Pulsafeeder MPC Vector User Manual

Automatic Flow Control for Chemical Feed Pumps

Installation, Operation & Maintenance Manual

BULLETIN No. IOM-MPCV-0206 Rv. J

Manufacturers of Quality Pumps, Controls and Systems

Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623

Telephone: (585) 292-8000 Fax: (585) 424-5619 http://www.pulsa.com pulsa@idexcorp.com

MPC VECTOR™ FACTORY SERVICE POLICY

Your MPC VECTOR is a state of the art microprocessor based motor speed control for use with Pulsafeeder Eclipse Non-Metallic Gear Pumps. It includes extensive on-board diagnostics. If you are experiencing a problem with your MPC VECTOR, 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 unit 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 parts by Pulsafeeder personnel.

Certain components may be purchased for replacement. Refer to Section 19 – 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 modifications will void the Pulsafeeder warranty. Out-of-warranty repairs will be subject to Pulsafeeder’s standard bench fees and testing costs associated with replacement components.

FCC Warning

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

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.

Table of Contents

1. I

NTRODUCTION

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

1.2 MPC VECTOR Standard Features ......................................................................................... 2

2. S

AFETY CONSIDERATIONS

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

2.2 Electrical Safety ...................................................................................................................... 3

2.3 Mechanical Safety................................................................................................................... 3

2.4 Hydraulic Safety...................................................................................................................... 3

3. E

QUIPMENT INSPECTION

4. S

TORAGE INSTRUCTIONS

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

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

5. I

NSTALLATION AND WIRING

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

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

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

5.3.1 Controller Layout ................................................................................................................ 6

5.3.2 Power Wiring Information .................................................................................................. 8

5.3.3 Power Wiring Diagram ....................................................................................................... 9

5.3.4 Input/Output Signal Wiring ................................................................................................ 10

5.4 Check Wiring and Close Access Cover................................................................................ 11

5.5 Confirm Correct Incoming Power ......................................................................................... 11

6. S

TART UP AND OPERATION

6.1 Overview .................................................................................................................................. 12

6.2 Critical Parameters ................................................................................................................. 12

6.3 Keypad/Lamp Operation ........................................................................................................ 13

6.4 Confirm Display and Keypad Functionality ......................................................................... 13

6.5 Motor Parameter Setup .......................................................................................................... 14

6.6 Setting Max Flow and Max Speed ......................................................................................... 14

6.7 Flow Display ............................................................................................................................ 16

6.8 Wrapping up ............................................................................................................................ 16

6.9 Factory Re-Initialization ......................................................................................................... 17

7. I

NPUT/OUTPUT SETUP

7.1 Analog Input Setup ................................................................................................................. 18

7.1.1 Analog Input 1 – Setpoint .................................................................................................. 18

7.1.2 Analog Input 2 – Flowmeter Feedback ............................................................................. 18

7.2 Digital Input Setup .................................................................................................................. 18

7.2.1 Multi-purpose Digital Inputs .............................................................................................. 18

7.3 Analog Output Setup .............................................................................................................. 19

7.4 Digital Output Setup ............................................................................................................... 19

8. C

ALIBRATIONS

8.1 Pump Flow Calibration ........................................................................................................... 20

8.1.1 WET Flow Calibration ......................................................................................................... 20

8.1.2 DRY Flow Calibration ......................................................................................................... 22

8.2 Analog Input Calibration ........................................................................................................ 24

..................................................................................................................................... 1

.................................................................................................................... 3

....................................................................................................................... 4

...................................................................................................................... 4

.................................................................................................................. 5

.................................................................................................................. 12

.......................................................................................................................... 18

..................................................................................................................................... 20

iii

8.2.1 “WET” Analog Input Calibration (with a field signal) ......................................................24

8.2.2 “DRY” Analog Input Calibration (keypad only, no signal present)................................ 26

8.3 Analog Output Calibration .....................................................................................................28

8.4 PulsaGuard Pump Protection ................................................................................................ 30

8.4.1 PulsaGuard Calibrations, using Flow Meter Feedback................................................... 30

8.4.2 PulsaGuard Calibrations, no Flow Meter Feedback ........................................................31

8.5 Display Contrast Adjustment................................................................................................. 32

8.6 Tuning the Control Algorithm................................................................................................ 33

9. F

LOW METER INPUT

9.1 Flow Meter Installation ...........................................................................................................36

10. M

OTOR PARAMETER SETUP AND TUNING

11. A

LARM AND ERROR MESSAGES

11.1 Error Log ..................................................................................................................................41

11.1.1 Viewing the Error Log .........................................................................................................41

11.1.2 Clearing Error Log Entries .................................................................................................42

11.2 Error Messages ....................................................................................................................... 42

12. S

PECIFICATIONS

13. M

ODEL IDENTIFICATION

14. M

ENU MAPS

15. F

ACTORY DEFAULT VALUES

16. R

ETRIEVAL OF SETUP INFORMATION

17. S

PECIAL KEY PRESS ACCESS

18. T

ROUBLESHOOTING GUIDE

19. S

PARE PARTS

20. A

PPENDIX 1, HANDHELD WIRING

20.1 Removal and Connection of the Cable from the Handheld: ............................................... 54

20.2 Removal and Connection of the Cable from the Base Unit:............................................... 55

21. A

PPENDIX 2,

21.1 PID Controller Theory: ............................................................................................................ 58

21.2 Three Control Components: ..................................................................................................60

21.3 PID Basic Summary, what happens when I… ......................................................................61

21.4 Putting it all together to run the MPC Vector ....................................................................... 62

21.5 Troubleshooting ...................................................................................................................... 63

.........................................................................................................................................48

PID T

.............................................................................................................................36

..............................................................................................38

............................................................................................................41

...................................................................................................................................44

........................................................................................................................47

.................................................................................................................51

.....................................................................................................51

...............................................................................................................51

...................................................................................................................52

......................................................................................................................................53

...........................................................................................................54

HEORY AND ADJUSTMENT

........................................................................................58

Conventions

For the remainder of this bulletin, the following Conventions are in effect.

Revision History:

2-2006 Rev A First Release 3-2006 Rev B New menu maps Digital I/O features added 4-2006 Rev C Add “Speed Mode Flow Cal” instructions Misc. minor updates and changes for spelling, grammar, etc 7-2006 Rev D, E New illustrations, new dimensional diagram, change to MPC Vector name, added

5-2007 Rev F Updated signal connections diagram

9-2007 Rev G Added notes and diagram for digital outputs, section 5.3.4 and 7.4

1-2008 Rev H Update to match new software revision, multiple changes (3.01) 3-2008 Rev J Further updates and corrections for new software version (3.01)

WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT. PAY CLOSE ATTENTION TO ANY WARNING

Notes are general information meant to make operating the equipment easier.

model string, minor text revision, added 3 phase information for low Hp motors.

Added hand-held wiring diagram Added PID tutorial information in appendix Added startup and parameter setup information section 6

Corrected steps in Dry Flow Cal for Speed Control section Other minor text changes and additions

Safety Considerations:

1. Read and understand all related instructions and documentation before attempting to install or

maintain this equipment

2. Observe all special instructions, notes, and cautions.

3. Act with care and exercise good common sense and judgment during all installation, adjustment, and

maintenance procedures.

4. Ensure that all safety and work procedures and standards that are applicable to your company and

facility are followed during the installation, maintenance, and operation of this equipment.

1. Introduction

The MPC VECTOR is a microprocessor based motor speed control device, for use with Pulsafeeder pumps. It has been designed for simplicity, yet still has many advanced features that allow the MPC VECTOR to operate in a wide variety of environments and applications. This product is not just a variable speed drive. It is a state of the art multifunctional controller, which provides functionally no one stand-alone variable speed drive does. What makes this product unique is that it combines functionality of three devices in one:

• Vector type variable speed drive.

• Input output processor (4-20 mA in and out, digital input/output), including PID loop for closed loop flow

control.

• Power monitor for detection of run-dry conditions

This instruction manual covers the MPC VECTOR control only. For information and safety precautions specific to the pump or any other accessories, please refer to the appropriate IOM.

1.1 Description

The MPC VECTOR is an advanced pump controller that is physically separated from the pump's enclosure. Its purpose is to precisely adjust output flow of a process media by means of pump motor speed control.

The MPC VECTOR is designed for a wide variety of control applications. If delivered with a pump and motor, the device is factory configured. Field configuration may be required in certain installations. 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. Pump output is displayed as Gallons or Liters per Hour (GPH/LPH), Gallons or Liters per Minute (GPM/LPM), or Revolutions per Minute (RPM).

Digital and analog inputs will support a variety of industry standard signals to offer flexible remote control.

The MPC VECTOR 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 realtime display of signal level. This eliminates the need for external meters.

The MPC VECTOR will accept, and automatically adjust to, either 60 Hz or 50 Hz input power. No special modifications, settings, or adjustments are required. MPC VECTOR controller can be supplied with a 60 Hz, 50 Hz, or dual rated 50/60 Hz motor. The controller/motor combination allows for 60 Hz rated pump flow (1800 rpm motor speed) 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.

Minimum motor speed is limited under all circumstances to 31 rpm. Please note that in certain applications, the practical minimum speed (to achieve flow and pressure) may be higher than 31 rpm. This can be dependent on product viscosity and other application-specific variables.

Input Frequency MPC VECTOR Motor Max MPC VECTOR Output

60 Hz (USA and similar) 60 Hz (or dual rated) 60 Hz / 1800 rpm

50 Hz (Europe, Asia, etc) 50 Hz or 60 Hz or dual rated 60 Hz / 1800 rpm

The motor used with the MPC VECTOR is a three-phase motor; however the three-phase power is generated internally by the MPC VECTOR itself. Do not be confused by the motor nameplate. Input power to the MPC VECTOR is single-phase or three-phase AC 230 volts (see Section 12, Specifications for acceptable voltage range). The nameplate on the side of your MPC VECTOR controller will list the appropriate supply requirements for your controller.

Motor Hp Rating MPC VECTOR Input Power* Output to Motor**

1 208/230 VAC 1 or 3 phase 230 VAC 3 phase

2 208/230 VAC 1 or 3 phase 230 VAC 3 phase

3 208/230 VAC 1 or 3 phase 230 VAC 3 phase

5 208/230 VAC 3 phase only 230 VAC 3 phase

* all input ratings are 50 or 60 Hz ** output to pump motor is always 60 Hz maximum frequency

The AC drive used in the MPC VECTOR 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. Further motor selection information can be found in Section 12, Specifications at the end of this manual.

1.2 MPC VECTOR Standard Features

• User keypad and display for ease of operation

• Display pump operation in GPH, LPH, GPM, LPM, or RPM

• One 4-20 mA analog input signal for flow control

• One analog (mA) input for flow feedback control (with an external, user supplied flow metering device

which provides an analog signal)

• Sensorless vector motor speed control

• Two configurable digital inputs

• Three configurable digital outputs (transistor type, 40 VDC maximum)

• Analog 4-20 mA feedback output

• NEMA 4X and IP56 ratings (for controller housing)

• 230 Volts, 50 or 60 Hz, single or three phase AC power for 1 through 3 Hp systems

• 230 Volts, 50 or 60 Hz, three phase (only) AC power for 5 Hp systems

• Security code lockout of menus

• Standard configurable pump protection utilizing proprietary PulsaGuard technology

2. Safety Considerations

• Read and understand all related instructions and documentation 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

maintenance procedures.

• Ensure that all safety rules, work procedures, and standards that are applicable to your company and facility

are followed during the installation, maintenance, and operation of this equipment.

2.1 General Safety

The MPC VECTOR was designed as a controller for operation solely with the Pulsafeeder Eclipse series of non-metallic gear pumps. Use for any other application is considered unsafe and voids all certification markings and warranties.

2.2 Electrical Safety

The MPC VECTOR is an industrial process controller. Improper application and use can be hazardous. You are solely responsible for its use.

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

The MPC VECTOR 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.

Wait a minimum of 5 minutes after disconnecting power before servicing the MPC VECTOR or pump motor. Capacitors retain a charge even after power is removed from the controller.

2.3 Mechanical Safety

Users should note that the pump motor is always under the control of the MPC VECTOR, 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 VECTOR was designed to be service free. It contains no user-maintainable components. Disassemble the MPC VECTOR enclosure only for initial field wiring, or as instructed to do so within this manual. Evidence of unauthorized disassembly shall void the warranty.

2.4 Hydraulic Safety

Thoroughly review and adhere to the contents of the pump Installation, Operation, Maintenance and Instruction manual for any pump used with the MPC Vector control. As a microprocessor controlled device, the MPC VECTOR may activate the pump motor without warning – generating hydraulic pressure and fluid flow. Care should be taken to protect both users and systems should the pump activate.

3. Equipment Inspection

When you receive your order, check all equipment for:

• Completeness against the shipping document / purchase order

• For any evidence of shipping damage.

Shortages or damage should be reported immediately to the carrier and your Pulsafeeder Representative.

4. Storage Instructions

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

4.1 Short Term (0 - 12 months)

The MPC VECTOR 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.

4.2 Long Term (12 months or more)

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

Special note for long-term storage:

If AC input power has not been applied to the MPC VECTOR for a period greater than 12 months, the controller must be prepared for operation. The MPC VECTOR 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.

5. Installation and Wiring

5.1 Location

Review the Safety section (Section 2) prior to installing the MPC VECTOR. It contains information required to properly install and operate the MPC VECTOR in an industrial environment.

The site selected for the installation of your MPC VECTOR is largely dependent on that of the gear pump. Review the Installation, Operation, and Maintenance manual provided with your gear pump. It details system related issues that are important to proper operation of the pump. Consider the following MPC VECTOR related issues when selecting a site. Avoid locations where the MPC VECTOR would be subjected to extreme cold or heat. Note the warning statement on the next page. The installation of this device must comply with national, state and local codes.

The MPC VECTOR controller must be secured to an appropriate support before use. Use appropriate hardware to secure the MPC VECTOR controller and pump to a smooth vertical surface. No assembly is required for the MPC VECTOR controller itself.

AC TO MOTOR

AC POWER IN

Figure 1 – Typical Installation.

VOID LOCATIONS WHERE THE

HEAT [LESS THAN

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

MPC VECTOR

0°°°° C

ELSIUS

AND VOID ITS WARRANTY

MPC VECTOR

(32°°°° F

AHRENHEIT) OR GREATER THAN 40

WOULD BE SUBJECTED TO EXTREME COLD OR

°°°° C

ELSIUS

(104 °°°°

5.2 Installation Notes

The MPC VECTOR is a microprocessor-based controller that uses electro-static sensitive CMOS components. Do not make any (high or low voltage) electrical connections without adequately grounding the MPC VECTOR 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 VECTOR’s internal ground plate is adequate to satisfy this requirement.

Calibration is an important element of successful MPC VECTOR operation. If a flow meter is being used for process feedback the flow meter must be calibrated prior to MPC VECTOR calibration according to manufacturer recommendations.

Conduit connections can carry fluids and vapors into the MPC VECTOR 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 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.

5.3 Electrical Wiring

Wait a minimum of 5 minutes after disconnecting power before servicing the MPC VECTOR or pump motor. Capacitors retain a charge even after power is removed from the controller.

1. Make the motor connections between the control unit and the pump motor (ref. Figure 3).

2. Make the incoming AC power connections and the outgoing power connections to the pump motor (ref.

Section 5.3.2). These will allow you to operate the MPC VECTOR and attached Eclipse pump.

3. Decide which signal (control) Inputs and Outputs (e.g., 4-20mA in) will be used and make those

connections (ref. Section 5.3.4).

4. Power-up and test the MPC VECTOR to confirm the connections and check for proper operation.

5. Configure the software via the menu system for the desired operational conditions. Depending on the

anticipated function, users may need to enter settings for the following:

a. Analog input signal, so the MPC VECTOR can accept a process input signal

b. Digital input settings, for example start/stop and/or tank level inputs

c. Digital output settings, for example auto/manual status and/or alarm outputs

6. Conduct a final power-up and test the MPC VECTOR to confirm the connections and check for proper

operation.

7. Go to the Section 6 – Start Up and Operation for details on how to perform the power-up tests.

5.3.1 Controller Layout

The design of the MPC VECTOR incorporates all control circuitry onto one easily accessed circuit board. This board is located on the inside of the main controller. Gain access to this board by removing the 2 cover screws allowing the cover to hinge open.

Figure 2 – Controller Layout and Dimensions

5.3.2 Power Wiring Information

• Verify the correct supply voltage (230VAC single-phase or three-phase) with the nameplate

affixed to your MPC VECTOR. Ensure that your supply voltage matches the MPC VECTOR configuration.

• The 1 hp, 2 hp, and 3 hp AC drives use single phase or three phase 230VAC input. The 5 hp

AC drive must be powered by three phase 230VAC input only.

• Wires should be routed within the enclosure in a manner that maintains separation between

high voltage and low voltage conductors. High voltage conductors should be routed to the side opposite the control circuitry.

• Incoming power wiring should adhere to all applicable local and national electrical codes and

regulations. 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.

The MPC VECTOR 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 the branch circuit (see Table 1). A circuit breaker or disconnect switch 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 VECTOR controller installation, and must be marked or labeled to identify it as the power disconnect for the MPC VECTOR.

Recommended Minimum Wiring and Circuit Breaker

Power

Requirements

MPC VECTOR

and 1.0 Hp motor

MPC VECTOR

and 2.0 Hp motor

MPC VECTOR

and 3.0 Hp motor

MPC VECTOR

and 5.0 Hp motor

Actual

10.6 A 15 A 14 AWG 2.0 mm2 5.8 A 10 A 14 AWG 2.0 mm

14.8 A 20 A 14 AWG 2.0 mm2 9.1 A 15 A 14 AWG 2.0 mm

19.7 A 25 A 12 AWG 3.5 mm2 12.4 A 20 A 14 AWG 2.0 mm

Single Phase 208/230 VAC Three Phase 208/230 VAC

Circuit

Draw

--- --- --- --- 19.6 A 25 A 12 AWG 3.5 mm2

Breaker

Wire

Size

Wire

Size

Actual

Draw

Circuit

Breaker

Wire

Size

Wire

Size

Table 1 – Sizing Branch Circuits

The MPC VECTOR controller is provided with a 7/8” thru hole for incoming AC power wiring and a 7/8” thru hole for motor wiring at the bottom of the enclosure. Utilize the appropriate conduit fittings to route and seal the supply wires into the MPC VECTOR enclosure.

The power wires are secured to the terminal strip at the bottom end of the AC drive as per Table 2. Remove approximately 0.20 – 0.25” 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

secure the conductor, making certain that the terminal grips the wire, not the insulation. Ensure that all wiring meets applicable local and national codes and requirements.

5.3.3 Power Wiring Diagram

MPC VECTOR Drive

Terminal

L1 Line 1 Line 1

L2 N/C Line 2

L3 Line 2 Line 3

Ground Plate Ground Ground

Single Phase 208/230 VAC Three Phase 208/230 VAC

Table 2 – AC Drive Terminals

Figure 3 – AC Power Connections

Wait a minimum of 5 minutes after disconnecting power before servicing the MPC VECTOR or pump motor. Capacitors retain a charge even after power is removed from the controller.

5.3.4 Input/Output Signal Wiring

4-20 INPUT

(

)

(

)

Signal wiring is routed through the two unused conduit openings at the base of the MPC VECTOR. All input/output signals are connected to the terminal strips at the edge of the MPC VECTOR circuit board except for flow meter feedback which is connected to a separate terminal block. Use caution to observe proper wire location and signal polarity. Always cap or plug unused openings. Wires should be routed with in the enclosure in a manner that maintains separation between high voltage and low voltage conductors. Ensure all low voltage wiring is installed as per any applicable local and national electrical codes and regulations.

Utilize 16 to 22 AWG, 250 V shielded cable with a 75o C insulation rating (or better) for all signal input and output wiring. Recommended strip length is 0.39” or 10 mm. Refer 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 MPC VECTOR enclosure. Do not remove the factory provided plug from openings that are not required for field wiring.

T IS RECOMMENDED THAT A WRIST STRAP BE WORN WHEN MAKING CONNECTIONS TO ANY PRINTED

CIRCUIT BOARD

GROUND

J20

J11

J23

J14

ANALOG IN 2

ANALOG IN 1

F L O W M E T E R S I G N A L

P R O C E S S S I G N A L

DIGITAL INPUT

GROUND

DIGITAL IN 2

DIGITAL IN 1

4-20 OUTPUT

ANALOG OUT 1

GROUND

DIGITAL OUTPUT

GROUND

DIGITAL OUT 3

DIGITAL OUT 2

DIGITAL OUT 1

REMOTE

BLACK/WHITE

WHITE

SHIELD

BLACK/GREEN -GREEN

Figure 4a – Signal Connections

BLACK/RED

RED

Digital output signals can drive devices such as relays or indicator lamps. 5 to 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 Section 12, Specifications, for more information).

Figure 4b – Sample Digital Output Connections, (power can be in the range of 5 – 24 VDC)

5.4 Check Wiring and Close Access Cover

Double-check all of your electrical connections. Pay attention to polarity of all inputs and outputs – both low and high voltage. Additionally, insure that all 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 secured. 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 2 screws.

5.5 Confirm Correct Incoming Power

ITHOUT PRIOR OPERATING KNOWLEDGE, IT IS IMPOSSIBLE TO TELL IF THE PUMP MOTOR WILL RUN WHEN POWER IS APPLIED TO THE NECESSARY STEPS TO ENSURE THAT ALL ASPECTS OF SAFETY HAVE BEEN CONSIDERED (E.G., ELECTRICAL, HYDRAULIC, ETC

.).

Turn on power at the mains or distribution panel. If the MPC VECTOR's incoming power is connected correctly, the backlighting on the MPC VECTOR’s display will illuminate (depending on lighting conditions, it may be necessary to shade the display to confirm illumination). If the display is not illuminated, first check the line voltage with a voltmeter. If the voltage is not correct, return to Section

5.3.2 – Power Wiring Information. Otherwise, proceed with the next step.

MPC VECTOR. Y

OU ARE RESPONSIBLE FOR TAKING THE

6. Start Up and Operation

6.1 Overview

Once all electrical connections have been made, your MPC VECTOR is ready for setup and operation. The following sections detail the procedures required to complete the MPC VECTOR start up.

HEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT WITHIN THE

ENCLOSURE EVEN WHEN THE MOTOR IS

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

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

6.2 Critical Parameters

For proper operation of the MPC VECTOR control, at startup the following parameters and calibrations must be entered and/or verified:

Parameter(s) Reference IOM Section

OFF.

MPC VECTOR

Pump maximum flow Section 6.6

Flow meter calibration (if using this feature) Ref flowmeter IOM as required

Flow calibration in speed mode Section 8.2

Motor calibration for Vector mode Section 10

4-20 mA analog signal calibration Section 8.3

Flow meter type setup Section 9

6.3 Keypad/Lamp Operation

Green = Manual Control Off = Automatic Control

MANUAL

Key Function Description

Motor On/Off Press to start pump, press again to stop pump

Lamp Color Description

Auto/Manual

Enter

Arrow Up

Arrow Down

Green, Amber,

Red, Off

Press to toggle between automatic operation 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

Press to accept changes in menus, to move cursor forwards when entering values, and to access lower level menus.

Press to adjust values upwards, and to scroll through menu options

Press to adjust values downwards, and to scroll through menu options

Off = Motor off Green = Motor on

Amber = Remote standby Red (blinking) = Error

Green, Off

Table 3 – Keypad and Lamp Operation

6.4 Confirm Display and Keypad Functionality

The example display messages are shown in English for demonstration purposes. If an alternate language has been set, the text is displayed as a translation of the English version.

Now that you have confirmed that the MPC VECTOR is receiving power, it is necessary to confirm that the display and keypad are functioning properly. On normal power-up, the display appears for approximately 2 seconds.

P U L S A F E E D E R INC.

F W : 0 0 . 0 0 / 0 0.00

The first four digits displayed are the software revision for the MPC VECTOR control board, and the second four indicate the software revision for the remote board.

The revision numbers should be identical for both units. Unpredictable or unstable operation may result from mismatched software revisions.

Please note that it may be necessary to adjust the display contrast. Please refer to Section 8.6 if this is required.

6.5 Motor Parameter Setup

The MPC VECTOR controller interfaces closely with the Eclipse pump motor. The MPC VECTOR needs to know certain details about the motor in order to function properly. End users may have to input or adjust motor parameters before operation. Use the following as a guide:

If you: Have received your MPC VECTOR and Eclipse pump and motor as a unit from the factory, and Your MPC VECTOR to motor wiring distance is less than 25 feet

Then you should not have to perform any parameter setup or calibration. All parameters and setup have been completed for you at the factory.

If you: Are using the MPC VECTOR with a motor that did not come from the factory, or

Your MPC VECTOR to motor wiring distance is greater than 25 feet, or

You are replacing the motor on an existing setup

Then you may have to enter the motor parameters, and you will have to perform a motor auto-setup procedure. Please reference Section 10, Motor Parameter Setup and Tuning, before proceeding with operation of your MPC VECTOR controller.

6.6 Setting Max Flow and Max Speed

What is Max Flow?

The value entered into the Max Flow is largely used for display purposes. It limits the flow rates that can be entered during normal operations, as well as during analog calibration routines and PulsaGuard calibration. Internally it is also used in PID calculations.

What should my Max Flow be set to?

Max Flow can vary for a gear pump based on the viscosity of the fluid being pumped and the system pressure. It is recommended that the Max Flow be set 10% higher than your pump is rated for at 0PSI. This will allow for a full range of data entry.

What if I try to set my pump to a flow higher than it can actually achieve for my current pressure and viscosity?

The pump has internal software protections and validations which prevent the motor from exceeding 1800 RPM (approximate). If the pump can only achieve 2.5GPM at 1800 RPM for your system configuration and the flow rate is set to 10GPM, the motor will spin at 1800 RPM and produce 2.5GPM.

What is Max Speed?

Max Speed is the maximum speed that the motor can spin, according to the manufacturer. This is largely unused by the MPC Vector at the moment and will not affect operations. It is recommended that this value is kept at 1800 RPM.

Setting Max Flow

1) Begin at the main screen displaying the current flow/speed setpoint

S E T P T 0 . 0 0 G P M F L O W 0 . 0 0 G P M

2) Press the MENU key to access the menus.

- M E N U -

C A L I B R A T I O N

3) Press the UP or DOWN arrow keys until you get to System Setup.

- M E N U -

S Y S T E M S E T U P

4) Press the ENTER key to access System Setup Menus.

S Y S T E M S E T U P

S T A T U S

5) Press the UP key until you see the Information setup option.

S Y S T E M S E T U P

I N F O R M A T I O N

6) Press the ENTER key to access the Information screens.

P U L S A F E E D E R , INC

F W : 1 . 0 4 / 1 .04

7) Press the UP or DOWN arrow keys until you see Max flow and Speed displayed.

M A X : 6 . 0 0 G P M M A X : 1 8 0 0 R P M

8) Press the Enter key to allow Max Flow to be edited. A blinking cursor will appear

M A X : 6 . 0 0 G P M M A X : 1 8 0 0 R P M

9) Press the UP or DOWN arrow keys to manipulate the flow rate until you reach your max flow.

M A X : 8 . 5 0 G P M M A X : 1 8 0 0 R P M

10) Press the ENTER key to accept the new Max Flow rate. Note that the blinking cursor has moved to the

Max Speed location.

M A X : 8 . 5 0 G P M M A X : 1 8 0 0 R P M

11) Press the ENTER key again to save the Max Flow and Max Speed. Note that the blinking cursor

should disappear at this point.

M A X : 8 . 5 0 G P M M A X : 1 8 0 0 R P M

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