Bulletin L-21 Series MPCJR Pump Controller Installation and Operating Manual MERCOID A Division of Dwyer Instruments, Inc. 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 FR# M1-443341-00 Rev.
CONTENTS Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS Inputs: 0 (or 4) to 20 mA DC or 0 (or 2.0) to 10.0 VDC selectable. Input Impedance: Current input: 10 ohms, Voltage input: 5K ohms. Output Ratings: Control Relays: SPDT, rated 10A @ 240 VAC res., 1/4 hp @120 VAC, 1/3 hp @ 240 VAC; Alarm Relays: SPST, 3A @ 240 VAC res., 1/10 hp @ 120 VAC; Other: 15 VDC @ 20 mA for output one and output two. Control Type: On/off, reverse or direct acting.
GETTING STARTED 1. Install the control as described 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 MPCJR’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.
INSTALLATION Mount the instrument in a location that will not be subject to excessive temperature, 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.
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 should be made in accordance with the National Electrical Code per Article 300, and local regulations.
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 Use of a fuse (1/8W Fast-Blow) in the loop is recommended to protect the control input circuitry.
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. DO NOT run signal wiring in the same conduit or chase as the power wiring. Erratic operation or damage to the control circuitry will result.
FRONT PANEL FUNCTIONS Key functions are as follows: INDEX: Pressing the INDEX key advances the display to the next menu item. May also be used in conjunction with other keys as noted below. 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. UP ARROW & ENTER: Pressing these keys simultaneously brings up the secondary menu starting at the S P 1 H menu item.
INDEX & 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. INDEX & ENTER: Pressing these keys simultaneously and holding them for 5 seconds allows recovery from the various error messages.
Security Level Selection Three levels of security are provided. The S E C r 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 UP ARROW or 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.
Lead/Lag Operation The Mercoid® MPCJR 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® MPCJR pump controller has a pair of set points each for pump 1 and pump 2. If the lead/lag feature is turned off, S P 1 H and S P 1 L control pump 1 and S P 2 H and S P 2 L control pump 2.
OPERATION RV, RC ISOLATED ANALOG RETRANSMISSION The analog retransmission option allows the Process Variable or the Set Variable to be sent as an analog signal to an external device. The signal may be either 0 to 10 VDC (Option RV) or 0 (or 4) to 20 mA DC (Option RC). The output may be changed in the field from one to the other by the toggle switch located on the top printed circuit board. Wire the output as shown on page 5.
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.
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 process. 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.
Secure Menu Press the Press UP ARROW and Enter keys for 5 Seconds to start the menu. INDEX to advance to the next menu item. Press DOWN ARROW to change the value in the display. Press UP ARROW or ENTER to retain the value. OUTPUTS ARE DISABLED (TURNED OFF) WHILE CONTROL IS IN THE SECURE MENU. SECr Security Code: See the Security Level Selection and the Password Table on page 10, in order to enter the correct password. Factory Default is 4 . InP Input Type: Select one of the following.
SCAL Scale Low: Select 1 0 0 to 9 9 9 9 counts below S C A H . The total span between S C A L and S C A H must be within 11998 counts. Maximum setting range is - 1 9 9 9 to + 9 9 9 9 counts. Factory Default is - 5 . 7 . SCAH Scale High: Select 1 0 0 to 9 9 9 9 counts above S C A L . The total span between S C A L and S C A H must be within 11998 counts. Maximum setting range is - 1 9 9 9 to + 9 9 9 9 counts. Factory Default is 2 3 . 1 .
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 1 t = A b S or A 2 t = A b S ), simply set the value at which the alarm is to occur. When setting the alarm value for a deviation alarm (A 1 t = d E o r A 2 t = d E ), set the difference in value from the Set Point (S P 1 H ) desired.
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 A HAZARD IS CREATED BY THIS ACTION. BE SURE TO TEST ALL COMBINATIONS OF HIGH AND LOW ALARM INHIBIT ACTIONS BEFORE PLACING CONTROL INTO OPERATION. The following menu items apply only to the alarms.
A1LP Alarm 1 Lamp: Select O o n or O o F F . Factory default is O o n . O o n Alarm Lamp is ON when alarm contact is closed. O o F F Alarm Lamp is OFF when alarm contact is closed. AL2 Alarm 2 function: Select O F F , L o , H i , or H i L o . Factory default is L o . OFF Alarm 2 is disabled. No Alarm 2 menu items appear in the Secondary or Secure menus. Lo Low Alarm Only. A 2 L o appears in the Secondary Menu. Hi High Alarm Only. A 2 H i appears in the Secondary Menu. HiLo High and Low Alarms.
FiLt Digital Filter: Select O F F or 1 to 9 9 . 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 . The remaining menu items appear if the corresponding option was purchased with the control. POL (Analog Retransmission Output, see page 13) Process Output Low: Select -1999 counts to any value less than P O H . Factory default is -5 . 7 .
DIAGNOSTIC ERROR MESSAGES DISPLAY MEANING No display lighted Display is blank. Instrument is not getting power, or the supply voltage is too low. FAIL 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 This message appears if the Serial Communications has timed out.
DIAGNOSTIC ERROR MESSAGES DISPLAY MEANING SP OUTPUTS UFL or OFL Underflow or Overflow: Process value has exceeded input range ends. Set point outputs active Alarms active Check calibration appears as an alternating message if the instrument calibration nears tolerance edges. Set point outputs active Alarms active Check calibration appears as a flashing message if the instrument calibration exceeds specification.
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. ITEM DEFAULT SET AT DESCRIPTION Home Position, Process Variable & PU SP IH SP1H's Value displayed MENU Primary MENU Secondary MENU Secure ITEM SPIH SPIL SP2H SP2L A1Hi A2Lo DEFAULT SET AT 23.1 -5.7 23.1 -5.7 23.1 2.0 ITEM SECr InP InPC LdL9 05UP dPt PEA DEFAULT 4 Curr 0.0 On OFF 0.0 XX UAL SCAL SCAH SPL XX -5.7 23.1 -5.
MENU Secure DEFAULT SET AT DESCRIPTION Alarm 1 Function (selectable off, lo, hi, Hi or hilo) Alarm Type 1 (selectable abs ALt AbS (absolute) or de (deviation)) Alarm 1 Reset (selectable onof (auto) A IrE OnOF or hold (manual)) Alarm 1 Power Interrupt (selectable on OFF A IP i or off) Alarm 1 Inhibit (selectable on or off) OFF A I iH Alarm 1 Output State (selectable close CLOS A I ST or open) Alarm 1 Lamp condition when contact O on A I LP is closed (selectable on or off) Alarm 2 function ( selectable off,
PROGRAMMIMG EXAMPLE Example: • Keep Empty, two pump (duplex) • Depth 25 feet • Pump 1: Start at 6 feet Stop at 3 feet Pump 2: Start at 12 feet Stop at 9 feet • Low level alarm: 1 foot, fixed, auto reset • High level alarm: 20 feet, fixed, auto reset • Want Lead/Lag function on • No communication options • Want 4-20 mA retransmission • Using with a 4-20 mA input. EXAMPLE PROGRAMMING CHART MENU Secondary ITEM SPIH SPIL SP2H SP2L A1Hi A2Lo DEFAULT SET AT 23.1 6.0 -5.7 3.0 23.1 12.0 -5.7 9.0 23.1 20.0 2.0 1.
EXAMPLE PROGRAMMING CHART continued MENU Secure ITEM SECr InP InPC LdL9 05UP dPt PEA DEFAULT 4 Curr 0.0 On OFF 0.0 XX URL SCAL SCAH SPL XX -5.7 23.1 -5.7 SPH SISt 23.1 POut SET AT 4 Curr 0.0 On On 0.
EXAMPLE PROGRAMMING CHART continued MENU ITEM AL I A Lt A IrE AIPi AIiH AIST AILP Secure AL2 A2t A2rE A2Pi A2iH A2St A2ULP FILt POL POH DEFAULT SET AT DESCRIPTION Hi Hi Alarm 1 Function (selectable off, lo, hi, or hilo) AbS AbS Alarm Type 1 (selectable abs (absolute) or de (deviation)) OnOF O n O F Alarm 1 Reset (selectable onof (auto) or hold (manual)) OFF OFF Alarm 1 Power Interrupt (selectable on or off) OFF OFF Alarm 1 Inhibit (selectable on or off) CLOS C L O S Alarm 1 Output State (selectable clos
