Idex Pulsafeeder MPC Vector Instruction manual

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

ii
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. If the problem is not covered or cannot be solved, please contact your local authorized Sales
Representative or our Technical Service Department at [phone] for further assistance.
Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include
purchasing a replacement unit or returning the unit to the factory for inspection and repair. All returns require
a Return Material Authorization (R.M.A.) number to be issued by Pulsafeeder. Replacements purchased under
a possible warranty situation may be credited after an examination of the original parts by Pulsafeeder
personnel.
Certain components may be purchased for replacement. Refer to 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. Parts returned for warranty consideration that test satisfactorily, will be sent
back to the originator via freight collect.
Any field modifications will void the Pulsafeeder warranty. Out-of-warranty repairs will be subject to
Pulsafeeder’s standard bench fees and testing costs associated with replacement components.
FCC Warning
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1)
This device may not cause harmful interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
Copyright
Copyright © 2006, 2007, 2008, 2010 Pulsafeeder, Inc. All rights reserved.
Information in this document is subject to change without notice. No part of this publication may be
reproduced, stored in a retrieval system or transmitted in any form or any means electronic or mechanical,
including photocopying and recording for any purpose other than the purchaser’s personal use without the
written permission of Pulsafeeder.

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Table of Contents
1.MPC VECTOR OPERATION ................................................................................................................... 1
1.1MPC VECTOR Standard Features......................................................................................... 1
1.2Description.............................................................................................................................. 1
1.2.1System Input/Output Power Ratings ................................................................................ 2
1.2.2Handheld User Interface Operation .................................................................................. 3
1.2.3System Modes..................................................................................................................... 4
1.2.4Normal System Operational Modes.................................................................................. 5
1.2.5Control Modes..................................................................................................................... 6
2.SAFETY CONSIDERATIONS.................................................................................................................... 9
2.1General Safety......................................................................................................................... 9
2.2Electrical Safety...................................................................................................................... 9
2.3Mechanical Safety................................................................................................................... 9
2.4Hydraulic Safety...................................................................................................................... 9
3.EQUIPMENT INSPECTION....................................................................................................................... 10
4.STORAGE INSTRUCTIONS...................................................................................................................... 10
4.1Short Term (0 - 12 months).................................................................................................... 10
4.2Long Term (12 months or more) ........................................................................................... 10
5.INSTALLATION AND WIRING .................................................................................................................. 11
5.1Installation Notes.................................................................................................................... 11
5.2Controller Location................................................................................................................. 11
5.2.1Controller Mounting and Layout....................................................................................... 12
5.2.2NEMA 4X Version................................................................................................................ 12
5.2.3OPEN CHASSIS Panel Mount Version.............................................................................. 14
5.3Electrical Wiring...................................................................................................................... 15
5.3.1Pump Motor Wiring............................................................................................................. 17
5.3.2AC Line 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 Display and Keypad Functionality......................................................................... 29
6.4Motor Parameter Setup.......................................................................................................... 30
6.5Flow Display and Units .......................................................................................................... 30
6.6Setting Max Flow and Max Speed......................................................................................... 30
6.7Wrapping up............................................................................................................................ 32
6.8Factory Re-Initialization......................................................................................................... 33
7.INPUT/OUTPUT SETUP.......................................................................................................................... 34
7.1Analog Input Setup................................................................................................................. 34
7.1.1Analog Input 1 – Set point ................................................................................................. 34
7.1.2Analog Input 2 – Flow meter Feedback............................................................................ 34
7.1.3Analog Input Testing.......................................................................................................... 34
7.2Digital Input Setup.................................................................................................................. 35
7.2.1Multi-purpose Digital Inputs .............................................................................................. 35
7.2.2Testing Digital Inputs ......................................................................................................... 35
7.3Analog Output Setup.............................................................................................................. 36
7.4Digital Output Setup............................................................................................................... 36
7.4.1Multi-purpose Digital Outputs ........................................................................................... 36
7.4.2Testing Digital Outputs ...................................................................................................... 36
8.CALIBRATIONS..................................................................................................................................... 38
8.1Pump Flow Calibration........................................................................................................... 38
8.1.1Open Loop Pump Flow Calibration................................................................................... 38
8.1.2Closed Loop Pump Flow Scaling and Calibration........................................................... 42
8.1.3Set point Calibration and Range Setup............................................................................ 46

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8.1.4Analog Output Calibration .................................................................................................51
8.2PulsaGuard Pump Protection................................................................................................52
8.3Closed Loop Flow PulsaGuard Protection...........................................................................53
8.4Open Loop Speed PulsaGuard Protection...........................................................................53
8.4.1PulsaGuard Calibration - Closed Loop Flow Control......................................................53
8.4.2PulsaGuard Calibrations- Open Loop Speed Control.....................................................54
8.5Display Contrast Adjustment.................................................................................................55
8.6Tuning the Control Algorithm................................................................................................56
9.FLOW METER INPUT .............................................................................................................................59
9.1Flow Meter Installation and Activation .................................................................................59
10.AC INPUT VOLTAGE SETTING ...............................................................................................................61
11.MOTOR PARAMETER SETUP AND TUNING ..............................................................................................62
11.1Motor Parameter Setup and Calibration...............................................................................64
12.ALARM AND ERROR MESSAGES............................................................................................................65
12.1Error Log..................................................................................................................................65
12.1.1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Motor Type and Turndown Requirements............................................................................71
15.MODEL IDENTIFICATION ........................................................................................................................73
16.MENU MAPS.........................................................................................................................................74
17.FACTORY DEFAULT VALUES .................................................................................................................92
18.RETRIEVAL OF SETUP INFORMATION .....................................................................................................92
19.TROUBLESHOOTING GUIDE ...................................................................................................................93
20.SPARE PARTS......................................................................................................................................95
21.APPENDIX 1,HANDHELD WIRING ..........................................................................................................96
21.1Removal and Connection of the Cable from the Handheld:...............................................96
21.2Removal and Connection of the Cable from the Base Unit:...............................................96
22.APPENDIX 2,PID THEORY AND ADJUSTMENT........................................................................................100
22.1PID Controller Theory:............................................................................................................100
22.2Three Control Components: ..................................................................................................102
22.3PID Basic Summary, what happens when I…......................................................................103
22.4Putting it all together to run the MPC Vector.......................................................................104
22.5Troubleshooting......................................................................................................................105

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Conventions
For the remainder of this bulletin, the following Conventions are in effect.
AWARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH
THE EQUIPMENT AND THE PERSONNEL OPERATING IT.PAY CLOSE
ATTENTION TO ANY WARNING.
Notes are general information meant to make operating the equipment easier.
Safety Considerations:
1. Read and understand all related instructions and documentation before attempting to install or
maintain this equipment
2. Observe all special instructions, notes, and cautions.
3. Act with care and exercise good common sense and judgment during all installation, adjustment, and
maintenance procedures.
4. Ensure that all safety and work procedures and standards that are applicable to your company and
facility are followed during the installation, maintenance, and operation of this equipment.

1
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.
Pumps utilizing stroke length control must keep the stroke length constant. For maximum flow rate
adjustment 100% stroke length is recommended.
This product is not just a variable speed drive. It is a state of the art multifunctional controller, which provides
functionally that no one stand-alone variable speed drive does. What makes this product unique is that it combines
functionality of several devices in one:
Vector type variable speed drive.
Input output processor (4-20 mA in and out, digital input/output), including PID loop for closed loop flow control.
A user configurable pump calibration engine allowing process flow units as the main controllable parameter.
A remotely located hand-held local pump control user interface.
Power monitor for detection of run-dry conditions
This instruction manual covers the MPC VECTOR controller only. For information and safety precautions specific
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 (Remote location up to 1000 feet from pump)
Display pump operation in GPH, LPH, GPM, LPM, or RPM
One 4-20 mA analog input signal for flow or speed control
One 4-20 mA analog input for flow feedback control (with an external, user supplied flow meter)
Sensorless vector motor speed control
Two configurable digital dry contact inputs
Three configurable open collector/drain digital outputs (transistor type, 40 VDC maximum)
Analog 4-20 mA output for flow or speed
Available in NEMA 4X (IP56) ratings or an OPEN CHASSIS panel mount
208-230 Volts, 50/60 Hz, single or three phase AC input power for 1-3 HP motors
208-230 Volts, 50/60 Hz, three phase (only) AC input power for 5 HP motors
380,415,440,460,480 Volts, 50/60Hz, 3 phase for 1-5HP motors
Security code lockout of configuration menus
Standard configurable pump protection utilizing proprietary PulsaGuard technology
1.2 Description
The MPC VECTOR is designed for a wide variety of control applications. If delivered with a pump and motor, the
device is factory configured. Field configuration may be required in certain installations. Local setup and control is
achieved through the keypad and a backlit two-line liquid crystal display. Basic operation is simple with dedicated

2
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.
The MPC VECTOR is designed to simplify and automate the calibration of pump flow and analog signals. Flow
calibration uses on-screen prompting and automated pump operation to ease flow setup. Once calibration is provided, all
subsequent flow monitoring may be done using flow units. Analog signal calibration is also accomplished by simple
keypad entry. It includes a real-time display of signal level. This eliminates the need for external meters.
The MPC VECTOR is an advanced pump flow rate controller whose purpose is to precisely adjust output flow of a
process media by means of pump motor speed control. The MPC Vector can be controlled and monitored via remote
SCADA control or a local hand-held user interface. The controller can operate in two system level modes, two
operational modes, and two control modes. See below for detail on mode descriptions.
1.2.1 System Input/Output Power Ratings
The MPC VECTOR will accept, and automatically adjust to, either 50 Hz or 60 Hz input power. No special
modifications, settings, or adjustments 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 operating from a 50 Hz input.
Note: Users in locations with 50 Hz AC supply do not have to de-rate pump flow with this controller.
Minimum motor speed will be pump and motor type dependent and can be user configurable via a turndown ratio to work
with various applications. (See SYSTEM SETUP: turndown/motor setup)
Input Frequency MPC VECTOR Motor Max MPC VECTOR – Output
60 Hz (USA and similar) 60 Hz (or dual rated) 60 Hz / 1800 rpm
50 Hz (Europe, Asia, etc) 50 Hz or 60 Hz or dual rated 60 Hz / 1800 rpm
The motor, used in conjunction with MPC VECTOR controller, whether supplied from Pulsafeeder or by the user must
be a three-phase inverter duty/ready) motor. The three-phase power delivered to the pump motor is generated
internally by the MPC VECTOR controller. Input power ratings provided to the MPC VECTOR can be single-phase
208-230, three-phase 208- 230, or 3 phase 480VAC (see Section 13 Specifications for acceptable voltage ranges and
tolerances). The nameplate on the front of your MPC VECTOR controller will list the appropriate supply requirements
for your controller.
Motor Hp Rating MPC VECTOR Input Voltage* Motor Voltage Rating**
1 208/230/240 VAC 1 or 3 phase
380/415/440/460/480 VAC (3 phase only)
208-230 VAC
400VAC/460 VAC
2 208/230 VAC 1 or 3 phase
380/415/440/460/480 VAC (3 phase only)
208-230 VAC
400VAC/460 VAC
3 208/230 VAC 1 or 3 phase
380/415/440/460/480 VAC (3 phase only)
208-230 VAC
400VAC/460 VAC

3
5 208/230 VAC 3 phase only
380/415/440/460/480 VAC (3 phase only)
230 VAC
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. Control of these key motor parameters
results in longer motor life and more reliable overall operation. Further motor selection information can be found in
Section 14 Pump Motor Selection.
1.2.2 Handheld User Interface Operation
Figure 1-1 Local Handheld User Interface Elements
Key Function Description
Motor On/Off Press to start pump, press again to stop pump
Auto/Manual Press to toggle between automatic (remote) and manual
(local) control of the pump

4
Menu Press to adjust controller settings, to exit the menu system,
to move cursor back when entering values, or to step back to
higher level menus
Enter Press to accept changes in menus, to move cursor forward
when entering values, and to access lower level menus.
Arrow Up Press to increase value, and to scroll up through menu
options
Arrow Down Press to decrease value, and to scroll down through menu
options
Lamp Color Description
Off, Green,
Red
Off = Motor off Green = Motor on
Red (blinking) = System Error
Green, Off Green = Manual (Local) Control
Off = Automatic (Remote) Control
Table 1-2 – Keypad and Lamp Operation
1.2.3 System Modes
The MPC VECTOR operates at two system level modes, normal system control mode and system configuration
mode. Normal system control mode allows the user to change flow rates or motor RPM in order to adjust
process flow conditions to suit their 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 Configuration Mode
System configuration mode allows the user to set up the pump controller for the particular customer
application. The configuration mode has 4 major categories for the user to setup their pump application. Most
configurations must be done in the pump off state.
Shown below are the major configuration categories and the sub categories within each configuration area.
Configuration
Menu Sub Menu Description
Calibration
Pump Flow Pump flow calibration for open and closed loop flow setups. 2
point calibration
Analog Input Allows 4-20 mA signal calibration for speed control in sensorless
vector speed control and flow in closed loop control.
Analog Output Provides 4-20 mA output calibration of current output vs. speed in
sensorless vector mode and flow in closed loop mode
Motor Provides motor nameplate data entry and calibration of the chosen
MANUAL
ON