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Pulsafeeder MPC Installation, Operation & Maintenance Manual

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Installation,
Operation &
Maintenance
Manual
IOM-CTL-2000-Rev.I
72-900-05 Rev A (Pulsafeeder SPO)
MPC
SPEED CONTROLLER
®

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Summary of Contents for Pulsafeeder MPC

  • Page 1 Installation, Operation & Maintenance Manual ® SPEED CONTROLLER IOM-CTL-2000-Rev.I 72-900-05 Rev A (Pulsafeeder SPO)

  • Page 2: Mpc™ Factory Service Policy

    MPC™ FACTORY SERVICE POLICY Your MPC is a state of the art microprocessor based motor speed control 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.

  • Page 3: Table Of Contents

    8.3.5 Lightning strikes or other electrical noise sources........... 10 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...
  • Page 4 NFORMATION ....................... 47 PECIAL EYPRESS CCESS ......................48 ROUBLESHOOTING UIDE & S ....................49 AINTENANCE PARE ARTS 19.1 Operating Precautions ......................49 19.2 Cleaning and Decontamination .................... 49 19.3 User Replaceable Parts for the MPC ................... 50 72-900-05 Rev A...

  • Page 5: For The Remainder Of This Bulletin, The Following Conventions Are In Effect

    Conventions 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 HIS MANUAL MUST BE CONSULTED IN ALL CASES WHERE THE ARNING YMBOL IS MARKED HAZARDS...

  • Page 6: Introduction

    Pulsafeeder mechanical and hydraulic 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 standard features are covered in this manual and most options have instructions where applicable.

  • Page 7: Mpc Standard Features

    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, settings, or adjustments are required. All MPC controllers are supplied with a motor rated at 60 Hz, regardless of the supply frequency.

  • Page 8: Options

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

  • Page 9: Mechanical Safety

    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.

  • Page 10: Pump Suitability To Site Of Installation

    - 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 POWER CONNECTED TO THE MPC CONTROL UNIT. DO NOT OPERATE MPC UNIT WITH THE COVER REMOVED.

  • Page 11: Transport And Storage

    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.
  • Page 12 Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current regulations at all times. (Pulsar Pump arrangement shown)

  • Page 13: Storage Instructions

    -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.

  • Page 14: Installation And Wiring

    MPC in 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.

  • Page 15: Installation Notes

    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...

  • Page 16: Electrical Wiring

    8.4 Electrical Wiring The MPC has many advanced features that may make wiring the unit appear complicated. Wiring is actually very simple – one high voltage connection is all that is required to take advantage of the majority of the MPC's features.
  • Page 17 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.
  • Page 18 2 – C IGURE ONDUIT ONNECTION AYOUT...

  • Page 19: Power Wiring Information

    C22.2#61010-1 and EN61010-1 3 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...

  • Page 20: Power Wiring Diagram

    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.
  • Page 21 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...
  • Page 22 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.

  • Page 23: Control Input/Output Signal 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.
  • Page 24 Figure 4 – Signal Connections...

  • Page 25: Check Wiring And Close Access Cover

    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...
  • Page 26 with a voltmeter. If the voltage is not correct, return to 5.3.2 - Power Wiring Information. Otherwise, proceed with the next step.

  • Page 27: Start Up And Operation

    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...

  • Page 28: Keypad/Lamp Operation

    Keypad/Lamp Operation Function Description Press to start pump motor, press again to stop Motor On/Off pump motor Press to toggle between automatic operation and Auto/Manual manual control of the pump Press to adjust controller settings, to exit the menu 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...

  • Page 29: Flow Display

    Note that even after the additional calibrations are done, the MPC will still not display the low flow that the pump is producing.
  • Page 30 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.

  • Page 31: Input/Output Setup

    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.

  • Page 32: Pump Flow Calibration

    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.
  • Page 33 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;...
  • Page 34 X X . X X X 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...
  • Page 35 X X . X X X 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...

  • Page 36: Analog Input Calibration

    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).
  • Page 37 (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.
  • Page 38 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.

  • Page 39: Analog Output Calibration

    10.7. Analog Output Calibration 1. The starting display will be: S E T P T X X . X X X F L O W X X . X X X 2. Press the MENU key - M E N U - C A L I B R A T I O N Press the ENTER key C A L I B R A T I O N...

  • Page 40: Display Contrast Adjustment

    (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.

  • Page 41: Alarm And Error Messages

    LOW LEVEL ALARM Internal fault AC DRIVE FAULT ALARM The MPC has detected that the motor shaft is not rotating at the expected speed Motor error ALARM MPC controller is not receiving correct signals from the cam sensor in the pump eccentric box...
  • Page 42 The Red LED will flash, however no message will flash on the screen. The Red LED will stop flashing once the error condition has been corrected. MPC does not receive valid indication from the ALARM stroke position sensor, the flow display will not be...

  • Page 43: Extending Your Hand-Held Controller

    12. Extending your Hand-Held Controller 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.
  • Page 44 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.
  • Page 45 BLACK/RED GREEN BLACK/GREEN WHITE BLACK/WHITE Figure 5a – Handheld Remote Wiring TAPE END TAPE SHIELD BLK/GRN AN00446-006 Figure 5b – Wire Preparation Detail, Base Unit End...
  • Page 46 Figure 6 – Handheld Remote...

  • Page 47: Specifications

    Hp motor MPC and 0.33 7.0 A 10 A UL, CUL, 3.5 A 10 A UL, CUL, Hp motor MPC and 0.5 Hp 9.4 A 15 A UL, CUL, 5.2 A 10 A UL, CUL, motor MPC and 0.75 16.8 A...
  • Page 48 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 register as “active”). Do not apply power to these terminals. * Digital input functions: 1.
  • Page 49 Standard selection is rated for indoor, dry environment, other options available Can be mounted on the pump or up to 1000’ away from the Keypad: pump Standard cable length 6 feet Display: Backlit 2 line extended temperature 16 character LCD Enclosure: NEMA 4X and IP56 ratings Altitude:...

  • Page 50: Menu Maps

    14. Menu Maps Pulsafeeder, Inc. FW XX.XX/XX.XX Pump Serial Num: XXXXX MPC Part Number: MPCXXXXXXX-XXXX SETPT: 0.0 % SETPT: 0.00SPM SETPT: 0.0 % SETPT: 0.00GPH FLOW: 0.0 % SPEED: 0.00SPM SPEED: 0.0 % FLOW: 0.00GPH STROKE SET TO & XXX.X%...
  • Page 51 -MENU- ANALOG I/O ANALOG INPUT #1 ANALOG I/O ANALOG INPUT #1 INACTIVE ANALOG INPUT #1 ANALOG INPUT #1 <INACTIVE> <ACTIVE> ANALOG INPUT #1 ANALOG INPUT #1 INACTIVE ACTIVE -MENU- DIGITAL I/O SIGNAL PURPOSE DIGITAL I/O DIGITAL INPUT #1 INACTIVE DIGITAL I/O SIGNAL PURPOSE SIGNAL PURPOSE SIGNAL PURPOSE...

  • Page 52: Factory Default Values

    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...

  • Page 53: Troubleshooting Guide

    18. Troubleshooting Guide Problem Potential Cause Solution DISPLAY No Display No power supplied. Check power source. plug & circuit breaker Back- Supply power wired incorrectly. Check wiring. lighting Supply power outside of Check voltage/frequency against specification. specification. No Text on Contrast out of adjustment.

  • Page 54: Maintenance & Spare Parts

    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.

  • Page 55: User Replaceable Parts For The Mpc

    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...
  • Page 56 ® SPEED CONTROLLER A Unit of IDEX Corporation IOM-CTL-2000-Rev.I 27101 Airport Road 72-900-05 Rev A (Pulsafeeder SPO) Punta Gorda, FL 33982 +1 (941) 575-3800 pulsatron.com...

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