White Knight CPC-1 User Manual
CPC-1: Closed Loop Controller Manual
Manual available online at wkfluidhandling.com
Manual Version 1.0.1 Manual Part# 18200-LM-0037
Manual content and data are subject to change without notification. The most recent version of the manual can be found online at:
http://wkfluidhandling.com/owners-manuals
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Manual version 1.0.1
Table of Contents
1. System Recommendations .................................................................................................................................2
1.1 Precautions .......................................................................................................................................................2
1.2 System Environment Recommendations/Requirements ..................................................................................2
1.3 Installation Advantages .....................................................................................................................................2
1.4 Getting Started ..................................................................................................................................................3
2. Parts List .............................................................................................................................................................4
2.1 CPC-1 Closed Loop Controller .........................................................................................................................4
2.2 Power Adapter with Crimp Pins ........................................................................................................................5
2.3 Cable: 26 Pin & 44 HD D-Sub to Wire Leads ...................................................................................................5
2.4 Breakout Board: 26 Pin HD D-Sub to Screw Terminals ...................................................................................5
2.5 Din Rail Power Supply ......................................................................................................................................5
2.6 Quick connect boards. Using field wire-able connectors to make connections easier. ....................................5
3. Non-Stock Items Needed....................................................................................................................................6
3.1 I/P Air Regulator ................................................................................................................................................6
3.2 Pressure Transducer ........................................................................................................................................6
3.3 Flow Meter ........................................................................................................................................................6
4 System Overview .....................................................................................................................................................6
5 Setup .......................................................................................................................................................................7
5.1 Plumbing the system .........................................................................................................................................7
5.2 Supply Air Pressure ..........................................................................................................................................7
5.3 Wiring Setup ......................................................................................................................................................7
5.3.1 Powering the CPC-1 ......................................................................................................................................8
5.3.2 Digital Connections ........................................................................................................................................8
5.3.2.1 Power Digital Ports: ....................................................................................................................................8
5.3.2.2 Digital Input Ports ........................................................................................................................................9
5.3.2.3 Digital Output Ports .................................................................................................................................. 10
5.3.3 Analog Connections .................................................................................................................................... 11
5.3.3.1 Common Ground ..................................................................................................................................... 11
5.3.3.2 Supplemental low power supply .............................................................................................................. 12
5.3.3.3 Analog Inputs ........................................................................................................................................... 12
5.3.3.4 Analog Outputs ........................................................................................................................................ 13
5.3.3.5 Wiring Summary ...................................................................................................................................... 13
6 PC to CPC-1 Communication: .............................................................................................................................. 14
6.1 Ethernet Connection: ..................................................................................................................................... 14
6.2 RS-232 Connection: ....................................................................................................................................... 14
7 Desktop Software ................................................................................................................................................. 14
7.1 Installation ...................................................................................................................................................... 14
Manual Version 1.0.2
7.2 Using the software ......................................................................................................................................... 14
7.2.1 Controls Window ......................................................................................................................................... 15
7.2.1.1 Sensor Gauges ........................................................................................................................................ 15
7.2.1.2 System Alarms ......................................................................................................................................... 16
7.2.1.3 Operation Mode setup ............................................................................................................................. 16
7.2.1.4 Additional Menu Items ............................................................................................................................. 16
7.2.2 Setup Window ............................................................................................................................................. 18
7.2.2.1 Process Settings ...................................................................................................................................... 18
7.2.2.2 Analog I/O Settings .................................................................................................................................. 19
7.2.2.3 Digital I/O Settings ................................................................................................................................... 20
7.2.3 Advanced Window ...................................................................................................................................... 21
7.2.3.1 Terminal Tab ............................................................................................................................................ 21
7.2.3.2 Customize PID Gains Tab ....................................................................................................................... 21
7.2.3.3 Configurations Tab ................................................................................................................................... 22
8 Standalone Operation ........................................................................................................................................... 22
8.1 Using Digital Communication ......................................................................................................................... 23
8.1.1 Operation Mode .......................................................................................................................................... 23
8.1.2 Set Point Modification ................................................................................................................................. 23
8.1.3 Leak Detect Reset ...................................................................................................................................... 23
9 Troubleshooting .................................................................................................................................................... 24
9.1 Issues connecting to CPC-1 via Ethernet, preform the actions below ........................................................... 24
9.2 Issues Connecting to CPC-1 via RS-232, preform the actions below ........................................................... 24
9.3 Issues with Stable Flow ................................................................................................................................. 24
10 Appendix 1: 44 Pin D-Sub Connection Table ..................................................................................................... 26
11 Appendix 2: 26 Pin HD D-Sub Connection Table ............................................................................................... 29
12 Appendix 3: Dimensional Drawings .................................................................................................................... 32
13 Ordering Instructions .......................................................................................................................................... 33
1 Manual version 1.0.2
1. System Recommendations
DO NOT OPEN CONTROL BOX
Do not open the control box. White Knight is not responsible for any damage caused by opening the
Control Box.
Environmental Temperature
This product is rated to withstand environmental temperatures up to 70°C.
Grounding
All electrical components must be grounded to minimize risk of sparks. Follow proper procedures for
grounding all products in the system.
Flow and Pressure Monitoring
The CPC-1 is able to take in both a pressure transducer and flow meter signals at the same time. While
troubleshooting purposes.
Non-stock Items Needed
The Closed Loop Control system makes use of several off the shelf items that White Knight does not
product. See section 3 of this manual for detailed descriptions of needed parts.
System Limitations
The CPC controls the parameters of the system based off of the selected pump and would not protect
system components that are not rated as high as the pump the controller is programmed to control.
Flow and Pressure
White Knight recommends the installation of a pressure transducer as well as a flow meter to allow for
without any addition or change to system components.
1.1 Precautions
supply. There is a large variety of products and suppliers and the end user may obtain their preferred
1.2 System Environment Recommendations/Requirements
increased monitoring as well as the ability to switch between flow and pressure control within a system
1.3 Installation Advantages
only one is needed for the desired control process, the other can be input for monitoring and
2 Manual version 1.0.2
1.4 Getting Started
Installing the CPC-1 for the first time it is recommended that you follow these steps:
1) Verify that you received all of the components that you ordered. Note: cables and breakout board for the
controller are options that can be selected at the time of purchase.
2) Check that you have a compatible power supply to power the controller. See Section 5.3.1
3) Check that you have a compatible communication cable for setting up the controller. See Section 6
4) Download the setup software from www.wkfluidhandling.com/cpc-1.
5) Verify that your computer is able to connect to the controller.
a) Power up the controller with correct power source
b) Connect the communication cable correctly. (Ethernet cables should go from the controller to a network
switch, not your PC)
c) Install and launch the Smart Control Software.
d) The connections dialog should appear at launch. Verify that your controller appears on the list and click
the connect button. See Section 7.2
e) Once connectivity is verified disconnect from the software, and disconnect power and communication
cable.
6) Install CPC-1 in the desired location.
7) Connect 44 pin and 26 pin connectors and use the wiring guide in Section 5.3.2 and 5.3.3 to connect system.
8) Connect to controller (same as before) and configure the CPC-1 settings to match your system needs.
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2. Parts List
#
Description
Part Number
Component
2.1
Control Box
CPC-1
Standard
Power Adapter With Crimp Pins
Standard
2.4
44 Pin HD D-Sub to Screw Terminals
8600-XX-0018
Optional
2.3
44 Pin HD D-Sub to wire leads Cable 1-Meter
8600-XX-0013
Optional
2.4
26 Pin HD D-Sub to Screw Terminals
8600-XX-0019
Optional
2.3
26 Pin HD D-Sub to wire leads Cable 1-Meter
8600-XX-0014
Optional
2.5
24 Volt Power Supply - 60 Watt
8600-XX-0015
Optional
Power port
Ethernet
Indicator Lights
44-Pin Connector for
26-Pin Connector for
Analog Communications
RS-232 Serial Port
Figure 1: The CPC-1 Controller and its communication ports.
* For size of items in parts list see section 12
2.1 CPC-1 Closed Loop Controller
The CPC-1 control box is a small I/O communication device that controls the supply air pressure to the pump in
order to maintain either flow or pressure changes. The control box has:
• 44-pin HD D-Sub Connector: Sends and receives digital signals.
• Indicator Lights: Show when each digital signal is active.
• 26-pin HD D-Sub Connector: Sends and receives analog signals.
• Power Port: Takes 18-36 VDC input to power the controller.
• Ethernet Connector: Can be used by the setup software to configure the controller.
• RS 232 serial communication: Can be used by the setup software to configure the controller.
Figure 1 shows an image of the CPC-1 controller. Note: the production version will come with a din rail mount,
where the beta version does not.
Digital Communications
4 Manual version 1.0.2
2.2 Power Adapter with Crimp Pins
2.3 Cable: 26 Pin & 44 HD D-Sub to
2.4 Breakout Board: 26 Pin HD D-Sub
to Screw Terminals
2.5 Din Rail Power Supply
Analog Output Connectors:
Analog Input Connectors:
different pinouts.
Power Connectors:
• Pin 2: 24 VDC Power
2.6 Quick connect boards. Using field wire-able connectors to make connections easier.
• Pin 1: 24 VDC Power
• Pin 2: Ground
• Pin 3: Voltage Output
• Pin 4: Voltage Reference
• Pin 5: Current Output
• Pin 6: Current Reference
• Pin 1: Ground
• Pin 1: 24 VDC Power
• Pin 2: Ground
• Pin 3: Analog Input
• Pin 4: Voltage Reference
• Pin 5 & 6: If Input is a
current input jumper two
pins together.
Note: Temp Connector has
5 Manual version 1.0.2
3. Non-Stock Items Needed
The Closed Loop Control system makes use of several off the shelf items that White Knight does not supply.
There is a large variety of products and suppliers so the end user may obtain their preferred products. Below is a
brief description of these components and the CPC-1 interface requirements.
3.1 I/P Air Regulator
An electronic proportional air regulator is required for the closed loop control system. Minimum specifications for
I/P air regulator are:
• Supports a pressure range from 0 to 100 PSI.
• Supports air flow requirement for selected WK pump. (See pump’s manual)
• Ability to set pressure using analog signal*.
* The CPC-1 only supports analog voltage analog outputs (0-5 VDC, 0-10 VDC), if an analog current signal (0-20
mA or 4-20mA) is required then the 4-20 mA Expansion Board or a signal conditioner is required.
3.2 Pressure Transducer
A pressure transducer is only required for systems in which pressure control is desired. However, for systems that
are using flow control a pressure transducer can be added into the system for system monitoring. The minimum
specifications for the pressure transducer are:
• Support the full range of system pressures up to 100 PSI
• Output pressure reading via analog signal*
* If the pressure transducer outputs an analog current signal then a 500 ohms resistor or smaller can be
connected between the signal and ground connections to convert the signal to a voltage signal. (The 420 mA Analog Expansion Board will already have a 250 ohm resistor correctly placed for this conversion)
3.3 Flow Meter
A flow meter is only required for systems in which flow control is desired. However, for systems that are using
pressure control a flow meter can be added into the system for system monitoring. The minimum specifications
for the flow meter are:
• Support the full range of system flows.
• Output flow reading via analog signal*
* If the flow meter outputs an analog current signal then a 500 ohms resistor or smaller can be connected
between the signal and ground connections to convert the signal to a voltage signal. (The 4-20 mA
Analog Expansion Board will already have a 250 ohm resistor correctly placed for this conversion)
4 System Overview
Closed loop control is a self-monitoring system that will maintain one process variable independent of changes in
the system. The CPC-1 closed loop controller has two different control modes:
Pressure Control – Uses feedback from a pressure transducer to maintain a set line pressure at a
desired point in the system. Pressure transducers are able to detect small changes in the system with little to no
time delay. Thus a pressure controlled system is more responsive to changes in the system, such as a point of
use with multiple valves that open and close frequently. A pressure control system can also be used to maintain
flow in the system where a fixed pressure through a fixed orifice can result in a steady flow.
Flow Control – Uses feedback from a flow meter to maintain a desired flow rate in the system. Flow
meters generally use a rolling average to detect flow in the system, which results in a less responsive sensor.
6 Manual version 1.0.2
Thus a flow controlled system is slow to respond to changes in the system. Flow control processes are frequently
Fluid to
PLC
Commands
Pressure
Transducer
Air
Regulator
Pulse
Dampener
WK Pump
Supply Air
Fluid to
Flow
Meter
CPC-1
Analog Flow Signal
Analog Pressure Signal
Figure 2: Control Process diagram where elements shown in green can be obtained from a
third-party distributer. Note: Depending on which model of I/P Air regulator is selected they
may be two separate components or they may be one consolidated unit.
used in plating or mixing operations where the flow doesn’t change, but where the filter may clog over time. The
flow control will slowly adjust the pressure as flow restrictions build up in a filter. Using flow control can lengthen
the usable life of a filter because the control will maintain the correct flow.
The CPC-1 is able to take in both a pressure transducer and flow meter signals at the same time. While only one
is needed for the desired control process, the other can be input for monitoring and troubleshooting purposes.
Note: White Knight does not supply pressure transducers or flow meters. See Non-Stock Items Needed for more
information about selecting a pressure transducer and flow meter.
System
Pump
5 Setup
5.1 Plumbing the system
Assemble the system plumbing as normal and include the correct sensors that are required for the closed loop
control process; a pressure transducer for pressure controlled systems or a flow meter for flow controlled
processes. These sensors should be placed in the critical path close to the point of use. In some cases it may be
advantageous to add both sensors into the system; this will allow additional flexibility for implementing closed loop
control allowing the end operator to monitor both sensors, and have the ability to switch control methods.
5.2 Supply Air Pressure
The supply air going into the closed loop control system should be set to 100 PSI. The supply air is then directed
into the air regulator. The air regulator controls how much air is supplied to the pump and pulse dampener. See
Figure 2 for illustration of the air flow.
5.3 Wiring Setup
The CPC-1 has the following on device connections interfaces:
7 Manual version 1.0.2
• 18-36 VDC Power Connector
Pin Name
Pin #
Wire Color
Designation
Levels
Notes
Power:
Source
Outputs
15
Red/
Black Stripe
Power Source
12-24 VDC
The voltage input into these pins power
all of the source type outputs.
* The voltage input will equal the voltage
output from these ports.
27
Red/
White Stripe
Ground Reference
0 VDC
Power:
Sink Outputs
8
Green
Power Source
12-24 VDC
The voltage input into these pins will
power the sink type outputs.
11
Orange
Ground Reference
0 VDC
Figure 3: External Power Connector
Figure 4: External power / Power over Ethernet Selection jumpers.
PoE EXT
Default setup supporting external power shown.
Table 1: Wire connections for powering the digital ports. All ports
should be connected.
• Ethernet/PoE Connection
• Serial to RS-232 connection
• 44 Pin HD D-Sub connection for Digital Communications
• 26 Pin HD D-Sub connection for Analog Communications
5.3.1 Powering the CPC-1
There are two methods of powering the CPC-1: 18-36 VDC power connector and Power over Ethernet, PoE. By
default the CPC-1 is setup to use the external power adapter. Simply connect an appropriate DC power to the
connector as shown in Figure 3.
To setup PoE find the jumpers on the bottom face of the controller that are labeled EXT and PoE, see Figure 4.
Move the jumpers from EXT to PoE locations. Now the Power over Ethernet connection can be used.
5.3.2 Digital Connections
5.3.2.1 Power Digital Ports:
The digital ports are not powered by the controller. An external power supply is required in order for the digital
ports to be active. Use Table 1 for digital port power connections.
8 Manual version 1.0.2
Pin Name
Pin #
Wire Color
Designation
Levels
Notes
Digital Input:
Line Pressure
Control
On/Off
[DI_0]
7
Brown
Reference High VDC
24 V = Not Active, Off
0 V = Active, On
These Three digital inputs
control how the controller
will operate. In the case
that multiple signals are
received by the controller,
then the system will chose
the operations mode in
the following priority:
1. Line Pressure Control
2. Flow Rate Control
3. Supply Pressure Control
The priority system allows
the user to setup a
Pressure or Flow control
operation during active
process, and a basic supply
pressure control to
operate when the system
is inactive to keep the fluid
moving.
33
Light Green/
Red Stripe
Reference Low VDC
0 V = Not Active, Off
24 V = Active, On
Digital Input:
Flow Rate Control
On/Off
[DI_1]
22
Gray/
Black Stripe
Reference High VDC
24 V = Not Active, Off
0 V = Active, On
3
Red
Reference Low VDC
0 V = Not Active, Off
24 V = Active, On
Digital Input:
Supply Pressure
Control
On/Off
[DI_2]
36
Yellow/
Red Stripe
Reference High VDC
24 V = Not Active, Off
0 V = Active, On
18
Green/
Black Stripe
Reference Low VDC
0 V = Not Active, Off
24 V = Active, On
Digital Input:
Analog Set Point
On/Off
[DI_3]
6
Blue
Reference High VDC
24 V = Not Active
0 V = Active
The set point for each
operation mode can be set
though the set point
analog port. This digital
input tells the controller to
use the analog port to as
the set point for the active
control mode.
32
Gray/
Red Stripe
Reference Low VDC
0 V = Not Active
24 V = Active
Digital Input:
Reset Leak Alarm
[DI_4]
21
Brown/
Black Stripe
Reference High VDC
24 V = Not Active
0 V = Active
Once a leak has been
detected by the system,
the controller will shut off
the pump. This digital port
is used to deactivate the
leak alarm so that normal
pump operation can
continue.
2
White
Reference Low VDC
0 V = Not Active
24 V = Active
Power:
Input High
37
Violet/
Red Stripe
Reference Voltage High
12-24 VDC
The Voltage input into this pin will be the
reference for all digital high inputs.
Power:
Input Low
19
Orange/
Black Stripe
Reference Voltage Low
0 VDC
The Voltage input into this pin will be the
reference for all digital low inputs.
Table 2: Digital Input Connection Table, Continued on next page
5.3.2.2 Digital Input Ports
Digital inputs by default are set to receive signals from a high voltage reference connection. However each digital
input can be configured to receive the signal from the low voltage reference. To configure high or low voltage
reference ports use the desktop software.
9 Manual version 1.0.2
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