Pulsafeeder Pulsar DLCM Manual do Utilizador Página 1

INSTALLATIONOPERATIONMAINTENANCEINSTRUCTIONBULLETIN No. IOM-PS-DLCM-1101-Rev EManufacturer’s of Quality Pumps,Controls and SystemsEngineered Pump Oper

43. Equipment InspectionWhen you receive your order, check all equipment for:i Completeness against the shipping document / purchase orderi For any e

9411. Trouble Shooting Guide11.1 System DiagnosticsYour DLCM contains extensive diagnostics that allow it to determine the source of common problems

95MENU (DIAGNOSTICS) [cont]Symptom Probable Cause Possible SolutionDIAG 7/11DRIVE TEMP:FAILThe DLCM internal temperature hasexceeded the rating.Re-loc

96PULSAR DC MOTORSymptom Probable Cause Possible SolutionMotor will not start. No power supplied. Check power source to DLCM.. Motor wired incorrectly

97ANALOG INPUTSymptom Probable Cause Possible SolutionInput wired incorrectly. Check wiring.Input not wired to correct channel. Refer to Section 5 – I

98ALARM RELAY OUTPUT (Low Voltage J5)Symptom Probable Cause Possible SolutionNo Output Output wired incorrectly. Check wiring.External Device not pow

99UNITSSymptom Probable Cause Possible SolutionUnits do notincrement withchange in %.Unit not properly calibrated. Calibrationbeyond display resoluti

100Failed to detect shaft rotation with themotor turned onThe tachometer has failed. Remove power tothe DLCM and pump motor. Turn the powerback on a

101ENCODER ERRORSymptom Probable Cause Possible SolutionEncoder defective. Contact Technical ServicesBroken or jammed gears – contact TechnicalService

10211.1.2 Tachometer TroubleshootingThe DLCM utilizes the Tachometer sensor installed in the gear box to determine motor speed. Thissensor detects t

10316. Slowly rotate the pump motor observing the high and low multi-meter readings. The output shouldnow transition from a value below 0.35VDC when

55. Installation5.1 LocationReview the Safety section prior to installing the DLCM. It contains information required to properlyinstall and operate

10412. Conversion (Manual to DLCM)Your PULSAR can be easily converted from a Manual Stroke Adjustment Mechanism to the DLCM. TheDLCM effectively re

105Figure 25 – DLCM/Eccentric mating components7. Locate the face on the bottom of the DLCM that mates with the face of the lip of the eccentric box.

10613. General RepairsThe DLCM contains no user-serviceable components within its main enclosure. In the un-likely event thatyour DLCM needs to be r

10713.2 DLCM Replacement The following procedure assumes that you have received your replacement DLCM and are ready toperform the replacement.1. If

1085. Remove the Tachometer Sensor Input Cable on the Field Wiring Board.a) Disconnect the wire (typically brown) connected to Pin 1 of J10.b) Disco

1097. Remove the four screws and Teflon Gaskets that retain the conduit adapter(refer to Figure 28).Figure 28 – Conduit Adapter Screw RemovalWhen remo

11012. Note the position of the PULSAR adjustment shaft 'flats'. They mate with a slot in the DLCM drivecoupling of the output shaft. The

11114. Orient the DLCM properly at a comfortable height above the pump and align the slot in the DLCMcoupling with the 'flats' on the adjust

112Figure 33 – Shaft Alignment

11316. Align the Conduit Adapter with the mating surface on the DLCM. A card edge in the DLCM housing will mate with an edge connector on the Conduit

6AVOID LOCATIONS WHERE THE DLCM WOULD BE SUBJECTED TO EXTREME COLD OR HEAT[LESS THAN –18° CELSIUS (0° FAHRENHEIT) OR GREATER THAN 40 ° CELSIUS (104 °F

11414. PulsaNet SpecificationFor simplicity, the DLC, DLCM, MLC, MLCM, NEMA-4X and NEMA-7 variations will ALL be referredto as the DLC unless otherwi

11514.3 MODBUS MessagingThe MODBUS protocol was written for use with PLC’s. Programmable Logic Controllers (PLC’s)typically have relay outputs, digi

11614.5 CoilsCoils are discrete, single bit outputs like the ALARM OUTPUT and DIGITAL OUTPUT.Notes:i Read only.i The coil information is packed as 8

11714.7 Input RegistersThese 16-bit input registers contain Analog (4-20mA) and Thermistor input readings.Notes: i The input information is returned a

118Function Address DDE Ref. Purpose Data FormatRead (0x03) 0x0008 400009 Screen Character: Row 1, Column 9 Word (0x0 – 0xFFFF) [Note #1]Read (0x03)

119Function Address DDE Ref. Purpose Data FormatRead (0x03) 0x003A 400059 Flash Character: Row 2, Column 11 Word (0x0 – 0xFFFF) [Note #1]Read (0x03)

120Notes:1. There is one character per 16-bit value, which resides in the least significant byte.2. The most significant byte contains the cursor st

12112. Reading returns the current condition from RAM that can be either 0=Security Off, 1=Tamper Proof,2=Calibration Settings. Writing while securit

122SUPPORTED FUNCTION CODES and SUB-FUNCTION CODES0x01 READ COIL STATUS (bits) SUPPORTED0x02 READ INPUT STATUS (bits). SUPPORTED0x03 READ HOLDING REGI

12315. MODBUS Mode15.1 IntroductionThe serial communications supplied with the DLC/M is similar in operation to that with the 4-20mAsignal. The [MO

75.3.1 Getting StartedThe field wiring of the DLCM is accomplished through a rear access cover at the back of the unit –near the PULSAR gearbox and mo

12416. Spare PartsUser replaceable parts for the DLCM.Table 4: Miscellaneous Replacement PartsPulsafeeder P/N Description QtyNP250012-000 Clear Lexa

125Diagnostic FormPulsafeeder, Inc.2883 Brighton-Henrietta TL RoadRochester, New York, 14623 Attn: Technical ServicesTelephone (585) 292-8000 Fax (585

126(Page 1 of 2)What area did the problem fall into: (Refer to Bulletin No. IOM-PS-DLCM-1101-Rev E, Section 11 – Trouble Shooting Guide) Check the one

127(Page 2 of 2)

BULLETIN No. IOM-PS-DLCM-1101-Rev EEngineered Pump Operations2883 Brighton-Henrietta Townline RoadRochester, New York 14623Telephone: (585) 292-800

85.3.2 Finding your way around the Field Wiring BoardThe electrical connections are segregated on the Field Wiring Board. The high voltage connection

95.4 High Voltage ConnectionsThere are only three high voltage connections to be made on the DLCM: supply power (J1), PULSARmotor load (J3), and Alar

10The DLCM with an attached pump motor and alarm load, should be connected to its own branchcircuit. Size the supply wire and protective element acco

115.4.2 PULSAR MotorIn most cases the DLCM is supplied with a factory installed DC motor. If a motor was not supplied, itis important to select the p

125.4.3 Alarm RelayThe Alarm Relay is an output that is configured by the operator. Refer to Section 7 – GeneralOperation for specific instructions o

135.5.1 Analog InputsThe DLCM can accept either one or two analog input signals. These signals ultimately control thepump’s flow. Analog Input #1 is

iiDLCM™ FACTORY SERVICE POLICYYour DLCM is a state of the art microprocessor based stroke length and motor speed control for use withPULSAR Diaphragm

145.5.2 Alarm InputThe Alarm Dry Contact Input is designed to operate with the PULSAlarm leak detection option. It issoftware configurable to generat

155.6 Low Voltage Output ConnectionsThere are two types of Low Voltage outputs: Analog (e.g., 4-20mA) and Transistor based Dry Contact.The Low Voltag

165.6.1 Current OutputThe Current Output Channel can follow one of three signals:a) Calibrated flowb) Calibrated stroke lengthc) True motor speedIt

175.6.3 Run Status or Stroke CounterThe Status output can be configured through software to indicate that the pump motor is on or togenerate a pulse w

18Figure 8 – Tachometer and Pump Motor Thermostat ConnectionsTo connect the Tachometer Input, connect the wire labeled VDC (typically brown) to the co

195.8 Motor ThermostatThe motor thermostat has been supplied as an equipment safety measure. This allows the DLCM pumpmotor to operate without the d

20Important Wiring DetailSlave to SlaveWhen connecting two Slaves, the wiring is straight through. For example: Connect the transmit linesto the tra

215.10 Fuse ReplacementAlthough Fuse replacement is not a part of normal installation, it is possible that fuse failure will resultfrom improper wiri

226. Start Up Instructions6.1 OverviewOnce all electrical connections have been made, your DLCM is ready for Start-up. The following ninesections

236.1.1.1 Display: This is a 2 line by 16 character alpha-numeric Liquid Crystal Display (LCD) located above thekeypad. It is back-lit with a yello

iiiTable of Contents1. INTRODUCTION...

246.1.1.3 Manual Adjustment Knob:The manual adjustment knob is mechanically attached to the PULSAR stroke length adjustmentmechanism. The DLCM uses

256.1.3 Confirm Correct Incoming PowerDouble check that the wiring access cover is on and tightened down. Whenever power is supplied tothe DLCM, the

26The keypad can be tested by depressing each key separately. Most, but not all keys will cause the texton the display to change. Do not be alarmed

27 Menu Factory Re-initialization:Use this procedure if the display and key pad appear to be functioning properly, but you suspect otherproblems with

286.1.7 Set Time and DateThe clock on your DLCM has been activated at the factory, but you should set it to the local time anddate of the installation

296.1.8 Flow Calibration (1-point).Your DLCM is factory calibrated at rated flow and pressure (1-point). Nevertheless, you shouldalways perform a cal

3014. Pressing [ENTER] on the last position will cause the {CONFIRM CHANGE? / YES} screen to bedisplayed. Press [ENTER] to accept. Your 1-point cali

316. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT ANALOG MAX /100% = XXmA} screen is displayed. Adjust your PLC to ou

327. General OperationThis section covers the General Operation of the DLCM as it relates to software. It includes detailedinstructions and example

33You can "skip" a calibration point by entering a flow value of 0.0000. “Skipping” a point means thatit will be omitted from the mathemati

iv7.2 Menu ...41

3410. When you are ready, press [ENTER], which will start the pump motor for a period of 60 seconds. Thescreen will show a 60 second timer and displa

35 Change Constants Procedure1. Navigate to the Change Constants menu by pressing [CAL]. The {CALIBRATE / PUMP FLOW}menu is displayed. Press [ENTE

36TUNE FLOW 60.0%0.1000 GUsing [UP] or [DOWN] enter the volume displaced for 1 minute of pump flow at the current motorspeed and stroke length. The

37Send the low analog signal to the DLCM (i.e., 0mA, 1mA, 4mA or 1 volt input to the J4 Current 1terminals) from the signal generating device (e.g., P

387.1.2.2 Analog Input #2 CalibrationThe following is a minimal procedure for calibrating Analog Input #2 if the 2 – Signals option is to beused. In

396. You are now ready to set the Signal Ratio. This option allows you to scale the Analog signal input tothe pump output. Use this option only if y

407.1.4 Analog Output Signal CalibrationDepending upon the option selected, {STROKE & SPEED} or {STROKE POSITION} or {MOTORSPEED}, the DLCM will g

417.2 MenuThe default values of the DLCM Controller have been factory set, but you may want to configure theDLCM to meet your specific application.Th

427.2.1 Alarm, and Error messagesWhen an error occurs, the DLCM flashes Alarm and Error messages alternately with the standarddisplay. If the error i

437.2.2 DiagnosticsThe DLCM is supplied with a complete diagnostic menu. It will alert you if something has failed, thetime and date of the failure,

vDIAGNOSTIC FORM...

448. Press [UP] to scroll to the next sub-menu. The DLCM is equipped with a thermistor to monitorinternal enclosure temperatures. If the temperatur

4512. Press [UP] to scroll to the next sub-menu. The total Stroke count of the pump is displayed here. Toreset the Stroke count, press [ENTER] and y

463. The time will now be flashing with the cursor located under the hour position. Press [UP] or [DOWN]to adjust the time to your local time.12 HR

479. If "AUTO CHANGE" was selected in the previous step, the DLCM prompts you for the current day ofthe week. Press [UP] to scroll through

482. The menu for having the DLCM freeze at the last signal is displayed. ANALOG SIG FAILFREEZE @LAST SIGTo accept this action, press [ENTER]. Go to s

49If {MANUAL MODE} is selected, the DLCM will enter the manual mode as soon as the signal loss isdetected. It will remain in Manual Mode until it is

505. The {ERROR MESSAGE / ENABLED} screen is displayed. ERROR MESSAGEENABLEDTo accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} scr

51Here are some general guide lines:− Increase this value as you increase the number of nodes on the network.− Increase this value as you decrease t

52c) Go To Default

53Press [UP] or [DOWN] to select the desired option.MODBUS FAIL #XFREEZE @LAST SIGPress[UP]MODBUS FAIL #XMOTOR OFFPress[UP]MODBUS FAIL #XGO TO DEFA

viConventionsFor the remainder of this bulletin, the following Conventions are in effect.A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH

54The STROKE & SPEED output actually represents Calibrated Flow where 0% flow may notcorrelate to 0% stroke position.Press [ENTER] to accept this

557.2.8 End Point Set UpThe End Point Set Up menu is a powerful tool that allows you to modify the performance of yourDLCM. The term 'End Points

56At the 100% Adjustment (maximum value on the x-axis), the DLCM is operating at 100% strokelength and 100% motor speed. This results in a 100% flow

57Figure 15 – Typical End Point ExampleA better way to accomplish this is to modify the Maximum End Point for Stroke Length. If we changethe Maximum

58 End Point Set Up procedure1. Press [MENU] to enter the {–MENU–} sub-system. Press [UP] or [DOWN] until {–MENU– / ENDPOINT} is displayed. 2. Pre

59The leak sensor switch must be a dry contacting type. Refer to Section 5-Installation: Low VoltageInputs for wiring information.If you select the &

60The level sensor or Start/Stop switch must be a dry contacting type. Refer to Section 5-Installation:Low Voltage Input Connections.If you select th

6110. If you want the PULSAR motor to stay on when a Drum Level is sensed, press [UP] to scroll to{NO}.and press [ENTER].LEVEL SWITCHMOTOR OFF? NO11

627.2.11 Digital Output Set UpThis sub-menu allows you to determine if the Digital Output is to be used as a counter for pumpstrokes, as a remote mot

63 Digital Output Set Up Procedure1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– / DIGITALOUTPUT}.–MENU–DIGITAL

11. IntroductionThe DLCM is an advanced microprocessor based controller designed for use with the PULSAR diaphragmmetering pump. It controls the out

647.2.12 Motor Thermostat Set UpThis sub-menu allows you to configure the DLCM to interact with the pump motor thermostat.Depending on the applicatio

655. The {MOTOR THERMOSTAT / ALARM RELAY? YES} screen is displayed.MOTOR THERMOSTATALARM RELAY? YESPress [UP] to select between {YES} and {NO}.MOTOR

667.2.14 Power Failure Set UpThis sub-menu allows you to configure the way the DLCM reacts when power is restored after a poweroutage. Additionally

677.2.15 Alarm Relay This sub-menu sets up the alarm relay outputs as normally open or normally closed.These screens configure both the high voltage

68 Analog Mode Set Up Procedure1. Press [MENU] once and then [UP] or [DOWN] until the screen {–MENU– / ANALOG MODE} isdisplayed.-MENU-ANALOG MODEPre

69Press [UP] or [DOWN] to set the {#1 SAMPLE SIZE}. The ‘#1’ refers to the signal that controls theSTROKE adjustment.Increase the number of samples t

70 MODBUS mode setup procedure:1. Press [MENU]. Press [UP] or [DOWN] until the {–MENU– / MODBUS MODE} screen is displayed.–MENU-MODBUS MODEPress [E

717.2.17.2 {STROKE & SPEED / 2 – SIGNALS} Setup8. With the {STROKE & SPEED / 1 – SIGNAL} screen displayed (refer to step 3), press [UP] to d

727.2.18 SecurityThe DLCM has three modes of security:− None (OFF)− Tamper Proof− CalibrationWith Tamper Proof security active, the DLCM will lockou

737. If the pin number is not correct or you don’t want the selected security level, press [UP] to change thedisplay to {CONFIRM CHANGE? / NO}CONFIRM

21.2 DLCM Standard Featuresi DC Motor Speed Control with tachometer feedbacki Manual Stroke Length Controli Keypadi Back-lit 2 line 16 character LCD

747.2.20 Contrast AdjustThe DLCM display contrast can be adjusted to a desired setting. Contrast Adjustment Procedure1. Press [MENU]. Press [UP] o

75If you are installing this DLCM into an existing network, retrieve the following parameters (boldindicates default DLCM values not network defaults)

76Press [UP] or [DOWN] to set the parity type. DATA PARITYEVENPress[UP]DATA PARITYODDPress[UP]DATA PARITYNONEPress [ENTER] to accept.6. The Class se

77To set or view Slaves manually, press [UP] or [DOWN]. As you do so, the display will show theaddress followed by the status,IDENTIFY SLAVES1

787.2.22.1 Loopback Test ProcedureThe Loopback test is helpful in the identification of wiring errors. While this menu is displayed theDLCM transmit

797.2.23 Language All displayed text can be displayed in English, Spanish, French or German. Language Set Up Procedure1. Press [MENU]. Press [UP]

80Press [UP] to change the value to {YES}. Press [ENTER] to accept your selection. The followingmessage is displayed:PLEASE WAIT5. The first screen

817.4 Varying the Flow Rate - ManuallyWhen the DLCM is in Manual Mode, pump flow rate can be increased by pressing [UP]. The flow rate isdecreased by

827.6.2 RepeatingA Repeating Batch will start at a specified time and run for a specified duration. It will stop for aspecified period of time and th

83 Batching system Set Up procedure:1. Press [BATCH], to enter the batch set-up menu.2. The display will come up as {BATCHES / ACTIVE} or {BATCHES

32. Safety ConsiderationsThe DLCM is a sophisticated microprocessor based controller for use only with PULSAR diaphragmmetering pumps. It yields tre

847. The cursor then moves to minutes field. Use [UP] or [DOWN] to scroll through the numbers 0-5. Setthe first digit of the minute value one positi

8516. When the batch has operated for the specified time period, it will automatically shut off the pump'smotor. 17. If this a One Time Only batc

868. Diagrams: Installation / ComponentDIAGRAM 1 – DLCM Wiring Diagram

87Diagram 2 – Serial Communications – RS 485 Connections

889. Specifications9.1 OverviewThe DLCM controller for Pulsar Pumps is an upgrade from the DLC stroke length controller, whichprovides all of the sa

89Low Voltage Inputs (cont)Inputs Field WiringLocationSpecification / DescriptionPULSAlarm(Leak Detection)J4 Pin 3 is +J4 Pin 4 is –Dry Contact. (Opti

90High Voltage Inputs Inputs Field WiringLocationSpecification / DescriptionLine Power:J1 Factory configured to one of the following:115VAC ±10%, 50/6

9110. Factory Default ValuesCALIBRATIONPump Flow 1-Point Calibration on PULSAR at Rated Flow and Pressure.Analog Input 4.0 - 20.0mA @ 100% RatioAnalo

92NUMBER FORMATSeparators X , XXX . XX (Comma / Decimal)Position PULSAR dependent (e.g., 9.99999, 0.999999, etc.)Factory set to match pumphead size.

93FACTORY DECIMAL POSITION SETTINGS (cont.)RATED CAPACITY RANGE UNITS –MENU – / DECIMAL POSITION0.00599999 to 0.0599999 CMH 0.9999991.58503 to 15.8503