Pulsafeeder MPC Instruction manual

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

72-900-05 Rev A
ii
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. 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
MPC 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 MPC by Pulsafeeder personnel.
Certain components may be purchased for replacement. Refer to Section 19 –
Maintenance & 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 MPC warranty. Out-of-
warranty repairs will be subject to Pulsafeeder's standard bench fees and
testing costs associated with replacement components.
FCC Warning
This equipment generates and uses radio frequency energy. If not installed and
used properly, in strict accordance with the manufacturer’s instructions, it may
cause interference to radio communications. Operation of this equipment in a
residential area is likely to cause interference. In such cases, the user at their
own expense will be required to take whatever measures necessary to correct
the interference.
Copyright
Copyright © 2007-2014 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.

72-900-05 Rev A
iii
Table of Contents
INSTALLATION,OPERATION &MAINTENANCE MANUAL................................................................................. I
MPC™ FACTORY SERVICE POLICY.....................................................................................................I
TABLE OF CONTENTS.................................................................................................................................. III
FOR THE REMAINDER OF THIS BULLETIN,THE FOLLOWING CONVENTIONS ARE IN EFFECT. ...............................V
1. INTRODUCTION ...................................................................................................................................... 1
2. FORWARD ............................................................................................................................................. 1
3. DESCRIPTION ........................................................................................................................................ 1
3.1 MPC Standard Features........................................................................................................2
3.2 Options...................................................................................................................................3
4. SAFETY CONSIDERATIONS ..................................................................................................................... 3
4.1 General Safety .......................................................................................................................3
4.2 Electrical Safety.....................................................................................................................3
4.3 Fire Safety ..............................................................................................................................3
4.4 Mechanical Safety .................................................................................................................4
4.5 Hydraulic Safety ....................................................................................................................4
4.6 Liability Exclusion.................................................................................................................4
5. PUMP SUITABILITY TO SITE OF INSTALLATION......................................................................................... 5
6. TRANSPORT AND STORAGE.................................................................................................................... 6
6.1 Consignment receipt and unpackaging..............................................................................6
6.2 Handling .................................................................................................................................6
6.3 Lifting......................................................................................................................................6
6.4 Recycling and end of product life........................................................................................6
7. STORAGE INSTRUCTIONS ....................................................................................................................... 8
7.1 Short Term (0 - 12 months)...................................................................................................8
7.2 Long Term (12 months or more)..........................................................................................8
8. INSTALLATION AND WIRING.................................................................................................................... 9
8.1 Location..................................................................................................................................9
8.2 Installation Notes...................................................................................................................10
8.3 Installation guidelines for EMC compliance.......................................................................10
8.3.1 The cover must be installed properly..........................................................................10
8.3.2 Shielded cables used for analog inputs and outputs................................................10
8.3.3 Proper Earth grounding ................................................................................................10
8.3.4 Ensure Power mains are properly filtered for isolation from line transients,.........10
8.3.5 Lightning strikes or other electrical noise sources...................................................10
8.4 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 Control Input/Output Signal Wiring .............................................................................18
8.5 Check Wiring and Close Access Cover ..............................................................................20
8.6 Confirm Correct Incoming Power........................................................................................20
9. START UP AND OPERATION.................................................................................................................... 22
9.1 Overview.................................................................................................................................22
9.2 Keypad/Lamp Operation.......................................................................................................23
9.3 Confirm Display and Keypad Functionality........................................................................23
9.4 Flow Display...........................................................................................................................24
9.5 Wrapping up...........................................................................................................................24
10. INPUT/OUTPUT SETUP.................................................................................................................. 26
10.1 Analog Input Setup................................................................................................................26

72-900-05 Rev A
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10.2 Digital Input Setup.................................................................................................................26
10.3 Analog Output Setup.............................................................................................................26
10.4 Digital Output Setup..............................................................................................................26
10.5 Pump Flow Calibration..........................................................................................................27
10.6 Analog Input Calibration.......................................................................................................31
10.7. Analog Output Calibration....................................................................................................34
10.8 Display Contrast Adjustment...............................................................................................35
10.9 Changing the Motor Base Frequency..................................................................................35
11. ALARM AND ERROR MESSAGES ................................................................................................... 36
12. EXTENDING YOUR HAND-HELD CONTROLLER................................................................................ 38
12.1 Obtain New Cable:.................................................................................................................38
12.2 Removal and Connection of the Cable from the Handheld: .............................................38
13. SPECIFICATIONS .......................................................................................................................... 42
14. MENU MAPS ................................................................................................................................ 45
15. FACTORY DEFAULT VALUES......................................................................................................... 47
16. RETRIEVAL OF SETUP INFORMATION............................................................................................. 47
17. SPECIAL KEYPRESS ACCESS ....................................................................................................... 47
18. TROUBLESHOOTING GUIDE........................................................................................................... 48
19. MAINTENANCE &SPARE PARTS ................................................................................................... 49
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
v
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.THIS MANUAL MUST
BE CONSULTED IN ALL CASES WHERE THE WARNING SYMBOL IS MARKED
IN ORDER TO FIND OUT THE NATURE OF THE POTENTIAL HAZARDS AND
ANY ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM.
CAUTION, POSSIBILITY OF ELECTRIC SHOCK AND/OR
ELECTROCUTION HAZARD!
Notes are general information meant to make operating the
equipment easier.
Tips have been included within this bulletin to help the operator
run the equipment in the most efficient manner possible. These
“Tips” are drawn from the knowledge and experience of our
staff engineers, and input from the field.
Revision History:
Rev E (3-25-05)
-Section 3.1 Description, added 3-phase vs. single-phase info
-Change description of digital output specification
-New figure 2 (pump mounting)
-Updated analog in, analog out, and flow calibration instructions
-Update error handling text, Section 11
-Add specifications for voltage range and ELCB’s
-Add safety warnings about inrush current and capacitor discharge
throughout
Rev F (7-25-06)
-Added nametag diagram and note on proper input voltage selection
on page 9
-Added section 8.5 on adjusting motor base frequency
-Added sample digital output diagram in section 5.3.4
Rev H (9-26-07)
-Added clarification on digital output capability, sections 1.2, 5.3.4,
and 7.4
-Motor information added, sections 1.2, 1.3, and 11
-Added missing step in calibration instructions, section 8.1.1
Rev I (05-22-2014)
Updated to reflect requirements of UL 61010-1 3rd Edition

1. Introduction
The Metering Pump Controller (MPC) is a microprocessor based motor speed
control device, for use with 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. For
information specific to the metering pump or any other accessories, please refer
to the appropriate IOM.
2. Forward
The pumps to which these “instructions” refer to are designed for use in industrial
areas and therefore cannot be treated as retail products. The present
documentation gives instructions to be used by qualified personnel only. It must
be used in compliance with the regulations, laws and technical standards in force
and cannot, under any circumstances, take the place of plant standard or
additional regulations, including any which are not legally enforceable, which
have been issued with the scope of ensuring safety.
Equipment with special manufacturing or constructive variances may differ in
details with respect to this description.
In case of any difficulty, please contact PULSAFEEDER, INC. Technical Service.
The MPC is rated for NEMA 4x locations as identified on the controller
nameplate.
3. Description
The MPC is an advanced pump controller that is physically attached to the
pump. Its purpose is to precisely adjust output flow of a process media by
means of pump motor speed control.
The MPC is designed for a wide variety of control applications. The device is
factory configured and calibrated for the attached pump. The human/machine
interface is user friendly. Local setup and control is achieved through the
keypad and a backlit two-line liquid crystal display. Basic operation is simple
with dedicated function keys eliminating the need for a sophisticated menu
system. The MPC responds immediately to user commands. Pump output is
displayed as Gallons per Hour (GPH), Liters per Hour (LPH), Strokes per
Minute (SPM), Percent Speed, or Percent Flow (% of total pump capacity).
Digital and analog inputs will support a variety of industry standard signals to
offer flexible remote control.
The MPC 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 eliminate stopwatches, calculators and human inaccuracies.
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 readily accepts PULSAlarm®leak detection and tank level inputs.
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.
The controller/motor combination allows for full pump speed and flow even
when operating from a 50 Hz input. Users in locations with 50 Hz AC supply do
not have to de-rate pump flow with this controller.
The motor used with the MPC is a three-phase motor; however the three-phase
power is generated internally by the MPC itself. Do not be confused by the
motor nameplate. Input power to the MPC is single-phase AC only; either 115
or 230 volts (see Section 13, Specifications for acceptable input voltage
range). The nameplate on the rear of the MPC controller lists the appropriate
supply requirements.
At lower stroke frequencies (below 3:1 turndown), the MPC employs intermittent
motor actuation technology. This allows the user to achieve reliable low-end
performance not usually associated with variable speed controllers. By
completing a full pump stroke at constant speed, and varying the interval
between strokes, hydraulic stability and process consistency is maintained.
The AC drive used in the MPC maintains tight control over voltage and current
supplied to the pump motor. This results in lower motor operating temperatures
and less stress on motor windings, resulting in longer motor life and more
reliable overall operation. This holds true even when metering in the lower flow
ranges where the MPC uses intermittent operation.
3.1 MPC Standard Features
Remote keypad and display for ease of operation
Display pump flow in GPH, LPH, Strokes per Minute, or % of full pump
flow
One 4-20 mA analog input signal for flow control
One 4-20 mA analog output signal for flow feedback
Two configurable digital inputs
Three configurable digital outputs
Advanced turndown capability
NEMA 4X and IP56 ratings
Available for 115 or 230 Volts, 50 or 60 Hz, single phase AC power
Security code lockout of menus
Commercial duty motor as standard for indoor, dry locations only

3.2 Options
Variable hand-held controller cable length, up to 1,000 feet from pump
Alternate motor selections available for outdoor, washdown, chemical
duty, and other special applications
4. 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.
Ensure that all safety rules, work procedures, and standards that are
applicable to your company and facility are followed during the
installation, maintenance, and operation of this equipment.
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.
4.2 Electrical Safety
The MPC can be considered an industrial process controller. Improper
application and use can be hazardous. You are solely responsible for its
use.
The MPC's electrical installation must conform to all relevant electrical
codes. Installation and electrical maintenance must be performed by a
qualified electrician. Before installing or servicing this device, all power
must be disconnected from the source at the main distribution panel.
The MPC 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.
Certain wiring procedures may require that the user wear a wrist strap to
dissipate static charges.
4.3 Fire Safety
In case of electrical fire, use a Class C fire extinguisher. Never use water
to extinguish a Class C fire.
Class C fires involve electrical equipment, such as appliances, wiring,
circuit breakers and outlets. Never use water to extinguish class C fires -
the risk of electrical shock is far too great! Class C extinguishers do not

have a numerical rating. The C classification means the extinguishing
agent is non-conductive. Geometric symbol (blue circle)
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.
4.4 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.
The MPC was designed to be service free. It contains no user-
maintainable components. Disassemble the MPC enclosure only for
initial field wiring, or as instructed to do so within this manual. Evidence
of unauthorized disassembly shall void the warranty.
4.5 Hydraulic Safety
Thoroughly review and adhere to the contents of the pump Installation,
Operation, Maintenance and Instruction manual for installation of the
Pulsafeeder metering pump. As a microprocessor controlled device, the
MPC may activate the pump motor without warning –generating
hydraulic pressure and fluid flow. Care should be taken to protect both
users and systems should the pump activate.
4.6 Liability Exclusion
Pulsafeeder, Inc. is unable to monitor the observance of the
instructions given in this manual, nor verify the actual working
conditions and installation of the equipment, the correct operation,
the using and maintenance of the equipment and accessories. An
incorrect installation, or misuse of the equipment, may cause
serious damage and may pose a danger to persons or property.
Any anomalies must be reported to the maintenance supervisor.
The user is not authorized to tamper with the machine for any
reason.
Attempts to disassemble, modify or tamper in general by
unauthorized personnel will void the guarantee and will release
Pulsafeeder, Inc. from any liability for damage caused to persons or
property resulting from such actions.

Pulsafeeder, Inc. is considered released from any liability in the following
cases:
-improper installation;
-improper use of the equipment by non-professional or
inadequately trained operators;
-use not in compliance with regulations in the Country of use;
-lack of maintenance or improperly performed;
-use of non-original spare parts or incorrect parts for the model in
question;
-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. DANGER OF ELECTRONIC SHOCK AND
MECHANICAL PINCH HAZARD!
INSTALLATION AND REPAIRS SHOULD ONLY BE PERFORMED BY
AUTHORIZED PERSONNEL!
FOLLOW ALL SAFETY/ LOCAL LOCK-OUT, TAG-OUT
PROCEEDURES!
5. Pump Suitability to Site of Installation
Upon equipment receipt, verify that pumps have not received any damage due to
transportation and are complete with every eventual accessory. In case anomalies or
damages are discovered prior to installation, please contact PULSAFEEDER, INC.
Technical Service.