Mercoid Series MPC, Installation And Operating Manual

Page 1: ...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 Series MPC Pump Controller Installation and Operating Manual FR MI 443247 00 Rev 3 ...

Page 2: ...re Operation 11 12 Over Temperature Operation 12 13 Analog Retransmission Operation 13 Pump Run Time Operation 13 Serial Communication Operation 14 Menu Selections 15 Secondary Menu 15 16 Secure Menu 17 23 Alarm Type and Action 20 22 Diagnostic Error Messages 24 25 Programming Chart 26 28 Programming Example 28 31 3 596 91 3 mm Panel Thickness 0 250 6 53 mm Max Panel cut out 3 620 x 3 620 in 0 032...

Page 3: ...X 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 Differen...

Page 4: ...th 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 485 RS 485 Modbus RTU Serial Communications Allows remote computer to read and write all control parameters RV ...

Page 5: ...efore 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 CAUTION It is not necessary to remove the instrument chassis from the housing for ins...

Page 6: ...Res 1 10 HP 120 VAC 290 3120 Analog Retransmission Figure 2 Wiring WIRI Wire show 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 shoul...

Page 7: ... 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 s Use intain ecure e per mmon 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 w...

Page 8: ... 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 Option 485 DIP Switch Positions Half Duplex Full Duplex 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 DATA IN 30 DATA OUT 32 DATA GROUND 31 PIN DESCRIPTION 1 SHIELD 2 TRAN...

Page 9: ...h a system test See page 18 for explanation of system test function 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 item or selects the item to OFF The minimum value obtainable is 1999 regardless of decimal point placement ENTER The ENTER key is used to ...

Page 10: ...ror 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 SP1H value Pump 1 On Set Point on the bottom display Error messages may over ride ...

Page 11: ...he access level to for example 2 at the SECr menu item press the UP ARROW key until the upper display shows the password 1101 Press the ENTER key The display will blink and return with the level value 2 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 instructio...

Page 12: ...may be the maximum or minimum allowed In normal operation when the SP1H 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 SP2H point both pumps will be turned on until the SP2L point is reached where one of the pumps will turn off When SP1L is reached remaining running pump will turn off The last pump off will not be the...

Page 13: ... 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 P0t is programmed for the action of the MPC bas...

Page 14: ... automatic There are no further programming steps required The values of P0L and P0H must be within the programmed scale range The scale range is set by the SCAL and SCAH 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 Pump Run Time key on the front of the unit will display...

Page 15: ... 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 L0rE menu item in the Secondary M...

Page 16: ...o 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 SP1H Pump 1 On Set Point Factory Default 23 1 feet SP1L Pump 1 Off Set Point Factory Default 0 0 feet SP2H Pump 2 On Set Point Factory Default 23 1 feet SP2L Pump 2 Off Set Point Factory Default 0 0 feet A1Hi Alarm 1 High Factory Default 23 1 feet A2Lo Alarm 2 Low Factory...

Page 17: ...ess the ENTER 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 P10t Pump 1 Reset for Over Temperature Displays when pump 1 is in normal operating condition based on temperature input Displays FA1L if pump 1 has met the condition of over temperature Press the EN...

Page 18: ...t will be affected Factory default is 0 0 S1St Set Point 1 State Select P1n or P0ut Factory default is P0ut P1n Pump In Direct Action As the input increases the output will increase P0ut Pump Out Reverse Action As the input increases the output will decrease S2St Set Point 2 State Select P1n P0ut or 0FF Factory default is P0ut P1n Pump In Direct Action As the input increases the output will increa...

Page 19: ...ck into service until the over temperature condition has ceased PSF Pump Seal Failure Select AUt0 or rES See page 11 AUt0 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 ceas...

Page 20: ...ault is 0FF 0n Alarm Power Interrupt is 0n Output will automatically reset on power up if no alarm condition exists 0FF Alarm Power Interrupt is 0FF Output will be in the alarm condition on power up regardless of condition of process S2iH Setpoint 2 Inhibit Select 0n or 0FF Factory default is 0FF 0n Alarm Inhibit is 0n Alarm action is suspended until the process value first enters a non alarm cond...

Page 21: ...arm is required 20 counts above the SP1H then set A Hi to 20 If SP1H 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 A rE 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 A iH is selected ON an ...

Page 22: ...owledge by simultaneously pressing the INDEX DOWN ARROW keys for 5 seconds A1Pi Alarm 1 Power Interrupt Select 0n or 0FF Factory default is 0FF 0n Alarm Power Interrupt is 0n 0FF Alarm Power Interrupt is 0FF A1iH Alarm 1 Inhibit Select 0n or 0FF Factory default is 0FF 0n Alarm Inhibit is 0n Alarm action is suspended until the process value first enters a non alarm condition 0FF Alarm Inhibit is 0F...

Page 23: ...oint will track with SP1H A2rE Alarm 2 Reset Select 0n0F or HoLd Factory default is 0n0F 0n0F Automatic Reset HoLd Manual Reset Reset acknowledge by simultaneously pressing the INDEX DOWN ARROW keys for 5 seconds A2Pi Alarm 2 Power Interrupt Select 0n or 0FF Factory default is 0FF 0n Alarm Power Interrupt is On 0FF Alarm Power Interrupt is OFF A2iH Alarm 2 Inhibit Select 0n or 0FF Factory default ...

Page 24: ... not addressed within the time set in the nAt No Activity Timer see Secure Menu the CHEC L0rE error message will be displayed Addr Option 232 or 485 Serial Communications Control Address Set from1 to FF This number hexadecimal base 16 must match the address number used by the host computer Factory default is 32 bAUd Option 232 or 485 Serial Communications Communication Baud Rate Select 300 1200 24...

Page 25: ...essage may occur during operation if a failure is detected Displays flash This message appears if the Serial Communications has timed out Action Required Check that the power supply is on or that the external fuses are good The display alternates between FA1L tESt and one of the following messages FACt dFLt Memory may be corrupted Press the ENTER key and the DOWN ARROW key to start the factory def...

Page 26: ...ssage 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 Action Required Input signals may normally go above or below range ends If not check input and correct Remove the instrument for service and or recalibration To reset use the INDEX ENTER keys Remove the instr...

Page 27: ...Point P1rn XXXX Total ON Time for Pump 1 in HOURS since last reset P2rn XXXX Total ON Time for Pump 2 in HOURS since last reset P1SF Pump 1 Reset for Seal Failure or FAIL P2SF Pump 2 Reset for Seal Failure or FAIL P1OT Pump 1 Reset for Over Temperature or FAIL P2OT Pump 2 Reset for Over Temperature or FAIL Menu Item Default Set At Description SECr 4 Security Selection SCAH 23 1 Scale High value de...

Page 28: ...or de deviation A1rE OnOf Alarm 1 Reset selectable onof auto or hold manual Secure A1Pi OFF Alarm 1 Power Interrupt selectable on or off A1iH OFF Alarm 1 Inhibit selectable on or off A1St CLOS Alarm 1 Output State selectable close or open A1LP O On Alarm 1 Lamp condition when contact is closed selectable on or off A1td OFF Alarm 1 Time Delay selectable off or 1 to 8000 seconds AL2 Lo Alarm 2 funct...

Page 29: ...w default is in feet LorE rE Local Remote for computer communications Addr 32 Control Address for computer Secure communications bAUd Baud Rate for computer communications nAt OFF No Activity Timer for computer communications Stor YES Store Menu for Hi speed writes selectable yes or no ...

Page 30: ... 1 value default is in feet SP1L 0 0 Set Point 1 off value default is in feet SP2H 23 1 Set Point 2 value default is in feet SP2L 0 0 Set Point 2 off value default is in feet A1Hi 23 1 Alarm 1 high value default is in feet A2Lo 2 0 Alarm 2 low value default is in feet SFS1 120 Pump 1 Seal Failure Set Point Secondary SFS2 120 Pump 2 Seal Failure Set Point P1rn XXXX Total ON Time for Pump 1 in HOURS...

Page 31: ...Secure selectable automatic or manual reset Pump Seal Failure controller action selectable automatic or manual reset System Test Selectable on or off Pump Run Time Rest Selectable on or off Set Point High value default is in feet Set Point Low value default is in feet Set Point 1 Power Interrupt selectable on or off Set Point 1 Inhibit selectable on or off Set Point 2 Power Interrupt selectable on...

Page 32: ...larm 2 Type selectable abs absolute or de deviation A2rE OnOf Alarm 2 Reset selectable onof auto or hold manual A2Pi OFF Alarm 2 Power Interrupt selectable on or off A2iH OFF Alarm 2 Inhibit selectable on or off A2St CLOS Alarm 2 Output State selectable close or open A2LP O on Alarm 2 Lamp condition when contact is closed selectable on or off A2td OFF Alarm 2 Time Delay selectable Off or 1 to 8000...