistance.
Pressing MENU will clear all non-fatal errors, provided the error condition
is no longer present.
Stroke length position is not set correctly for
current operation
is no remote input (mA signal or remote on/off) to
12. Extending your Hand-Hel d Controll er
Cable Length
Part Number
Notes
The hand-held controller for your MPC can be placed as far as 1000 feet from
the pump with optional cable. It is recommended that all calibrations be
completed before the cable is lengthened, as these tasks are easier when the
pump and hand-held controller are close to each other.
To replace the cable for the hand-held unit:
POWER TO THE UNIT MUST BE OFF! A GROUNDING WRIST STRAP
SHOULD BE WORN WHEN MAKING CONNECTIONS TO ANY PCB
12.1 Obtain New Cable:
The following standard length cables are available from Pulsafeeder for use with
the MPC:
6 feet NP530130-000 Standard, supplied with all MPC controllers
Others per foot NP530147-000 (1
ft)
NOTE: do not exceed 1,000 feet total length
12.2 Removal and Connection of the Cable from the Handheld:
1. Open the handheld unit by removing the 4 screws on the face of the unit.
2. Open the unit by separating the cover from the base.
3. Disconnect the keypad from the Remote PCB by gently removing the
connector at the end of the keypad’s tail from the header on the PCB.
4. Make a note of what color lead is in each position of the terminal block
“J5”. Cut the tie-wrap that secures the cable. Loosen e ach o f the 6
positions on the terminal block “J5” and remove each lead.
5. Loosen the outer domed nut on the liquid tight, releasing the tension on
the cable. Pull the cable through the liquid tight. Thread the new cable
through the liquid tight with enough length to reconnect to the terminal
block.
6. Cut the shield wire as close as possible to the outer insulation at the
remote end only.
7. Wrap the end of the cable with electrical tape to insulate any remaining
shield so that it will not contact the circuit board, equipment case, or any
other parts.
8. Referring to the notes taken earlier, connect each lead of the new cable to
the proper position of the terminal block; tighten the screw terminal to hold
lead. NOTE: It is recommended that you insert and secure one lead at a
time.
9. Tighten the dome nut of the liquid tight to secure/seal cable.
10. Replace cover and tighten screws. Be sure the o-ring is in its groove,
paying special attention to the corners. NOTE: Do not over tighten.
Wait a minimum of 3 minutes after disconnecting power before
servicing the MPC or pump motor. Capacitors retain a charge even after
power is removed from the controller.
1. Remove the 10 screws that are securing the cover to the side of the main
unit.
2. CAUTION: The cover is wired and should be folded down gently being
sure not to pull any of the wires that are connected to it.
3. Make a note of what color lead is in each position of the terminal block
“J14”. Loosen each position of terminal block “J14” and remove each lead.
4. Loosen the outer domed nut on the liquid tight, releasing the tension on
the cable. Pull the cable through the liquid tight. Thread the new cable
through the liquid tight with enough length to reconnect to the terminal
block.
5. Prepare the end of the cable as per figure 5b on the following page.
Ensure that the shield is fully insulated until the point where it enters the
terminal. No part of the shield should be allowed to come in contact with
the circuit board, equipment case, or any other surface.
6. Note that the black-green lead is not utilized at this end of the cable.
7. Referring to the notes taken earlier, connect each lead of the new cable to
the proper position of the ter min al block , an d tighten the screw terminal to
hold the lead. NOTE: It is recommended that you insert and secure one
lead at a time.
8. Tighten the dome nut of the liquid tight to secure/seal cable.
9. Replace cover carefully being sure not to crimp any of the cables/leads
between cover and enclosure and tighten screws.
Power the unit on, if all connections were properly made the unit will power as
normal and the display will show the start up screen.
BLACK/WHITE
WHITE
BLACK/GREEN
GREEN
BLACK/RED
RED
TAPE SHIELD
CUT
BLK/GRN
TAPE END
AN00446-006
Figure 5a – Handheld Remote Wiring
Figure 5b – Wire Preparation Detail , Base Unit End
Figure 6 – Handheld Remote
13. Specifications
Control Inputs
Wiring
Specification / Description
Analog In #1
J11 pins 4-6
4-20mA control signal
Analog In #2
J11 pins 5-6
Not presently available – future release
Digital In #1
J11 pins 1-3
User to provide dry-contact input *
Turndown: Up to 1000:1 with a steady state accuracy of +/- 2 % (added
to pump accuracy rating)
3:1 with a steady state accuracy of +/- 1 % (added to pump accuracy
rating)
Operation mode: AC motor speed control with speed and stroke length
feedback
Manual stroke length control
Recommended Minimum Wiring and Circuit Breaker
Power
Requirements
MPC and 0.25
Hp motor
MPC and 0.33
Hp motor
MPC and 0.5 Hp
motor
MPC and 0.75
Hp motor
MPC and 1.0 Hp
motor
MPC and 1.5 Hp
motor
NOTE: AC drive capacitors will cause in-rush current demand when power is first
applied to the unit. Applicable national and local electrical codes take precedence
115 VAC Operation 230 VAC Operation
Actual
Draw
Circuit
Breaker
Wire
Size
7.0 A 10 A 14
AWG
7.0 A 10 A 14
AWG
9.4 A 15 A 14
AWG
16.8 A 25 A 12
AWG
16.8 A 25 A 12
AWG
24.2 A 35 A 10
AWG
over recommendations in these tables.
Wire
Size
2.5
mm
2.5
mm
2.5
mm
4.0
mm
4.0
mm
6.0
mm
Safety
Approvals1
UL, CUL,
2
2
2
2
2
2
CE
UL, CUL,
CE
UL, CUL,
CE
UL, CUL 9.4 A 15 A 14
UL, CUL 9.4 A 15 A 14
UL, CUL 12.2 A 20 A 14
Actual
Draw
Circuit
Breaker
3.5 A 10 A 14
3.5 A 10 A 14
5.2 A 10 A 14
Wire
Size
AWG
AWG
AWG
AWG
AWG
AWG
Wire
Size
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
2.5
mm2
Safety
Approvals
UL, CUL,
CE
UL, CUL,
CE
UL, CUL,
CE
UL, CUL
UL, CUL
UL, CUL
1
Max current 30mA; Input resistance 200 Ohm
Internally protected with resetable fuse
Minimum signal accepted = 2.4 mA
Maximum signal accepted = 24 mA
Digital In #2
J11 pins 2-3
User to provide dry-contact input *
*All digital inputs require a dry contact input
(maximum of 2K Ohm contact resistance to regist er as
Control Outputs
Wiring
Specification / Description
Analog Out #1
J23 pins 5-
4-20mA output for pump flow indication
Internally protected with resetable fuse
Digital Out #1
J23 pins 1-
4
Transistor-based output, various functions *
Digital Out #2
J23 pins 2-
4
Transistor-based output, various functions *
Digital Out #3
J23 pins 3-
4
Transistor-based output, various functions *
All digital outputs maximum 40 VDC, maximum 500
NOTE: requires external power source
“active”). Do not apply power to these terminals.
* Digital input functions:
1. Remote on/off control of metering pump
2. Level input from supply tank
3. Leak detection of the metering pump
4. Flow detection, with use of external flow switch
accessory
6
Max voltage out 12 Volts; Max current out 30mA;
Max load resistance 300 Ohm
mA
* Digital output functions:
1. Triggering an external relay due to a fault condition
2. Auto/Manual status
3. On/Off status
4. Pulse output – Indication each time the pump strokes
5. Leak detection status indication
6. Tank level status indication
Calibration: Controller includes an on board program for signal and flow
calibration.
Input Voltage: 115 (105-125 acceptable range) or 230 (208 – 240 acceptable
range) VAC
Note: factory configured only for correct input voltage range
(specified at time of purc hase) Single phase input only 50 or 60
Hz.
Input frequency range 48 Hz to 62 Hz
Motor Req: Commercially available motor supplied by the manufacturer of
the pump controller.
Standard selection is rated for indoor, dry environment, other
options available
Keypad: Can be mounted on the pump or up to 1000’ away from the
pump
Standard cable length 6 feet
Display: Backlit 2 line extended temperature 16 character LCD
Enclosure: NEMA 4X and IP56 ratings
Altitude: 3300 Ft (1000 M) above sea level (de-rate 5% per additional
3300 Ft).
Humidity: 0-90% (non-condensing)
Temperature: 0o C (32o F) Minimum operating temperature
40o C (104o F) Maximum operating temperature
Earth Leakage
Current: Size Earth Leakage Circuit Breakers (ELCB) to a detection level
of 30 mA or greater
Transient Voltage Max Impulse withstand 1500V (115VAC Models), 2500V
(230VAC Models) at 50uS
Voltage Overload 150% for 60 seconds or 180% for 30 seconds
Pollution Degree Suitable for Pollution Degree 1 environment only (conduit
entries must be sealed against ingress of fluids and vapors)
ENTER TO RESET
TOTAL: 0
SYSTEM SETUP
TOTAL STROKES
LANGUAGE
FRANCAIS
LANGUAGE
<FRANCAIS>
SPEED:
SETPT:
SYSTEM SETUP
ENTER VOLUME
VOL = 00.000 GAL
TIMER: XXX SEC
ENTER TO START
SET STROKE 100%
VOL = 00.000 GAL
ENTER VOLUME
TIMER: XXX SEC
SECURITY
CODE = 0000
SYSTEM SETUP
SET STROKE 50%
ENTER TO START
CALIBRATION
PUMP FLOW
0.00GPH
0.00GPH
SYSTEM SETUP
SECURITY
-MENUSECURITY
CALIBRATION
SN: XXXXX
Pump Serial Num:
-MENU-
SETPT:
FLOW:
ENGLISH
LANGUAGE
LANGUAGE
<ENGLISH>
ENGLISH
LANGUAGE
SYSTEM SETUP
LANGUAGE
YES=ENTR NO=MENU
ARE YOU SURE?
LANGUAGE
DEUTSCHE
<DEUTSCHE>
LANGUAGE
TO FACTORY INIT
FACTORY INIT
SYSTEM SETUP
PRESS ENTER
SET 100% FLOW TO
20.0 mA
SET 0% FLOW TO
04.0 mA
CALIBRATION
ANALOG OUTPUT
FLOW:
SETPT:
STROKE SET TO
0.0 %
0.0 %
XXX.X%
APPLY MAX mA
SPEED 000.0%
MAX SETPT 0.0mA
ENTER TO START
APPLY MIN mA
SPEED 000.0%
MIN SETPT 0.0mA
ENTER TO START
CALIBRATION
ANALOG INPUT
0.00SPM
0.00SPM
SPEED:
SETPT:
LANGUAGE
ESPANOL
LANGUAGE
<ESPANOL>
TOTAL FLOW
SYSTEM SETUP
TOTAL: 0.0
ENTER TO RESET
<GPH>
FLOW UNITS
FLOW UNITS
SYSTEM SETUP
FLOW UNITS
GPH
0.0 %
0.0 %
FW: XX.XX/XX.XX
Pulsafeeder, Inc.
SYSTEM SETUP
INFORMATION
ENTER TO STOP
ENTER TO STOP
&
FW XX.XX/XX.XX
Pulsafeeder, Inc.
FLOW UNITS
LPH
FLOW UNITS
<LPH>
SN: XXXXX
Pump Serial Num:
MPC Part Number:
MPCXXXXXXX-XXXX
CALIBRATING.....
CALIBRATING.....
MPCXXXXXXX-XXXX
MPC Part Number:
RESETTING PUMP
TO FACTORY INIT
CALIBRATED
PUMP FLOW
CALIBRATED
ANALOG OUTPUT
ANALOG INPUT
CALIBRATED
MAX FLOW XX.XGPH
MAX SPEED XXXSPM
FLOW DETECT
SYSTEM SETUP
FLOW DETECT
DELAY: 000 SEC
CALIBRATION
VOLUME
CALIBRATION
FLOW
FLOW: 000.00 GPH
SET STROKE 50%
FLOW: 000.00 GPH
SET STROKE 100%
PUMP FLOW
CALIBRATED
14. Menu Maps
ALARM IND.
SIGNAL PURPOSE
SIGNAL PURPOSE
<ALARM IND.>
NORMAL CLOSED
<NORMAL CLOSED>
NORMAL OPEN
<NORMAL OPEN>
<NORMAL CLOSED>
<NORMAL OPEN>
NORMAL OPEN
REMOTE ON/OFF
SIGNAL PURPOSE
<REMOTE ON/OFF>
NORMAL CLOSED
ANALOG INPUT #1
ANALOG INPUT #1
DIGITAL I/O
DIGITAL OUTPUT #3
DIGITAL OUTPUT #2
DIGITAL I/O
DIGITAL I/O
DIGITAL OUTPUT #1
DIGITAL I/O
DIGITAL INPUT #2
DIGITAL INPUT #1
DIGITAL I/O
DIGITAL I/O
-MENU-
NORMAL OPEN
AUTO/MAN STAT
<AUTO/MAN STAT>
SIGNAL PURPOSE
SIGNAL PURPOSE
NORMAL CLOSED
<NORMAL CLOSED>
<NORMAL OPEN>
AUTO/MAN STAT
SIGNAL PURPOSE
NORMAL OPEN
<NORMAL OPEN>
<NORMAL CLOSED>
NORMAL CLOSED
SWITCH STATE
SIGNAL PURPOSE
SIGNAL PURPOSE
INACTIVE
<INACTIVE>
INACTIVE
ANALOG INPUT #1
INACTIVE
<INACTIVE>
<NORMAL CLOSED>
<NORMAL OPEN>
NORMAL CLOSED
NORMAL OPEN
LEAK DETECT
SIGNAL PURPOSE
<LEAK DETECT>
ANALOG INPUT #1
ACTIVE
<ACTIVE>
ANALOG I/O
ANALOG INPUT #1
ANALOG I/O
-MENU-
INACTIVE
ANALOG INPUT #1
<LEAK DETECT>
NORMAL OPEN
NORMAL CLOSED
<NORMAL OPEN>
<NORMAL CLOSED>
SIGNAL PURPOSE
LEAK DETECT
SIGNAL PURPOSE
NORMAL OPEN
ON/OFF
SIGNAL PURPOSE
SIGNAL PURPOSE
<ON/OFF>
NORMAL CLOSED
<NORMAL CLOSED>
<NORMAL OPEN>
NORMAL OPEN
<NORMAL CLOSED>
<NORMAL OPEN>
NORMAL CLOSED
<TANK LEVEL>
SIGNAL PURPOSE
<TANK LEVEL>
<STROKE IND.>
SIGNAL PURPOSE
NORMAL CLOSED
STROKE IND.
SIGNAL PURPOSE
<NORMAL OPEN>
<NORMAL CLOSED>
NORMAL OPENNORMAL OPEN
NORMAL CLOSED
<NORMAL CLOSED>
<NORMAL OPEN>
SIGNAL PURPOSE
<TANK LEVEL>
SIGNAL PURPOSE
<TANK LEVEL>
AN00446-003 REV B
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE S WITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE SWI TCH STATE
SWITCH STATE
SWITCH STATE
SWITCH STATE
SIGNAL PURPOSE
<FLOW DETECT>
FLOW DETECT
SWITCH STATE
<NORMAL CLOSED>
SWITCH STATE
NORMAL CLOSED
SWITCH STATE
<NORMAL OPEN>
SWITCH STATE
NORMAL OPEN
SWITCH STATE
15. Factory Default Values
Parameter
Factory Set Value
Digital Input #1
INACTIVE, normally closed
Digital Input #2
INACTIVE, normally closed
Analog Input #1
INACTIVE
Analog Input #2
NOT AVAILABLE this revision
Digital Output #1
STROKE Indication, normally closed
Digital Output #2
AUTO/MANUAL Indication, normally closed
Digital Output #3
Alarm Indication, normally closed
Security Code
Default = 0000
Language
ENGLISH
MODE
Local (Manual)
UNITS
GPH (gallons per hour)
In This SCREEN
Press MENU and ENTER at the same time to:
SETPT XX.XXX
FLOW XX.XXX
MENU
ANALOG I/O
MENU
DIGITAL I/O
Shows current status of digital inputs and outputs
Press DOWN arrow to see digital out #3
16. Retrieval of Setup Information
Users can access the system setup: information menu, which will list the
following data, this may be helpful in troubleshooting:
Controller software revisions
Pump serial number
MPC model number
Pump maximum flow
Pump maximum speed
17. Special Keypress Access
View the stroke position of the pump
Show calibration and RAW data for analog inputs
Press the MENU key to exit from any of these special screens.
18. Troubleshooting Guide
Problem Potential Cause Solution
DISPLAY
No Display
No power supplied.
Check power source. plug & circuit
breaker
Backlighting
Supply power wired incorrectly.
Check wiring.
Supply power outside of
specification.
Check voltage/frequency against
specification.
No Text on
Contrast out of adjustment .
Adjust as per section 10.8
Software did not initiate
properly.
Remove and re-apply Ac power
POWER
No power
No power supplied.
Check power source. Plug &
Circuit Breaker
Indicators
Supply power wired incorrectly.
Check wiring.
Supply power outside of
specification.
Check voltage/frequency against
specification.
Display
19. Maintenance & Spare Parts
All maintenance work must be carried out only when the MPC and
connected equipment is stopped and disconnected from mains supply
(including auxiliary circuits). Maintaining original characteristics over time
must be ensured by an efficient maintenance and inspection plan,
developed and managed by qualified technicians, taking into account the
service and the actual environmental conditions in which it operates.
19.1 Operating Precautions
All operations must be per form ed by qualified personnel.
Work on the unit should only be performed with safety supervisor
authorization, after having verified that:
a) Disconnect power at the source (follow your local lockout tag out
procedures)
b) The power line is disconnected and no parts are energized, including any
auxiliaries
c) Ensure that any risk of accidental restart has been excluded
d) Consult Manufacturers Pump Operating Manual for instructions on
minimizing risk due to pressurized or chemically dangerous conditions with
in the Pump system
e) With pump switched off, that the ON-OFF valves on the suction and
discharge pipelines are closed.
f) Pump has been adequately cleaned, when operating in environments
exposed to aggressive chemicals
g) Maintenance personnel shall refer to the Installation and Wiring section
for safe return to service
after repair
Since the machine object of supply is a product designed and intended for
operation in industrial areas, additional measures must be adopted and
assured by the person respons ible for the installation, should more restrictive
safety conditions be required.
19.2 Cleaning and Decontamination
The MPC enclosure may be cleaned with water and mild detergent.
Decontamination shall occur when the MPC is exposed to a release of
process chemicals. Follow the SDS for clean-up in the event of a chemical
spill.
19.3 User Replaceable Parts for the MPC
Pulsafeeder P/N Description
W770401-188 Housing cover bolt
W774030-188 Housing cover washer
NP460056-000 Housing cover gasket
NP530091-000 ½” wiring liquidtight connector
NP530137-000 ¼” wiring liquidtight connector
NP530511-006 Hand-held unit (complete)
NP140070-000 Hand-held unit angle-mount bracket
NP140066-PVC Hand-held unit “snap-in” bracket
W213946-NTR Hand-held enclosure gasket
NP550113-000 Membrane keypad for hand-held
NP530130-000 Cable, for hand-held, 6 foot length
NP83XXXXXP-XXXX Stroke cover with position sensor
NP030013-000 Bearing cap with eccentric sensor
W772568-STL ½” conduit opening plug
W772585-018 ¼” conduit opening plug
A unit of IDEX Corporation
MPC®
IOM-CTL-2000-Rev.I
2883 Brighton Henrietta Town Line Road
Rochester NY 14623
+1 (585) 292-8000
pulsa.com
pulsa@idexcorp.com
SPEED CONTROLLER
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