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Installation, Operation &
Maintenance Manual

Universal Control
for Pulsa and
Eclipse. Suitable
for any Gear,
Reciprocating or
Positive
Displacement
Pumps.

Microprocessor Based Positive

Displacement Pump Speed Controller

BULLETIN No. IOM-MPCVector UMPC-11/201010 Rv. A

Содержание Pulsafeeder MPC Vector

Страница 1: ...ance Manual Universal Control for Pulsa and Eclipse Suitable for any Gear Reciprocating or Positive Displacement Pumps Microprocessor Based Positive Displacement Pump Speed Controller BULLETIN No IOM...

Страница 2: ...placement Refer to 20 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 Par...

Страница 3: ...Input Wiring 17 5 3 3 Control Input Output Signal Wiring 23 5 4 Check Wiring and Close Access Cover 27 6 SYSTEM CONFIGURATION 27 6 1 Overview 27 6 2 Critical System Configuration Steps 27 6 3 Confirm...

Страница 4: ...1 Viewing the Error Log 65 12 1 2 Clearing Error Log Entries 65 12 2 Alarm and Error Message System Behavior 66 13 SPECIFICATIONS 69 14 PUMP MOTOR SELECTION 71 14 1 General Specifications 71 14 2 Mot...

Страница 5: ...afety 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 Ac...

Страница 6: ......

Страница 7: ...c to the pump or any other accessories please refer to the appropriate IOM 1 1 MPC VECTOR Standard Features Local Manual and Remote operational modes User keypad and display for ease of operation Remo...

Страница 8: ...are required The 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...

Страница 9: ...p motor resulting in lower motor operating temperatures and less stress on motor windings Control of these key motor parameters results in longer motor life and more reliable overall operation Further...

Страница 10: ...eir needs System Configuration mode allows the user to setup the controller for various user applications thus customizing the pump rate controller for a particular process 1 2 3 1 System Configuratio...

Страница 11: ...time for flow detect digital input Flow Meter Allows activation deactivation of flow meter for closed loop flow control Security Enables Disables and sets password protection number PulsaGuard Activat...

Страница 12: ...t will command the pump to run at that fixed user flow rate More complex flow rate control can be performed by using a 4 20mA current loop and a remote start stop digital input signal The digital inpu...

Страница 13: ...for sensorless vector control Changing stroke length requires recalibration Point 1 Speed1 Flow1 Drawdown Flow Rate GPH Speed Setpoint Handheld Remote 175 1750 2 4 25 Turndown Limit Reached SPEED SETP...

Страница 14: ...8 Figure 1 3 Closed Loop Control Feedback Block Diagram Figure 1 4 Closed Loop Flow Calibration Curve...

Страница 15: ...he 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 Ce...

Страница 16: ...e 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...

Страница 17: ...tion describes the installation steps necessary for a successful installation Review the Safety section Section 2 prior to installing the MPC VECTOR It contains information required to properly instal...

Страница 18: ...NEMA 4X enclosure and an OPEN CHASSIS custom mountable panel 5 2 1 Controller Mounting and Layout The MPC VECTOR is provided in two form factors a NEMA 4X enclosure and an OPEN CHASSIS custom mountabl...

Страница 19: ...13 230 480 VAC Controller Layout and Dimensions for detailed mounting dimensions Figure 5 2 NEMA 4x 230 480 VAC Controller Layout and Dimensions Control I O Wiring AC Input wiring Pump Motor Wiring...

Страница 20: ...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 The main MPC Vector control boar...

Страница 21: ...t 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...

Страница 22: ...ntrol wiring a Analog input signal s so the MPC VECTOR can accept a process input signal or flow meter input b Analog output signal for user monitoring of speed or flow c Digital input signals for exa...

Страница 23: ...e the conductor Torque Requirement 2 0 lb in 0 2 Nm making certain that the terminal grips the wire not the insulation Ensure that all wiring meets applicable local and national codes and requirements...

Страница 24: ...drive and a minimum 75 Degrees C insulation rating Copper wire only 5 3 2 1 AC Input Wire and Circuit Breaker Sizing General Input Wiring Guidance The MPC VECTOR requires one connection to an external...

Страница 25: ...8 230 VAC Three Phase 208 230 VAC Actual Draw Circuit Breaker Wire Size Wire Size Actual Draw Circuit Breaker Wire Size Wire Size MPC VECTOR and 1 0 Hp motor 10 6 A 15 A 14 AWG 2 0 mm2 5 8 A 10 A 14 A...

Страница 26: ...MPC VECTOR and 3 0 Hp motor 6 2A 10 A 14 AWG 2 0 mm2 MPC VECTOR and 5 0 Hp motor 10 6 15A 14 AWG 2 0 mm2 Table 5 2 Sizing Branch Circuits 400 480VAC 5 3 2 2 230 VAC Model NEMA 4x and 480VAC Panel Mou...

Страница 27: ...ECTOR Drive Terminal Single Phase 208 230 VAC Three Phase 208 230 480 VAC L1 Line 1 Line 1 L2 N C No Connect Line 2 L3 Line 2 Neutral Line 3 Ground Plate Chassis Earth Ground Chassis Earth Ground Tabl...

Страница 28: ...MA 4x AC Input Wiring Termination Details At this point power wiring is complete At this point you should apply power to the MPC VECTOR and your attached pump to ensure proper power wiring connection...

Страница 29: ...ltage wiring is installed per any applicable local and national electrical codes and regulations Unused conduit openings should be plugged as required to avoid ingress of moisture and contaminants int...

Страница 30: ...on 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 Warning MPC VECTOR Outputs are not re...

Страница 31: ...de 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 Inputs can be wired normal open or normally...

Страница 32: ...w meter based systems The analog input is use to provide a 4 20 mA flow feedback signal in order to provide closed loop flow control 5 3 3 7 2 Set point Analog Input 1 Analog input 1 is dedicated as a...

Страница 33: ...al connections have been made your MPC VECTOR is ready for initial setup calibration and operation All setup occurs using the handheld remote user interface The following sections detail the procedure...

Страница 34: ...on 11 Motor Parameter Setup and Tuning Step 6 Optional ONLY IF USING FLOW METER If using closed loop flow control Flow Meter Activation Test flow meter 4 20 input Section 9 Flow Meter Input Step 7 Opt...

Страница 35: ...e functioning properly On normal power up the following display sequence appears Figure 6 1 MPC VECTOR Display Power Up Sequence Upon power application the display will show all black squares approx 2...

Страница 36: ...he motor parameters and you will have to perform a motor calibration procedure Please reference Section 11 Motor Parameter Setup and Tuning before proceeding with operation of your MPC VECTOR controll...

Страница 37: ...ETPT 0 00GPM FLOW 0 00GPM 2 Press the MENU key to access the menus MENU CALIBRATION 3 Press the UP or DOWN arrow keys until you get to System Setup MENU SYSTEM SETUP 4 Press the ENTER key to access Sy...

Страница 38: ...issioned for use Note that you cannot configure the software in a way that would damage the MPC VECTOR Typically whenever you are about to set a critical value e g Calibrate Flow you are always prompt...

Страница 39: ...racters on the display or exaggerated numerical values Commonly a user has entered incorrect parameters or made changes to the setup of the control Once a re initialization has been performed all oper...

Страница 40: ...low meter input signal must be configured properly prior to use Use Menu System Setup Flow Meter Meter Type Analog to enable the process feedback analog input The flow meter type must be set to ANALOG...

Страница 41: ...esting Digital Inputs The MPC VECTOR allows for testing of the two digital inputs The user must provide a dry contact closure from a PLC SCADA or a switch to the digital input under test See Section 5...

Страница 42: ...site response Digital output circuits are transistor based and limited to 24 VDC maximum 500 mA current limit per output see Section 5 3 3 5 Digital Output Wiring Example Open Collector Drain and Sect...

Страница 43: ...37 This page is intentionally left blank...

Страница 44: ...sed loop flow control flow meter based systems For details on theory of operation refer to Section 1 2 5 Control Modes Refer to Section 16 Menu Maps for key press sequences 8 1 1 Open Loop Pump Flow C...

Страница 45: ...1 1 Open Loop Dry Flow Calibration The open loop Dry Flow Calibration routine does not require the pump to run Instead the user must input 2 known flow rate versus speed points These points may come f...

Страница 46: ...em will check the dry calibration values and if the values are acceptable will complete the calibration PUMP FLOW CALIBRATED 8 1 1 2 Open Loop Wet Flow Calibration The Open Loop Wet Flow Calibration r...

Страница 47: ...o the next screen This allows for shorter drawdowns using the ENTER key All other keys abort the calibration RUNNING 60 SECS W I L L C O U N T D O W N MOTOR 1800 RPM 6 0 S E C O N D S W I L L E L A P...

Страница 48: ...d Calibration NOTE Be sure to set flow meter to active See Section 7 1 2 Analog Input 2 Flow meter Feedback Closed loop flow control calibration and scaling requires the following Two calibration spee...

Страница 49: ...MENU CALIBRATION 2 Press the ENTER key to access Pump Flow Calibration screen CALIBRATION PUMP FLOW 3 Press the ENTER key to access Dry Pump Flow Calibration screen PUMP FLOW DRY CAL 4 Press ENTER to...

Страница 50: ...range of the pump See your flow meter s IOM to set analog 4 20 mA output range versus the flow rate measured To optimize feedback it is best to set your flow meter 4mA to 0 flow and 20mA to a value s...

Страница 51: ...al will be 60 seconds Pressing the ENTER key will take the user immediately to the next screen Shorter drawdowns are available by using the ENTER key to terminate at the desired interval All other key...

Страница 52: ...libration values and if the values are acceptable will complete the calibration PUMP FLOW CALIBRATED 8 1 3 Set point Calibration and Range Setup Set point calibration and range setup will allow the us...

Страница 53: ...ll range of flow rates available and maximizes the available pump flow rates Commanded Flow Rate GPH Figure 8 5 Set point Input4 20 Scaling Calibration Flow If the MPC VECTOR is configured for Closed...

Страница 54: ...e UP and DOWN arrow keys to change the Speed Flow corresponding to the Analog Input Value 10 Press the ENTER key once more to accept the calibration value APPLY MIN MA ENTER TO START 11 Apply your des...

Страница 55: ...nals The minimum signal range is 3 mA The most likely source of this error is the user did not change the value of the incoming analog signal when moving from the MIN calibration to the MAX calibratio...

Страница 56: ...ursor will show you that you are adjusting the Current mA MAX SETPT 0 0MA FLOW 0 00GPM 8 Press the UP and or DOWN keys to adjust the Current set point MAX SETPT 20 0MA FLOW 0 00GPM 9 Press the ENTER k...

Страница 57: ...on The analog output calibration routine maps the motor speed as of maximum motor speed configured in Section 6 5 Flow Display and Units The MPC VECTOR will display calibrated pump flow in GPH LPH GPM...

Страница 58: ...n SET 100 SPEED TO 20 0 MA 8 Use the UP and DOWN arrow keys to adjust as in step 6 above 9 Press the ENTER key once more to accept the calibration value ANALOG OUTPUT CALIBRATED 10 Analog output signa...

Страница 59: ...g without flow meter feedback PulsaGuard can read the motor current and shut off the pump if the current drops below the shut off level and stays under that level for 10 seconds effectively protecting...

Страница 60: ...MENU 7 Run the pump to meet desired low setpoint conditions You may adjust the speed of the motor using the UP and DOWN arrow keys The output current of the motor will be displayed on the screen In th...

Страница 61: ...BRATED 14 PulsaGuard Pump Protection is now calibrated and enabled 8 5 Display Contrast Adjustment Should adjustment of the contrast level of the remote handheld display become necessary use the follo...

Страница 62: ...down the MPC VECTOR set point response time This is done by adjusting the PID Controller parameter coefficients The user may adjust the Proportional coefficient kp the Integration coefficient ki and t...

Страница 63: ...1 Press the ENTER key DERIVATIVE X XXX 12 Press the UP and or DOWN keys to adjust kd DERIVATIVE 0 050 13 You may back out without saving the new PID coefficients at this point by hitting the MENU key...

Страница 64: ...D screen SYSTEM SETUP PID PARAMETERS 6 Press the ENTER key PID PARAMETERS COEFFICIENTS 7 Press the UP arrow key PID PARAMETERS SAMPLING PERIOD 8 Press the ENTER key SAMPLING PERIOD PERIOD XXXMS 9 Pres...

Страница 65: ...ifications 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 Section 13 Specifications Your flo...

Страница 66: ...hange the sensor type SENSOR TYPE INACTIVE 9 Press the UP arrow key until the analog flow meter option is displayed SENSOR TYPE ANALOG 10 Press the ENTER key to accept the new configuration SENSOR TYP...

Страница 67: ...d motor current ensuring protection of your pump motor 1 Starting from the main operational screen SETPT XX XXX FLOW XX XXX 2 Press the MENU key MENU CALIBRATION 3 Press the UP arrow key MENU SYSTEM S...

Страница 68: ...of the motor Note that the ranges listed in the table below reflect absolute min max accepted by the drive and may not match a specific application These do not have to be set in any particular order...

Страница 69: ...on the nameplate as PF If the Power Factor is given as a percentage always use the decimal equivalent for example a power factor of 84 would be entered as 0 84 If the Power Factor is not provided by t...

Страница 70: ...ress the ENTER key MOTOR VOLTAGE 230 5 Use UP and DOWN arrows to adjust value as required then press the ENTER key MOTOR FREQUENCY 60 6 Use UP and DOWN arrows to adjust value as required then press th...

Страница 71: ...SETUP STATUS 5 Press the ENTER key again to view the current status NO ERROR 6 Press the DOWN key to view the most recent system error ALARM LEAK DETECT 7 Continue pressing the DOWN key to scroll thro...

Страница 72: ...will stop when the leak detection input is activated When the leak input is deactivated the pump motor will not start and will require a manual restart PUMP FLOW NOT DETECTED The flow detection monito...

Страница 73: ...67 Continues next page...

Страница 74: ...dentified error record error number and consult factory USER NOTIFICATIONS These are errors in setup or calibration They will display on the screen for several seconds They can be corrected by properl...

Страница 75: ...on off control of pump 2 Level input from supply tank 3 Leak Detection with external device 4 Flow detection with external device Control Outputs Wiring Specification Description Analog Out 1 J23 pins...

Страница 76: ...er than 25 feet 7 6 meters see motor information next page Consult factory for distances greater than 100 feet 30 5 meters Keypad Mounted to MPC VECTOR main enclosure can be made remote from the enclo...

Страница 77: ...for the correct frame size Motors may or may not need feet and or a C face mount depending on equipment 14 2 Motor Type and Turndown Requirements Motor turndown is defined by the ratio of motor base...

Страница 78: ...cases should be minimized AC drive motor control waveforms are formed from a DC bus and are chopped to create an AC control waveform These waveforms create motor wiring high voltage spikes These spik...

Страница 79: ...VAC B 2 Hp 1 5 kW Drive Input 208 230 VAC C 3 Hp 2 2 kW Drive Input 208 230 VAC D 5 Hp 3 7 kW Drive Input 208 230 VAC 3 phase only E Fractional to 1HP 0 75kW 480 VAC 3 phase only F 2 Hp 1 5 kW Drive...

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Страница 98: ...MANUAL Indication normally closed Digital Output 3 ALARM Indication normally closed Security Code Default 0000 Language ENGLISH MODE Local Manual UNITS GPM gallons per minute 18 Retrieval of Setup In...

Страница 99: ...ot seated properly Open Handheld Front Cover and measure voltage and check J4 for proper connection See Figure 21 1 Handheld Remote Wiring LCD display not readable no text on display too light too dar...

Страница 100: ...odule display reads PF Current Overload has occurred and drive shuts down Check pump for binding or mechanical failure Drive module display reads F1 F9 Drive has internal fault Consult factory Problem...

Страница 101: ...ring 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 c...

Страница 102: ...is in each position of the terminal block J5 Cut the tie wrap that secures the cable Unscrew each screw on the terminal block J5 and remove each lead 5 Loosen the outer domed nut on the liquid tight r...

Страница 103: ...minal block 5 Prepare the end of the cable as per Figure 7 on the following page Ensure that the shield is fully insulated until the point where it enters the terminal No part of the shield should be...

Страница 104: ...7 Wire Preparation Detail Base Unit End AN00446 002 BLACK GREEN GREEN RED BLACK RED GREEN BLACK GREEN WHITE BLACK WHITE BLACK WHITE WHITE SHIELD BLACK RED RED DRIVE AC J20 J11 J14 J23 REMOTE MAY DAMAG...

Страница 105: ...99 Figure 8 Handheld Remote...

Страница 106: ...a semi technical discussion of PID Control Loops you can skip ahead to Section 21 3 22 1 PID Controller Theory The basic PID Control Loop consists of an input command the control system and feedback s...

Страница 107: ...e flow meter it acts on the error between the actual flow rate and the desired set point it s goal being to eliminate the error between the two as much as possible Sampling Rate In the digital world t...

Страница 108: ...rror summation The sum of the errors is then multiplied by an integral coefficient Ki which is also called the integral gain Because the integral component is a historical component it can take some t...

Страница 109: ...s used mainly to tune the system to reach a certain set point to eliminate any offset the might be present for example the desired flow rate is 5 0 GPH but the system settles and runs at a consistent...

Страница 110: ...ector flow reading matches flow meter feedback Step 2 Choosing the test set point In order to tune the PID loop it is necessary to choose a test speed For most purposes the test flow should be set to...

Страница 111: ...y cases a PI controller alone is sufficient to control the pump flow If derivative gain is added start with a low setting 0 05 or so and keep adjusting in 0 05 increments until desired settling time i...

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Страница 114: ...and Keypad Functionality BULLETIN No IOM MPCVector UMPC 11 201010 Rv A...

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