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Idex Pulsafeeder MPC Vector Installation, Operation & Maintenance Manual

Universal control for pulsa and eclipse. suitable for any gear, reciprocating or positive displacement pumps.
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Installation, Operation &
Maintenance Manual
Universal Control
for Pulsa and
Eclipse. Suitable
for any Gear,
Reciprocating or
Positive
Displacement
Pumps.
BULLETIN No. IOM-MPCVector UMPC-11/201010 Rv. A
Microprocessor Based Positive
Displacement Pump Speed Controller

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Summary of Contents for Idex Pulsafeeder MPC Vector

  • Page 1 Installation, Operation & Maintenance Manual Universal Control for Pulsa and Eclipse. Suitable for any Gear, Reciprocating or Positive Displacement Pumps. BULLETIN No. IOM-MPCVector UMPC-11/201010 Rv. A Microprocessor Based Positive Displacement Pump Speed Controller...
  • Page 2 MPC VECTOR™ FACTORY SERVICE POLICY Your MPC VECTOR is a state of the art microprocessor based motor speed controller for use with positive displacement type pumps. The controller 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.

  • Page 3: Table Of Contents

    Table of Contents     MPC V ........................1 ECTOR PERATION     MPC VECTOR Standard Features ..................1     Description ..........................1     1.2.1 System Input/Output Power Ratings ................2     1.2.2 Handheld User Interface Operation .................. 3  ...
  • Page 4   8.1.4 Analog Output Calibration ....................51     PulsaGuard Pump Protection ....................52     Closed Loop Flow PulsaGuard Protection ................53     Open Loop Speed PulsaGuard Protection ................53     8.4.1 PulsaGuard Calibration - Closed Loop Flow Control ............53  ...
  • Page 5 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 AY CLOSE ATTENTION TO ANY WARNING Notes are general information meant to make operating the equipment easier. Safety Considerations: 1.

  • Page 7: Mpc Vector Operation

    1. MPC Vector Operation The MPC VECTOR is a microprocessor based motor speed control device, for use with positive displacement 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 positive displacement pump environments and applications.

  • Page 8: System Input/Output Power Ratings

    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. Digital and analog outputs provide for system monitoring.

  • Page 9: Handheld User Interface Operation

    208/230 VAC 3 phase only 230 VAC 380/415/440/460/480 VAC (3 phase only) 400VAC/460 VAC Table 1-1 Available MPC Vector Input/Motor Output Ratings * 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, resulting in lower motor operating temperatures and less stress on motor windings.

  • Page 10: System Modes

    Press to adjust controller settings, to exit the menu system, Menu to move cursor back when entering values, or to step back to higher level menus Press to accept changes in menus, to move cursor forward Enter when entering values, and to access lower level menus. Press to increase value, and to scroll up through menu Arrow Up options...

  • Page 11: Normal System Operational Modes

    Parameters pump motor. PulsaGuard Provides setup of run dry feature and calibration Digital I/O Digital Input Allows enabling the input, defining whether active high or low, 1&2 and defining its use Digital Output Allows enabling the output, defining whether active high or low, 1,2 &3 and defining its use Analog I/O...

  • Page 12: Control Modes

    Operations and monitoring that can occur from local operational mode include the following:  Observation and entry of flow rate and RPM set points  Starting/stopping the pump via Motor On/Off Motor ON/OFF turns the pump on or off at anytime ...
  • Page 13 1.2.5.1 Sensorless Vector Flow Control Sensorless Vector control mode does not use a feedback signal that monitors the flow rate of the process fluid to the controller. Sensorless Vector control uses a flow rate versus speed algorithm. Flow rates and speed are entered via a user assisted drawdown calibration procedure in order to derive flow accuracy (See Section 8.1.1 Open Loop Pump Flow Calibration).
  • Page 14 Figure 1-3 Closed Loop Control Feedback Block Diagram Figure 1-4 Closed Loop Flow Calibration Curve...

  • Page 15: Safety Considerations

    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.

  • Page 16: Equipment Inspection

    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.

  • Page 17: Installation And Wiring

    5. Installation and Wiring 5.1 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.

  • Page 18: Controller Mounting And Layout

    Figure 5-1 – Typical Installation (Gear Pump Shown) MPC VECTOR VOID LOCATIONS WHERE THE WOULD BE SUBJECTED TO EXTREME COLD OR HEAT 40  C (104  F 0 C (32 F LESS THAN ELSIUS AHRENHEIT OR GREATER THAN ELSIUS AHRENHEIT MPC VECTOR DIRECT SUNLIGHT...
  • Page 19 230/480 VAC Controller Layout and Dimensions for detailed mounting dimensions Control Wiring AC Input wiring Pump Motor Wiring Figure 5-2 – NEMA 4x 230/480 VAC Controller Layout and Dimensions...

  • Page 20: Open Chassis Panel Mount Version

    5.2.3 OPEN CHASSIS Panel Mount Version The OPEN CHASSIS design of the MPC VECTOR incorporates all control circuitry onto one easily accessed open-frame chassis for 230 VAC designs. Note: 480 (3 phase) VAC designs require a control transformer to step down one phase of 480VAC to 230 VAC for control electronic power supply.

  • Page 21: Electrical Wiring

    Figure 5-3 OPEN CHASSIS Panel Mount Controller Layout and Dimensions 5.3 Electrical Wiring IF THE CONTROLLER WAS PREVIOUSLY POWERED, 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.
  • Page 22 Shown below is a summary of the electrical wiring steps necessary to install an MPC VECTOR (see appropriate sections to follow for details) Connect the 3 phase pump motor. Connect the Supply Voltage, single or three phase. 3. (Optional) Connect your pump’s application control wiring a.

  • Page 23: Pump Motor Wiring

    5.3.1 Pump Motor Wiring Using a VFD rated cable route the 3 phase motor connections between the MPC Vector AC drive connections marked U, V, and W as shown in Figure 5-4 MPC VECTOR Pump Motor Wiring Termination below. Next terminate the VFD cable at the pump motor location, being careful to wire the proper motor voltage connections (generally L1, L2, L3, refer to your motor voltage wiring diagram for dual voltage rated motors).
  • Page 24  Wires should be routed within the enclosure in a manner that maintains separation between high voltage (power) and low voltage (control) 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.
  • Page 25 Figure 5-5 MPC VECTOR Product Label 230 VAC Models - Single and Three Phase See Table 5-1 Sizing Branch Circuits (208/230VAC) below for recommended wire and circuit breaker sizing information. Recommended Minimum Wiring and Circuit Breaker Power Single Phase 208/230 VAC Three Phase 208/230 VAC Requirements Actual...
  • Page 26 480 VAC Models – Three Phase See Table 5-2 – Sizing Branch Circuits (400/480VAC) below for recommended wire and circuit breaker sizing information. Recommended Minimum Wiring and Circuit Breaker Power Three Phase 400/480 VAC Requirements Actual Circuit Wire Wire Draw Breaker Size Size...
  • Page 27 Figure 5-6 230 VAC Single and Three Phase Line Input Wiring **Note: 480 VAC Panel Version wired directly into drive MPC VECTOR Drive Three Phase Single Phase 208/230 VAC Terminal 208/230/480** VAC Line 1 Line 1 N/C(No Connect) Line 2 Line 2/Neutral Line 3 Ground Plate...
  • Page 28 5.3.2.3 480 VAC NEMA 4x Enclosure Input Wiring Make the incoming 480 VAC three phase power connections. See Figure 5-7 480VAC NEMA 4x AC Input Wiring Termination Details to assist with wiring details. Note that input wiring for 480 VAC NEMA 4x models is routed to a supplied terminal strip block.

  • Page 29: Control Input/Output Signal Wiring

    5.3.3 Control Input/Output Signal Wiring 5.3.3.1 Determination of Input and Outputs Based upon system configuration and control required, decide which control signal Inputs and Outputs (i.e., remote start/stop, 4-20mA in/out, etc.) will be used for your pump application and make the appropriate digital and analog connections.
  • Page 30 Figure 5-8 –I/O Terminal Strip Details (Panel & NEMA4x Shown) 5.3.3.5 Digital Output Wiring Example (Open Collector/Drain) MPC VECTOR Digital non-isolated output signals can drive DC (direct current) devices such as LED’s, relays, indicator lamps, or any device that does not require more than 500mA of current. Activation of a digital output from the MPC VECTOR provides a low impedance connection to the external power supply’s ground, allowing current flow through the user device.
  • Page 31 Figure 5-9 – Sample Digital Output Connections, (power can be in the range of 5 – 40 VDC) 5.3.3.6 Digital Input Example Wiring Digital Inputs 1 and 2 provide monitoring of dry contact (voltage free) type inputs. Contact resistance when closed must not exceed 500 ohms in order to be recognized as an active closure.
  • Page 32 5.3.3.7 Analog Input Wiring Example Analog inputs require a loop powered (current sourcing) transmitter capable of driving a minimum 250 ohm resistive load. The transmitter maybe a two wire or three wire type. The analog inputs are not isolated. Some installations may require an analog input isolator. See Figure 5-11– Sample Analog Input Connections below for wiring details.

  • Page 33: Check Wiring And Close Access Cover

    Figure 5-12– Sample Analog Output Connections 5.4 Check Wiring and Close Access Cover Double-check all of your electrical connections. Pay attention to polarity of all inputs and outputs. Additionally, insure that all terminals are clamping onto the bare conductor and not on its insulation. Ensure that wires will not be trapped or pinched when front cover is replaced and secured.
  • Page 34 Section 6.3 Step 1 Confirm Handheld Remote Operation Confirm Display Section 6.5 Step 2 Set flow units Flow Display Units Section 10 AC Input Voltage Step 3 (Optional) Set AC Line Voltage Setting Only for 200-208 and 380-400 VAC installations Section 6.6 Setting Max Flow Step 4...

  • Page 35: Confirm Display And Keypad Functionality

    Section 7.1 Analog Input Setup Section 8.1.3 Analog Input #1 signal setup, test, and calibration Step 11 (Optional) Analog Input Calibration 6.3 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.

  • Page 36: Motor Parameter Setup

    Please note that it may be necessary to adjust the display contrast. Please refer to Section 8.5 Display Contrast Adjustment if adjustment is required. 6.4 Motor Parameter Setup The MPC VECTOR controller interfaces closely with the positive displacement pump motor. The MPC VECTOR needs to know certain details about the motor (generally found on the motor nameplate) in order to function properly and optimize performance.
  • Page 37 The pump has internal software protections and validations which prevent the motor from exceeding 1800 RPM (approximate). Example: 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.

  • Page 38: Wrapping Up

    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.

  • Page 39: Factory Re-Initialization

    6.8 Factory Re-Initialization Factory Re-initialization is typically not required. When re-initializing your MPC VECTOR, all of the current 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 MPC VECTOR is operating abnormally.

  • Page 40: Input/Output Setup

    7. Input/Output Setup Use the “DIGITAL I/O” and “ANALOG I/O” menus to activate and configure the input and output for the functions required for the application. Users may also reference Section 16 Menu Maps for additional configuration assistance. 7.1 Analog Input Setup Two Analog Inputs are provided for the User.

  • Page 41: Digital Input Setup

    7.2 Digital Input Setup 7.2.1 Multi-purpose Digital Inputs Each of the 2 Digital INPUTS can be selected as: Inactive Tank Level Input Leak Detection (using external device) Remote ON/OFF Input Flow verification Input 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 dry contact will activate the pump.

  • Page 42: Analog Output Setup

    Analog Output Setup No activation is required for the analog output. The 4-20 mA Analog output is always available at the corresponding terminals (see Section 5.3.3.8 Analog Output Example Wiring). The analog output follows and is proportional to percent motor speed. This output must be calibrated for current output (4-20mA) versus percent speed.
  • Page 43 This page is intentionally left blank...

  • Page 44: Calibrations

    8. Calibrations MPC VECTOR IS NOT FACTORY CALIBRATED AS THE CALIBRATIONS ARE SYSTEM DEPENDENT AND MPC VECTOR FLOW METER DEPENDENT OU MUST ALWAYS PERFORM A CALIBRATION WITH THE INSTALLED IN YOUR SYSTEM PRIOR TO USE AILURE TO PROPERLY CALIBRATE THE UNIT MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS As a convention in this manual: “WET”...
  • Page 45 For GPM (Gallons Per Minute): Shown below is the two point calibration curve for the example data presented in the above table. These values represent the speed-to-flow characterization of your pump. The two speed values, 180 RPM (10%) and 1800 RPM (100%), will correspond to 2.5 and 25 GPH, respectively for this pump. The speed values can be used for set point input calibration, see Section 8.1.3 Set point Calibration and Range Setup .
  • Page 46 P U M P F L O W D R Y C A L 4. Press ENTER to edit the high speed (“HI SPEED” where the default = 1800 RPM) and flow rate calibration point. H I S P E E D : 1 8 0 0 R P M F L O W : 2 5 .
  • Page 47 3. Press the ENTER key to access Wet Pump Flow Calibration screen. P U M P F L O W W E T C A L 4. Press the ENTER key to begin Flow Calibration S E T M O T O R S P E E D H I G H : 1 8 0 0 R P M 5.

  • Page 48: Closed Loop Pump Flow Scaling And Calibration

    12. Press the ENTER key to start the motor and advance to the draw down interval count down screen. The default interval will be 60 seconds. Pressing the ENTER key will take the user immediately to the next screen. Shorter drawdowns are available using the ENTER key.
  • Page 49 Figure 8-2 Example Flow Meter Current Output vs. Flow Rate Curve 8.1.2.1 Closed Loop Dry Flow Calibration The closed loop Dry Flow Calibration routine does not require the pump to run. Instead, the user must input 2 known flow meter flow rates versus current output points. The user will be prompted for these values. This process can be used when it is not possible or not safe to run the pump during calibration.
  • Page 50 9. After setting the low speed calibration point, press the ENTER key to accept the calibration flow rate and save the two point calibration. 10. At this point, the system will check the dry calibration values, and if the values are acceptable will complete the calibration.
  • Page 51 1. Press the MENU key to access the Calibration Menu. - M E N U - C A L I B R A T I O N 2. Press the ENTER key to access Pump Flow Calibration screen. C A L I B R A T I O N P U M P F L O W 3.

  • Page 52: Set Point Calibration And Range Setup

    S E T M O T O R S P E E D L O W : 1 8 0 R P M 11. Press the ENTER key to accept the calibration speed. P R E S S E N T E R T O S T A R T M O T O R HE MOTOR WILL START WHEN THE ENTER KEY IS PRESSED MAKE SURE THAT YOUR SYSTEM IS...
  • Page 53 Figure 8-4 Set point Input 4-20 mA Scaling/Calibration (Speed) Set point Range/Calibration for Closed Loop Systems (Flow Control) If your system is configured for closed loop flow control (e.g., flow meter feedback), the applied set point input is used to control the flow rate of the pump. In the example shown below, the user has scaled/calibrated the 4mA signal to correspond to 2.5 GPH and 20 mA to correspond to 25 GPH.
  • Page 54 - M E N U - C A L I B R A T I O N 3. Press the ENTER key C A L I B R A T I O N P U M P F L O W 4.
  • Page 55 If you receive the following message: C U R R E N T D E L T A O U T O F R A N G E This indicates that there is not a wide enough range between your maximum and minimum analog signals. The minimum signal range is 3 mA.
  • Page 56 8.1.3.2 “DRY” Set point Input Calibration (keypad only, no signal present) 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 3.

  • Page 57: Analog Output Calibration

    Press ENTER to accept the Current Setpoint. The cursor will blink on the bottom line indicating that the Flow setpoint may be adjusted. 12. Press the UP and/or DOWN arrow keys to adjust the Max Flow setpoint. M A X S E T P T 2 0 . 0 M A F L O W : 5 .

  • Page 58: Pulsaguard Pump Protection

    C A L I B R A T I O N 3. Press the ENTER key C A L I B R A T I O N P U M P F L O W 4. Press the UP ARROW key to access the analog output calibration C A L I B R A T E D A N A L O G O U T P U T 5.

  • Page 59: Closed Loop Flow Pulsaguard Protection

    8.3 Closed Loop Flow PulsaGuard Protection When a flow meter is installed in the system, PulsaGuard will turn off your motor if the present system flow rate is below a user desired low flow threshold for more than 10 seconds. This will protect the pump in under-loaded or overloaded conditions, which would cause the flow to be reduced below the user’s acceptable threshold limit.

  • Page 60: Pulsaguard Calibrations- Open Loop Speed Control

    7. Press the ENTER key to complete the PulsaGuard Calibration. P U L S A G U A R D C A L I B R A T E D 8.4.2 PulsaGuard Calibrations- Open Loop Speed Control PulsaGuard may be calibrated WET or DRY. A WET calibration requires that the user simulate underloaded conditions.

  • Page 61: Display Contrast Adjustment

    12. Use the UP and DOWN keys to adjust the current setpoint. M I N S E T P O I N T S E T P T : 2 . 0 A 13. Press the ENTER key to accept the calibration value. P U L S A G U A R D C A L I B R A T E D 14.

  • Page 62: Tuning The Control Algorithm

    8.6 Tuning the Control Algorithm This option should only be used by control systems engineers who are familiar with tuning PID loops. This is not intended for the casual user. Changing these values may result in the system oscillating without settling on the set point or never reaching the set point at all.
  • Page 63 8. Press the UP and/or DOWN keys to adjust, k P R O P O R T I O N A L 0 . 1 0 0 9. Press the ENTER key. I N T E G R A L X .
  • Page 64 Modifying the Sampling Interval, when Flow Meter feedback is used 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 3.

  • Page 65: Flow Meter Input

    9. Flow Meter Input The MPC VECTOR accepts flow meter process feedback from an analog (4-20mA) flow metering device. The manufacturer of the flow meter is not important but the process signal must conform to a set of minimum specifications in order to work with the MPC VECTOR. See section 13 Specifications 9.1 Flow Meter Installation and Activation Prior to installation make sure your flow meter conforms to the MPC VECTOR’s flow meter specifications (refer to Specifications...
  • Page 66 S Y S T E M S E T U P S T A T U S 5. Press the DOWN key five (5) times S Y S T E M S E T U P F L O W M E T E R 6.

  • Page 67: Ac Input Voltage Setting

    10. AC Input Voltage Setting Warning: Do not set this parameter if your installation line voltage is 230 or 480 VAC. If your AC line input voltage is 200-208 VAC or 318-400 VAC then you must set parameter number 01 to a value of 2, indicating low line voltage to the AC drive.

  • Page 68: Motor Parameter Setup And Tuning

    12. Press the MENU key several times to return to main operational screen Your MPC VECTOR is now ready for use with lower voltage ratings of 200-208 or 318-400 VAC. 11. Motor Parameter Setup and Tuning The MPC VECTOR controller must know several motor characteristics before the motor can be calibrated. This calibration allows the controller to maintain precise control over the operation of the motor.
  • Page 69 Param. Name Description Range Typical Note Motor Rated Speed Nameplate RPM Rating 300 – 65,000 RPM 1800 RPM Motor Rated Amps Nameplate FLA Rating 0.0 – 480 Amps Various Motor Rated Volts Nameplate Voltage Rating 0 – 600 Volts 230/480 Motor Base Frequency Nameplate Frequency 25 –...

  • Page 70: Motor Parameter Setup And Calibration

    11.1 Motor Parameter Setup and Calibration 1. Navigate to the CALIBRATION menu and press ENTER, and scroll (UP/DOWN) to the MOTOR PARAM option. The starting display will be: C A L I B R A T I O N M O T O R P A R A M 2.

  • Page 71: Alarm And Error Messages

    12. 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 will also flash. The menus can still be accessed by pressing the menu key. This allows the user to try and fix the source of the error if possible.

  • Page 72: Alarm And Error Message System Behavior

    12.2 Alarm and Error Message System Behavior The following table gives an example of these messages and when you can expect them to be displayed. Message Displayed When: Error Clearing/Pump Response 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 screen.
  • Page 73 Continues next page…...
  • Page 74 NON-FATAL ERRORS: The pump and controller can still be run while these conditions exist. The Red LED will flash and the error will flash on the screen. The Red LED and error message will cease once the error condition has been corrected. The flow set point has not been attained for duration of 60 seconds.

  • Page 75: Specifications

    13. Specifications Control Inputs Wiring Specification / Description Analog In #1 J11 pins 4(+) and 6(-) 4-20mA control signal Max current 30mA; Input resistance 200 Ohm Internally protected with self resetting fuse Minimum signal accepted = 2.4 mA Maximum signal accepted = 24 mA Analog Flow Meter J11 pins 5(+) and 6(-) 4-20mA flow meter feedback signal...
  • Page 76 Note: factory configured only for correct input voltage range (specified at time of purchase) Single Phase or Three-Phase (Single-Phase not available for 5 hp) 50 or 60 Hz. Tolerance: Input voltage +10%/-15% maximum Input frequency range 48 Hz to 62 Hz Motor Req: Commercially available motor supplied by the manufacturer of the pump controller See Section 14 for motor selection requirements...

  • Page 77: Pump Motor Selection

    14. Pump Motor Selection Your MPC VECTOR pump controller can accept input power in the at frequency ranges of both 50 and 60 Hz power. This allows your controller to be run from 50 and 60 Hz line frequency locales. Your motor supply frequency may be 50 or 60 Hz and is independent of your supply input frequency as the motor’s input supply frequency is generated by the AC drive.
  • Page 78 Motor Cooling Motor cooling will be dependent upon motor selection. Premium efficiency motors will generally provide cooling from a shaft mounted fan. Typical motor type would be Totally Enclosed Fan Cooled (TEFC). Motors of this type should use a maximum turndown of 10:1 as low speed operation leads to inefficient fan cooling, resulting in premature bearing and winding failure.

  • Page 79: Model Identification

    15. Model Identification Position Sample Specifies Options 1 and 2 EP – MPC VECTOR Enclosure Type C – Enclosure meets NEMA 4X specifications P – Panel Open Chassis, Remote NEMA 4X Motor HP/Input Voltage Rating A - Fractional to 1.0 Hp (0.75kW); Drive Input: 208-230 VAC B - 2 Hp (1.5 kW);...

  • Page 80: Menu Maps

    16. Menu Maps...

  • Page 98: Factory Default Values

    17. 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 INACTIVE Digital Output #1 ON/OFF indication, normally closed Digital Output #2 AUTO/MANUAL Indication, normally closed Digital Output #3 ALARM Indication, normally closed Security Code...

  • Page 99: Troubleshooting Guide

    19. Troubleshooting Guide Problem Potential Cause Solution POWER No AC drive red LEDs lit Improper AC line input wiring or low Check L1, L2, L3 for proper voltage Should see “---“after power up line input voltage. (230/480 VAC) and wiring. Check sequence.
  • Page 100 DRIVE ERRORS AND FAULTS Drive module display reads “CL” Drive has gone into a current limit Check for pump binding or drive/ motor mode to protect the pump motor. combination being undersized. Drive module display reads “nld” An attempt was made to start the Perform a motor calibration as outlined controller prior to calibrating the pump in Section 6.4 Motor Parameter Setup...

  • Page 101: Spare Parts

    20. Spare Parts User replaceable parts for the MPC VECTOR. Pulsafeeder P/N Description NP530091-000 ½” wiring liquid-tight connector NP530137-000 ¼” wiring liquid-tight connector W213946-NTR Hand-held enclosure gasket NP250079-RYT Replacement Handheld front cover NP550113-000 Front Cover Membrane Switches/LED NP250078-RYT Replacement Handheld back cover W772568-STL ½”...

  • Page 102: Appendix 1, Handheld Wiring

    21. Appendix 1, Handheld Wiring The hand-held controller for your MPC can be placed as far as 1000 feet from the main control unit. 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 103 Wait a minimum of 5 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 screws that are securing the cover of the main unit. 2.
  • Page 104 REMOTE MIS-WIRING OF J5 MAY DAMAGE UNIT. BLACK/RED GREEN BLACK/GREEN WHITE BLACK/WHITE BLACK/WHITE WHITE SHIELD BLACK/GREEN - GREEN BLACK/RED AN00446-002 Figure 21-1 Handheld Remote Wiring TAPE END TAPE SHIELD Figure 7 – Wire Preparation Detail, Base Unit End...
  • Page 105 Figure 8 – Handheld Remote...

  • Page 106: Appendix 2, Pid Theory And Adjustment

    22. Appendix 2, PID Theory and Adjustment The PID control method allows the MPC Vector to accurately maintain a specific desired set point for flow rate from the pump it is connected to. The PID Control Loop is a widely accepted general purpose control algorithm which is built into the MPC Vector. A PID control loop consists of three components which each have their own specific responsibilities in the control loop;...
  • Page 107 Basic MPC Vector Control Loop PID Control Pulsafeeder Flow Requested Output System Pump Meter Flow Rate Flow Requested flow rate from the user Motor speed command from the control system Flow output from the pump Flow measurement from the flow meter Flow output from flow meter The function we are controlling is liquid flow from the pump, and the variable being controlled by the MPC Vector is motor speed.

  • Page 108: Three Control Components

    22.2 Three Control Components: The PID controller has three adjustable internal components, all of which contribute to the final output value; they are proportional, integral, and derivative. Proportional Component The proportional component of the control system (also known as “gain”) is concerned with the current error (“current”...

  • Page 109: Pid Basic Summary, What Happens When I

    22.3 PID Basic Summary, what happens when I… When the proportional control is increased: Initial rise time to set point gets faster Overshoot once set point is reached tends to increase (gets worse) Steady-state error can be reduced but will never be eliminated Settling time (ability to hold set point) is not strongly affected Proportional is used mainly to affect the initial startup of the system, how quickly it reaches the desired set point.

  • Page 110: Putting It All Together To Run The Mpc Vector

    22.4 Putting it all together to run the MPC Vector The proportional, integral, and differential components are all added together into a command sum which is used to set the motor speed. The motor speed command does have software protection which prevents the motor speed from ever exceeding the max motor speed or from being negative and therefore if the command loop is unstable, no damage can be caused to the drive, motor, or pump.

  • Page 111: Troubleshooting

    Once you see the oscillation, back the integral gain down by 0.05 – 0.1. Start the pump again and make sure that the flow rate does not overshoot the set point significantly. Note: you may want to use a stopwatch to time how long it takes to get to 80% of the set point, especially if you are using the PulsaGuard pump protection.
  • Page 114 and Keypad Functionality BULLETIN No. IOM -MPCVector UMPC-11/201010 Rv. A...

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