Mercoid MPC Level Controller Manual PDF
Contents
1. nf n n nN M 21 22 23 24 25 26 FUER gt Connect Transmitter minus to terminal 3 fi f i f f Level Transmitter f 6005005 27 28 29 30 31 32 20 c amp c C C For three or four wire transmitters follow the wiring instructions provided with your transmitter DO NOT wire the 24 Volt Power Supply across the input of the control Damage to the control input circuitry will result WIRING FOR 485 AND 232 SERIAL COMMUNICATION OPTIONS Wire power and outputs as shown on page 5 Wiring for options is shown in Figure 4 below All wiring shown below is Class 2 Shielded twisted pair is recommended for Option 485 Figure 4 Wiring for Options DB 25 WIRING 3 AS L T VIEWED FROM WIRE SIDE 21 22 23 24 25 26 11 DATA IN 30 gt DATA OUT 32 2 12 DATA GROUND 31 HEN qus 3 13 C gt 4 14 PIN DESCRIPTION PIN DESCRIPTION c gt 1 SHIELD 6 DSR 5 E 2 TRANSMIT 7 GROUND 3 RECEIVE 8 DCD c 4 RTS 20 DTR 6 16 5 CTS c i i itions RS 232 DB 9 WIRING 7 Option 485 DIF Switch Positions a VIEWED FROM WIRE SIDE Half Duplex Full Duplex DATA OUT 32 DATA IN 30 PEETUS ai ae c 3 OFF PIN DESCRIPTI2. There are no further programming steps required The values of POL and POH must be within the programmed scale range The scale range is set by the S AL and SCRH in the Secure menu PUMP RUN TIME OPERATION The pump run time is indicated in hours of operation since the last time that the run time meter was reset for a specific pump The E Pump Run Time key on the front of the unit will display run time for both pumps when depressed Run time for pump 1 is in the top display and pump 2 is in the lower display To reset the pump run time go to the menu items P irn and Pera in the Secondary Menu When in the corresponding menu item hold the ENTER button for approximately two seconds The display will blank out for about 1 second and the run time will display 0 These menu items can be locked out by the P St menu item in the Secure Menu 13 OPTION 232 485 SERIAL COMMUNICATION OPERATION The serial communications options allow the control to be written to and read from a remote computer or other similar digital device Communication is allowed either through a RS 485 Option 485 port or a RS 232 Option 232 port Wire the communication lines as shown on Page 7 Wiring for the RS 485 is run from control to control in a daisy chain fashion with a termination resistor 120 ohms across the transmit and receive terminals of the last control in the chain Set the RS 485 DIP switch for half or full duplex as appropriate for your application The DIP sw
3. Alarm 2 Power Interrupt selectable on or off EE Alarm 2 Inhibit selectable on or off a5 Alarm 2 Output State selectable close or open D on 7 an Alarm 2 Lamp condition when contact is closed selectable on or off EF re o n E o ly mi Alarm 2 Time Delay selectable Off or 1 to 8000 seconds a as i n A ae DUM ES MERCOID A Division of Dwyer Instruments Inc Mercoid P O BOX 258 MICHIGAN CITY INDIANA 46361 U S A Phone 219 879 8000 Fax 219 872 9057 www dwyer inst com e mail lit dwyer inst com Copyright 2010 by Dwyer Instruments Inc Printed in U S A 10 10
4. Enter Secondary Locked 2 Secure Locked 1101 Secondary Unlocked 3 Secure Locked 1011 Secondary Unlocked 4 Secure Unlocked 111 10 LEAD LAG OPERATION The Mercoid MPC pump controller is designed to easily operate a pair of pumps in the most efficient manner possible The controller has a lead lag feature that allows two pumps to operate in an alternating fashion to minimize wear The Mercoid MPC pump controller has a pair of set points each for pump 1 and pump 2 If the lead lag feature is turned off SP IH and SP it control pump 1 and SP H and SPet control pump 2 If the lead lag feature is turned on pumps 1 and 2 will be controlled in the alternating fashion described below In all cases the P1 lamp will indicate activity of pump 1 and the P2 lamp will indicate activity of pump 2 The lead lag operation is set in the Secure menu with the item d1 9 Lead Lag On After installation set the SP iH to the high level pump on point for standard operation Set SP iL to the low level pump off point Set the SP2H to the level where you want BOTH pumps to turn on emergency pump on Set the SP t to the level where you want the second pump to turn off emergency pump off The controller will not allow you to set SP iH below SP it SP it above SP iH SPOH below SPet or SPet above SPeH The controller will not allow you to set any set point or alarm point above or below the programmed scale No error messages
5. Go or GFF Factory default is GFF En Alarm Inhibit is Gn Alarm action is suspended until the process value first enters a non alarm condition GFF Alarm Inhibit is GFF Alarm 1 Output State Select CLOS or GP En Factory default is C185 1065 Closes Contacts at Alarm Set Point GPEn Opens Contacts at Alarm Set Point Alarm 1 Lamp Select 8 on or Goff Factory default is on on Alarm Lamp is ON when alarm contact is closed Goff Alarm Lamp is OFF when alarm contact is closed Alarm 1 Time Delay Select OFF or to 8000 seconds Factory default is OFF OFF Alarm function will operate when triggered at programmed Alarm Set Point 1 888080 Alarm function will only operate once the programmed time has elapsed after the alarm was triggered by the Alarm Set Point 21 Ate Alarm 2 function Select GFF Lo Hs H Lo SF Gt or SF amp t Factory default is Lo OFF Alarm 2 is disabled No Alarm 2 menu items appear in the Secondary or Secure menus Lo Low Alarm Only Reto appears in the Secondary Menu Hs High Alarm Only ARCH appears in the Secondary Menu Hito High and Low Alarms Both Reto and ReH appear in the Secondary Menu and share the same Alarm 2 Relay output SF Seal Failure ONLY will trigger Alarm t Over Temperature Failure ONLY will trigger Alarm SF t Both Seal Failure and Over Temperature Failure will trigger Alarm With the Alarm Function settings on GFF SF Gt SFOt certain alarm related menu items
6. OFF Alarm Inhibit is GFF Setpoint 2 Time Delay Select from 0 to 60 seconds Factory default is 0 This will set a time delay for setpoint 2 on power up of the MPC that will assure that setpoint 2 will not be brought into use until after the programmed time delay The Peak feature stores the highest input the control has measured since the last reset or Power On At Power On PEA is reset to the present input To manually reset the value PEA must be in the lower display Press ne ENTER key to reset PEA will be reset and display the present input value The Valley feature stores the lowest input the Controller has measured since the last reset or Power On At Power On UAL is reset to the present input To manually reset the value URL must be in the lower display Press the Coa ENTER key UAL will be reset and display the present input value 19 ALARM TYPE AND ACTION Caution In any critical application where failure could cause expensive product loss or endanger personal safety a redundant limit controller is required When setting an alarm value for an absolute alarm A it R55 or Act fibS simply set the value at which the alarm is to occur When setting the alarm value for a deviation alarm A it dE or Aet dE set the difference in value from the Set Point SP iH desired Since the input for the MPC is driven from a transmitter the input display can be programmed in different ways Regardless of the position of the deci
7. automatic or manual reset D r9 3p DOO POL gt X 25 D r 8 E Li A T lt E E a 2 2 E E la E i car a uu ar V DR Mo My oe O c3 c ni Da x Set Point High value default is in feet Set Point Low value default is in feet DEF Set Point 1 Power Interrupt selectable on or off GEF Set Point 1 Inhibit selectable on or off SiH Sor ree ES Point 2 Power Interrupt Selectable on or E Peak highest input value seen since last reset n n Lu n Valley lowest input value seen since last reset 30 EXAMPLE PROGRAMMING CHART continued SetAt Description amp Ha Alarm 1 Function selectable off lo hi hilo sf ot or sfot Alarm Type 1 selectable abs absolute mo mix RE i MR Str QaQE GaGF Alarm 1 Reset selectable onof auto or hold manual ae art cae a oe MA 1 Power Interrupt selectable on or off GEE Alarm 1 Inhibit Alarm 1 Inhibit selectable on or off on or off Alarm 1 Output State selectable close or open Gon flan Alarm 1 Lamp condition when contact is closed selectable on or off Secure NEF GEF Alarm 1 Time Delay selectable off or 1 to 8000 seconds fke ate to Lo Alarm2 function selectable off lo hi hilo sf ot or sfot Ed cuc e 445 Alarm 2 Type selectable abs absolute or de deviation em SaG Alarm 2 Reset selectable onof auto or hold manual A
8. should be made in accordance with the National Electrical Code per Article 300 and local regulations All line voltage output circuits must have a common disconnect and be connected to the same pole of the disconnect Input wiring for probe or transmitter is rated CLASS 2 Control wiring is as shown in Figure 2 below Figure 2 Wiring Pump 1 Over Tem Analog Retransmission p p Pump 2 Over Temp 24 VDC Voltage 9 O 50 mA Current Isolated Pump 1 Seal Output Sensor Inputs Pump 2 Pump 2 Alarm 1 Output Contacts Alarm 2 Contacts NOTES 1 For supply connections use 100 ao n No 16 AWG or larger wires rated i f 167 F 75 C s 400 Hz Single PH or at least 167 F Uo or In 132 to 240 VDC 5VA accordance with an equivalent HE national standard _ Max Output Ratings 2 Maximum ambient temperature Relay HP iD ie rating 131 F 55 C 1 3 HP 240 VAC 3 Use copper conductors only 1 z Alarm 3A 9 240 VAC Res 4 Terminals 1 6 11 12 21 32 1 10 HP 120 VAC are class 2 SELV 290 3120 If not using pump over temperature inputs then jumper terminals 22 to 23 and 22 to 24 WIRING FOR TRANSMITTER INPUTS USING INTEGRAL POWER SUPPLY Wire power and outputs as shown on previous page Wiring for two wire transmitters shown below in Figure 3 All wiring shown in Figure 3 is Class 2 Figure 3 Transmitter Wiring Connect Transmitter Plus to terminal 11 1
9. Bulletin L 20 Series MPC Pump Controller Installation and Operating Manual SETPOINT I II d PUMP CONTROLLER MN Mero CE n MERCOID M A Division of Dwyer Instruments Inc LISTED I rcoid P O BOX 258 MICHIGAN CITY INDIANA 46361 U S A Db Phone 219 879 8000 Fax 219 872 9057 www dwyer inst com e mail lit dwyer inst com FR M1 443247 00 Rev 4 CONTENTS DIMENSIONS acy Re oT stes s osi Eh oo S ACA Deas e dus es dai e Crea d du 1 Specifications cio px dee ede epe edere RR ad Rh dee Be Pe dee qe 2 Getting Started ar ereceneR A RE anew ROS disi Sida es 3 Model Identification ee seme peru ek tee e ex red bx pun aed 3 Installation s ieu urbe Xue E dole weld SHS ES ee oe oes rp EE na 4 WIKINGs uinum buceo hate PIS X aoe eee whee PC Ib epis pede eee d 5 7 Front Panel FUNCIONS 22 52 eee t E rem ERR pede pe iR De e Uns 8 9 Home DISplay xou epe ERE EROR EV o aded ox edat cb WA os o oa kat aee 9 Security Level Selector 592a dit naye Ede t E A E on aes 10 Lead Lag Operation exuta e bare do trek ia haces 11 Seal Failure Operations s Me ae ye once e port doped EA eee 11 12 Over Temperature Operation eux bsec ERG RUE SER ademas iud ue aas 12 13 Analog Retransmission Operation o ooooocccccco eh 13 Pump Run Time Operation zei besii resce piegi ranega tetas 13 Serial Communication Operation oocooccocccoc nh 14 Menu Selections zu Rte eR SETA A Xoo Ree E FERE o eue i 15 Secon
10. ER key to reset If pump 2 seal failure is still in the fail condition then the control will not reset If the seal failure input is no longer in fail condition then the display will revert to Pump 1 Reset for Over Temperature Displays when pump 1 is in normal operating condition based on temperature input Displays FA it if pump 1 has met the condition of over temperature Press the ue ENTER key to reset If pump 1 temperature input is still in the fail condition t he control will not reset If the temperature input is no longer in fail condition then the display will revert to Pump 2 Reset for Over Temperature Displays when pump 2 is in normal operating condition based on temperature input Displays FA it if pump 2 has me the condition of over temperature Press the ENTER key to reset If pump 2 temperature input is still in the fail condition then the control will not reset If the temperature input is no longer in fail condition then the display will revert to 16 Secure Menu Press the INDEX key for 5 Seconds to start the menu Press K i INDEX to advance to the next menu item Press UP ARROW or DOWN ARROW to change the value in the display Press ENTER to retain the value OUTPUTS ARE DISABLED TURNED OFF WHILE CONTROL IS IN THE SECURE MENU SEC SCRH SEAL dPt Se5t Ldt8 laPC Security Code See the Security Level Selection and the Password Table on page 10 in o
11. INTO OPERATION The following menu items apply only to the alarms AL Alarm 1 function Select OFF Lo H or H Lo Factory default is H OFF Alarm 1 is disabled No Alarm 1 menu items appear in the Secondary or Secure menus Lo Low Alarm Only A ito appears in the Secondary Menu 20 Hi High Alarm Only A iH appears in the Secondary Menu H Lo High and Low Alarms Both A to and A iH appear in the Secondary Menu and share the same Alarm 1 Relay output SF Seal Failure ONLY will trigger Alarm Ge Over Temperature Failure ONLY will trigger Alarm SF t Both Seal Failure and Over Temperature Failure will trigger Alarm With the Alarm Function settings on OFF SF Gt SF amp t certain alarm related menu items will disappear as those menu items do not apply Rit RIP A ILP A itd Alarm 1 Type Select 465 or dE Factory default is AbS R55 Absolute Alarm that may be set anywhere within the values of S AL and SCAH and is independent of SP iH dE Deviation Alarm that may be set as an offset from SP iH As SP iH is changed the Alarm Point will track with SP iH Alarm 1 Reset Select 8n8F or Hold Factory default is GaGF GnGF Automatic Reset Hoid Manual Reset Reset acknowledge by simultaneously pressing the INDEX amp EA DOWN ARROW keys for 5 seconds Alarm 1 Power Interrupt Select Un or GFF Factory default is OFF En Alarm Power Interrupt is n CFF Alarm Power Interrupt is OFF Alarm 1 Inhibit Select
12. ON 123456 123456 1 DCD c 2 RECEIVE 27 28 31 3 TRANSMIT 4 DTR 5 GROUND 6 DSR 7 RTS 8 CTS Terminal 29 30 31 32 Option 485 Y receive Z receive A transmit B transmit Option 232 not used data out data ground data in For half duplex operation wire only A and B Do not connect to Y and Z FRONT PANEL FUNCTIONS Alarm Lamps Pump 1 PRESENT LEVEL Pump 1 Seal On Lamp P1 Failure Lamp Pump 2 Pump 2 Seal On Lamp z Failure Lamp Level Pump 1 Over Display Temperature Lamp 1st Set Point SETPOINT Pump 2 Over Display GT Temperature Lamp se C2 LS Test Pump Run Lamp r Time Lamp Mercoid PUMP CONTROLLER a pl Key functions are as follows INDEX Pressing the Gap INDEX key for 2 seconds will bring up the Secondary menu starting at the 5P iH menu item Holding the key for 5 seconds will bring up the Secure menu starting with the menu item 5 tr Once in the menus pressing the INDEX key advances the display to the next menu item May also be used in conjunction with other keys as noted below t SYSTEM TEST When Test menu item is On depressing this key for three seconds will make the MPC Pump Controller go through a system test See page 18 for explanation of system test function F UP ARROW Increments a value changes a menu item or selects the item to ON The maximum value obtainable is 9999 regardless of decimal point placement DOWN ARROW Decrements a value changes a menu
13. ROGRAMMING CHART 60 Set Point 1 value default is in feet RN a Set Point 1 off value default is in feet Set Point 2 value default is in feet Set Point 2 off value default is in feet a RD 35 pu r a nu D PS copak Es pes pn n Lm e Se es Po Dies Rea li eu e ud E H D r at G E Secondary Pin MEM Total ON Time for Pump 1 in HOURS since last reset rn Total ON Time for Pump 2 in HOURS since last reset _ Pump 1 Reset for Seal Failure or FAIL _ Pump 2 Reset for Seal Failure or FAIL Pump 1 Reset for Over Temperature or FAIL Pump 2 Reset for Over Temperature or FAIL 29 ID X no LN 2n Mm n is 4 me E pa pa 2 c m L A 1 aa PU e y M n n no Mio a Sy Pr n X t Y l D Mo ca re EXAMPLE PROGRAMMING CHART continued pes T et D eee Security Selection c 2 i Scale High value default is in feet at Low value default is in feet Decimal Point Decimal Point Positioning ESI el Point 1 State selectable POut Pumping Out or PIn Pumping In Set Point 2 State selectable POut Pumping Out PIn Pumping or off FE Input eS F SUP pam Input selectable A or EDS NCC Pump Over Temperature controller action selectable automatic or manual reset RUEGO Pump Seal Failure controller action selectable
14. Run Time to be reset Set Point High Select from the highest input range value to 5 t value This will set the maximum SP iH or SPeH value that can be entered The value for SP iH or P2H will stop moving when this value is reached Factory Default is 23 Set Point Low Select from the lowest input range value to SPH value This will set the minimum P it or SPet value that can be entered The value for SP IL or SPet will stop moving when this value is reached Factory Default is 8 8 Setpoint 1 Power Interrupt Select Go or GFF Factory default is OFF En Alarm Power Interrupt is Go Output will automatically reset on power up if no alarm condition exists OFF Alarm Power Interrupt is OFF Output will be in the alarm condition on power up regardless of condition of process Setpoint 1 Inhibit Select Go or GFF Factory default is GFF En Alarm Inhibit is Go Alarm action is suspended until the process value first enters a non alarm condition CFF Alarm Inhibit is GFF Setpoint 2 Power Interrupt Select Go or GFF Factory default is OFF Gn Alarm Power Interrupt is Ge Output will automatically reset on power up if no alarm condition exists OFF Alarm Power Interrupt is OFF Output will be in the alarm condition on power up regardless of condition of process Setpoint 2 Inhibit Select Go or GFF Factory default is GFF Ga Alarm Inhibit is n Alarm action is suspended until the process value first enters a non alarm condition
15. This number must match the baud rate used by the host computer Factory default is 9660 nfit Option 232 or 485 Serial Communications No Activity Timer Set from GFF or to 99 minutes Factory default is OFF 1 99 Maximum time between host computer accesses If timer counts to 0 CHET LOrE will be displayed OFF No Activity Timer function is disabled Stor Option 232 or 485 Serial Communications Store to EEPROM Select YES or no YES Menu item changes made through serial communications are stored directly to EEPROM no Menu item changes made through serial communications are stored in RAM Settings are lost if power is disconnected 23 DIAGNOSTIC ERROR MESSAGES Display Meaning SP Outputs Action Required No display lighted Display is blank Instrument is not getting power or the supply voltage is too low Set point outputs inactive Alarms inactive Check that the power supply is on or that the external fuses are good FRI tESt Fail test appears upon power up if the internal diagnostics detect a failure This message may occur during operation if a failure is detected Displays flash Set point outputs inactive Alarms inactive The display alternates between FA it t St and one of the following messages FACE dFLE Memory may be corrupted Press the ENTER key and the DOWN ARROW key to start the factory default procedure Recheck controller programming c t FRCt Unrecov
16. agree with an external reference or to compensate for sensor error Note inP is reset to zero when the input type is changed or when decimal position is changed 17 GsuP PGE PSE tESt Zero Suppression Select Un or GFF Factory default is Un OFF The input range will start at O zero Input En The input range will start at 4 00 mA or 2 00 V Input Type Select one of the following Refer to the Input wiring section for the proper wiring Factory Default is Curr Cure DC Current Input 0 0 to 20 0 or 4 0 to 20 0 mA UoLt DC Voltage Input 0 0 to 10 0 or 2 0 to 10 0 volts Reserved Pump Over Temperature Select RUEO or c 5 When pump temperature sensor indicates that there is an over temperature condition the pump will be held out of service and the corresponding pump over temperature lamp is lit on the controller If using the MPC with two pumps and lead lag on then the remaining pump becomes the lead pump If lead lag is turned off then the remaining pump becomes controlled by Set Point 1 See page 12 AUtG X The pump will be automatically placed back into service and the lamp turned off when the over temperature condition has ceased rES The pump will remain out of service and the lamp lit until the corresponding manual reset P 8 or POB is reset in the Secondary menu The pump cannot be brought back into service until the over temperature condition has ceased Pump Seal Failure Select AVEG or c 5 See page 11 Rut
17. are generated The displayed value will stop at an allowable point just above or below as the case may be the maximum or minimum allowed In normal operation when the 5 iH point is reached one of the pumps will turn on When lead lag is turned on pumps 1 and 2 will alternate If the level reaches the SPeH point both pumps will be turned on until the S Pet point is reached where one of the pumps will turn off When P iL is reached remaining running pump will turn off The last pump off will not be the next pump on Lead Lag Off If lead lag is turned off SP IH and SP control pump 1 and P2H and SPet control pump 2 There is no alternating function SEAL FAILURE OPERATION The Mercoid MPC Pump Controller is designed to work with most types of submersible pump moisture sensors to detect outer seal failure Most often the moisture sensor is a conductance device that detects moisture in the oil chamber indicating an outer seal failure Using a 2 5 VDC power supply sent to the moisture sensor the MPC Pump Controller monitors the resistance between the probe lead wires or the single probe lead wire and ground The resistance set point is adjustable over the range of 10K to 500K ohms adjustable in 10K ohm steps and is set with Secondary menu items 5F5 and SF528 When the resistance of the moisture sensor decreases below the resistance set point the MPC controller goes into the programmed seal failure mode 11 In the Secure menu the val
18. ckup Nonvolatile memory no batteries required Serial Communications Optional RS 232 or RS 485 with Modbus protocol Ambient Operating Temperature RH 14 to 131 F 10 to 55 C 0 to 90 up to 104 F 40 C non condensing 10 to 50 at 131 F 55 C non condensing Weight 16 oz 454 g Front Panel Rating Meets UL Type 4X IP66 Loop Power Supply isolated 24 VDC 50 mA regulated Seal Failure Moisture Sensor Power Supply to Moisture Sensor 2 5 VDC Search Current 3 micro amps Resistance Sensitivity 10K to 500K ohms Resistance Resolution 10K ohm steps Over Temperature Input Dry contact on Transistor switch NPN open collector type Current 1 mADC Isolation Shares common ground with transmitter input Alarm On Off Differential 1 count Set Point Range Selectable Power Voltage Stability 0 05 over the power voltage range Temperature Stability 100 ppm C typical 200 ppm C maximum Common Mode Rejection 140 db minimum at 60 Hz Normal Mode Rejection 65 db typical 60 db at 60 Hz Isolation Relay 1500 VAC to all other inputs and outputs 24 VDC Loop Power 500 VAC to other inputs and outputs Process Output 500 VAC to other inputs and outputs Seal Failure Input 500 VAC to other inputs and outputs Storage Temperature 40 to 176 F 40 to 80 C Agency Approvals UL 508 CE Modbus is a registered trademark of Schnieder Automation GETTING STARTED 1 Install the control as described
19. d time has elapsed after the alarm was triggered by the Alarm Set Point 22 Fat Digital Filter Select GFF or to 99 In some cases the time constant of the sensor or noise could cause the display to jump enough to be unreadable If this value is set too high controllability will suffer Factory default is 3 POH Analog Retransmission Output see page 13 Process Output High Select from any value greater than POL to 9999 counts Factory default is 23 1 POL Analog Retransmission Output see page 13 Process Output Low Select 1999 counts to any value less than P amp H Factory default is 2 2 The remaining menu items appear if the corresponding option was purchased with the control LOr Option 232 and 485 Serial Communications Local Remote Status Select LOC or c Factory default is rE LOC The host computer is advised not to send remote commands Any write commands sent to the controls will be rejected rt The host computer is allowed to send write commands If the control is not addressed within the time set in the aft No Activity Timer see Secure Menu the CHEE LOrE error message will be displayed Addr Option 232 or 485 Serial Communications Control Address Set from to FF This number hexadecimal base 16 must match the address number used by the host computer Factory default is 38 bad Option 232 or 485 Serial Communications Communication Baud Rate Select 388 i288 2488 4860 9688 or 9288
20. dary Men sedes p ERR eds rey esee EXbpbpe E EE 15 16 Secure Menu exse ee REDE e rdc iom get UB Rh LR 17 23 Alarm Type and Action cessio e pr RR ERE 3 E Eee a Ea 20 22 Diagnostic Error Messages ocio dira ER SERI IE Edu Pact cedes 24 25 Programming Chait si xen ipae RE E eue Que sor Rus d os ears ER d 26 28 Programming Example hu Rea oen Re eI arem ea s 28 31 DIMENSIONS 4 500 3 774 95 9 MPC PRESENT LEVEL Gc aa ED UB a ED 3E ml 3 774 we 91 3 mm 95 9 E SETPOINT En ean SYSTEM Mercojd PUMP CONTROLLER Y Panel cut out 3 620 x 3 620 in 0 032 0 000 92 x 92 mm 0 8 0 0 Allow for 0 5 in 13 mm clearance at the rear of the instrument yo Panel Thickness 0 250 6 53 mm Max Meets IP66 UL Type 4X SPECIFICATIONS Inputs 4 to 20 mA DC or 2 0 to 10 0 V DC selectable Input Impedance Current input 10 ohms Voltage input 100K ohms Output Ratings Control Relays SPDT rated 10A 240 VAC res 1 4 hp 120 VAC 1 3 hp Q 240 VAC Alarm Relays SPST 3A 240 VAC res 1 10 hp 120 VAC Control Type on off reverse or direct acting Power Requirements 100 to 240 VAC nominal 1096 1596 50 to 400 Hz single phase 132 to 240 VDC nominal 10 15 Power Consumption 7 5 VA maximum Accuracy 0 25 of span 1 least significant digit Display Two 4 digit 7 segment 0 56 high LED s Display Resolution 1 count Memory Ba
21. e When pump moisture sensor indicates that there is a seal failure condition the corresponding pump seal failure lamp is lit on the controller The pump will remain in service with only the lamp indication of failure The lamp will automatically turn off when failure condition ceases rES When pump moisture sensor indicates that there is a seal failure condition the corresponding pump seal failure lamp is lit on the controller If the MPC is being used with two pumps and the lead lag feature turned on then the failed pump will automatically become the lag pump the remaining pump the lead pump and the alternation discontinued The seal failure action is reset manually with the values of P SF and PeSF in the Secondary menu The control will only reset if the pump moisture sensor is no longer in a failed condition System Test Select Bn or GFF When Un is selected the System Test key on the front panel will be activated By depressing this key for 3 seconds the controller will simulate an input from SEAL to SERH and back to SCRL over a period of 32 seconds This test will run continuously until the SYSTEM TEST key is pressed again When the controller is in System Test Mode the lamp above the System Test Key will be ON 18 PcSt SPH SPL SiH SeP Se H Set PER UAL Pump Run Time Reset Select n or GFF Selecting 8a will allow Pump Run Time to be reset in the Secondary menu while an 8FF selection will not allow Pump
22. e corresponding manual reset P iUt or PeGt is reset in the Secondary menu described in the next paragraph The pump cannot be brought back into service until the over temperature condition has ceased Once the pump has cooled down the MPC Pump Controller can be reset with the values of P iUt and Peat in the Secondary menu The item P 8 or PeGt will display FA it if the pump has met the condition of over temperature Press the Co ENTER key to reset If the pump temperature sensor is still in the fail condition then the control will not reset If the temperature input is no longer in the fail condition then the display will revert to 12 ANALOG RETRANSMISSION OPERATION The analog retransmission allows the Process Variable to be sent as an analog signal to an external device The signal may be either 2 to 10 VDC option RV or 4 to 20 mADC standard The output may be changed in the field from one to the other by the toggle Switch located on the top printed circuit board factory standard is mADC Wire the output as shown on page 5 To set up the analog retransmission first determine the scale range that the analog signal will represent The maximum scale is 9999 counts In the Secure menu set P amp L for the scale value that will be represented by the low end of the analog signal 2 Volts or 4 mA Set P amp H for the scale value that will be represented by the high end of the analog signal 10 Volts or 20 mA Operation is automatic
23. emperature shock or vibration see Specifications for specific tolerances All models are designed for mounting in an enclosed panel Select the position desired for the instrument on the panel Prepare the panel by cutting and deburring the required opening From the front of the panel slide the housing through the cut out The housing gasket should be against the housing flange before installing From the rear of the panel slide the mounting collar over the housing Hold the housing with one hand and using the other hand push the collar evenly against the panel until the springs are compressed The ratchets will hold the mounting collar and housing in place Figure 1 Panel Cut Out Dimensions Panel cut out 3 620 x 3 620 in 0 032 0 000 92 x 92 mm 0 8 0 0 CAUTION It is not necessary to remove the instrument chassis from the housing for installation If the instrument chassis is removed from the A housing you must follow industry standard practice for control and protection against Electro Static Discharge ESD Failure to exercise good ESD practices may cause damage to the instrument WIRING Do not run transmitter wiring or other class 2 wiring in the same conduit as power leads Use only the probe or transmitter for which the control has been programmed Maintain separation between wiring of sensor auxiliary in or out and other wiring See the Secure Menu for input selection Supply connections
24. erable error return to factory for service This message appears if the Serial Communications has timed out Set point outputs active Alarms inactive 24 Restore the communications line and switch the Lor to Lac DIAGNOSTIC ERROR MESSAGES Display Meaning SP Outputs Action Required UFL or GFL Underflow or Overflow Process value has exceeded input range ends Set point outputs active Alarms active Input signals may normally go above or below range ends If not check input and correct CHEC CAL RrER Alternates with PV Check calibration appears as an alternating message if the instrument calibration nears tolerance edges Check calibration appears as a flashing message if the instrument calibration exceeds specification This message appears if the ambient temperature of the control approaches the ends of tolerance This message appears if the ambient temperature of the control is out of range or RJC sensor is broken Set point outputs active Alarms active Set point outputs inactive Alarms active Set point outputs active Alarm active Set point outputs active Alarms active 25 Remove the instrument for service and or recalibration To reset use the INDEX amp ENTER keys Remove the instrument for service and or recalibration To reset use the INDEX amp ENTER keys Correct the ambient temperature condition
25. et Point 2 State selectable POut Pumping Out PIn Pumping In or off D p Wis wm 2 rept n as E rr Secure L Ly DT P b AS aa n Lu Lead Lag selectable on or off Input Correction Zero Suppression selectable on or off Input selectable current or voltage ERR Pump Over Temperature controller action selectable automatic or manual reset 26 Menu item Default SetAt Description amp EN c EN Eat Aute selectable automatic or manual reset t st do System Test Selectable on or off 3 Pump Run Time Rest Selectable on or off Set Point High value default is in feet selectable on or off Set Point 2 Power Interrupt Valley lowest input value seen since last reset Alarm 1 Function selectable off lo hi hilo sf ot or sfot Alarm Type 1 selectable abs absolute or de deviation Alarm 1 Reset selectable onof auto or hold manual Alarm 1 Power Interrupt selectable on or off Alarm 1 Inhibit selectable on or off Alarm 1 Output State selectable close or open Alarm 1 Lamp condition when contact is closed selectable on or off Alarm 1 Time Delay selectable off or 1 to 8000 seconds or de deviation hold manual Alarm 2 Power Interrupt selectable on or off Alarm 2 Inhibit selectable on or off Alarm 2 Output State selectable close or open Alarm 2 Lamp condition when contact i
26. he input from the pump moisture sensor The controller will activate the Seal Failure condition based on a decrease of resistance to the set point Selectable resistance range is from 10K to 500K ohms with the factory default at 120K ohms SFS2 Pump 2 Seal Failure Set Point Select 10 to 500 in any increment of 10 Sets the resistance set point at which the controller will trip the Seal Failure based on the input from the pump moisture sensor The controller will activate the Seal Failure condition based on a decrease of resistance to the set point Selectable resistance range is from 10K to 500K ohms with the factory default at 120K ohms 15 Pesr P ide Pot Pump 1 Run Time Total ON Time for Pump 1 in HOURS since last reset 0000 9999 hours Pump 2 Run Time Total ON Time for Pump 2 in HOURS since last reset 0000 9999 hours Pump 1 Reset for Seal Failure Displays when pump 1 is in normal operating condition based on seal failure input Displays FA it if pump 1 has met the condition of a seal failure Press the ENTER key to reset If pump 1 seal failure is still in the fail condition then the control will not reset If the seal failure input is no longer in fail condition then the display will revert to Pump 2 Reset for Seal Failure Displays when pump 2 is in normal operating condition based on seal failure input Displays FA it if pump 2 has met the condi tion of seal failure Press the Er ENT
27. itch is located on the communications board plugged into the center of the bottom board of the control Select the control address and communication baud rate with the Addr and bAUd menu items in the Secure Menu THE BAUD RATE AND ADDRESS MENU ITEMS WILL TAKE EFFECT ON THE NEXT POWER UP OF THE CONTROL BE SURE TO POWER CYCLE THE CONTROL BEFORE USING THE NEW BAUD RATE AND ADDRESS In operation you have the option of preventing a write command from the host computer To prevent the host from writing to the control change the t8r menu item in the Secondary Menu to LGC To allow the host to write commands to the control set L rE to c The host does have the ability to change the L amp r state but it is not automatic If your system depends on constant reading or writing to and from the host you may wish to set the No Activity Timer aRt to monitor the addressing of the control When the t r is set to rE and the oft is set to any value other than GFF the control will expect to be addressed on a regular basis If the control is not addressed in the time set by the value of nft then the control will display the error message CHEC Lor To clear the message set LGrE to LOC 14 MENU SELECTIONS Notation Conventions for the Menus Because of the number of features available in this control information is included that may not apply to your specific control All usable features are included in this book but may not be used in your pr
28. item or selects the item to OFF The minimum value obtainable is 1999 regardless of decimal point placement ENTER The Co ENTER key is used to store the value of menu items once they are changed to a new value If the 353 ENTER key is not pressed after changing the value the item will revert to the previously stored value RUN PUMP RUN TIME Pressing this key will cause the MPC Pump Controller to display the total run time in hours that the pump s have been on since the last reset EA INDEX amp DOWN ARROW Pressing these keys simultaneously will allow backing up one menu item or if at the first menu item they will cause the display to return to the primary menu If an alarm condition has occurred these keys may be used to reset the alarm Ca INDEX amp ENTER Pressing these keys simultaneously and holding them for 5 seconds allows recovery from the various error messages The following menu items will be reset ALH Alarm inhibit CHEC CAL Check calibration error Correct the problems associated with the above conditions before using these reset keys More than one error could be present Caution is advised since several items are reset at one time THE HOME DISPLAY The home display is the normal display while the control is operating If no errors or functions are active the HOME display will indicate the Process Variable the level that is being measured on the top display and the 5 iH value Pump 1 On Set Point on the bo
29. mal point a change of one in the right most digit is referred to as a count For example if there were no decimal point selected a change from 235 to 236 is a change of one count If the decimal point were selected at 8 8 a change of 23 5 to 23 6 is a change of one count When setting up an alarm for deviation the deviation is set in counts For example if a low alarm is required to be 5 counts below the SP iH then set A to to 5 If a high alarm is required 20 counts above the SP iH then set A H to 20 If SP 1H is changed the alarm will continue to hold the same relationship as originally set When Alarm Power Interrupt A P is programmed ON and Alarm Reset R r is programmed for Hold the alarm will automatically reset upon a power failure and subsequent restoration if no alarm condition is present If Alarm Inhibit 8 H is selected ON an alarm condition is suspended upon power up until the process value passes through the alarm set point once Alarm inhibit can be restored as if a power up took place by pressing both the ES noex and 73 ENTER keys for 5 seconds WARNING IF INHIBIT IS ON AND A POWER FAILURE OCCURS DURING A HIGH ALARM RESTORATION OF POWER WILL NOT CAUSE THE ALARM TO OCCUR IF THE PROCESS VALUE DOES NOT FIRST DROP BELOW THE HIGH ALARM SETTING DO NOT USE THE ALARM INHIBIT FEATURE IF AHAZARD IS CREATED BY THIS ACTION BE SURE TO TEST ALL COMBINATIONS OF HIGH AND LOW ALARM INHIBIT ACTIONS BEFORE PLACING CONTROL
30. ocess To increase clarity the following conventions are used 1 Certain features or functions shown in this book are contextual This means that Menu Items may or may not appear depending on other Menu Item selections Whenever this occurs a notation is made in the Menu Item that controls or directs other menu items If you are looking for a particular menu item and can t find it check the menu item that is its control for proper setting 2 The symbol is used in two ways It is used inside a group of characters to indicate which set point function SP1 or SP2 is being affected It is also used before a group of characters of a menu item to indicate that there may be more than one selection or value for that menu item Secondary Menu Press the 23 INDEX key for 2 seconds to start the menu Press INDEX to advance to the next menu item Press ES UP ARROW or A DOWN ARROW to change the value in the display Press JENTER to retain the value SP iH Pump 1 On Set Point Factory Default 23 feet SP iL Pump 1 Off Set Point Factory Default 8 8 feet SP2H Pump 2 On Set Point Factory Default 22 feet SPeL Pump 2 Off Set Point Factory Default 2 8 feet Aix Alarm 1 High Factory Default 23 feet Reto Alarm 2 Low Factory Default 2 8 feet SES 1 Pump 1 Seal Failure Set Point Select 10 to 500 in any increment of 10 Sets the resistance set point at which the controller will trip the Seal Failure based on t
31. on page 4 2 Wire the control following the instructions on pages 5 through 7 Page 5 contains basic wiring for the control If using the Series MPC s transmitter power supply follow the additional directions on page 6 Wiring instructions for the 232 and 485 series communication options is included on page 7 3 Familiarize yourself with the front key pad functions and read the menu structure prior to starting the programming process A programming chart with the menu structure and spaces to write your programming values is included on pages 26 through 28 This chart can be a helpful tool to save time in programming For further assistance programming examples are included on pages 28 through 31 MODEL IDENTIFICATION Model MPC Options Options RS 232 Modus RTU Serial Communications Allows remote computer to read and write all control parameters RS 485 Modbus RTU Serial Communications Allows remote computer to read and write all control parameters Analog retransmission of input 2 to 10 VDC Input Ranges Process Input Types The 0 to 20 mADC 4 to 20 mADC 0 to 10 VDC and 2 to 10 VDC inputs are fully scalable from a minimum of 100 count span placed anywhere within the range of 1999 to 9999 Decimal point position is adjustable from the zero place 9999 tenths 999 9 hundredths 99 99 or thousandths 9 999 INSTALLATION Mount the instrument in a location that will not be subject to excessive t
32. rder to enter the correct password Factory Default is 4 Scale High Select 188 to 9999 counts above SCRL The total span between SCRL and SCRH must be within 11998 counts Maximum setting range is 999 to 9999 counts Factory Default is 23 Scale Low Select 188 to 9999 counts below SCAH The total span between SCAL and SCRH must be within 11998 counts Maximum setting range is 999 to 9999 counts Factory Default is 8 8 Decimal Point Positioning Select 6 0 8 08 or 6 6868 All Menu items related to the input will be affected Factory default is 8 8 Set Point 1 State Select P tn or POut Factory default is P ut Pin Pump In Direct Action As the input increases the output will increase PGut Pump Out Reverse Action As the input increases the output will decrease Set Point 2 State Select P tn POut or GFF Factory default is PGut Pin Pump In Direct Action As the input increases the output will increase P ut Pump Out Reverse Action As the input increases the output will decrease GFF This setting is for applications when the MPC is used with only one pump systems All Menu items relating to Set Point 2 will not appear Lead Lag Select n or GFF Factory default is Un See page 11 Gn The Lead Lag function is enabled The outputs of 5P and P will alternate OFF The Lead Lag function is disabled Input Correction Select 500 counts This feature allows the input value to be changed to
33. s Ventilate the area of the cabinet or check for clogged filters If RJC broken return to factory for service Correct the ambient temperature conditions Ventilate the area of the cabinet or check for clogged filters If RJC broken return to factory for service PROGRAMMING CHART Use the charts on this and the next page to record the values in your application You may want to photocopy the pages if you plan to make programming changes Set At Home Position Process Variable amp SP1H s Value displayed Set At Set Point 1 value default is in feet u D I ar E Zalo c ca 2 Set Point 1 off value default is in feet Set Point 2 value default is in feet wm n a na zc ua RT Set Point 2 off value default is in feet uu D o po m uM q LI I Li 1 L I D X aia Y Gn zn X a O BLA dE nt px EA ES E Ooo i OO Total ON Time for Pump 1 in HOURS PR E E y y DR ly Ue Secondary n al ig e ltlu since last reset Pump 1 Reset for Over Temperature or FAIL Pump 2 Reset for Over Temperature or FAIL alo nul Ua Py sls pa z lo n Ed Set At wm an 73 un n e Lay ej i l ey V zm po 23 mw Decimal Point Positioning Set Point 1 State selectable POut Pumping Out or PIn Pumping In p o S
34. s closed selectable on or off Alarm 2 Time selectable Off or 1 to Digital Filter Process Output High default is in feet 27 a pal A S n i Ly mx Ln D n rule a es cap m n 55 n 7 pu M zc M 0 Ton rey Iyar ES Ze rt za ES or c2 Ic 38 Af c on n 7n mE e a m emm L3 Fag iz 2 M n A a s i z 4 c Depa Dba tao ming 00 Y D n i mU lal 2 a js a o c3 A 9 3 Id e EN ES Ji y YD ES a VL zo at 20 an M VUL CUA zb o an c3 y wy O EJ 20 20 im L m 7 o gt ed E o a 3 UE a zm no Es D r3 5 q i UN ns a RID Process Output Low default is in feet communications Secure communications I communications selectable yes or no 28 PROGRAMMING EXAMPLE Example Keep Empty two pump duplex Depth 25 feet Pump 1 Start at 6 feet A Stop at 3 feet Pump 2 Start at 12 feet Stop at 9 feet Low level alarm 1 foot fixed auto reset Start 2 High level alarm 20 feet fixed auto reset Stop 2 P Want Lead Lag function on Start 1 Automatic reset of pump Stop 1 over temperature and seal PBLT or Level Transmitter failure Low level TO Alarm No communication options Want 4 20 mA retransmission Using with a 4 20 mA input EXAMPLE P
35. till in the fail condition then the control will not reset If the moisture sensor is no longer in the fail condition then the display will revert to OVER TEMPERATURE OPERATION Most pumps have an installed normally closed thermostat for over temperature protection of the pump The thermostat has a preset value from the pump manufacturer at which point the pump needs to be shut down The Mercoid MPC detects when the thermostat signal changes to open and shuts down the pump In the Secure menu the value of PGt is programmed for the action of the MPC based on the condition of the over temperature When the pump temperature sensor indicates that there is an over temperature condition the pump will be held out of service and the corresponding pump over temperature lamp is lit on the controller If using the MPC with two pumps with the lead lag function turned on then the failed pump will automatically be taken out of service the remaining pump will become the lead pump and the alternation will be discontinued When controlling two pumps with the lead lag function off the failed pump will automatically be taken out of service and the remaining pump will be controlled by the 8 iH and S it set points If POE is set to RULE then the pump will be automatically placed back into service and the lamp turned off when the over temperature condition has ceased If set to c 5 then the pump will remain out of service and the lamp lit until th
36. ttom display Error messages may over ride the HOME display See ERROR MESSAGES on pages 24 and 25 While in the Secondary Menu if no key is pressed for a period of 30 seconds the display will return to the HOME position displaying the process value While in the Secure Menu if no key is pressed for a period of 60 seconds the display will return to the HOME position displaying the process value Outputs are disabled turned off when the Secure Menu is active SECURITY LEVEL SELECTION Three levels of security are provided The SEC menu item security level may be viewed or changed at any time regardless of the present security level in the Secure menu The display shows the current security level To change security levels change the password value using the a UP ARROW or B3 DOWN ARROW keys and pressing the ENTER key Refer to the password table following for the correct value to enter for the security level desired To set the access level to for example at the SEC menu item press the UP ARROW key until the upper display shows the password 18 Press the ENTER key The display will blink and return with the level value e in the upper display The password values shown in the table cannot be altered Retain a copy of these pages for future reference This is the only reference made to password values in this instruction book Password Table Security Level Displayed Value Password Menu Status When Viewed Value To
37. ue of PSF is programmed for the action of the MPC based on the condition of a seal failure If set to RUEG when pump moisture sensor indicates that there is a seal failure condition then the corresponding pump seal failure lamp is lit on the controller The pump will remain in service with only the lamp indication of failure The lamp will be turned off automatically when the seal failure condition has ceased If PSF is set to r 5 when pump moisture sensor indicates that there is a seal failure condition then the corresponding pump seal failure lamp is lit on the controller If the MPC is only being used with one pump or being used with two pumps with the lead lag function turned off then no action is taken by the MPC with the operation of the pumps The failure indication lamp will be manually reset as described in the next paragraph If the MPC is being used with two pumps with the lead lag function turned on then the failed pump will automatically become the lag pump the remaining pump will become the lead pump and the alternation will be discontinued The lamp indication and pump alternation can be manually reset as described in the next paragraph Once the pump has been repaired the seal failure action can be reset with the values of P SF and PSF in the Secondary menu The item P SF or P2SF will display FA i if the corresponding pump has met the condition of a seal failure Press the ENTER key to reset If the pump moisture sensor is s
38. will disappear as those menu items do not apply Ret Aer amp ReP Re H Rest ALLP Retd Alarm 2 Type Select 55 or d Factory default is 5 R55 Absolute Alarm that may be set anywhere within the values of SEAL and SCftH and is independent of SP iH dE Deviation Alarm that may be set as an offset from SP iH As SP iH is changed the Alarm Point will track with SP iH Alarm 2 Reset Select BaF or Hold Factory default is GaGF OnGF Automatic Reset Hold Manual Reset Reset acknowledge by simultaneously pressing the MR INDEX amp ES DOWN ARROW keys for 5 seconds Alarm 2 Power Interrupt Select Un or GFF Factory default is OFF En Alarm Power Interrupt is On CFF Alarm Power Interrupt is OFF Alarm 2 Inhibit Select Go or GFF Factory default is OFF Un Alarm Inhibit is On Alarm action is suspended until the process value first enters a non alarm condition OFF Alarm Inhibit is OFF Alarm 2 Output State Select CLOS or GPEn Factory default is 105 L05 Closes Contacts at Alarm Set Point GPEn Opens Contacts at Alarm Set Point Alarm 2 Lamp Select 8 on or Goff Factory default is 8 on 8 on Alarm Lamp is ON when alarm contact is closed GoFF Alarm Lamp is OFF when alarm contact is closed Alarm 2 time Delay Select GFF or to 8060 seconds Factory default is OFF GFF Alarm function will operate when triggered at programmed Alarm Set Point i 8000 Alarm function will only operate once the programme
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