White Knight CPC-1 User manual

Manual Version 1.0.1 Manual Part# 18200-LM-0037
CPC-1: Closed Loop Controller Manual
Manual available online at wkfluidhandling.com

Manual version 1.0.1
Manual content and data are subject to change without notification. The most recent version of the manual can be found online at:
http://wkfluidhandling.com/owners-manuals
Page Left Intentionally Blank

Manual Version 1.0.2
Table of Contents
1. System Recommendations .................................................................................................................................2
1.1 Precautions .......................................................................................................................................................2
1.2 System Environment Recommendations/Requirements ..................................................................................2
1.3 Installation Advantages .....................................................................................................................................2
1.4 Getting Started ..................................................................................................................................................3
2. Parts List .............................................................................................................................................................4
2.1 CPC-1 Closed Loop Controller .........................................................................................................................4
2.2 Power Adapter with Crimp Pins ........................................................................................................................5
2.3 Cable: 26 Pin & 44 HD D-Sub to Wire Leads ...................................................................................................5
2.4 Breakout Board: 26 Pin HD D-Sub to Screw Terminals ...................................................................................5
2.5 Din Rail Power Supply ......................................................................................................................................5
2.6 Quick connect boards. Using field wire-able connectors to make connections easier. ....................................5
3. Non-Stock Items Needed....................................................................................................................................6
3.1 I/P Air Regulator ................................................................................................................................................6
3.2 Pressure Transducer ........................................................................................................................................6
3.3 Flow Meter ........................................................................................................................................................6
4 System Overview .....................................................................................................................................................6
5 Setup .......................................................................................................................................................................7
5.1 Plumbing the system .........................................................................................................................................7
5.2 Supply Air Pressure ..........................................................................................................................................7
5.3 Wiring Setup ......................................................................................................................................................7
5.3.1 Powering the CPC-1 ......................................................................................................................................8
5.3.2 Digital Connections ........................................................................................................................................8
5.3.2.1 Power Digital Ports: ....................................................................................................................................8
5.3.2.2 Digital Input Ports ........................................................................................................................................9
5.3.2.3 Digital Output Ports .................................................................................................................................. 10
5.3.3 Analog Connections .................................................................................................................................... 11
5.3.3.1 Common Ground ..................................................................................................................................... 11
5.3.3.2 Supplemental low power supply .............................................................................................................. 12
5.3.3.3 Analog Inputs ........................................................................................................................................... 12
5.3.3.4 Analog Outputs ........................................................................................................................................ 13
5.3.3.5 Wiring Summary ...................................................................................................................................... 13
6 PC to CPC-1 Communication: .............................................................................................................................. 14
6.1 Ethernet Connection: ..................................................................................................................................... 14
6.2 RS-232 Connection: ....................................................................................................................................... 14
7 Desktop Software ................................................................................................................................................. 14
7.1 Installation ...................................................................................................................................................... 14

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7.2 Using the software ......................................................................................................................................... 14
7.2.1 Controls Window ......................................................................................................................................... 15
7.2.1.1 Sensor Gauges ........................................................................................................................................ 15
7.2.1.2 System Alarms ......................................................................................................................................... 16
7.2.1.3 Operation Mode setup ............................................................................................................................. 16
7.2.1.4 Additional Menu Items ............................................................................................................................. 16
7.2.2 Setup Window ............................................................................................................................................. 18
7.2.2.1 Process Settings ...................................................................................................................................... 18
7.2.2.2 Analog I/O Settings .................................................................................................................................. 19
7.2.2.3 Digital I/O Settings ................................................................................................................................... 20
7.2.3 Advanced Window ...................................................................................................................................... 21
7.2.3.1 Terminal Tab ............................................................................................................................................ 21
7.2.3.2 Customize PID Gains Tab ....................................................................................................................... 21
7.2.3.3 Configurations Tab ................................................................................................................................... 22
8 Standalone Operation ........................................................................................................................................... 22
8.1 Using Digital Communication ......................................................................................................................... 23
8.1.1 Operation Mode .......................................................................................................................................... 23
8.1.2 Set Point Modification ................................................................................................................................. 23
8.1.3 Leak Detect Reset ...................................................................................................................................... 23
9 Troubleshooting .................................................................................................................................................... 24
9.1 Issues connecting to CPC-1 via Ethernet, preform the actions below ........................................................... 24
9.2 Issues Connecting to CPC-1 via RS-232, preform the actions below ........................................................... 24
9.3 Issues with Stable Flow ................................................................................................................................. 24
10 Appendix 1: 44 Pin D-Sub Connection Table ..................................................................................................... 26
11 Appendix 2: 26 Pin HD D-Sub Connection Table ............................................................................................... 29
12 Appendix 3: Dimensional Drawings .................................................................................................................... 32
13 Ordering Instructions .......................................................................................................................................... 33

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1. System Recommendations
1.1 Precautions
1.2 System Environment Recommendations/Requirements
1.3 Installation Advantages
DO NOT OPEN CONTROL BOX
Do not open the control box. White Knight is not responsible for any damage caused by opening the
Control Box.
Environmental Temperature
This product is rated to withstand environmental temperatures up to 70°C.
Grounding
All electrical components must be grounded to minimize risk of sparks. Follow proper procedures for
grounding all products in the system.
Flow and Pressure Monitoring
The CPC-1 is able to take in both a pressure transducer and flow meter signals at the same time. While
only one is needed for the desired control process, the other can be input for monitoring and
troubleshooting purposes.
Non-stock Items Needed
The Closed Loop Control system makes use of several off the shelf items that White Knight does not
supply. There is a large variety of products and suppliers and the end user may obtain their preferred
product. See section 3 of this manual for detailed descriptions of needed parts.
System Limitations
The CPC controls the parameters of the system based off of the selected pump and would not protect
system components that are not rated as high as the pump the controller is programmed to control.
Flow and Pressure
White Knight recommends the installation of a pressure transducer as well as a flow meter to allow for
increased monitoring as well as the ability to switch between flow and pressure control within a system
without any addition or change to system components.

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1.4 Getting Started
Installing the CPC-1 for the first time it is recommended that you follow these steps:
1) Verify that you received all of the components that you ordered. Note: cables and breakout board for the
controller are options that can be selected at the time of purchase.
2) Check that you have a compatible power supply to power the controller. See Section 5.3.1
3) Check that you have a compatible communication cable for setting up the controller. See Section 6
4) Download the setup software from www.wkfluidhandling.com/cpc-1.
5) Verify that your computer is able to connect to the controller.
a) Power up the controller with correct power source
b) Connect the communication cable correctly. (Ethernet cables should go from the controller to a network
switch, not your PC)
c) Install and launch the Smart Control Software.
d) The connections dialog should appear at launch. Verify that your controller appears on the list and click
the connect button. See Section 7.2
e) Once connectivity is verified disconnect from the software, and disconnect power and communication
cable.
6) Install CPC-1 in the desired location.
7) Connect 44 pin and 26 pin connectors and use the wiring guide in Section 5.3.2 and 5.3.3 to connect system.
8) Connect to controller (same as before) and configure the CPC-1 settings to match your system needs.

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2. Parts List
#
Description
Part Number
Component
2.1
Control Box
CPC-1
Standard
Power Adapter With Crimp Pins
Standard
2.4
44 Pin HD D-Sub to Screw Terminals
8600-XX-0018
Optional
2.3
44 Pin HD D-Sub to wire leads Cable 1-Meter
8600-XX-0013
Optional
2.4
26 Pin HD D-Sub to Screw Terminals
8600-XX-0019
Optional
2.3
26 Pin HD D-Sub to wire leads Cable 1-Meter
8600-XX-0014
Optional
2.5
24 Volt Power Supply - 60 Watt
8600-XX-0015
Optional
* For size of items in parts list see section 12
2.1 CPC-1 Closed Loop Controller
The CPC-1 control box is a small I/O communication device that controls the supply air pressure to the pump in
order to maintain either flow or pressure changes. The control box has:
• 44-pin HD D-Sub Connector: Sends and receives digital signals.
• Indicator Lights: Show when each digital signal is active.
• 26-pin HD D-Sub Connector: Sends and receives analog signals.
• Power Port: Takes 18-36 VDC input to power the controller.
• Ethernet Connector: Can be used by the setup software to configure the controller.
• RS 232 serial communication: Can be used by the setup software to configure the controller.
Figure 1 shows an image of the CPC-1 controller. Note: the production version will come with a din rail mount,
where the beta version does not.
Power port
Ethernet
Indicator Lights
44-Pin Connector for
Digital Communications
26-Pin Connector for
Analog Communications
RS-232 Serial Port
Figure 1: The CPC-1 Controller and its communication ports.

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2.6 Quick connect boards. Using field wire-able connectors to make connections easier.
2.2 Power Adapter with Crimp Pins
2.3 Cable: 26 Pin & 44 HD D-Sub to
Wire Leads
2.4 Breakout Board: 26 Pin HD D-Sub
to Screw Terminals
2.5 Din Rail Power Supply
Analog Output Connectors:
•Pin 1: 24 VDC Power
•Pin 2: Ground
•Pin 3: Voltage Output
•Pin 4: Voltage Reference
•Pin 5: Current Output
•Pin 6: Current Reference
Analog Input Connectors:
•Pin 1: 24 VDC Power
•Pin 2: Ground
•Pin 3: Analog Input
•Pin 4: Voltage Reference
•Pin 5 & 6: If Input is a
current input jumper two
pins together.
Note: Temp Connector has
different pinouts.
Power Connectors:
•Pin 1: Ground
•Pin 2: 24 VDC Power

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3. Non-Stock Items Needed
The Closed Loop Control system makes use of several off the shelf items that White Knight does not supply.
There is a large variety of products and suppliers so the end user may obtain their preferred products. Below is a
brief description of these components and the CPC-1 interface requirements.
3.1 I/P Air Regulator
An electronic proportional air regulator is required for the closed loop control system. Minimum specifications for
I/P air regulator are:
• Supports a pressure range from 0 to 100 PSI.
• Supports air flow requirement for selected WK pump. (See pump’s manual)
• Ability to set pressure using analog signal*.
* The CPC-1 only supports analog voltage analog outputs (0-5 VDC, 0-10 VDC), if an analog current signal (0-20
mA or 4-20mA) is required then the 4-20 mA Expansion Board or a signal conditioner is required.
3.2 Pressure Transducer
A pressure transducer is only required for systems in which pressure control is desired. However, for systems that
are using flow control a pressure transducer can be added into the system for system monitoring. The minimum
specifications for the pressure transducer are:
• Support the full range of system pressures up to 100 PSI
• Output pressure reading via analog signal*
* If the pressure transducer outputs an analog current signal then a 500 ohms resistor or smaller can be
connected between the signal and ground connections to convert the signal to a voltage signal. (The 4-
20 mA Analog Expansion Board will already have a 250 ohm resistor correctly placed for this conversion)
3.3 Flow Meter
A flow meter is only required for systems in which flow control is desired. However, for systems that are using
pressure control a flow meter can be added into the system for system monitoring. The minimum specifications
for the flow meter are:
• Support the full range of system flows.
• Output flow reading via analog signal*
* If the flow meter outputs an analog current signal then a 500 ohms resistor or smaller can be connected
between the signal and ground connections to convert the signal to a voltage signal. (The 4-20 mA
Analog Expansion Board will already have a 250 ohm resistor correctly placed for this conversion)
4 System Overview
Closed loop control is a self-monitoring system that will maintain one process variable independent of changes in
the system. The CPC-1 closed loop controller has two different control modes:
Pressure Control – Uses feedback from a pressure transducer to maintain a set line pressure at a
desired point in the system. Pressure transducers are able to detect small changes in the system with little to no
time delay. Thus a pressure controlled system is more responsive to changes in the system, such as a point of
use with multiple valves that open and close frequently. A pressure control system can also be used to maintain
flow in the system where a fixed pressure through a fixed orifice can result in a steady flow.
Flow Control – Uses feedback from a flow meter to maintain a desired flow rate in the system. Flow
meters generally use a rolling average to detect flow in the system, which results in a less responsive sensor.

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Thus a flow controlled system is slow to respond to changes in the system. Flow control processes are frequently
used in plating or mixing operations where the flow doesn’t change, but where the filter may clog over time. The
flow control will slowly adjust the pressure as flow restrictions build up in a filter. Using flow control can lengthen
the usable life of a filter because the control will maintain the correct flow.
The CPC-1 is able to take in both a pressure transducer and flow meter signals at the same time. While only one
is needed for the desired control process, the other can be input for monitoring and troubleshooting purposes.
Note: White Knight does not supply pressure transducers or flow meters. See Non-Stock Items Needed for more
information about selecting a pressure transducer and flow meter.
5 Setup
5.1 Plumbing the system
Assemble the system plumbing as normal and include the correct sensors that are required for the closed loop
control process; a pressure transducer for pressure controlled systems or a flow meter for flow controlled
processes. These sensors should be placed in the critical path close to the point of use. In some cases it may be
advantageous to add both sensors into the system; this will allow additional flexibility for implementing closed loop
control allowing the end operator to monitor both sensors, and have the ability to switch control methods.
5.2 Supply Air Pressure
The supply air going into the closed loop control system should be set to 100 PSI. The supply air is then directed
into the air regulator. The air regulator controls how much air is supplied to the pump and pulse dampener. See
Figure 2 for illustration of the air flow.
5.3 Wiring Setup
The CPC-1 has the following on device connections interfaces:
Fluid to
Pump
PLC
Commands
Pressure
Transducer
Air
Regulator
Pulse
Dampener
WK Pump
Supply Air
Fluid to
System
Flow
Meter
CPC-1
Analog Flow Signal
Analog Pressure Signal
Figure 2: Control Process diagram where elements shown in green can be obtained from a
third-party distributer. Note: Depending on which model of I/P Air regulator is selected they
may be two separate components or they may be one consolidated unit.