PULSAR DLCM NEMA TYPE 4X
Installation, Operation &
Maintenance Instruction Manual
PULSAR® DLCM
NEMA TYPE 4X
DIGITAL STROKE LENGTH & MOTOR
SPEED CONTROLLER
Bulletin No.: IOM-CTL-DLCM-2004 Rev A
Copyright © 2001-2015 Pulsafeeder, Inc. All rights reserved.
PULSAR is a registered trademark of Pulsafeeder, Inc.
ii
Factory Service Policy
PULSAR® DLCM Controllers are microprocessor- based stroke length and motor speed
controllers intended for use with PULSAR Diaphragm Metering Pumps. They include extensive
on-board diagnostics. If you are experiencing a problem with your PULSAR DLCM Controller, first
review the diagnostic menu, then consult the troubleshooting guide. If the problem is not covered
or cannot be solved, please contact your local PULSA Series Sales Organization or our Technical
Service Department at (585) 292-8000 for further assistance. Do not open or tamper with the
DLCM enclosure as this will void the warranty set forth below.
Trained individuals are available to help you diagnose your problem and arrange a solution.
Solutions may include purchasing a replacement unit or returning the DLCM to the factory for
inspection and repair.
All returns require a Return Material Authorization (RMA) number to be issued by Pulsafeeder.
Replacements purchased under a possible warranty situation may be credited if, after an
examination of the original PULSAR DLCM Controller by Pulsafeeder, it is determined that the
issue is covered by the warranty set forth below.
Certain components may be purchased for replacement. Refer to Section 15: Spare Parts for
more information and part numbers. Parts purchased to correct a warranty issue may be credited
if after examination of the original parts by Pulsafeeder personnel it is determined that the issue is
covered by the warranty set forth below. Parts returned for warranty consideration that test
satisfactorily or are otherwise not covered by the warranty set forth below will be returned freight
collect unless Pulsafeeder is directed otherwise.
Field modifications will void the warranty set forth below. Out-of-warranty repairs will be subject to
Pulsafeeder's standard bench fees and testing costs associated with replacement components.
Warranty
Pulsafeeder warrants its PULSAR DLCM Controllers to be free of defects in material and
workmanship under normal use and service for a period of one year from the date of shipment
from Pulsafeeder’s factory in Rochester, New York, USA. This warranty applies only to products
which are properly stored, installed, operated and maintained. In order to be considered properly
stored, installed, operated and maintained, a product (i) must be shaded from direct sunlight, (ii)
must not be used in conditions that expose them to ambient temperatures below 32°F/0°C or
above 120°F/49°C, (iii) must be protected against environmental conditions, and (iv) must be
stored, installed, operated and maintained in accordance with all instructions and directions in
Pulsafeeder’s installation, operation and maintenance manuals for the product.
Before returning a product or part for warranty consideration, the claimant must first contact
Pulsafeeder, describe the claim, identify the product model and serial numbers for which claim is
being made, and submit proof of purchase and date of startup. If Pulsafeeder is willing to accept
the warranty claim without return of the product or part, it shall so advise the claimant. If
Pulsafeeder believes the warranty claim may potentially be a valid but is not willing to accept the
warranty claim without return of the product or part, it will provide a written return authorization to
the claimant. Following receipt of the written return authorization, the claimant may deliver the
product or part to Pulsafeeder at its factory in Rochester, New York, USA, freight and duties
iii
prepaid. The written return authorization must be included with the returned product or part.
Pulsafeeder has no liability or obligation with respect to products or parts that are returned
without a written return authorization.
Upon receipt of the returned product or part, a thorough examination will be conducted by
Pulsafeeder to determine the cause of the issue with the product or part and whether it is covered
by this warranty. This determination shall be made by Pulsafeeder in its sole reasonable
judgement. If Pulsafeeder determines the issue with the returned product or part is not covered
by this warranty, a report of Pulsafeeder’s findings will be sent to the claimant.
Pulsafeeder’s sole liability and obligation and the claimant’s exclusive right and remedy under this
warranty shall be limited to the replacement or repair of the defective product or part. The
decision whether to replace or repair shall be made by Pulsafeeder in its sole discretion. Without
in any way limiting the foregoing, Pulsafeeder shall not be liable under this warranty (i) for any
costs of removal, installation, transportation or any other changes which may arise in connection
with a warranty claim, (ii) for any loss, damage, injury, cost or expense directly or indirectly
related to the use or failure of its products, including, but not limited to, any loss of or damage to
other products, machinery, buildings or property and any injury to persons, or (iii) for
consequential damages (including, but not limited to, loss of time, inconvenience, loss of product
being pumped, loss of production, loss of business, or loss of contract),
This warranty shall be null and void with respect to a Pulsa Series or PULSAR Metering Pump if
in the sole reasonable judgment of Pulsafeeder (i) it has been tampered with, dissembled,
repaired or altered by anyone other than Pulsafeeder (unless authorized by Pulsafeeder in writing
and then only if carried out strictly in accordance with Pulsafeeder’s written instructions and
directions), (ii) it has not been properly stored, installed, operated and maintained, or (iii) it has
been used for a purpose or application for which it is not fit or appropriate. This warranty does
not cover normal wear and tear of a product or damage to a product during shipment or after
receipt.
PURCHASERS AND USERS OF PULSAR DLCM CONTROLLERS ARE SOLELY
RESPONSIBLE FOR DETERMINING THE FITNESS AND APPROPRIATENESS OF SUCH
PRODUCTS FOR THE PURPOSES AND APPLICATIONS FOR WHICH THEY ARE USED, AND
PULSAFEEDER SHALL HAVE NO LIABILITY OR OBLIGATION UNDER THIS WARRANTY OR
OTHERWISE IF A PULSAR DLCM CONTROLLER IS USED FOR A PURPOSE OR
APPLICATION FOR WHICH IT IS NOT FIT OR APPROPRIATE.
THIS WARRANTY IS PULSAFEEDER’S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ALL IMPLIED
WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
WHICH WARRANTIES ARE HEREBY EXPRESSLY EXCLUDED.
NO DISTRIBUTOR OR OTHER PERSON IS AUTHORIZED TO MAKE ANY WARRANTY OR
GUARANTEE OR AGREE TO OR ACCEPT ANY LIABILITY OR OBLIGATION ON BEHALF OF
PULSAFEEDER OTHER THAN AS EXPRESSLY PROVIDED HEREIN.
iv
Liability Exclusion and Limitation
To the maximum extent permitted by law:
 Pulsafeeder shall have no responsibility or liability for any personal injury, property
damage or other loss or damage of any kind with respect to any PULSAR DLCM
Controller that:

is not properly stored, installed, operated and maintained. In order to be considered
properly stored, installed, operated and maintained, a PULSA DLCM Controller (i)
must be shaded from direct sunlight, (ii) must not be used in conditions that expose
them to ambient temperatures below 32°F/0°C or above 120°F/49°C, (iii) must be
protected against environmental conditions, and (iv) must be stored, installed,
operated and maintained in accordance with all instructions and directions in
Pulsafeeder’s installation, operation and maintenance manuals for the product .

is tampered with, dissembled, repaired or altered (except as may be authorized by
Pulsafeeder in writing and then only if carried out strictly in accordance with
Pulsafeeder’s written instructions and directions)

is used for a purpose or application for which it is not fit or appropriate

is damaged during shipment or after receipt
 Pulsafeeder shall have no responsibility or liability for any:

costs of removal, installation, transportation or any other changes which may arise in
connection with a warranty claim or other issue with a PULSAR DLCM Controller

loss, damage, injury, cost or expense directly or indirectly related to the use or failure
of its products, including, but not limited to, any loss of or damage to other products,
machinery, buildings or property and any injury to persons

consequential damages (including, but not limited to, loss of time, inconvenience, loss
of product being pumped, loss of production, loss of business, or loss of contract)
Information in this manual is subject to change without notice. No part of this manual may be
reproduced, stored in a retrieval system, or transmitted in any form or any means, electronic or
mechanical, including photocopying and recording, for any purpose other than installing, operating
and maintaining the PULSAR DLCM Controller for which it is provided without the written permission
of Pulsafeeder.
FCC Warning
This equipment generates and uses radio frequency energy. If not installed and used properly, in
strict accordance with the manufacturer’s instructions, it may cause interference to radio
communications. Operation of this equipment in a residential area is likely to cause interference
in which cases the user, at his own expense, will be required to take whatever measures
necessary to correct the interference.
Copyright © 2001 - 2015 Pulsafeeder, Inc. All rights reserved.
Information in this document is subject to change without notice. No part of this publication may
be reproduced, stored in a retrieval system or transmitted in any form or any means electronic or
mechanical, including photocopying and recording for any purpose other than the purchaser’s
personal use without the written permission of Pulsafeeder.
v
Conventions
For the remainder of this bulletin, the following conventions are in effect.
A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE
EQUIPMENT AND THE PERSONNEL OPERATING IT. THIS MANUAL MUST BE CONSULTED IN
ALL CASES WHERE THE WARNING SYMBOL IS MARKED IN ORDER TO FIND OUT THE
NATURE OF THE POTENTIAL HAZARDS AND ANY ACTIONS WHICH HAVE TO BE TAKEN TO
AVOID THEM.
CAUTION, POSSIBILITY OF ELECTRIC SHOCK.
NOTES ARE GENERAL INFORMATION MEANT TO MAKE OPERATING THE EQUIPMENT
EASIER.
TIPS HAVE BEEN INCLUDED WITHIN THIS BULLETIN TO HELP THE OPERATOR RUN THE
EQUIPMENT IN THE MOST EFFICIENT MANNER POSSIBLE. THESE “TIPS” ARE DRAWN FROM
THE KNOWLEDGE AND EXPERIENCE OF OUR STAFF ENGINEERS, AND INPUT FROM THE
FIELD.
IS A PROCEDURE HEADING. A PROCEDURE HEADING INDICATES THE STARTING
 THIS
POINT FOR A PROCEDURE WITHIN A SPECIFIC SECTION OF THIS MANUAL.

Revision History
REV LEVEL
BRIEF DESCRIPTION
DATE
-
New bulletin number
08/28/2015
A
2.2 Explosive Atmosphere
11/20/2015
REVISION LOG
-
New, updated to current certified design
A
Updated atmosphere safety and warnings for explosion hazards
vi
Table of Contents
1
2
3
4
5
6
Introduction ............................................................................................................................................................. 1
1.1 Description ........................................................................................................................................................ 1
1.2 DLCM Standard Features ................................................................................................................................ 2
1.3 Options .............................................................................................................................................................. 2
1.4 Accessories ...................................................................................................................................................... 2
Safety Considerations ........................................................................................................................................... 2
2.1 General Safety .................................................................................................................................................. 2
2.2 Explosive Atmosphere Safety......................................................................................................................... 3
2.3 Electrical Safety................................................................................................................................................ 3
2.4 Fire Safety ......................................................................................................................................................... 3
2.5 Mechanical Safety ............................................................................................................................................ 4
2.6 Hydraulic Safety ............................................................................................................................................... 4
2.7 Liability Exclusion ............................................................................................................................................ 4
2.8 Pump Suitability to Site of Installation .......................................................................................................... 4
Transport and Inspection ...................................................................................................................................... 5
3.1 Consignment receipt and un-packaging ....................................................................................................... 5
3.2 Handling ............................................................................................................................................................ 5
3.3 Lifting ................................................................................................................................................................ 5
3.4 Recycling and end of product life .................................................................................................................. 5
Storage Instructions............................................................................................................................................... 5
4.1 Storage Length ................................................................................................................................................. 5
4.1.1 Short Term (0 - 12 months) .................................................................................................................. 5
4.1.2 Long Term (12 months or more) ......................................................................................................... 6
Installation ............................................................................................................................................................... 6
5.1 Location ............................................................................................................................................................ 6
5.2 Installation Notes ............................................................................................................................................. 7
5.3 Electrical Wiring ............................................................................................................................................... 7
5.3.1 Getting Started ...................................................................................................................................... 8
5.3.2 Finding your way around the Field Wiring Board ............................................................................. 9
5.4 High-Voltage Connections ............................................................................................................................ 10
5.4.1 Supply Power ...................................................................................................................................... 10
5.4.2 CE Compliance.................................................................................................................................... 11
5.4.3 PULSAR Pump Motor ......................................................................................................................... 12
5.4.4 Alarm Relay ......................................................................................................................................... 12
5.5 Low-Voltage Input Connections ................................................................................................................... 13
5.5.1 Analog Inputs ...................................................................................................................................... 13
5.5.2 Alarm Input .......................................................................................................................................... 14
5.5.3 Level Input (Remote Start/Stop) ........................................................................................................ 14
5.6 Low-Voltage Output Connections ................................................................................................................ 15
5.6.1 Current Output .................................................................................................................................... 15
5.6.2 Alarm Dry Contact Output ................................................................................................................. 16
5.6.3 Run Status or Stroke Counter ........................................................................................................... 16
5.7 Tachometer Input ........................................................................................................................................... 17
5.8 Motor Thermostat ........................................................................................................................................... 18
5.9 Serial Communications Input ....................................................................................................................... 18
5.9.1 Important Wiring Detail ...................................................................................................................... 18
5.10 Fuse Replacement ....................................................................................................................................... 19
Startup Instructions ............................................................................................................................................. 20
6.1 Overview ......................................................................................................................................................... 20
6.1.1 User Interface Familiarization ............................................................................................................ 20
6.1.2 Check Wiring and Close Access Cover ............................................................................................ 22
6.1.3 Confirm Correct Incoming Power ..................................................................................................... 22
6.1.4 Confirm Display and Keypad Functionality ..................................................................................... 23
6.1.5 Performing a Factory Re-initialization .............................................................................................. 23
6.1.6 Test Pump Motor................................................................................................................................. 24
6.1.7 Set Time and Date ............................................................................................................................... 25
6.1.8 Flow Calibration (1-point) .................................................................................................................. 25
6.1.9 Analog Input Calibration .................................................................................................................... 26
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7
8
9
10
11
12
13
14
General Operation ................................................................................................................................................ 28
7.1 General Operation Instructions .................................................................................................................... 28
7.1.1 Pump Flow Calibration .................................................................................................................... 28
7.1.2 Analog Input Signal Calibration ..................................................................................................... 32
7.1.3 Reverse Acting Analog Input Signal Calibration.......................................................................... 36
7.1.4 Analog Output Signal Calibration .................................................................................................. 37
7.2 Menu ................................................................................................................................................................ 38
7.2.1 Alarm and Error Messages ............................................................................................................. 39
7.2.2 Diagnostics ...................................................................................................................................... 40
7.2.3 Set Time and Date ........................................................................................................................... 42
7.2.4 Analog Signal Failure Setup ........................................................................................................... 44
7.2.5 MODBUS Signal Failure Setup ....................................................................................................... 47
7.2.6 Analog Output Setup ....................................................................................................................... 50
7.2.7 Motor Speed Display ....................................................................................................................... 51
7.2.8 End-Point Setup ............................................................................................................................... 51
7.2.9 Leak-Detection Failure Setup ......................................................................................................... 55
7.2.10 Level / Remote / Start-Stop Setup .................................................................................................. 57
7.2.11 Digital Output Setup ........................................................................................................................ 59
7.2.12 Motor Thermostat Setup ................................................................................................................. 61
7.2.13 Over Temperature Setup ................................................................................................................. 62
7.2.14 Power Failure Setup ........................................................................................................................ 63
7.2.15 Alarm Relay ...................................................................................................................................... 64
7.2.16 Analog Mode .................................................................................................................................... 64
7.2.17 MODBUS Mode ................................................................................................................................ 67
7.2.18 Security............................................................................................................................................. 69
7.2.19 Number Format ................................................................................................................................ 71
7.2.20 Contrast Adjust ................................................................................................................................ 71
7.2.21 Serial Communications ................................................................................................................... 72
7.2.22 Serial Diagnostics ........................................................................................................................... 74
7.2.23 Language .......................................................................................................................................... 77
7.2.24 Factory Defaults Reset Procedure ................................................................................................. 77
7.3 Units ................................................................................................................................................................ 78
7.4 Varying the Flow Rate - Manually ................................................................................................................. 78
7.5 Mode ................................................................................................................................................................ 79
7.6 Batch ............................................................................................................................................................... 79
7.6.1 One-Time Only ................................................................................................................................. 79
7.6.2 Repeating ......................................................................................................................................... 80
7.6.3 Overlapped ....................................................................................................................................... 80
Diagrams: Installation / Component ................................................................................................................... 84
Specifications ....................................................................................................................................................... 86
Factory Default Values ......................................................................................................................................... 89
Troubleshooting Guide ........................................................................................................................................ 92
11.1 System Diagnostics .................................................................................................................................... 92
11.2 Encoder Diagnostics................................................................................................................................. 100
11.2.1 Troubleshooting ............................................................................................................................ 101
11.2.2 Encoder/Gear Train Access.......................................................................................................... 103
11.2.3 Encoder Replacement ................................................................................................................... 104
11.2.4 Tachometer Troubleshooting ....................................................................................................... 105
Conversion (Manual to DLCM) .......................................................................................................................... 108
General Repairs .................................................................................................................................................. 110
13.1 Emergency Manual Pulsar Operation ..................................................................................................... 110
13.2 DLCM Removal and Replacement ........................................................................................................... 110
PULSAnet Specification .................................................................................................................................... 116
14.1 Introduction ............................................................................................................................................... 116
14.2 Operational Overview ............................................................................................................................... 116
14.3 MODBUS Messaging ................................................................................................................................. 117
14.4 PULSAnet DDE Server Messaging .......................................................................................................... 117
14.5 Coils ............................................................................................................................................................ 118
14.6 Input Bits (1X References) ....................................................................................................................... 118
14.7 Input Registers .......................................................................................................................................... 119
viii
14.8 Holding Registers ...................................................................................................................................... 119
14.9 MODBUS Mode .......................................................................................................................................... 124
14.9.1 Introduction .................................................................................................................................... 124
14.9.2 General Discussion ....................................................................................................................... 124
15 Spare Parts .......................................................................................................................................................... 124
ix
1
Introduction
The DLCM is an advanced microprocessor based controller designed for use with the PULSAR
diaphragm metering pump. It controls the output of the pump by varying its stroke rate and the
amount of fluid discharged with each stroke. It has many advanced features that allow it to
operate in a wide variety of industrial environments. The operation and maintenance of the
PULSAR metering pump is covered in the pump IOM. Please refer to this IOM for important
safety and operational instructions for your PULSAR pump.
This instruction manual covers all standard features of the DLCM and where applicable, specific
options.
1.1 Description
The DLCM integrates a motor speed controller and a stroke length controller into a single pump
mounted package. Its purpose is to precisely adjust the flow of a process media by adjusting the
pump motor speed and stroke length.
The DLCM is designed for the international industrial market. The device is factory configured
and calibrated for the attached pump. The man/machine interface is user friendly. Local setup
and control is achieved through the nine button keypad and a back-lit two-line liquid crystal
display. Pump output is displayed as a percentage of stroke length position and motor speed, or
in units of calibrated flow: CMH, GPH, LPH, CCH, CMM, GPM, LPM, or CCM. In addition, the
DLCM display supports any one of four languages: English, French, German or Spanish.
The DLCM supports a variety of remote control options. These inputs and outputs are fully
isolated for improved protection and reliability. A Batch feature, with up to three independent
programs, supplements the control features and allows for greater flow turn down.
The DLCM includes the PULSAnet Serial Communications system. This allows the DLCM to
interface digitally to other DLC’s, DLCM’s, PLC’s, or PC’s using the MODBUS™ communications
protocol over a 4 wire RS-485 network.
The DLCM is designed to simplify and automate the calibration of pump flow and analog signals.
Flow calibration uses on-screen prompting, automated pump operation, and automatic curve
fitting to eliminate the need for stop-watches, calculators and reduces the possibility of human
error. Analog signal calibration is also accomplished by simple key-pad entry. It includes real-time
display of signal levels.
This eliminates the need for external meters.
The DLCM readily accepts PULSAlarm leak detection, Level-Input detection or Remote
Start/Stop station inputs that can be configured to stop the pump and/or activate an alarm relay.
THE REMOTE START/STOP CANNOT BE CONFIGURED TO ACTIVATE THE ALARM
RELAY.
Failures are time and date stamped into memory for later retrieval. Other diagnostics include
analog signal failure and line power failure monitoring. These are also time and date stamped and
may be preset to control stroke position or motor status upon detection of a failure.
Security password protection may be activated to prevent tampering. All settings and diagnostics
have a battery back-up for up to 10 years in the absence of power.
The DLCM is available in any combination of 120/240 VAC, 50/60Hz. Protection exists to prevent
damage against over or under voltage conditions in the event the wrong power line source is
used.
1
1.2 DLCM Standard Features













DC Motor Speed Control with tachometer feedback
Manual Stroke Length Control
Keypad
Back-lit 2 line 16 character LCD display
NEMA 4X Enclosure
Two 4-20mA inputs for independent speed and stroke length control
One 4-20mA output
MODBUS RS-485 Serial Communications
10-Year Battery Backed Clock
Solid State Alarm Relay
Level Input/Remote Start-Stop Inputs
PULSAlarm Leak-Detection Interface
Diagnostics
1.3 Options

Operating Voltage/Frequency
1.4 Accessories

PULSAnet MODBUS DDE Server
2 Safety Considerations
The DLCM is a sophisticated microprocessor based controller for use only with PULSAR
diaphragm metering pumps. It yields tremendous control capacity – electrical, mechanical and (in
conjunction with the PULSAR pump) hydraulic in nature. In consideration of SAFETY, the user
should be mindful of this relative to his/her safety, that of co-workers and of the process
environment. Consider the following prior to the installation and operation of a DLCM controlled
PULSAR metering pump.




Read and understand all related instructions and documentation before attempting to install or
maintain this equipment
Observe all special instructions, notes, and cautions.
Act with care and exercise good common sense and judgment during all installation,
adjustment, and maintenance procedures.
Ensure that all safety rules, work procedures, and standards that are applicable to your
company and facility are followed during the installation, maintenance, and operation of this
equipment.
2.1 General Safety
The DLCM was designed as a motor speed controller and stroke length position actuator for
operation solely with the PULSAR metering pump. Use for any other application is considered unsafe and voids all certification markings and warranties.
2
2.2 Explosive Atmosphere Safety
EXPLOSION HAZARD -- DO NOT PERFORM INSTALLATION, CALIBRATION, OR
MAINTENANCE OF ANY KIND ON THIS DEVICE WHILE CIRCUIT IS LIVE AND/OR THE
AREA IS KNOWN TO BE HAZARDOUS.
Under expected operating conditions, and with the proper marking, this equipment is suitable for
use in:
1. Class I, Division 2, Groups A, B, C, D Hazardous Locations;
2. Class 1, Zone 2, Groups IIC
3. Non-hazardous locations only
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D or non-hazardous
locations only.
EXPLOSION HAZARD -- DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
ROMOVED OR THE AREA IS KNON TO BE NON-HAZARDOUS.
EXPLOSION HAZARD – SUBSTITUTION OF ANY COMPONENTS MAY IMPAIR SUITABILITY
FOR CLASS I, DIVISION 2.
EXPLOSION HAZARD – DO NOT REMOVE OR REPLACE FUSES UNLESS POWER HAS
BEEN DISCONNECTED OR THE AREA IS KNOWN TO BE FREE OF IGNITIBLE
CONCERNTRATIONS OF FLAMMABLE GASES OR VAPORS.
2.3 Electrical Safety
The DLCM can be considered an industrial stroke length controller with an integrated motor
speed controller. Improper application and use can be hazardous. You are solely responsible for
its use.
The DLCM's electrical installation must conform to all relevant electrical codes. Installation and
electrical maintenance must be performed by a qualified electrician.
Before installing or servicing this device, all power must be disconnected from the source at the
main distribution panel. Certain calibration functions must be completed while the electronic section
of the unit is exposed and power is applied to the unit, be certain to ensure that proper procedures
are followed and that fingers, tools, and wiring do not contact exposed circuitry and components.
The DLCM emits electro-magnetic energy and generates radio frequency interference. Its use is
restricted to industrial applications. The user bears all responsibility for shielding this
energy/interference.
2.4 Fire Safety
US & Canada Only
In case of electrical fire, use a Class C fire extinguisher. Fire extinguishers with a Class C rating are
suitable for fires in “live” electrical equipment. Never use water to extinguish a Class C fire.
Class C fires involve electrical equipment, such as appliances, wiring, circuit breakers and outlets.
Never use water to extinguish class C fires - the risk of electrical shock is far too great! Class C
extinguishers do not have a numerical rating. The C classification means the extinguishing agent is
non-conductive. This class is typically represented by a geometric symbol (blue circle).
Always refer to your country’s occupational, health & safety regulations to ensure the correct fire
extinguisher classification.
3
2.5 Mechanical Safety
When properly installed, the device has only one externally accessible moving part – the hand
adjustment knob. This component is under computer control and as such may actuate without
warning. Care should be taken to keep loose clothing away from this component. Hands and
fingers should be kept clear while the knob is turning under DLCM control.
The DLCM was designed to be service free. It contains no user-maintainable components.
Removal of the entire DLCM as an assembly from the pump is permissible. Do not disassemble
the DLCM enclosure unless instructed to do so in this manual. Evidence of disassembly shall void
the warranty.
2.6 Hydraulic Safety
Thoroughly review and adhere to the contents of the PULSAR Installation, Operation,
Maintenance and Instruction manual, for hydraulic installation of your PULSAR metering pump.
As a microprocessor-controlled device, the DLCM may activate the pump motor without warning
– generating hydraulic pressure and fluid flow. Care should be taken to protect both users and
systems should the pump activate.
2.7 Liability Exclusion
Pulsafeeder, Inc. is unable to monitor the observance of the instructions given in this manual, nor
verify the actual working conditions and installation of the equipment, the correct operation and
maintenance of the equipment and accessories. An incorrect installation, or misuse of the
equipment, may cause serious damage and may pose a danger to persons or property. Any
anomalies must be reported to the maintenance supervisor.
ATTEMPTS TO DISASSEMBLE, MODIFY OR TAMPER IN GENERAL BY UNAUTHORIZED
PERSONNEL WILL VOID THE GUARANTEE AND WILL RELEASE PULSAFEEDER, INC.
FROM ANY LIABILITY FOR DAMAGE CAUSED TO PERSONS OR PROPERTY RESULTING
FROM SUCH ACTIONS.
Pulsafeeder, Inc. is considered released from any liability in the following cases:







improper installation;
improper use of the equipment by non-professional or inadequately trained operators
use not in compliance with regulations in the Country of use;
lack of maintenance or improperly performed;
use of non-original spare parts or incorrect parts for the model in question;
total or partial failure to observe the instructions;
exceptional environmental events.
2.8 Pump Suitability to Site of Installation
Essential safety requirements against explosion hazard in dangerous areas are regulated by
European directives 94/9/CE dated 23rd of March 1994 (concerning equipment and devices)
Upon equipment receipt, verify that pumps have not received any damage due to transportation and
are complete with every eventual accessory. In case anomalies or damages are discovered prior to
installation, please contact PULSAFEEDER, INC. Technical Service.
The following standards apply to this product:




ISA 12.12.01-2013
UL 840
UL 508
CSA C22.2 No. 14-13
4
3 Transport and Inspection
3.1 Consignment receipt and un-packaging
Immediately after receipt of the equipment it must be checked against the delivery/shipping
documents for its completeness and that there has been no damage in transportation.
Check any crate, boxes or wrappings for any accessories or spare parts that may be packed
separately with the equipment or attached to side walls of the box or equipment.
Each product is marked with a unique serial number. Check that this number corresponds with the
documentation, and always reference this number in correspondence as well as when ordering
spare parts or accessories.
Shortages or damage should be reported immediately to the carrier and your Pulsafeeder
Representative.
3.2 Handling
Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on
their size and construction.
3.3 Lifting
A crane must be used for all controller/pump sets in excess of 25 kg (55 lb). Fully trained personnel
must carry out lifting, in accordance with local regulations.
Slings, ropes and other lifting gear should be positioned where they cannot slip and where a
balanced lift is obtained.
3.4 Recycling and end of product life
This device is RoHS compliant, and should be disposed of in accordance with current regulations.
Make sure that hazardous substances are disposed of safely and that the correct personal
protective equipment is used. The safety specifications must be in accordance with the
current regulations at all times.
4 Storage Instructions
The DLCM can be successfully stored for extended periods. The key to this success is
temperature and humidity control.
4.1 Storage Length
4.1.1 Short Term (0 - 12 months)
The DLCM should be stored in a temperature and humidity controlled environment. It is preferable
to keep the temperature constant in the range of -18 to 40° Celsius (0 to 104° Fahrenheit). The
relative humidity should be 0 to 90% non-condensing.
THE ADJUSTMENT KNOB SHOULD BE ROTATED IN ALTERNATE DIRECTIONS BY HAND
ONE FULL REVOLUTION EVERY SIX MONTHS.
If the DLCM is installed on the pump, it should not be removed during this period – provided the
above conditions can be applied to the pump as well. If the DLCM is removed from the pump, it
should be stored in the same pump mounted orientation. After removal of the DLCM from the
PULSAR metering pump, seal the eccentric box opening with a dust and moisture proof material.
If the DLCM was shipped in its own carton, it should be stored in that carton.
5
4.1.2 Long Term (12 months or more)
Storage of the DLCM for periods of longer than twelve months is not recommended. If extended
storage is unavoidable the DLCM should be stored in accordance with those conditions stipulated
for Short Term Storage. In addition, a porous bag of 85g (3 oz) silica gel or similar desiccant should
be placed beneath the wiring access cover. The cover should be re-installed to seal the desiccant
within the enclosure. The three conduit connections must be tightly capped. Inspect the unit
carefully for any signs of damage and remove the desiccant before placing it into operation.
SPECIAL NOTE FOR LONG-TERM STORAGE:
IF AC INPUT POWER HAS NOT BEEN APPLIED TO THE DLCM FOR A PERIOD GREATER
THAN 12 MONTHS, THE CONTROLLER MUST BE PREPARED FOR OPERATION. THE DLCM
SHOULD HAVE AC POWER APPLIED AT THE INPUT FOR A PERIOD OF 8 HOURS BEFORE
PLACING PUMP INTO NORMAL OPERATION. REFER TO INSTALLATION AND WIRING
SECTION FOR AC POWER CONNECTION INSTRUCTIONS.
5 Installation
5.1 Location
REVIEW THE SAFETY SECTION PRIOR TO INSTALLING THE DLCM. IT CONTAINS
INFORMATION REQUIRED TO PROPERLY INSTALL AND OPERATE THE DLCM IN AN
INDUSTRIAL ENVIRONMENT.
The site selected for the installation of your DLCM is largely dependent on that of the PULSAR
metering pump. Review the PULSAR Installation Operation Maintenance Instruction Manual
provided with your PULSAR metering pump. It details system related issues that are important to
proper operation of the PULSAR metering pump.
Consider the following DLCM related issues when selecting a site.



The DLCM should be mounted in an area where the operator has access to the front of the unit
and a clear view of the display panel and keyboard.
Avoid locations where the DLCM would be subjected to extreme cold or heat.
Note the warning statement on the next page. The installation of this device must comply with
national, state and local codes.
Figure 1 – Typical Installation
6
AVOID LOCATIONS WHERE THE DLCM WOULD BE SUBJECTED TO EXTREME COLD OR
HEAT [LESS THAN –18ºC (0ºF) OR GREATER THAN 40ºC (104ºF)] OR DIRECT SUNLIGHT.
FAILURE TO OBSERVE THIS WARNING COULD DAMAGE THE DLCM AND VOID ITS
WARRANTY.
5.2 Installation Notes
1. The DLCM is a microprocessor based controller that uses electro-static sensitive CMOS
components. Do not make any electrical connections (high or low voltage) without
adequately grounding the DLCM and the worker to eliminate an electro-static charge
between the two. A conductive wrist strap worn by the worker and attached to the DLCM
enclosure is adequate to satisfy this requirement.
2. Calibration is an important element of successful DLCM operation. Permanent
installation of a calibration column as depicted in Figure 1 is strongly recommended.
3. Conduit connections can carry fluids and vapors into the DLCM causing damage and
void the warranty. In accordance with any applicable codes provide sealed entries and
conduit drains near the point of entry as required. Care should be taken when installing
conduit to protect against fluid/vapor entry. If necessary, provide sealed entries or
conduit drains near the point of entry.
5.3 Electrical Wiring
The DLCM has many advanced features that may make wiring the unit appear complicated.
Wiring is actually very simple – one high-voltage connection is all that is required to take
advantage of a majority of the DLCM's features. It is highly recommended that you take a stepby-step approach to wiring and confirming proper DLCM operation:
1. Make the high-voltage connection. These will allow you to operate the DLCM and
attached PULSAR pump.
2. Power-up and test the DLCM to confirm the connections and check for proper operation.
3. Power-down the DLCM.
4. Decide which low-voltage Inputs (e.g., 4-20mA in) will be used and make those
connections.
5. Power-up and test the DLCM to confirm the connections and check for proper operation.
6. Power-down the DLCM.
7. Decide which low-voltage outputs (e.g., 4-20mA out) will be used and make those
connections.
8. Conduct a final power-up and test the DLCM to confirm the connections and check for
proper operation.
9. Go to Section 6: Startup Instructions for details on how to perform the power-up tests.
7
5.3.1 Getting Started
The field wiring of the DLCM is accomplished through a rear access cover at the back of the unit
– near the PULSAR gearbox and motor. The access panel is opened by removing the 4 retaining
screws (Phillips head screw driver required). Removal reveals the Field Wiring Board (refer to
Figure 2).
Figure 2 – Accessing the Field Wiring Board
THE FIELD WIRING ACCESS COVER HAS THE SERIAL NUMBER TAG ON IT. KEEP THE
COVER WITH THE DLCM IT WAS REMOVED FROM. THE DLCM IS MARKED INTERNALLY
WITH THE SERIAL NUMBER. THE INTERNAL MARKING WILL BE USED FOR WARRANTY
CLAIMS.
The Field Wiring Board (refer to Figure 2) contains wiring blocks for making all of the electrical
connections. It is mechanically attached to the Conduit Adapter. The adapter in conjunction with
the Field Wiring Board forms a modular connector or plug. This allows the DLCM to be removed
from the PULSAR unit without disturbing the conduit connections.
REMOVE THE CONDUIT ADAPTER AND FIELD WIRING BOARD FOR DLCM
REPAIR/REPLACEMENT PURPOSES ONLY (REFER TO SECTION 12: BASIC REPAIRS) FOR
FURTHER INFORMATION.
8
5.3.2 Finding your way around the Field Wiring Board
The electrical connections are segregated on the Field Wiring Board. The high-voltage
connections are on the right-half side while the low-voltage connections are on the left. Refer to
Figure 3, Field Wiring Board for specific connection and fuse locations.
Figure 3 - Field Wiring Board
9
5.4 High-Voltage Connections
There are only three high-voltage connections to be made on the DLCM: supply power (J1),
PULSAR motor load (J3), and Alarm Relay Load (J2). Only the supply power and PULSAR motor
load connections are required. Refer to Figure 4 for connection location.
Figure 4 – High-Voltage Connections
THE POSITIVE (+) AND NEGATIVE (-) WIRES MAY NOT BE LABELED. DO NOT BE
CONCERNED WITH POLARITY WHEN HOOKING UP THE MOTOR. IT DOES NOT MATTER
WHAT DIRECTION THE MOTOR ROTATES.
5.4.1 Supply Power
THE DLCM REQUIRES ONE CONNECTION TO AN EXTERNAL POWER SOURCE. IT USES
THIS SAME CONNECTION TO POWER ITS OWN SUPPLY, THE DC PUMP MOTOR AND THE
ALARM RELAY OUTPUT. YOU MUST TAKE THESE EXTERNAL LOADS INTO
CONSIDERATION WHEN SIZING THE BRANCH CIRCUIT.
The DLCM with attached PULSAR motor is not fuse protected. You are responsible for correctly
sizing the protection element (i.e., fuse or circuit breaker at the distribution panel). Use the work
sheet on the next page for correctly sizing the branch protection element.
10
The DLCM, with an attached pump motor and alarm load, should be connected to its own branch
circuit. Size the supply wire and protective element according to local code requirements. Use 14
AWG, 105˚C insulation wire or better. Attach the supply to the J1 terminal block labeled 'LINE
POWER IN'. Make 3 connections: Neutral, Earth (ground) and Hot as labeled.
115VAC +/- 10%
50/60 Hz
230VAC +/- 10%
50/60 Hz
Device
Current Requirement (Amp)
Device
Current Requirements (Amp)
DLCM
1A
(1A Max.)
DLCM
.5A
(.5A Max.)
Pump Motor*
+
(8A Max.)
Pump Motor*
+
(5A Max.)
Alarm Relay*
+
(1A Max.)
Alarm Relay*
+
(1A Max)
Total**
=
Total**
=
*In-rush current requirements should be considered. All values RMS.
**Calculation is for guideline purposes only. User must consult local electrical codes when sizing
branch circuits. Protection must not exceed 10Amps RMS at 115VAC or 5.5Amps RMS at
230VAC.
Branch Circuit Protective Element Sizing Worksheet
The operating voltage and frequency of the DLCM are factory configured – an internal motor and
capacitor are sized according to voltage and frequency. If the power supplied to the unit does not
match the factory configuration, the DLCM will display either an {OVER VOLTAGE} or {UNDER
VOLTAGE} diagnostic message on power-up. This is possible because the microprocessor and
display are powered by a switching power supply. It detects the incoming power and selfregulates its output. This power supply is protected by a 7.4 Joule surge suppression device. The
microprocessor will not operate the internal stroke adjustment motor, potentially causing damage,
until the voltage problem is corrected.
HIGH-VOLTAGE CIRCUITS (E.G., BRANCH) SHOULD BE RUN IN SEPARATE CONDUIT. DO
NOT COMBINE HIGH-VOLTAGE (I.E., GREATER THAN 100VAC) LINES AND LOW-VOLTAGE
(I.E., LESS THAN 32VDC) LINES IN A COMMON CONDUIT! FAILURE TO COMPLY WILL
RESULT IN ELECTRICAL INTERFERENCE THAT MAY RESULT IN IMPROPER (AND
POSSIBLY UNSAFE) OPERATION.
5.4.2 CE Compliance
The DLCM’s DC motor, when running, can generate conducted emissions in excess of the limits
specified by EN55011. To suppress these emissions a Line Filter kit (NP530314-000: Kit, Line
Filter DLCM CE) must be installed in the distribution panel between the DLCM and the Protection
Element as shown in Figure 4.1 Line Filter Installation.
NOTE: THE LINE FILTER MUST BE INSTALLED BETWEEN THE PROTECTION ELEMENT
AND DLCM. IT IS SIZED TO SUPPLY POWER TO ONLY ONE (1) DLCM. DO NOT FEED
MULTIPLE DLCM’S THROUGH A SINGLE LINE FILTER.
FIGURE 4.1 LINE FILTER INSTALLATION
11
5.4.3 PULSAR Pump Motor
In most cases the DLCM is supplied with a factory installed DC motor. If a motor was not
supplied, it is important to select the proper type. Refer to the chart below for acceptable DLCM
motors (refer to Section 9: Specifications for motor details):
MOTORS MUST BE PERMANENT MAGNET, SCR DRIVE RATED DC MOTORS. THE DLCM
CANNOT CONTROL MOTORS WITH SEPARATE FIELD WINDINGS.
Part Number
Developed HP
Armature Voltage
Full Load Current
Enclosure Type
90 V
90 V
2.5 amps
3.2 amps
TENV
TENV
180 V
180 V
1.6 amps
5.0 amps
TENV
TENV
For 115 V line power
NP500059-000
NP500050-000
1/4 HP
1/3 HP
For 230 V line power
NP500051-000
NP500053-000
1/3 HP
1.0 HP
Connect the permanent magnet DC pump motor to the J3 terminal block labeled 'PUMP MOTOR
OUT AC/DC’. Use 14 AWG, 105˚C insulation wire size or larger. If the DLCM supply voltage is
115VAC, you must use a 90Volt Armature motor. If the DLCM supply voltage is 230VAC, you must
use a 180Volt Armature motor.
THE DLCM USES SOLID-STATE RELAYS FOR ITS HIGH-VOLTAGE OUTPUTS (I.E., MOTOR
AND ALARM). IN THE 'OFF' STATE, THESE DEVICES TYPICALLY LEAK 20-30MA OF
CURRENT AT THE SUPPLY VOLTAGE TO THE ATTACHED DEVICE (OR TERMINAL
BLOCK)! THE SUPPLY POWER MUST BE DISCONNECTED AT THE MAIN BEFORE
WORKING ON ELECTRICAL CONNECTIONS OR ANY MOVING PUMP COMPONENTS (E.G.,
MOTOR, GEAR TRAIN, ETC.).
DOUBLE CHECK ALL CONNECTIONS TO CONFIRM GOOD ELECTRICAL CONTACT
BETWEEN THE TERMINAL BLOCK CLAMPS AND BARE WIRE. MAKE SURE THE CLAMP
IS ON THE WIRE, NOT THE INSULATION. INSURE THAT BARE WIRE IS NOT FRAYED AND
DOES NOT RISE ABOVE THE DIVIDERS BETWEEN TERMINALS.
At high motor turndown settings the DC motor can overheat under certain conditions. Nonstandard motors must include built-in thermal protection and a dry contact thermal switch for
connection to the DLCM’s Motor Thermostat input. 5.8: Installation, Motor Thermostat for
additional information.
5.4.4 Alarm Relay
The Alarm Relay is an output that is configured by the operator. Refer to Section 7: General
Operation for specific instructions on how to activate the Alarm Relay. The Alarm Relay Load
must not exceed 1 Amp at rated voltage. Connect the Alarm load to the J2 terminal block labeled
'ALARM RELAY OUT.' Use 14 AWG wire size or larger. Make three connections: Neutral, Earth
(ground) and Hot as labeled.
12
5.5 Low-Voltage Input Connections
There are two types of low-voltage inputs: Current (e.g., 4-20mA) and Dry Contact. The LowVoltage Input connection block is labeled J4 'INPUT' (refer to Figure 5). It contains four pairs of
inputs: Current 1, Alarm, Level and Current 2.
Figure 5 – Low-voltage Input
THE DRY CONTACT INPUTS ARE SELF-POWERED. SUPPLY ONLY A MECHANICAL
SWITCH CLOSURE TO ACTIVATE. DO NOT ATTACH EXTERNALLY POWERED
CIRCUITRY.
THE WIRE USED TO CONNECT LOW-VOLTAGE INPUTS, AND SERIAL COMMUNICATIONS
SHOULD BE RUN IN A CONDUIT SEPARATE FROM THE HIGH-VOLTAGE POWER. DO NOT
COMBINE HIGH-VOLTAGE (I.E., GREATER THAN 100VAC) LINES AND LOW-VOLTAGE (I.E.,
LESS THAN 32VDC) LINES IN A COMMON CONDUIT! FAILURE TO COMPLY WILL CAUSE
ELECTRICAL INTERFERENCE THAT MAY RESULT IN IMPROPER (AND POSSIBLY
UNSAFE) OPERATION.
5.5.1 Analog Inputs
The DLCM can accept either one or two analog input signals. These signals ultimately control the
pump’s flow. Analog Input #1 is used to control both the pump stroke length and speed (refer to
the note below) or the pump length stroke only. When Analog Input #2 is used, it controls motor
speed only.
THE DLCM CAN OPERATE USING ONLY ANALOG INPUT #1 TO CONTROL BOTH STROKE
LENGTH AND MOTOR SPEED. IF THIS IS THE DESIRED MODE OF OPERATION, THE
INSTALLED SOFTWARE WILL DETERMINE WHAT STROKE AND SPEED ARE REQUIRED
TO PRODUCE THE DESIRED FLOW RATE (REFER TO SECTION 7: GENERAL
OPERATION, END-POINT SETUP FOR FURTHER INFORMATION.
The Analog input accepts current inputs in the range of 0 to 25mA (e.g., 4-20mA) provided the
'span,' (the difference between the High and Low value), is greater than 2mA. Voltage signals in
the 0-5 volt range are accepted but displayed as current during Analog Input calibration.
Split-ranging, reverse acting, and ratio control are accomplished in the calibration routine in
Section 7: General Operation. No hardware adjustments are required. The channels are
electrically isolated, surge protected and fused for protection. The inputs are designed to avoid
damage in the event high-voltage is inadvertently applied.
To make the Stroke Length Control connection, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire for
13
hookup. Attach the analog signal generated by an external device (e.g., PLC) to the connection
points labeled '1-CURRENT1(+)' and '2-CURRENT1(-)' on the J4 terminal block labeled 'INPUT'
(refer to Figure 5). Attach the Positive lead to position 1 and the Negative lead to position 2.
To make the Motor Speed Control connection, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire for
hookup. Attach the analog signal generated by an external device (e.g.: PLC) to the connection
points labeled '7-CURRENT2(+)' and '8-CURRENT2(-)' on the J4 terminal block labeled 'INPUT'
(refer to Figure 5). Attach the Positive lead to position 7 and the Negative lead to position 8.
Position indicators are printed on the circuit board above the terminal. The DLCM will provide
approximately 200 ohms of resistance to a current loop. Each Analog Input is isolated from all
other inputs, outputs and earth ground. Follow the instructions in Section 7: General Operation
for Analog Input signal calibration and setup.
5.5.2 Alarm Input
The Alarm Dry Contact Input is designed to operate with the PULSAlarm leak-detection option. It
is software configurable to generate an alarm, activate the alarm relay and/or shut down the
PULSAR motor. The input is internally powered – only a mechanical switch closure is required for
activation. Use 0.32mm2 – 0.52m2 (22-20 AWG) wire. Attach one side of the switching device to
the position labeled '3-ALARM(+)' and the other side to the position labeled '4-ALARM(-)' of
connector J4-INPUT (refer to Figure 5). A resistance of 15K ohms or less is required across the
two connections for proper detection. Follow the instructions in Section 7: General Operation
for Alarm Input (Leak-Detection) software setup.
5.5.3 Level Input (Remote Start/Stop)
The Level Dry Contact Input is designed to monitor a single-point Level Input sensor and generate an
alarm, activate the alarm relay and/or shut down the PULSAR motor. It can also be used with a
Remote Start/Stop station (Dry Contact switch) to start and stop the pump’s motor. The input is
internally powered, only a mechanical switch closure is required for activation. Use 0.32mm2 –
0.52mm2 (22-20 AWG) wire. Attach one side of the switching device to the position labeled '5LEVEL(+)' and the other side to the position labeled '6-LEVEL(-) of connector J4-INPUT (refer to
Figure 5). A resistance of 15K ohms or less across the two terminals is required for proper
detection. Follow the instructions in Section 7: General Operation for Level / Start-Stop setup.
14
5.6 Low-Voltage Output Connections
There are two types of low-voltage outputs: Analog (e.g., 4-20mA) and Transistor based Dry
Contact. The Low-Voltage Output connection block is labeled J5 'OUTPUT' (refer to Figure 6). It
contains three- pairs of outputs: Current, Alarm and Motor Status/Stroke.
THE TRANSISTOR BASED DRY CONTACT OUTPUTS ARE OPTICALLY ISOLATED. TO
ACHIEVE TOTAL ISOLATION, THEY ARE NOT SELF-POWERED. THE EXTERNAL DEVICE
MUST SUPPLY AND DETECT A RETURN VOLTAGE LEVEL (32VDC MAX).
THE WIRE USED TO CONNECT LOW-VOLTAGE INPUTS, OUTPUTS AND SERIAL
COMMUNICATIONS SHOULD BE RUN IN A CONDUIT SEPARATE FROM THE HIGHVOLTAGE POWER. DO NOT COMBINE HIGH-VOLTAGE (I.E., GREATER THAN 100VAC)
LINES AND LOW-VOLTAGE (I.E., LESS THAN 32VDC) LINES IN A COMMON CONDUIT!
FAILURE TO COMPLY WILL RESULT IN ELECTRICAL INTERFERENCE THAT MAY
RESULT IN IMPROPER (AND POSSIBLY UNSAFE) OPERATION.
Figure 6 – Low-voltage Output
5.6.1 Current Output
The Current Output Channel can follow one of three signals:
1. Calibrated flow
2. Calibrated stroke length
3. True motor speed
It is calibrated to source current in the 0 to 20mA range (e.g., 4-20mA). The output can be
calibrated for reverse acting and split ranging and control. Refer to Section 7: General
Operation, Calibration for further details.
Current Output is used to control slave devices (e.g., DLCM's, ELMA's, PULSAMATIC’s, etc.) or
to fulfill closed loop system requirements. Attach the connection points labeled '1-CURRENT (+)
and '2- CURRENT (-)' on connector J5-OUTPUT (refer to Figure 6) to the external device. Use
0.32mm2 – 0.52mm2 (22-20 AWG) wire. Attach the Positive lead to position 1 and the Negative
lead to position 2. The analog output will drive against a maximum load of approximately 700
15
ohms. Thus, a single DLCM Analog Output could be used to drive two slave DLCM's. They, in
turn, could each drive two additional slaves. The Analog Output is isolated from all other inputs,
outputs and earth ground. Follow the instructions in Section 7: General Operation, Analog
Output Signal Calibration.
5.6.2 Alarm Dry Contact Output
The Alarm output is a solid state transistor closure. It indicates the present state of the alarm
relay output. If the Alarm Relay is on, the Alarm Dry Contact will be closed. If the Alarm Relay is
off, the Alarm Dry Contact will be open. It is commonly used to indicate an alarm status to
external control equipment (i.e., PLC, PC or other Manual controllers). Refer to Figure 6.
VCC (+5VDC) AND GROUND ARE PROVIDED ON TERMINALS 7 AND 8 OF CONNECTOR
J5. A 250 OHM RESISTOR FROM TERMINAL '7-VCC' TO TERMINAL '3-ALARM(+)' WILL
CAUSE A +5VDC SIGNAL TO APPEAR BETWEEN TERMINALS '4-ALARM(-)' AND '8DCGND' WHEN THE ALARM RELAY IS ON. THIS TECHNIQUE IS ONLY RECOMMENDED IF
THE INPUT ON THE EXTERNAL DEVICE IS ISOLATED FROM ALL OTHER INPUTS,
OUTPUTS AND GROUNDS.
An opto-coupler is used to achieve total isolation of this output. As such, the external control
equipment must generate the supply on the positive output and detect the return of that signal
from the DLCM. In a typical application, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire to attach the
terminal labeled '3-ALARM(+)' – the collector terminal – to the external equipment's logic supply.
Connect the terminal labeled '4-ALARM(-)' – the emitter terminal – to the positive input of the
equipment. The negative input of the equipment should be connected to its isolated ground. A
series resistance of 400 ohms is recommended – especially when sinking current (e.g., a photodiode of an opto-isolator). The Alarm output cannot be separately configured in the software, it
follows the Alarm Relay output.
5.6.3 Run Status or Stroke Counter
The Status output can be configured through software to indicate that the pump motor is on or to
generate a pulse with every pump stroke (for use with an external stroke counter). The factory
default for this output is to indicate Pump Motor Status. The Stoke output is not in phase with the
pump stroke but has a 50% duty cycle (e.g., the output is ON for half of the stroke and OFF for
the other half.).
An opto-coupler is used to achieve total isolation of this output. As such, the external control
equipment must generate the supply on the positive output and detect the return of that signal from
the DLCM. In a typical application, use 0.32mm2 – 0.52mm2 (22-20 AWG) wire to attach the
terminal labeled '5-STATUS(+)' – the collector terminal – to the external equipment's logic supply.
Connect the terminal labeled '6-STATUS(-)' – the emitter terminal – to the positive input of the
equipment. The negative input of the equipment should be connected to its isolated ground. A
series resistance of 400 ohms is recommended – especially when sinking current (e.g., a photodiode of an opto-isolator).
THERE IS ALSO AN INTERNAL STROKE COUNTER THAT IS RE-SETTABLE. REFER TO
SECTION 7.2: MENU – DIAGNOSTICS, DIAG. MENU 11/11.
16
5.7 Tachometer Input
The Tachometer Sensor is connected to the Tachometer Input. It senses motor rotation. This
input allows the DLCM to control motor speed.
Figure 7 – Tachometer Sensor Conduit Assembly
Figure 8 – Tachometer and Pump Motor Thermostat Connections
To connect the Tachometer Input, connect the wire labeled VDC (typically brown) to the
connection point labeled 1–TACH [+] on connector J-10 CONTROL. Connect the wire labeled
TACH (typically blue) to the connection point labeled 2–TACH [-] on connector J-10 CONTROL.
Make these connections using the 22 AWG wire provided with the Tachometer Sensor (refer to
Figure 8).
For additional information relating to the Tachometer Sensor, refer to Section 13: Repairs, DLCM
Replacement.
THE TACH INPUT IS DESIGNED FOR USE WITH THE SUPPLIED SENSOR ONLY. DO NOT
ATTEMPT TO USE ANY OTHER DEVICE (E.G.: MOTOR BASED TACHOMETER OUTPUTS).
17
5.8 Motor Thermostat
The motor thermostat has been supplied as an equipment safety measure. This allows the DLCM
pump motor to operate without the danger of overheating the motor windings.
In the event that the internal temperature of the motor exceeds the motor manufacturer’s
specification, the DLCM can be configured to:
1) Turn the motor off.
2) Sound an alarm.
3) Restart the motor when the temperature lowers to a safe level.
IT IS PERMISSIBLE TO RUN THE PUMP MOTOR THERMOSTAT IN THE SAME CONDUIT AS
THE PUMP MOTOR POWER. THE SIGNAL IS CONDITIONED TO PREVENT ERRONEOUS
OPERATION DUE TO CROSS-TALK.
FOR MORE INFORMATION ABOUT THE MOTOR THERMOSTAT SETTINGS, REFER TO
SECTION 7: GENERAL OPERATION, MOTOR THERMOSTAT SETUP.
To connect the Motor Thermostat to the DLCM, connect the two thermostat wires (typically these
wires are a smaller gauge wire) coming from the pump motor to the connection point labeled ‘3–
THERM [+]’ and ‘4–THERM [-]’ on connector J–10 CONTROL (refer to Figure 8).
5.9 Serial Communications Input
The Serial Communications input is used to communicate digitally with the DLCM. It allows
remote control and, if so configured, can be used to replace the analog input and output to allow
one or more DLCM’s to be slaved to a single DLC, DLCM, PLC, or PC master.
Figure 9 – Typical Serial Communications Connections
Use Belden™ Type 1590A data twist cable or equivalent. RJ-11 connectors (not supplied) are
used to plug into jacks J7 & J8 (refer to Figure 9).
The DLCM uses a 4-wire RS-485 network. This uses two wires for transmit and two wires for
receive. The RS-485 specification limits the total network length to 1200M (4000 ft). Multiple
device networks may also require termination at both the first and last device. See Section 8:
Diagrams: Installation for further details.
5.9.1 Important Wiring Detail
5.9.1.1 Slave to Slave
When connecting two Slaves, the wiring is straight through. For example: Connect the transmit
lines to the transmit lines and the receive lines to the receive lines (refer to the drawing below).
18
5.9.1.2 Master to Slave
When wiring between a Master and a Slave, the Transmit and Receive lines must be crossed.
For example: Connect the transmit lines to the receive lines (refer to the drawing below).
Figure 10 – Wiring Detail
5.10 Fuse Replacement
Although Fuse replacement is not a part of normal installation, it is possible that fuse failure will
result from improper wiring. The DLCM uses a total of 7 user replaceable fuses: 1 for the alarm
relay output, 2 for each of the Current Input and Output Channels. The table below details fuse
replacement information:
Designator
F1
F2-7
Function
Alarm Relay
Current I/O
Rating
1A @ 250VAC
50mA @ 250VAC
Wickman P/N
WK4048-ND
WK3022-ND
Pulsafeeder P/N
NP5300026-000
NP5300027-000
REPLACEMENT FUSE INFORMATION
Figure 11 details the location of these fuses on the Field Wiring Board.
Figure 11 – Fuse Location.
The Internal DLCM power supply is fused at 2 Amps. This fuse is not user serviceable. The
DLCM Stroke Length Adjustment Synchronous Motor is inherently protected. It can operate
continuously in a locked rotor state. The DLCM also monitors this motor's duty cycle to maintain a
50% balance between ON and OFF times. The serial ports and the Remote Run Status Output
are protected by self-resetting current limit devices. These components are not user serviceable.
19
6 Startup Instructions
6.1 Overview
Once all electrical connections have been made, your DLCM is ready for Startup. The following
nine sections detail the procedures required to complete a DLCM startup.
WHEN POWER IS SUPPLIED TO THE UNIT, LINE VOLTAGE IS PRESENT ON THE
FIELD WIRING BOARD LOCATED AT THE BACK OF THE UNIT EVEN WHEN THE
MOTOR IS OFF.
DURING STARTUP, IT IS NECESSARY TO RUN THE PUMP MOTOR. THIS WILL CAUSE
FLUID TO DISCHARGE FROM THE PUMP. YOU ARE RESPONSIBLE FOR SAFELY
DIVERTING FLOW FROM THE PUMP DURING STARTUP AND CALIBRATION.
6.1.1 User Interface Familiarization
There are four key elements that will be useful in starting-up the DLCM:
1.
2.
3.
4.
Display
Keypad
Manual Adjustment Knob
Pump Motor
Refer to Figure 12 to familiarize yourself with the location of these items before proceeding.
Figure 12 – Key DLCM startup elements.
6.1.1.1 Display
This is a 2 line by 16 character alpha-numeric Liquid Crystal Display (LCD) located above the
keypad. It is back-lit with a yellow-green light source for easy viewing in dark areas. Its contrast
can be adjusted by using the keypad.
20
6.1.1.2 Keypad
The Keypad is a sealed 9-button membrane style input device. It is easy to use and will guide you
quickly to specific functions. Refer to Figure 13 to familiarize yourself with the function of each
key before starting.
Figure 13 – Key Pad
MOTOR
Press this key to Start the PULSAR motor or place it in stand-by.
MENU
Press this key to access the Configuration Menu. Press the ARROW keys to
scroll through the Configuration Menu Items. Press [MENU] a second time to
exit the Configuration menu to the current operating mode (e.g., MANUAL
MODE).
UNITS
Press this key to cycle to the next flow unit type whenever a flow unit is
displayed at the operating mode (e.g., MANUAL MODE).
ARROWS
These keys are used to change values currently displayed on screen. Use
[DOWN] to decrease the value and [UP] to increase it. Pressing both [UP] and
[DOWN] simultaneously performs special editing and by-pass functions. This is
described further in Section 7: General Operation.
Use this key to accept a flashing value or parameter and proceed to the next
sub-menu screen.
This key is used to activate the [BATCH] processing menu. Press [BATCH] a
second time to exit the Batch Setup function.
ENTER
BATCH
CAL
Press [CAL] to activate the Calibration menu for Flow and Analog Signals. Press
[CAL] a second time to exit the Calibration function.
MODE
The [MODE] key is used to change the operating mode of the DLCM. For
example, press once to change from MANUAL to ANALOG. Press a second
time to change from ANALOG to MODBUS. Press a third time to change from
MODBUS back to MANUAL.
6.1.1.3 Manual Adjustment Knob
The manual adjustment knob is mechanically attached to the PULSAR stroke length adjustment
mechanism. The DLCM uses the shaft attached to this knob to make its automatic adjustments.
Visually, the knob is a good indication of what the DLCM is doing. For example, if the DLCM is
21
increasing the pump stroke length – moving from 0 to 100% -- the knob will turn counterclockwise until the desired position is achieved.
If you try to force the adjustment, the DLCM will automatically react to adjust the position to the
programmed setting. If you manually adjust the knob while performing a pump calibration, the
calibration session will be terminated.
While in the Analog Signal or MODBUS Mode – any attempts you make to change the stroke
setting using the Manual Control Knob to a value other than that specified by the remote signal
will cause the DLCM to make a correction.
THE MANUAL ADJUSTMENT KNOB SHOULD NOT BE ADJUSTED WHILE POWER IS
REMOVED FROM THE DLCM. IF THE KNOB IS MOVED WHILE THE DLCM POWER IS OUT,
UPON RE-STARTING THE DLCM WILL DETECT THE MOVEMENT AND PERFORM A ZERO
CALIBRATION.
WHEN THE DLCM IS PERFORMING A ZERO CALIBRATION (THE DISPLAY WILL READ
{CALIBRATING ZERO}), DO NOT TO TOUCH THE MANUAL ADJUSTMENT KNOB. DURING
A ZERO CALIBRATION THE DLCM IS SEARCHING FOR A HARD MECHANICAL STOP. ANY
MANUAL INTERVENTION COULD CAUSE THE DLCM TO INCORRECTLY DETECT THIS
STOP. THIS WILL RESULT IN AN IMPROPER CALIBRATION.
YOU MAY NOTICE THAT WHEN ADJUSTING FROM A LOWER TO A HIGHER VALUE (E.G.,
10% TO 20%) THE DLCM APPEARS TO 'OVER-SHOOT' ITS DESTINATION AND REVERSE
DIRECTION FOR APPROXIMATELY 1/16 OF A REVOLUTION. THIS BEHAVIOR IS NORMAL.
THE DLCM ALWAYS APPROACHES A NEW POSITION FROM THE SAME DIRECTION TO
ELIMINATE BACKLASH IN THE STROKE ADJUSTMENT MECHANISM.
6.1.2 Check Wiring and Close Access Cover
Double check all of your electrical connections. Pay attention to polarity of all inputs and outputs –
both low and high voltage. Additionally, insure that all clamp style terminals are clamping onto the
bare conductor, not on its insulation.
Replace the wiring access cover and its 4 retaining screws with associated washers.
USE A SCREWDRIVER TO TIGHTEN THE RETAINING SCREWS EVENLY (14 in-lb / 1.6 NM). FAILURE TO DO SO MAY CAUSE THE COVER TO LEAK AND VOID THE WARRANTY.
THE SUPPLIED TEFLON WASHERS ARE REQUIRED TO PROPERLY SEAL THIS COVER.
FAILURE TO REPLACE THESE COMPONENTS WILL VOID THE WARRANTY.
6.1.3 Confirm Correct Incoming Power
Check that the wiring access cover is on and tightened down. Whenever power is supplied to the
DLCM, the display's back-lighting will 'glow' with a yellow-green light. The presence of this backlighting is an excellent indication that the DLCM's incoming power has been wired successfully
and voltage is present. Characters may or may not appear on the display. This is normal and will
be covered in the next section.
WITHOUT PRIOR OPERATING KNOWLEDGE, IT IS IMPOSSIBLE TO TELL IF THE PULSAR
MOTOR WILL RUN WHEN POWER IS APPLIED TO THE DLCM. YOU ARE RESPONSIBLE
FOR TAKING THE NECESSARY STEPS TO ENSURE THAT ALL ASPECTS OF SAFETY
HAVE BEEN CONSIDERED (E.G., ELECTRICAL, HYDRAULIC, ETC.). IF IN DOUBT,
DISCONNECT THE MOTOR FROM J3 PRIOR TO APPLYING POWER.
THE DLCM DETECTS ANY ADJUSTMENTS MADE TO MANUAL ADJUSTMENT KNOB
WHILE ITS POWER IS OFF. IF IT DETECTS THAT THE KNOB POSITION HAS BEEN
CHANGED, IT WILL PERFORM A ZERO CALIBRATION WHEN THE MOTOR IS STARTED.
THIS ACTION IS NORMAL.
Turn on power at the main. If the DLCM's incoming power is connected correctly, the backlighting on the DLCM's display will illuminate (depending on lighting conditions, it may be
necessary to shade the display to confirm illumination). If the display is not illuminated, first check
22
the line voltage with a volt meter. If the voltage is not correct, return to Section 5: Installation:
High-Voltage Connections. Otherwise, proceed with the next step.
6.1.4 Confirm Display and Keypad Functionality
THE EXAMPLE DISPLAY MESSAGES ARE SHOWN IN ENGLISH FOR DEMONSTRATION
PURPOSES. IF AN ALTERNATE LANGUAGE HAS BEEN SET, THE TEXT IS DISPLAYED AS
A TRANSLATION OF THE ENGLISH VERSION.
Now that you have confirmed that the DLCM is receiving power, it is necessary to confirm that the
display and keypad are functioning properly. On normal power-up, the {SELF-TEST} display
appears for approximately 5 seconds. After that time, the display will change the message to one
of the following:
SELF-TEST
1.20
-Or-
TURN MOTOR ON
CALIBRATING ZERO
-Or-
10.0%
MANUAL MODE
-Or-
BATCH #1 RUNNING
10.0%
-Or-
PLEASE WAIT
CALIBRATING ZERO
-Or-
MOTOR STOPPED
At this time, the actual message is not important; the characters should be visible and form a
reasonable message.
If the display is blank (no-characters) then the display contrast must be adjusted. This is
accomplished by pressing and holding [MENU] while simultaneously pressing [UP]. This will
darken the display.
Be patient! You may have to hold both keys down for as long as 30 seconds before the
characters will become visible. If the display is too dark, press [MENU] and [DOWN]
simultaneously to decrease (lighten) the contrast. Once the contrast is properly adjusted, check
the message displayed. If it does not look similar to one of those shown above, proceed directly
to the next section to perform a Factory Re-initialization on your DLCM.
The keypad can be tested by depressing each key separately. Most, but not all keys will cause
the text on the display to change. Do not be alarmed if a single key does not invoke a change to
the display. This is normal. Different keys become active/inactive depending on the current
operating mode.
There are a number of functions that the DLCM performs (e.g., zero calibration) where the
keypad has no effect. If the stroke adjustment knob is not moving, at least one key on the key pad
should cause the text on the display to change. Go to Section 6.1.6. If this is not the case, refer
to Section 11, Troubleshooting.
6.1.5 Performing a Factory Re-initialization
WHEN RE-INITIALIZING YOUR DLCM, ALL OF THE SYSTEM SETTINGS WILL BE
OVERWRITTEN BY THE ORIGINAL FACTORY DEFAULT SETTINGS. THE CONTROLLER
MUST BE RE-CONFIGURED TO YOUR SPECIFICATIONS (E.G., RE-CALIBRATED).
If your DLCM appears to be functioning properly – the display is similar to one of those shown on
the previous page – skip to Section 6.1.6.
A FACTORY RE-INITIALIZATION RESTORES ALL FACTORY DEFAULTS TO THE DLCM'S
MEMORY, AND TYPICALLY IS NOT REQUIRED.
A Factory Re-initialization should be performed only if there is reason to believe that the internal
DLCM memory has become corrupted. A number of factors could cause this including: long-term
storage, disregard of electrostatic precautions (refer to Section 2: Safety) during installation,
improper wiring, voltage surges, etc. The condition usually manifests itself with inconsistent or
erratic operation – often associated with characters on the display. Depending on the state of
your DLCM, use one of the following procedures:
23
STARTUP FACTORY RE-INITIALIZATION
Use this procedure when you cannot read the display, or if the DLCM does not seem to be
responding to your key presses:
1. Cycle power to the unit (turn it OFF then ON).
2. Within the first 5 seconds of power on, depress and hold the [UNITS], [MODE], and
[ENTER] keys simultaneously for approximately 1 second.
3. The display will continue to display the version number while the DLCM’s memory is
restored. The display will then show {TURN MOTOR ON / CALIBRATING ZERO}.
Return to Section 6.1.4: Confirm the Display and Keypad Functionality.
MENU FACTORY RE-INITIALIZATION
Use this procedure if the display and key pad appear to be functioning properly, but you suspect
other problems with data corruption, erratic operation, etc. Factory Re-initialization can be found
in the Configure Menu. Perform the following steps:
1. Apply power to the unit. Wait for the {SELF-TEST} display to disappear. The unit should
display a standard power on screen.
2. Press [MENU]. The display will show the first menu item {DIAGNOSTICS}.
3. Press [DOWN]. The {FACTORY DEFAULTS} menu item should be displayed. If not,
continue pressing [DOWN] until it does.
4. Press [ENTER]. The prompt {FACTORY RESET? / NO} is displayed.
5. Press [UP]. The prompt will read {FACTORY RESET? / YES}.
6. Press [ENTER] to accept the {YES} prompt. The prompt {ARE YOU SURE? / NO} is
displayed.
7. Press [UP]. The prompt will read {ARE YOU SURE? / YES}.
8. Press [ENTER] to accept the {YES} prompt.
9. The display will read {PLEASE WAIT} for approximately 5 seconds while the DLCM’s
memory is restored. The display should then display {TURN MOTOR ON / TESTING
ENCODER}. Return to Section 6.1.4: Confirm Display and Keypad Functionality.
6.1.6 Test Pump Motor
THE LEVEL INPUT, PULSALARM AND SIGNAL LOSS INPUTS CAN BE CONFIGURED TO
SHUT THE MOTOR DOWN IF THEY ARE ENABLED. IF THIS IS THE CASE, A MESSAGE IS
DISPLAYED ON THE SCREEN INDICATING THE FAILURE. YOU CANNOT RE-START THE
MOTOR UNTIL THESE INPUTS HAVE BEEN CORRECTED OR THE {MOTOR OFF} OPTION
HAS BEEN DISABLED. REFER TO SECTION 7: GENERAL OPERATION FOR FURTHER
INFORMATION ON CONFIGURING THESE OPTIONS.
To test the PULSAR motor connection, press [MOTOR]. If the motor is running it should stop and
the display should read {MOTOR STOPPED} or {TURN MOTOR ON / CALIBRATING ZERO} or
{TURN MOTOR ON / TESTING ENCODER} as shown below.
MOTOR STOPPED
-Or-
TURN MOTOR ON
CALIBRATING ZERO
-Or-
TURN MOTOR ON
TESTING ENCODER
10.0%
MANUAL MODE
-Or-
BATCH #1 RUNNING
10.0%
-Or-
PLEASE WAIT
CALIBRATING ZERO
-Or-
If the display appears as shown above, but the PULSAR motor does not start, return to Section
5: Installation: High-Voltage Connections and check your wiring. If the wiring is correct, refer
to Section 11: Troubleshooting.
24
THE MOTOR SPEED MAY BE LOW ENOUGH THAT IT IS HARD TO TELL THAT IT IS
RUNNING. CHECK FOR FLUID DISCHARGE.
6.1.7 Set Time and Date
The clock on your DLCM has been activated at the factory, but you should set it to the local time
and date of the installation site.
Time and Date are set in the Configuration Menu. Below is an example that accepts some
software default values:
SET TIME AND DATE PROCEDURE
1. From the Current Operating Mode Display, press [MENU]. The {–MENU– /
DIAGNOSTICS-0} screen is displayed (refer to illustrations below).
2. Press [UP] one time. The {–MENU– / SET TIME AND DATE} screen is displayed.
3. Press [ENTER]. The date and time screen is displayed.
4. Press [ENTER] to accept the 24 Hour time setting.
5. Press [UP] or [DOWN] to adjust the hour value displayed to the local time. Press
[ENTER].
6. Press [UP] or [DOWN] to adjust the 10 minute value displayed to the local time. Press
[ENTER].
7. Press [UP] or [DOWN] to adjust the minute value displayed to the local time. Press
[ENTER] twice (to accept the default MM/DD/YY format setting).
8. Press [UP] or [DOWN] to adjust the month value displayed to the current month. Press
[ENTER].
9. Press [UP] or [DOWN] to adjust the day value displayed to the current day. Press
[ENTER].
10. Press [UP] or [DOWN] to adjust the year value displayed to the current year. Press
[ENTER] twice (accepting the default Daylight Savings NO setting).
The time and date information has now been set.
MENU
DIAGNOSTICS – 0
Press
[UP]
MENU
SET TIME AND DATE
Press
[ENTER]
24 HR
21:07
MM/DD/YY
1/22/01
Refer to Section 7: General Operation, Set Time and Date for more detailed instructions on
how to set the Time and Date information.
6.1.8 Flow Calibration (1-point)
Your DLCM is factory calibrated at rated flow and pressure (1-point). Nevertheless, you should
always perform a calibration with the PULSAR DLCM installed in your system. The only item
required to calibrate your DLCM is a means to measure the output of the pump (i.e., calibration
column, graduated cylinder, etc.).
1-POINT CALIBRATION PROCEDURE
1. Press [MOTOR] to start the motor (if the motor is not currently running).
2. Press [UNITS] repeatedly until a unit that is consistent with your flow measurement
device (i.e., calibration column) appears. For example, if your column reads in Liters then
set the display to LPM or LPH. Liters will be used in this example.
3. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
4. Press [ENTER]. The {LAST FLOW CAL / 11:32 1/22/01} screen is displayed.
5. Press [ENTER]. The {FLOW CALIBRATION / 1-POINT} screen is displayed.
6. Press [ENTER]. The {CALIBRATE ZERO? / YES} screen is displayed.
25
IF YOU ARE CONFIDENT WITH THE QUALITY OF YOUR ZERO CALIBRATION, PRESS [UP]
AND THE {CALIBRATE ZERO? / NO} SCREEN IS DISPLAYED. PRESS [ENTER] AND
CONTINUE WITH STEP 10.
7. Press [ENTER]. The {TURN MOTOR ON / TESTING ENCODER} screen is displayed, or
if the pump motor was ON when you started the calibration process, the {PLEASE WAIT
/ TESTING ENCODER} screen is displayed.
8. Turn the pump motor on if necessary and the encoder performs its self-test. When the
self-test is completed, the {PLEASE WAIT / CALIBRATING ZERO} screen is displayed.
The DLCM will adjust the stroke to the 0% position and the motor speed to 100%.
9. When the zero calibration is complete the {PLEASE WAIT / MOTOR CAL.} screen is
displayed.
PLEASE WAIT
MOTOR CAL.
With the stroke set at 0% the motor will run at 100% for a few seconds, and then
decrease speed to 5%.
IT WILL TAKE ANYWHERE FROM APPROXIMATELY 10 SECONDS TO 5 MINUTES TO
COMPLETE THE SPEED CHANGE. IF YOUR PUMP CONTINUES TO RUN AFTER 5
MINUTES THERE IS AN ERROR AND YOU SHOULD CONTACT TECHNICAL SERVICES.
10. The {PLEASE WAIT / XX% 100%} screen is displayed. The DLCM will adjust the stroke
to the 100% position. The PULSAR motor will shut off.
PLEASE WAIT
XX% 100%
11. The {ENTER TO START/ 100% 2.641718 G} screen is displayed. The value '2.641718'
represents the amount of fluid discharged over 60 seconds the last time a calibration was
performed at the 100% stroke setting. Record the fluid base reading from your calibration
column.
12. Press [ENTER]. The PULSAR motor will start to run. A timer is displayed counting down
from 60 seconds. After 60 seconds the motor will stop automatically.
TIMER: XX SEC
2.641718 G
13. The {ENTER VALUE 100% / 2.641718 G} screen is displayed. Calculate the measured
volume displaced from the calibration column and enter the new value one position at a
time using [UP] and [DOWN] to change an individual position. Press [ENTER] to move
the cursor to the next position.
14. Pressing [ENTER] on the last position will cause the {CONFIRM CHANGE? / YES}
screen to be displayed. Press [ENTER] to accept. Your 1-point calibration is now
complete.
Refer to Section7: General Operation, Calibration, Pump Flow for more detailed
instructions on how to perform DLCM calibration.
6.1.9 Analog Input Calibration
If you are not using the 0-20mA input to the DLCM for control, skip this section. To calibrate the
Input Current you must first correctly wire an external signal source. Refer to Section 5:
Installation, Low-voltage Input Connections, Analog Input. To perform a calibration, the
signal generating device (e.g., PLC) must be powered up and capable of altering its output from
minimum to maximum signal.
26
6.1.9.1
One-Signal Analog Input Calibration
THE FOLLOWING IS A MINIMAL PROCEDURE FOR CALIBRATING THE ANALOG INPUT IF
THE 1 – SIGNAL OPTION IS TO BE USED.
1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
2. Press [UP]. The {CALIBRATE / ANALOG IN} screen is displayed.
3. Press [ENTER]. The {0% = 4.0mA / 100% = 20.0mA} screen is displayed. These values
represent the previous calibration.
4. Press [ENTER]. The {INPUT ANALOG MIN / 0% = XXmA} screen is displayed. Adjust your
PLC to output a minimum signal (i.e., 4.0mA). The DLCM display will update as the incoming
signal changes.
5. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT ANALOG MAX
/ 100% = XXmA} screen is displayed. Adjust your PLC to output a maximum signal (i.e.,
20.0mA). Again, the DLCM display will update with the changing signal.
6. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT RATIO / 100%
= XX.XmA} screen is displayed.
7. Press [ENTER] to accept the 100% Ratio setting. The {CONFIRM CHANGE? / YES} screen
is displayed.
8. Press [ENTER]. Analog input calibration is now complete.
Refer to Section 7: General Operation, Analog Input Signal Calibration for more detailed
instructions on how to perform Analog Input calibration.
6.1.9.2
Two-Signal Analog Input Calibration
To calibrate a 2 Signal Analog Input, the DLCM factory default must first have been changed from
{STROKE & SPEED / 1-SIGNAL} to {STROKE & SPEED / 2-SIGNALS}. Refer to Section 7:
General Operation: {- MENU - / Analog Mode} for information on configuring the Analog Mode.
THE FOLLOWING IS A MINIMAL PROCEDURE FOR CALIBRATING THE ANALOG INPUT IF
THE 2 – SIGNALS OPTION IS TO BE USED.
1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
2. Press [UP]. The {CALIBRATE / ANALOG IN} screen is displayed.
3. Press [ENTER]. The {CALIBRATE / STROKE POSITION} screen is displayed.
4. Press [ENTER]. The {0% = 4.0mA / 100% = 20.0mA} screen is displayed. These values
represent the previous calibration.
5. Press [ENTER]. The {INPUT ANALOG MIN / 0% = XXmA} screen is displayed. Adjust your
PLC to output a minimum signal (i.e., 4.0mA). The DLCM display will update as the incoming
signal changes.
6. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT ANALOG MAX
/ 100% = XXmA} screen is displayed. Adjust your PLC to output a maximum signal (i.e.,
20.0mA). Again, the DLCM display will update with the changing signal.
7. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT RATIO / 100%
= XX.XmA} screen is displayed.
8. Press [ENTER] to accept the 100% Ratio setting. The {CONFIRM CHANGE? / YES} screen
is displayed.
9. Press [ENTER]. The DLCM is returned to the original operating mode.
10. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
11. Press [UP]. The {CALIBRATE / ANALOG IN} screen is displayed.
27
12. Press [ENTER]. The {CALIBRATE / STROKE POSITION} screen is displayed.
13. Press [UP]. The {CALIBRATE / MOTOR SPEED} screen is displayed.
14. Press [ENTER]. The {0% = 4.0mA / 100% = 20.0mA} screen is displayed. These values
represent the previous calibration.
15. Press [ENTER]. The {INPUT ANALOG MIN / 0% = XXmA} screen is displayed. Adjust your
PLC to output a minimum signal (i.e., 4.0mA). The DLCM display will update as the incoming
signal changes.
16. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT ANALOG MAX
/ 100% = XXmA} screen is displayed. Adjust your PLC to output a maximum signal (i.e.,
20.0mA). Again, the DLCM display will update with the changing signal.
17. When the displayed value stabilizes, press [ENTER] to accept it. The {INPUT RATIO / 100%
= XX.XmA} screen is displayed.
18. Press [ENTER] to accept the 100% Ratio setting. The {CONFIRM CHANGE? / YES} screen
is displayed.
19. Press [ENTER]. The 2 – Signals Analog Input Calibration is complete. The DLCM is returned
to its original operating mode.
20. Refer to Section 7: General Operation, Analog Input Signal Calibration, for more
detailed instructions on how to perform Analog Input calibration.
Wrapping Up
Your PULSAR DLCM is now commissioned for use. Refer to Section 7: General Operation for
specific instructions on how to access your DLCM's advanced features. Please don't be
intimidated by your DLCM, take time to explore and experiment with its features. Remember, you
cannot configure the software in a way that would damage the DLCM. Typically, whenever you
are about to set a critical value (e.g., Calibrate Flow), you are always prompted to confirm your
change before it takes effect. If you are ever dissatisfied with the configuration of your DLCM, you
can always return to the Factory Defaults by repeating Section 6.1.5.
7 General Operation
This section covers the General Operation of the DLCM as it relates to software. It includes
detailed instructions and example screens. The default values of the DLCM have been set at the
factory. You can over-ride these settings to tune the DLCM to your particular needs.
7.1 General Operation Instructions
7.1.1 Pump Flow Calibration
Pulsafeeder recommends performing at minimum a Two-Point flow calibration on every PULSAR
DLCM installed. Maintenance re-calibration should be performed periodically – at least every
three to four months – to account for component wear. Re-calibration of the pump is also
recommended whenever wet-end components are replaced.
THE DLCM DOES NOT AUTOMATICALLY COMPENSATE FOR CHANGING SYSTEM
CONDITIONS (E.G., DISCHARGE PRESSURE, FLUID VISCOSITY, ETC.). YOU SHOULD RECALIBRATE WHENEVER THE APPLICATION CONDITIONS CHANGE.
ALL FLOW CALIBRATIONS ARE PERFORMED AT 100% MOTOR SPEED. THE
CALIBRATION PROCESS AFFECTS THE STROKE ADJUSTMENT MECHANISM ONLY. THE
DLCM SELF-CALIBRATES ITS MOTOR SPEED.
28
MULTI-POINT CALIBRATION PROCEDURE
1. Press [CAL] to enter the Calibration Menu. Press [ENTER] to go to the calibrate pump flow
sub- menu:
CALIBRATE
PUMP FLOW
Press
[ENTER]
2. The DLCM displays the last time the pump was calibrated. Press [ENTER] to continue with
pump flow calibration.
LAST FLOW CAL
3:25
1/22/01
Press
[ENTER]
3. The display shows {FLOW CALIBRATION / 1 POINT}. The '1 POINT' text will be flashing.
FLOW CALIBRATION
1 POINT
Press
[UP]
Press [UP] to change flow calibration to 2 points, 3 points, 4 points or 5 points. The
calibration points correspond to the following stroke length values: 100, 75, 50, 25, and 10.
A 1-POINT CALIBRATION SHOULD BE AVOIDED IN APPLICATIONS WHERE THE
DISPLAYED FLOW RATE IS CRITICAL. FOR DISCHARGE PRESSURES LESS THAN 500
PSI (34.5 BAR), A MINIMUM 2-POINT CALIBRATION IS RECOMMENDED. FOR DISCHARGE
PRESSURES ABOVE 500PSI (34.5 BAR) A MINIMUM 3-POINT CALIBRATION IS
RECOMMENDED.
These percentage values correspond to the API standards. If you continue to press [UP] you
will also see the following options: {CHANGE CONSTANTS} and {TUNE}. These options are
for use after a multi-point calibration has been performed. For a standard multi-point
calibration, set the number of calibration points to use and press [ENTER] to continue.
YOU CAN "SKIP" A CALIBRATION POINT BY ENTERING A FLOW VALUE OF 0.0000.
“SKIPPING” A POINT MEANS THAT IT WILL BE OMITTED FROM THE MATHEMATICAL
REGRESSION TO ESTABLISH THE FLOW CURVE. VALUES WHICH ARE LESS THAN 10%
OF THE PUMPS’ RATED OUTPUT FLOW SHOULD BE SKIPPED.
4. Press [ENTER]. The {CALIBRATE ZERO? / YES} screen is displayed.
CALIBRATE ZERO?
YES
Press
[ENTER]
IF YOU ARE CONFIDENT WITH THE QUALITY OF YOUR ZERO CALIBRATION, PRESS [UP]
AND THE {CALIBRATE ZERO? / NO} SCREEN IS DISPLAYED. PRESS [ENTER] AND
CONTINUE WITH STEP 8.
5. Press [ENTER]. The {TURN MOTOR ON / TESTING ENCODER} screen is displayed, or if
the pump motor was ON when you started the calibration process, the {PLEASE WAIT /
TESTING ENCODER} screen is displayed.
TURN MOTOR ON
TESTING ENCODER
- Or -
PLEASE WAIT
TESTING ENCODER
6. Turn the pump motor on if necessary and the encoder performs its self-test. When the selftest is completed, the {PLEASE WAIT / CALIBRATING ZERO} screen is displayed.
PLEASE WAIT
CALIBRATING ZERO
29
7. The DLCM will now perform a ZERO CALIBRATION. First, it will turn on its motor and adjust
its speed to 100%. Then it will test the encoder's position by increasing the stroke
adjustment mechanism 2%. Then the DLCM will adjust in the opposite direction until it
reaches the mechanical zero stop (0% stroke setting). This ensures that the positioning
mechanism is working properly and calibrations will be accurate. The screen will display one
of four messages:
PLEASE WAIT
CALIBRATING ZERO
- Or
-
TURN MOTOR ON
TESTING ENCODER
PLEASE WAIT
MOTOR CAL
- Or
-
ENCODER ERROR
PRESS ENTER
If the {TURN MOTOR ON…} screen is displayed, start the PULSAR motor by pressing
[MOTOR]. The DLCM will adjust to the 100% position. If you get the {ENCODER ERROR…}
screen, refer to Section 11: Troubleshooting Guide.
8. The following screen is displayed.
PLEASE WAIT
XXX.X%
100%
If you get the {PRESS ENTER / TO START MOTOR} screen, start the PULSAR motor by
pressing [ENTER] or [MOTOR].
The XXX.X% represents the current stroke length adjustment setting and 100% is the stroke
length destination.
9. Once the destination setting has been reached, the PULSAR motor will shut down and the
display will show:
ENTER TO START
2.641718 G
THE DISPLAY IS SHOWING THE AMOUNT OF FLUID DISCHARGED FROM THE PUMP THE
LAST TIME THIS OPERATION WAS PERFORMED (E.G., 2.641718 GALLONS). THIS FLOW
RATE IS BASED ON 60 SECONDS OF PUMP OPERATION. FILL THE CALIBRATION
COLUMN IN THE SYSTEM TO THE PROPER LEVEL TO AVOID RUNNING THE PUMP DRY
DURING CALIBRATION.
10. When you are ready, press [ENTER], which will start the pump motor for a period of 60
seconds. The screen will show a 60 second timer and display its count down toward 0
seconds. During this time, the pump is operating at the designated stroke length setting and
100% motor speed.
TIMER:
60 SEC
2.641718 G
IF YOU ALREADY KNOW THE DISPLACED VOLUME, YOU CAN BYPASS THE 60 SECOND
TIMER BY PRESSING [UP] AND [DOWN] SIMULTANEOUSLY.
11. At the end of 60 seconds, the pump motor will automatically turn off. The display will
automatically change to prompt you to enter the new measured flow rate.
ENTER VALUE 100%
2.641718 G
Read the new measured flow from the calibration column. Enter the new value one position
at a time using [UP] or [DOWN]. Press [ENTER] to accept each digit setting and move the
cursor to the next position. Continue to use the arrow keys and press [ENTER] on the last
position to accept your setting.
30
IF YOU MAKE A MISTAKE ENTERING THE MEASURED FLOW RATE AND REALIZE IT
BEFORE PRESSING [ENTER] ON THE LAST POSITION, PRESS [UP] AND [DOWN]
SIMULTANEOUSLY AND THE CURSOR IS RETURNED TO THE FIRST DIGIT.
IF YOU WOULD LIKE TO "SKIP" A CALIBRATION POINT, ENTER A VALUE OF 0. ANY
MEASURED VOLUME WHICH TRANSLATES TO LESS THAN 10% OF THE MAXIMUM
RATED FLOW OF THE PUMP SHOULD BE DISREGARDED FROM THE CALIBRATION
ROUTINE. TO DO THIS, ENTER A VALUE OF 0.0000.
12. If a 2 through 5 point calibration was selected, the DLCM will automatically proceed to the
next stroke length setting and repeat steps 8, 9, 10, and 11 as described above. After the
DLCM has completed the above referenced process for all stroke length settings, it prompts
you to accept the data collected in the above referenced steps:
CONFIRM CHANGE?
YES
13. Press [ENTER] to accept the calibration. The DLCM will display a {PLEASE WAIT} message
while it performs the Least Squares curve fit to the data points and calculates the new flow
curve. Any point entered with a value of 0.0000 will be ignored by the curve fitting routine. If
you do not want to accept the new calibration, press [UP] to scroll to {NO} and press
[ENTER]. The display is then returned to its original operating mode.
CHANGE CONSTANTS PROCEDURE
1. Navigate to the Change Constants menu by pressing [CAL]. The {CALIBRATE / PUMP
FLOW} menu is displayed. Press [ENTER] twice. The {FLOW CALIBRATION / 1 POINT}
menu is displayed.
2. Press [UP] until {FLOW CALIBRATION / CHANGE CONSTANTS} is displayed.
FLOW CALIBRATION
CHANGE CONSTANTS
This option is used to set the slope and y-intercept in the equation that describes the linear
calibration curve: y = ax + b. Where 'a' is the slope and 'b' is the y-intercept. The input to this
equation (i.e., x) is given in flow (GPM). The output (i.e., y) represents stroke position in
percent (%). The units for the constants are given on screen. Values can be calculated from
two or more flow readings and associated stroke settings.
3. Press [ENTER] and the display prompts you to enter the slope value:
SLOPE
%/GPM
0.3785415569416
You edit the calculated slope value in the displayed units (%/GPM in the example above)
value one position at a time. Press [UP] or [DOWN] to set the digit. Press [ENTER] to move
to the next digit.
It is possible for the CHANGE CONSTANTS display of numbers to be larger than the 16
character screen. If you have a number that overflows the screen in one direction or the
other, a greater than (>) or less than (<) symbol is displayed to indicate this (e.g.,
<0.3785415569416>). Pressing [ENTER] as you edit the number string, moves the cursor
one position to the right. Pressing [ENTER] on the last displayed number will shift the display
one position to the left. This pattern will continue until the last digit in the string is reached.
Press [ENTER] on the last digit to accept your change.
4. The display prompts you to enter the y-intercept.
Y-INTERCEPT
0.00%
Use [UP] and [DOWN] to enter the calculated y-intercept value. The value can be positive or
31
negative (typically the value will be positive). Press [ENTER]. The {CONFIRM CHANGE? /
YES} menu is displayed. Press [ENTER] to accept your changes. The DLCM will convert the
constants to the other display units automatically.
The display is then returned to its original operating mode.
CALIBRATION / TUNE FLOW PROCEDURE
1. In this sub-menu the flow curve can be shifted to 'tune' the flow to one given point. The
reason you might perform this procedure is the process you are currently running is too
critical to be shut down to complete a full calibration. The Tune Flow procedure is a quick fix.
Before entering the TUNE sub- menu, you should measure the actual flow rate at a specific
stroke setting. For example, the DLCM is currently set at 60.0% stroke and it displays a
calibrated flow rate of 6.0 GPH. An actual flow measurement is taken and found to be 5.775
GPH. Leaving the stroke setting at 60%, tune the flow rate to 5.775 GPH.
SINCE THE {TUNE FLOW} SCREEN DISPLAYS FLOW PER MINUTE, THE FLOW PER HOUR
WILL HAVE TO BE CONVERTED. FOR EXAMPLE:
6.0 GPH / 60 minutes per hour = 0.1 GPM.
2. Navigate to the Change Constants menu by pressing [CAL]. The {CALIBRATE / PUMP
FLOW} menu is displayed. Press [ENTER] twice. The {FLOW CALIBRATION / 1 POINT}
menu is displayed. Press [UP] until {CALIBRATION / TUNE} is displayed. Press [ENTER] to
accept and continue with the {CALIBRATION / TUNE} menu. The following screen is
displayed:
TUNE FLOW
60.0%
0.1000 G
Using [UP] or [DOWN] enter the volume displaced for 1 minute of pump flow at the current motor
speed and stroke length. The percentage value displayed represents the net pump output (stroke
and motor speed). Press [ENTER]. The pump will now display the 5.775 GPH value at the 60.0%
stroke setting. Internally, the DLCM has retained the slope calculated at the last calibration and
has off-set the flow curve to satisfy the current reading requirement.
7.1.2 Analog Input Signal Calibration
The DLCM will accept analog input signals of 0-20mA, 4-20mA, 1-5mA, or 1-5 volts. The analog
input signal should be calibrated to the system. To perform a calibration, the signal generating
device (e.g., PLC) must be powered up, wired to the DLCM and capable of altering its output from
minimum to maximum signal. Refer to Section 5: Installation, Low-Voltage Input.
YOU ARE CALIBRATING THE ANALOG INPUT SIGNAL TO THE PERCENTAGE OF
CALIBRATED FLOW. THE 0% AND 100% VALUES DISPLAYED IN THIS SECTION REFER
TO A PERCENTAGE OF FLOW NOT STROKE POSITION.
THE STROKE POSITION CALIBRATION REFLECTS FLOW AT 100% MOTOR SPEED. THE
DLCM CALIBRATES MOTOR SPEED DIRECTLY. FOR EXAMPLE: IN A HIGH PRESSURE
APPLICATION, THE PULSAR BEGINS DISCHARGING FLUID AT 10% STROKE LENGTH.
THUS IT HAS 0% FLOW AT 10% STROKE. IF YOU CALIBRATE 0% = 4.0MA, AND THEN
INPUT A 4.0MA SIGNAL THE DLCM WILL ADJUST THE STROKE LENGTH TO 10%.
32
7.1.2.1
Analog Input #1 Calibration
The following is a minimal procedure for calibrating Analog Input #1. This will control the DLCM’s
Stroke Length (Calibrated) if the {2-Signal} option is configured. It will control Flow (Stroke Length
and Speed) if the {1-Signal} option is configured. For more information about the Analog Input
signal, refer to Section 7.2.15: Analog Mode.
ANALOG INPUT #1 CALIBRATION PROCEDURE
1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
CALIBRATE
PUMP FLOW
2. Press [UP] to scroll to the {CALIBRATE / ANALOG IN}.
CALIBRATE
ANALOG IN
Press [ENTER] to go to calibrate analog input sub-menu. If Two Signal is selected the
following is displayed:
CALIBRATE
STROKE POSITION
3. Press [ENTER]. The display shows the previous 0% and 100% flow analog signal calibration
values:
0%
=
100% =
4.0 MA
19.8 MA
IF YOU WOULD LIKE TO SKIP THE CALIBRATION AND CHANGE ONLY THE SIGNAL
RATIO, PRESS BOTH [UP] AND [DOWN] SIMULTANEOUSLY. SKIP TO STEP 6. PRESSING
BOTH [UP] AND [DOWN] CAN ALSO SKIP EITHER THE MIN. OR THE MAX CALIBRATION.
Press [ENTER] to continue with Analog Input Calibration.
4. The display prompts you to input the minimum analog signal value, 0% flow.
INPUT STROKE MIN
0% = XX.X MA
Send the low analog signal to the DLCM (i.e., 0mA, 1mA, 4mA or 1 volt input to the J4
Current 1 terminals) from the signal generating device (e.g., PLC). Refer to Section 5:
Installation, Low-Voltage Input and Figure 5 for the wiring instructions. It is highly
recommended that you use the actual signal the DLCM will be receiving during operation. The
DLCM will display its interpretation of the received signal. Do not be alarmed if the signal
does not match the instrument.
For example, your instrument is generating 4.0mA but the DLCM display reads 3.6mA. The
DLCM also accepts voltage inputs (0-5VDC), but displays only mA. It is only important that
the DLCM detects the full range of the instruments output. The DLCM will store this value as
the 0% analog signal value. As the analog signal varies, the DLCM will display the fluctuating
values. Wait approximately 10 seconds until the value displayed stabilizes and press
[ENTER] to accept it as the 0% flow analog signal value.
5. The display prompts you to input the maximum analog signal value, 100% flow. Send the
maximum analog signal to the DLCM (i.e., 10mA, 20mA or 5 volts).
INPUT STROKE MAX
100% = XX.X MA
As the signal varies, the DLCM will display the fluctuating values. Wait approximately 10
seconds until the value stabilizes and press [ENTER]. The DLCM stores this value as the
33
100% flow analog signal value.
If the range between the minimum and maximum analog signal values is less than or equal to
2mA, the DLCM will display the following:
RANGE TOO SMALL
RE-ENTER
Press [ENTER] to return to step 4 to input the analog signal values again.
6. You are now ready to set the Signal Ratio. This option allows you to scale the Analog signal
input to the pump output. Use this option only if you want to limit the range of operation of the
pump (e.g., you want to limit the pump's output from 0 to 50% flow over the 4-20mA range).
The display reads as follows:
To use the ratio option, Press [UP] or [DOWN] to set the ratio value. Press [ENTER] to
accept the setting.
STROKE RATIO
50% = 19.8 MA
IF YOU DO NOT WANT TO USE THE INPUT RATIO OPTION, ENTER A VALUE OF 100%
7. The DLCM prompts you to accept the analog signal calibration programmed in the above
referenced steps.
CONFIRM CHANGE?
YES
Press [ENTER] to accept. If you do not want to accept the new analog signal calibration,
press [UP] to scroll to {NO} and press [ENTER].
The display will then return to its original operating mode.
7.1.2.2
Analog Input #2 Calibration
The following is a minimal procedure for calibrating Analog Input #2 if the 2 – Signals option is to
be used. Input #2 controls the motor speed. For more information about the Analog Input signal,
refer to Section 7.2.16: Analog Mode.
ANALOG INPUT #2 CALIBRATION
1. Press [CAL]. The {CALIBRATE / PUMP FLOW} screen is displayed.
CALIBRATE
PUMP FLOW
2. Press [UP] to scroll to the {CALIBRATE / ANALOG IN}.
CALIBRATE
ANALOG IN
3. Press [ENTER] and the {CALIBRATE / STROKE POSITION} screen is displayed.
CALIBRATE
STROKE POSITION
4. Press [UP] to change to {CALIBRATE/MOTOR SPEED}
CALIBRATE
MOTOR SPEED
34
5. Press [ENTER] and the {0% = X.XmA / 100% = XX.XmA} screen is displayed.
The display shows the previous 0% and 100% flow analog signal values:
0%
=
100% =
4.0 MA
19.8 MA
IF YOU WOULD LIKE TO SKIP THE CALIBRATION AND CHANGE ONLY THE SIGNAL
RATIO, PRESS BOTH [UP] AND [DOWN] SIMULTANEOUSLY. SKIP TO STEP 8.
Press [ENTER] to continue with Analog Input Calibration.
6. The display prompts you to input the minimum analog signal value, 0% flow.
INPUT MOTOR MIN
0% = XX.X MA
Send the low analog signal to the DLCM (i.e., 0mA, 1mA, 4mA or 1 volt input to the J4 current
1 terminals) from the signal generating device (e.g., PLC). Refer to Section 5: Installation,
Low-Voltage Input Connections and Figure 5 for the wiring instructions. It is highly
recommended that you use the actual signal the DLCM will be receiving during operation. The
DLCM will display its interpretation of the received signal. Do not be alarmed if the signal
does not match the instrument. For example, your instrument is generating 4.0mA but the
DLCM display reads 3.6mA. It is only important that the DLCM detects the full range of the
instrument’s output. The DLCM will store this value as the 0% analog signal value. As the
analog signal varies, the DLCM will display the fluctuating values. Wait approximately 10
seconds until the value displayed stabilizes and press [ENTER] to accept it as the 0% flow
analog signal value.
7. The display prompts you to input the maximum analog signal value, 100% flow. Send the
maximum analog signal to the DLCM (i.e., 10mA, 20mA or 5 volts).
INPUT MOTOR MAX
100% = XX.X MA
As the signal varies, the DLCM will display the fluctuating values. Wait approximately 10
seconds until the value stabilizes and press [ENTER]. The DLCM will digitally store this value
as the 100% flow analog signal value.
If the range between the minimum and maximum analog signal values is less than or equal to
2mA, the DLCM will display the following:
RANGE TOO SMALL
RE-ENTER
Press [ENTER] to return to step 4 to input the analog signal values again.
8. You are now ready to set the Signal Ratio. This option allows you to scale the Analog signal
input to the pump output. Use this option only if you want to limit the range of operation of the
pump (e.g., you want to limit the pump's output from 0 to 50% flow over the 4-20mA range).
The display reads as follows:
SPEED RATIO
50% = 19.8 MA
To use the ratio option, Press [UP] or [DOWN] to set the ratio value. Press [ENTER] to accept
the setting.
IF YOU DO NOT WANT TO USE THE RATIO OPTION, ENTER A VALUE OF 100%.
35
9. The DLCM prompts you to accept the analog signal calibration programmed in the above
referenced steps.
CONFIRM CHANGES
YES
0% = XX.X MA
Press [ENTER] to accept. If you do not want to accept the new analog signal calibration,
press [UP] to scroll to {NO} and press [ENTER].
10. The DLCM will then return to its original operating mode.
7.1.3 Reverse Acting Analog Input Signal Calibration
To set up a reverse acting application, follow the above Analog Input Calibration procedure with
the following changes to step 6 and step 7. You can reverse Input #1 or Input#2 of the one and
two signal calibration procedures separately.
1. In step 4, when the display requests the minimum analog signal value (0% flow), you should
send the DLCM the high analog signal value (i.e., 10mA, 20mA or 5 volts).
INPUT ANALOG MIN
0% = XX.X MA
Send high (20 mA)
signal
The DLCM will store this as the 0% analog input signal value. As the analog signal varies,
the DLCM will display the fluctuating values. Wait approximately 10 seconds for the signal to
stabilize. Press [ENTER] to accept this as the 0% analog signal value.
2. In step 5, when the display requests the maximum analog signal value (100%), you send the
DLCM the low analog signal value (i.e., 0mA, 1mA, 4mA or 1 volt).
INPUT ANALOG MAX
100% = XX.X MA
Send low (4 mA)
signal
The DLCM will store this as the 100% analog input signal value. As the signal varies, the
DLCM will display the fluctuating values. Wait approximately 10 seconds for the signal to
stabilize. Press [ENTER] to accept this signal as the 100% analog signal value.
You can confirm the reverse acting input signal calibration by re-entering the Analog Input
Calibration menu. The first screen summarizes your calibration.
0% = 20.0 MA
100% = 4.0 MA
3. Press [CAL] again to cancel the calibration at this point.
36
7.1.4 Analog Output Signal Calibration
Depending upon the option selected, {STROKE & SPEED} or {STROKE POSITION} or {MOTOR
SPEED}, the DLCM will generate an analog output signal proportional to the selection. The signal
can be calibrated to a standard range of 0-20mA, 4-20mA, 1-5mA, or 1-5 volts. It should be
calibrated to the attached system.
For more information on configuring the Analog Output Signal refer to Section 7.2.6: Analog
Output Setup.
THE VALUE THAT THE DLCM DISPLAYS IS NOT PRECISELY CALIBRATED TO ITS
OUTPUT. THE VALUE THAT IS DISPLAYED (E.G., 4.0MA) IS FOR REFERENCE ONLY. IN
MANY CASES, THE DISPLAYED VALUE WILL NOT EXACTLY MATCH THE VALUE READ
BY THE ATTACHED EQUIPMENT.
THE ANALOG OUTPUT REFLECTS THE CALIBRATED OUTPUT (E.G., FLOW) NOT THE
MECHANICAL OUTPUT (E.G., STROKE POSITION).
IF THE PUMP MOTOR IS OFF, THE OUTPUT WILL REPRESENT THE MINIMUM VALUE
(0%) REGARDLESS OF THE OPTION SELECTED (E.G., {STROKE POSITION}).
1. Press [CAL] to enter the {CALIBRATE} sub-menu. Press [UP] twice to scroll to the {ANALOG
OUTPUT} selection:
2. Press [ENTER]. The screen that allows you to set the output at 0% is displayed.
OUTPUT AT 0%
4.0 ma
Using [UP] or [DOWN], set the value for the desired output. Note the value that you set is for
reference only. If you need a true 4.0mA's at the remote equipment, you should read the
actual value from the remote equipment and set the value here at whatever is required by
that equipment. For example, say a remote PLC needs exactly 4.0mA's at 0% stroke. The
PLC currently reads its input as 3.8mA and the DLCM reads its output as 4.0mA. Increase
the DLCM output (e.g., 4.2mA) until the PLC reads correctly.
3. Once you have set the 0% value press [ENTER] to accept it. The screen that allows you to
set the output at 100% is displayed.
OUTPUT AT 100%
20.0 MA
As described in step 2, set the output using [UP] or [DOWN]. When you are satisfied with
your settings press [ENTER] to accept it.
4. The DLCM will prompt you to accept the analog output calibrated values.
CONFIRM CHANGE?
YES
Press [ENTER] to accept the calibration. If you do not want to accept, press [UP] to display
{NO} and then press [ENTER].
The display will return to the last operating mode.
YOU CAN SET THE ANALOG OUTPUT TO REVERSE ACTING BY SIMPLY SETTING THE
OUTPUT AT 0% TO BE 20.0MA AND THE OUTPUT AT 100% TO BE 4.0MA.
37
7.2 Menu
The default values of the DLCM Controller have been factory set, but you may want to configure
the DLCM to meet your specific application.
The [MENU] key activates the Configuration Menu system. This consists of 23 different submenus as shown below. Press [UP] or [DOWN] to scroll through the sub-menus
- MENU DIAGNOSTICS – 0
Press
[UP]
- MENU SET TIME & DATE
Press
[UP]
- MENU ANALOG SIG FAIL
Press
[UP]
- MENU MODBUS SIG FAIL
Press
[UP]
- MENU ANALOG OUTPUT
Press
[UP]
- MENU MOTOR SPEED
Press
[UP]
- MENU END POINT
Press
[UP]
- MENU LEAK DETECTION
Press
[UP]
- MENU LEVEL SWITCH
Press
[UP]
- MENU DIGITAL OUTPUT
Press
[UP]
- MENU MOTOR THERMOSTAT
Press
[UP]
- MENU OVER TEMPERATURE
Press
[UP]
- MENU POWER FAILURE
Press
[UP]
- MENU ALARM RELAY
Press
[UP]
- MENU ANALOG MODE
Press
[UP]
- MENU MODBUS MODE
Press
[UP]
- MENU SECURITY
Press
[UP]
- MENU NUMBER FORMAT
Press
[UP]
- MENU CONTRAST ADJUST
Press
[UP]
- MENU SERIAL COMM
Press
[UP]
- MENU SERIAL DIAG.
Press
[UP]
- MENU LANGUAGE
Press
[UP]
- MENU FACTORY DEFAULTS
Pressing the [UP] key takes you back to the –MENU– DIAGNOSTICS-0 screen.
AS YOU GO THROUGH THIS SECTION OF THE MANUAL, THE SCREENS ARE DISPLAYED
AS DEFINED IN THE FACTORY DEFAULT SETTINGS. IF ANY OF THE SETTINGS ARE
CHANGED, (E.G., DURING INITIAL SETUP OR MODIFYING OPERATING PARAMETERS)
THE AVAILABILITY OF SCREENS DISPLAYED WITHIN A SUB-MENU ITEM SUB-SET MAY
CHANGE.
38
7.2.1 Alarm and Error Messages
When an error occurs, the DLCM flashes Alarm and Error messages alternately with the standard
display. If the error is catastrophic (e.g., Tachometer Failure), the catastrophic error message will
remain displayed until the problem is repaired.
The following table gives an example of these messages and when you can expect them to be
displayed.
MESSAGE
DISPLAYED WHEN
ANALOG SIG FAIL
or
ANALOG FAIL #1
or
ANALOG FAIL #2
The Analog signal has fallen below its calibrated range or
fallen rapidly (indicating an open circuit).
LEAK DETECTION
The PULSAlarm leak-detection diaphragm has failed.*
LEVEL SWITCH
The Drum Level switch has been activated.*
POWER FAILURE
The input power to the DLCM was interrupted while the
pump motor was running.*
OVER TEMPERATURE
The internal temperature of the DLCM has exceeded its
operating limit.*
ALARM RELAY
If configured, this message is displayed when the alarm
relay activates.
DUTY CYCLE
When displayed, indicates that the stroke adjustment
motor has run continuously for more than 20 minutes and
is now in a cool down phase.
MOTOR THERMOSTAT
The temperature of the DLCM Pump Motor has reached its
operating limit.*
REMOTE ON/OFF
If configured, displays when the remote On/Off switch is in
the Off position.
OVER SPEED / SHUT DOWN
The motor control circuit has failed. Remove all power
from the DLCM & Pump Motor. (Over speed shutdown)
TERMINATED / PRESS ANY KEY The Manual Control Knob moved during calibration.
TACHOMETER FAILURE
Failed to detect shaft rotation with the motor turned on.
POSITION ERROR
Motion has not been detected when expected for a fairly
long period of time.
OVER VOLTAGE
The digital command was not received within the timeout
period.
The incoming power exceeds the specified range.
UNDER VOLTAGE
The incoming power is below the specified range.
MODBUS SIG FAIL
*Refer to the Diagnostics Section (next section) for information on each of these messages.
39
7.2.2 Diagnostics
The DLCM is supplied with a complete diagnostic menu. It will alert you if something has failed,
the time and date of the failure, and allows you to clear the failure.
DIAGNOSTICS PROCEDURE
1. Press [MENU]. In a normal condition, the display reads {–MENU– / DIAGNOSTICS-0}.
- MENU DIAGNOSTICS – 0
IF A DIAGNOSTIC FAILURE WAS DETECTED, THE {DIAGNOSTICS - #} WOULD APPEAR.
THE '#' INDICATES THE NUMBER OF ITEMS THAT HAVE FAILED.
2. Press [ENTER] and the first diagnostic sub-menu is displayed. If the incoming power supply
to the DLCM was interrupted while the PULSAR motor was running, a failure will be
detected and logged.
DIAG MENU 1/11
POWER IN: OK
- Or -
DIAG MENU 1/11
POWER IN: FAIL
3. Press [UP] to scroll to the next sub-menu. If the analog signal fails, a failure will be detected
and logged. An analog input failure is detected if one of the following conditions occurs.
First, the signal falls below the calibrated range by 0.3mA (if the DLCM is calibrated with a
range of 4-20mA and the signal falls to 3.6mA then a failure will be logged). Second, if the
analog signal falls below 0.3mA and is changing at a rate of 8.8 mA per second or more a
failure will be logged. This second condition is primarily for the situation where the input is
calibrated for 0 to 20mA's. Refer to Section 7.2.4 Analog Signal Failure Setup for further
information.
DIAG MENU 2/11
ANALOG IN: OK
- Or -
DIAG MENU 2/11
ANALOG IN: FAIL
4. Press [UP] to scroll to the next sub-menu. If the MODBUS communications fails, a failure
will be detected and logged. A MODBUS signal failure is logged when the DLCM is in the
MODBUS mode and the DLCM has not received a valid digital command within the timeout
limit.
DIAG MENU 3/11
MODBUS: OK
- Or -
DIAG MENU 3/11
MODBUS: FAIL
5. Press [UP] to scroll to the next sub-menu. If a PULSAlarm leak-detection diaphragm rupture
is detected, the DLCM will show a failure in this diagnostic sub-menu.
DIAG MENU 4/11
LEAK DET.: OK
- Or -
DIAG MENU 4/11
LEAK DET.: FAIL
6. Press [UP] to scroll to the next sub-menu. If the Level switch is configured as a {DRUM
LEVEL} type and the switch is activated, the DLCM will show a failure in this diagnostic submenu. If the Level Input is configured as {START/STOP}, a failure will not be logged.
DIAG MENU 5/11
LEVEL SW: OK
- Or -
DIAG MENU 5/11
LEVEL SW: FAIL
7. Press [UP] to scroll to the next sub-menu. The DLCM is equipped with a pump motor
thermostat to monitor pump motor temperatures. If the temperature has exceeded its
operating limit, the DLCM will show a warning in this diagnostic sub-menu.
DIAG MENU 6/11
MOTOR TEMP.: OK
- Or -
40
DIAG MENU 6/11
MOTOR TEMP.: FAIL
8. Press [UP] to scroll to the next sub-menu. The DLCM is equipped with a thermistor to
monitor internal enclosure temperatures. If the temperature approaches its operating limit,
(70˚C or 158˚F) the DLCM will show a warning in this diagnostic sub-menu.
DIAG MENU 7/11
DRIVE TEMP: OK
- Or -
DIAG MENU 7/11
DRIVE TEMP: FAIL
9. Press [UP] to scroll to the next sub-menu. The DLCM is equipped with a clock that is
backed by a 10-year lithium battery. If the battery fails, the DLCM will show a failure in this
diagnostic sub-menu. Consult factory.
DIAG MENU 8/11
BATTERY: OK
- Or -
DIAG MENU 8/11
BATTERY: FAIL
IF THE BATTERY FAILS, MAINTAIN LINE POWER AND CONSULT THE FACTORY.
10. Press [UP] to scroll to the next sub-menu. If errors are detected with the RAM, EEPROM or
internal synchronous stroke adjustment motor, the FAIL message will flash in this diagnostic
sub-menu. The error is automatically cleared when the component is replaced and power is
applied to the DLCM.
The Motor: FAIL is only an indication that we shut down (Duty Cycle) the stroke adjustment
motor to keep from overheating it.
DIAG MENU 9/11
CIRCUIT: OK
- Or -
DIAG MENU 9/11
CIRCUIT: FAIL
If a failure occurs, you can access a sub-menu from the {DIAG MENU / CIRCUIT: FAIL}
screen by pressing [ENTER]. The lower level menus show more descriptive circuit
information.
Press [UP] to scroll between sub-menus.
The DLCM tests its RAM at power-up. The results are shown as follows.
CIRCUIT FAILURE
RAM: OK
- Or -
CIRCUIT FAILURE
RAM: FAIL
The DLCM tests EEPROM whenever it writes information to long term memory
CIRCUIT FAILURE
EEPROM: OK
- Or -
CIRCUIT FAILURE
EEPROM: FAIL
The {MOTOR: FAIL} message only indicates that the Stroke Adjustment motor has exceeded
its Duty Cycle limit.
CIRCUIT FAILURE
MOTOR: OK
- Or -
CIRCUIT FAILURE
MOTOR: FAIL
CIRCUIT FAILURES CAN ONLY BE CLEARED BY CYCLING THE POWER TO THE DLCM.
11. Press [UP] to scroll to the next sub-menu. The run time on the pump motor is displayed in
this diagnostic sub-menu. To reset the run time, press [ENTER] and you are prompted to
reset the total run time or continue counting the total operating hours.
DIAG MENU 10/11
RUN XXX
HRS
Press
[ENTER]
41
RESET RUN TIME?
NO
12. Press [UP] to scroll to the next sub-menu. The total Stroke count of the pump is displayed
here. To reset the Stroke count, press [ENTER] and you are prompted to {RESET COUNT?}
or continue with the original count.
DIAG MENU 11/11
STROKES
XXXX
Press
[ENTER]
RESET COUNT?
YES
IN STEPS 11 AND 12, IF YOU SELECT YES TO EITHER {RESET RUN TIME?} OR {RESET
COUNT?}, THE {ARE YOU SURE?} PROMPT IS DISPLAYED. PRESS [UP] AND [ENTER] TO
CONFIRM THE CHANGE.
13. Press [ENTER] on any of the ‘Fail’ diagnostic screens (with the exception of BATTERY: FAIL
and CIRCUIT FAIL) depicted above to display the time and date of the failure or more
descriptive information.
ONLY THE FIRST OCCURRENCE OF AN ERROR WILL BE LOGGED. THE ERROR MUST BE
CLEARED TO LOG FUTURE OCCURRENCES.
DIAG MENU 1/11
POWER IN: FAIL
Press
[ENTER]
POWER FAILURE
13:27
1/22/01
14. Press [ENTER] again, and you are prompted to clear the failure. Depending upon the type of
failure diagnosed, you may want to take other steps before clearing the failure and restarting
the pump. If so, press [ENTER] to keep the error date and time stamp. Otherwise, press [UP]
to scroll to {YES} and press [ENTER]. The DLCM will return to the first menu screen
depicted in step 1.
POWER FAILURE
CLEAR? NO
7.2.3 Set Time and Date
The clock/calendar is essential to the proper operation of the batch system and proper error time
stamping. The clock should be set during installation. It can be configured to operate without any
additional maintenance in most time zones.
SET TIME/DATE PROCEDURE
1. Press [MENU], then [UP] to display the menu:
- MENU SET TIME & DATE
Press [ENTER] to access the {Set Time and Date} sub-menu.
2. Flashing in the upper left hand corner of the display should be {24 HR}, which denotes a 24
hour clock. By pressing [UP], you can change this to a 12 hour {12 HR} clock.
THE 12 HOUR CLOCK SELECTION WILL ADD AN 'a' OR 'p' AFTER THE TIME.
Press [ENTER] to accept the desired time format.
12 HR
2:31a
MM/DD/YY
1/22/01
3. 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
2:31a
MM/DD/YY
1/22/01
42
THE CURSOR LOCATED UNDER THE DIGIT IN THE TIME, INDICATES THE CHARACTER
BEING CHANGED.
Once the hour is set, press [ENTER] and the cursor will move to the first digit in the minute
setting. Press [UP] or [DOWN] to set the correct tens of minutes digit, then press [ENTER].
12 HR
2:31a
MM/DD/YY
1/22/01
4. The cursor moves to the second digit of the minute setting. Press [UP] or [DOWN] to set the
correct second minute digit, then press [ENTER].
12 HR
2:31a
MM/DD/YY
1/22/01
5. If you selected the 12 hour format, the cursor moves under the a.m./p.m. character. Press
[UP] or [DOWN] to set the correct a.m./p.m. character ( a or p), then press [ENTER].
12 HR
2:31a
MM/DD/YY
1/22/01
6. The date format will now be flashing on the display. The date can be expressed in one of
three formats: MM/DD/YY, DD/MM/YY, YY/MM/DD.
Press [UP] or [DOWN] to scroll through the above referenced formats. When the format you
desire is displayed, press [ENTER] to accept this format and continue.
7. The date is now flashing on the display. Press [UP] or [DOWN] to change this to the current
date. Press [ENTER] to accept this value and the cursor moves to the next date position.
Continue to press [UP] or [DOWN]. Press [ENTER] on the last date field to accept your
setting.
12 HR
2:31 A
MM/DD/YY
1/22/01
YOU ARE NOT ALLOWED TO EXIT THE DATE FIELD IF THE DATE DOES NOT EXIST. FOR
EXAMPLE, JUNE 31 OR FEB 29 IN A NON- LEAP YEAR WOULD NEED TO BE CORRECTED
TO A VALID DATE.
8. The DLCM prompts you to change the time and date for {DAYLIGHT SAVINGS / NO}. Press
[UP] to scroll to {AUTO CHANGE}. The auto-change option complies with daylight savings
time changes as mandated by United States legislation. Press [ENTER] to accept the correct
configuration based on the location of the DLCM.
DAYLIGHT SAVINGS
AUTO CHANGE
THE TIMES CHANGE OVER ON THE FIRST SUNDAY IN APRIL AND ON THE LAST
SUNDAY IN OCTOBER.
9. If "AUTO CHANGE" was selected in the previous step, the DLCM prompts you for the
current day of the week. Press [UP] to scroll through the days of the week. Press [ENTER] to
accept the current day of the week.
DAY OF THE WEEK
WEDNESDAY
43
10. The DLCM prompts you to accept the time and date programmed in the above referenced
steps. {CONFIRM CHANGE? / YES}. Press [ENTER] to accept. If you do not want to accept
the new inputs, press [UP] to scroll to {NO} and press [ENTER].
CONFIRM CHANGE?
YES
11. The display will return to the {–MENU– / SET TIME & DATE} screen.
7.2.4 Analog Signal Failure Setup
This sub-menu allows you to set up the DLCM response if the analog signal fails. You can
program the DLCM to have one of the following responses:



Freeze at the last good analog input signal,
Shut the motor off,
Go to a default signal.
An analog input failure is detected if one of the following conditions occurs. First, the signal falls
below the lower calibrated range by 0.3mA. For example, if the DLCM is calibrated with a range
of 4-20mA and the signal falls to 3.6mA, then a failure is recognized. Second, if the analog signal
falls below 0.3mA and is changing at a rate of 8.8mA per second or more, a failure will be logged.
This second condition is primarily for the situation where the input is calibrated down to 0
(0.0mA).
When an Analog Input is calibrated in the 0-5mA or 0-20mA range and you are operating down
near the lower end (<2.5mA) the detection of a failed signal may not occur because the slew rate
(rate of change) is too low to be detected. If you are calibrated down to 0mA, operation after a
failure will be restored immediately because 0mA is an in-range signal. In this case you should
use the MOTOR OFF option rather than FREEZE or GO TO DEFAULT choices.
IF ANALOG INPUT SIGNAL FAILURE IS IMPORTANT TO OPERATION, AVOID
CALIBRATING TO 0 MA.
SIGNAL FAILURE RESPONSE (ONE-SIGNAL MODE) PROCEDURE
1. Press [MENU] and press [UP] or [DOWN] until {–MENU– / ANALOG SIG FAIL} is displayed.
- MENU ANALOG SIG FAIL
Press [ENTER] to continue to the Analog Signal Fail setup screens.
The first entry in the Analog Signal Failure menu determines how the DLCM recovers from a
failed analog input. You can select from two {RESTORE TO:} modes: Analog or Manual. If
{ANALOG MODE} is selected, the DLCM will resume automatically following the 4-20mA
input. If {MANUAL MODE} is selected, the DLCM will enter the manual mode as soon as the
signal loss is detected. It will remain in Manual Mode until it is changed manually (press
[MODE] on the front panel). The benefit of using a {RESTORE TO: / ANALOG MODE} is that
it's totally automatic. If so programmed, the DLCM can shut itself down, wait for a signal to
return, and then start itself back up.
Press [ENTER] to accept the factory default of {RESTORE TO: / ANALOG MODE} or press
[UP] and then press [ENTER] to select the {RESTORE TO: / MANUAL MODE}.
RESTORE TO:
ANALOG MODE
Press
[UP]
44
RESTORE TO:
MANUAL MODE
2. The menu for having the DLCM freeze at the last signal is displayed.
ANALOG SIG FAIL
FREEZE @ LAST SIG
To accept this action, press [ENTER]. Go to step 5. If you desire a different action, press
[UP].
3. The menu for having the DLCM shut the motor off is displayed.
ANALOG SIG FAIL
MOTOR OFF
To accept this action, press [ENTER]. Go to step 5. If you desire a different action, press
[UP].
4. The menu for having the DLCM go to a default signal (e.g.: 10%) is displayed.
ANALOG SIG FAIL
GO TO DEFAULT
To accept this action, press [ENTER].
5. The next display prompts for the uncalibrated percent of flow to be the default setting. Enter
the value using [UP] or [DOWN].
SIGNAL DEFAULT
10.0%
To accept this value, press [ENTER].
6. The {ERROR MESSAGE / ENABLED} screen is displayed.
ERROR MESSAGE
ENABLED
To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is
displayed.
If you desire a different action, press either [UP] or [DOWN] to display the {ERROR
MESSAGE / DISABLED} screen.
ERROR MESSAGE
DISABLED
To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is
displayed.
THE ERROR WILL STILL BE LOGGED WITH THE TIME AND DATE, BUT THE FLASHING
ERROR MESSAGE ON THE SCREEN IS SUPPRESSED. THIS IS FOR APPLICATIONS THAT
INTENTIONALLY INTERRUPT THE ANALOG SIGNAL IN THE NORMAL COURSE OF
OPERATIONS, STOPPING AND RE-STARTING THE PUMP.
45
ANALOG SIGNAL FAILURE (TWO-SIGNAL MODE) PROCEDURE
1. Press [MENU] and press [UP] or [DOWN] until {–MENU– / ANALOG SIG FAIL} is displayed.
- MENU ANALOG SIG FAIL
Press [ENTER] to continue to the Analog Signal Fail sub-menu.
The first entry in the Analog Signal Failure menu determines how the DLCM recovers from a
failed analog input. You can select from two {RESTORE TO:} modes: Analog or Manual. If
{ANALOG MODE} is selected, the DLCM will resume automatically following the 4-20mA
input after the signal is restored.
If {MANUAL MODE} is selected, the DLCM will enter the manual mode as soon as the signal
loss is detected. It will remain in Manual Mode until it is changed manually (press [MODE] on
the front panel). The benefit of using a {RESTORE TO: / ANALOG MODE} is that it's totally
automatic. If so programmed, the DLCM can shut itself down, wait for a signal to return, and
then start itself back up.
RESTORE TO:
ANALOG MODE
Press
[UP]
RESTORE TO:
MANUAL MODE
THE {RESTORE TO:} SETTING APPLIES TO BOTH CHANNELS (I.E., THERE IS ONLY ONE
SETTING).
2. With the desired selection displayed, press [ENTER].
RESTORE TO:
ANALOG MODE
THE SUB-SCREENS FOR {ANALOG FAIL #1 / STROKE POSITION}, AND {ANALOG FAIL #2
/ MOTOR SPEED} ARE IDENTICAL WITH THE EXCEPTION OF THE NUMBER (#1 OR #2)
DISPLAYED AT THE END OF THE FIRST LINE OF TEXT. IF FOR EXAMPLE {ANALOG FAIL
#1 / STROKE POSITION} IS SELECTED, SOME SUB- SCREENS WILL HAVE #1 DISPLAYED
AT THE END OF THE FIRST LINE OF TEXT.
3. The first of two channel selection screens is displayed: Press [UP] or [DOWN]
ANALOG FAIL #1
STROKE POSITION
Press
[UP]
ANALOG FAIL #2
MOTOR SPEED
Select the desired channel and press [ENTER]. (For the purpose of this manual, {ANALOG
FAIL #1 / STROKE POSITION} will be covered.)
4. The menu for having the DLCM freeze at the last signal is displayed.
ANALOG FAIL #1
FREEZE @ LAST SIG
To accept this action, press [ENTER] and then go to step 5. If you desire a different action,
press [UP].
a) The menu for having the DLCM shut the motor off is displayed.
ANALOG FAIL #1
MOTOR OFF
To accept this action, press [ENTER] and then go to step 5. If you desire a different action,
press [UP].
46
b) The menu for having the DLCM go to a default signal is displayed.
ANALOG FAIL #1
GO TO DEFAULT
To accept this action, press [ENTER].
c) The next display prompts for the percent of stroke or speed to be the default setting.
Enter the value using [UP] or [DOWN].
SIGNAL DEFAULT
0.0%
To accept this value, press [ENTER].
THE {ERROR MESSAGE / ENABLED} – {ERROR MESSAGE / DISABLED} OPTION IS
PROVIDED FOR USERS THAT ARE OPERATING IN THE TWO ANALOG INPUT CHANNEL
MODE, BUT ARE ONLY USING ONE ANALOG SIGNAL AND HAVE SET UP THE OTHER
CHANNEL TO “GO TO DEFAULT” (E.G.: CONTROLLING MOTOR SPEED, WHILE LEAVING
THE STROKE AT A FIXED POSITION LIKE 50% OR 100%). IN THIS SITUATION THE
SYSTEM IS CONFIGURED TO OPERATE WITHOUT ONE OF THE INPUT SIGNALS AND THE
OPERATOR DOES NOT WANT TO SEE THE ERROR MESSAGE DISPLAYED.
5. The {ERROR MESSAGE / ENABLED} screen is displayed.
ERROR MESSSAGE
ENABLED
To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is
displayed.
If you desire a different action, press either [UP] or [DOWN] to display the {ERROR
MESSAGE/ DISABLED} screen.
ERROR MESSSAGE
DISABLED
To accept this value, press [ENTER] and the {–MENU– / ANALOG SIG FAIL} screen is
displayed.
7.2.5 MODBUS Signal Failure Setup
This sub-menu allows you to set up the DLCM response if the MODBUS Signal fails. You can
program the DLCM to have one of the following responses:



Freeze at the last digital input signal,
Shut the motor off,
Go to a default setting.
A MODBUS Signal failure is detected if the DLCM does not receive a valid message.
MODBUS SIGNAL FAURE SETUP PROCEDURE.
1. Press [MENU] and press [UP] or [DOWN] until the display reads {–MENU– / MODBUS SIG.
FAIL}.
- MENU MODBUS SIG FAIL
Press [ENTER] to continue to the MODBUS Signal Fail sub-menus.
47
2. The {RESTORE TO:} menu is displayed. This setting determines how the DLCM will recover
from a failed MODBUS Signal. You can select from two {RESTORE TO:} modes – MODBUS
or Manual.
If {MODBUS MODE} is selected the DLCM will resume following the MODBUS signal
automatically when the signal is restored.
If {MANUAL MODE} is selected, the DLCM will enter manual mode as soon as the signal
loss is detected. The DLCM will remain in Manual Mode until it is changed manually (press
[MODE] on the front panel).
The benefit of using {RESTORE TO: / MODBUS MODE} is that it’s totally automatic. If so
programmed, the DLCM can shut itself down, wait for the signal to return and then start itself
back up.
RESTORE TO:
MODBUS MODE
Press
[UP]
RESTORE TO:
MANUAL MODE
Press [ENTER] to accept the factory default of {RESTORE TO: / MODBUS MODE} or press
[UP] and then press [ENTER] to select the {RESTORE TO: / MANUAL MODE}.
3. The next entry in the MODBUS SIG. FAIL sub-menu allows you to set the timeout value in
seconds. This defines the maximum interval between messages addressed to this node. If a
message is not received within this period, a MODBUS Signal failure will be detected. A
number of factors influence the value you should set here:
1)
2)
3)
4)
Number of nodes on the network
Type of master
Baud rate
Electrical environment.
Here are some general guide lines:





Increase this value as you increase the number of nodes on the network.
Increase this value as you decrease the communications baud rate.
Increase this value if the DLCM is a slave connected to a heavily loaded PC/PLC
master.
Increase this value if you are in an electrically noisy environment.
Decrease this value if the DLCM is mission critical on a small (2-3 node) network.
ALWAYS USE THE DEFAULT SETTING (2.5 SECONDS) AS A STARTING POINT.
TO ADJUST THE VALUE, PRESS [UP] OR [DOWN], PRESS [ENTER] TO ACCEPT THE
VALUE.
TIMEOUT
2.5 SECONDS
The screens to be displayed next are dependent on how your DLCM Serial Communications
(ACTIVE) and MODBUS mode (1 – SIGNAL or 2 – SIGNAL) have been configured. If you
have selected the 1 – SIGNAL option continues with step 4. If the 2 – SIGNAL option is
selected go to step 7.
4. The menu that selects the MODBUS Signal failure action is displayed. There are three
available options:
1) Freeze at last signal
2) Motor off
3) Go to Default
48
Press [UP] or [DOWN] to select the desired option. Press [ENTER] to accept your setting.
MODBUS SIG FAIL
FREEZE @ LAST SIG
Press
[UP]
MODBUS SIG FAIL
MOTOR OFF
Press
[UP]
MODBUS SIG FAIL
GO TO DEFAULT
5. If you selected {FREEZE @LAST SIG} or {MOTOR OFF} in step 4, proceed to step 6. If you
selected {GO TO DEFAULT}, you must set the default value.
Press [UP] or [DOWN] to set the default signal in percent.
SIGNAL DEFAULT
10.0%
Press [ENTER] to accept your setting.
6. The {ERROR MESSAGE} screen is displayed. Press [UP] or [DOWN] to select between
{ENABLED} or {DISABLED}
ERROR MESSAGE
ENABLED
Press
[UP]
ERROR MESSAGE
DISABLED
Press [ENTER] to accept your setting.
When the DISABLED setting is selected, the error will still be logged with the date and
time, but the flashing error message on the screen will be suppressed. This option is for
applications that intentionally interrupt the MODBUS Signal in the normal course of
operations, stopping and re- starting the pump.
If {2 – SIGNAL} is selected two additional screens are displayed:
MODBUS FAIL #1
STROKE POSITION
- Or -
MODBUS FAIL #2
MOTOR SPEED
7. Select the condition to alarm for {STROKE POSITION} or {MOTOR SPEED} and then press
[ENTER].
8. The menu that selects the MODBUS Signal failure action is displayed. There are three
available options:
1) Freeze at last signal,
2) Motor off,
3) Go To Default
Press [UP] or [DOWN] to select the desired option
MODBUS FAIL #X
FREEZE @ LAST SIG
Press
[UP]
MODBUS FAIL #X
MOTOR OFF
Press
[UP]
MODBUS FAIL #X
GO TO DEFAULT
Press [ENTER] to accept your setting.
In the example screens above, at the end of the {MODBUS FAIL} line the last two
characters are “#X”. In this case “X” will represent either “1” or “2” depending on which
option (STROKE POSITION #1 or MOTOR SPEED #2) you are alarming for.
49
9. If you selected {FREEZE @LAST SIG} or {MOTOR OFF} in step 8, proceed to step 10. If
you selected {GO TO DEFAULT}, you must set the default value.
Press [UP] or [DOWN] to set the default signal in percent.
SIGNAL DEFAULT
10.0%
Press [ENTER] to accept your setting.
10. The {ERROR MESSAGE} screen is displayed. Press [UP] or [DOWN] to select between
{ENABLED} or {DISABLED}.
ERROR MESSAGE
ENABLED
Press
[UP]
ERROR MESSAGE
DISABLED
Press [ENTER] to accept your setting.
WHEN THE DISABLED SETTING IS SELECTED, THE ERROR WILL STILL BE LOGGED
WITH THE DATE AND TIME, BUT THE FLASHING ERROR MESSAGE ON THE SCREEN
WILL BE SUPPRESSED. THIS OPTION IS FOR APPLICATIONS THAT INTENTIONALLY
INTERRUPT THE MODBUS SIGNAL IN THE NORMAL COURSE OF OPERATIONS,
STOPPING AND RE- STARTING THE PUMP.
7.2.6 Analog Output Setup
This sub-menu allows you to control the DLCM’s analog output channel. The Analog Output can
be set up to:
1) Send a signal to a recording device (e.g. chart recorder) located away from the
pump/controller.
2) Send a signal to a Programmable Logic Controller (PLC) to be used as a process
control.
3) Link DLCM’s together to allow more than one pump to follow a single input, with the
options of reverse-acting, split action and ratio as part of this special (second pump)
operation.
ANALOG OUTPUT SETUP PROCEDURE
THE ANALOG OUTPUT CAN BE CONFIGURED TO REPRESENT STROKE, SPEED, OR
STROKE AND SPEED.
1. Press [MENU] to enter the {–MENU–} sub-system. Press [UP] or [DOWN] until {–MENU– /
ANALOG OUTPUT} is displayed.
- MENU ANALOG OUTPUT
Press [ENTER] to set up the Analog Output Options.
There are three Analog Output options: {STROKE & SPEED}, {STROKE POSITION}, and
{MOTOR SPEED}. {STROKE & SPEED} is the Factory Default setting.
ANALOG OUTPUT
STROKE & SPEED
THE STROKE & SPEED OUTPUT ACTUALLY REPRESENTS CALIBRATED FLOW WHERE
0% FLOW MAY NOT CORRELATE TO 0% STROKE POSITION.
50
Press [ENTER] to accept this selection. You are then returned to the {–MENU– / ANALOG
OUTPUT} screen.
2. If the desired mode is {STROKE POSITION}, press [UP], and the {STROKE POSITION}
screen is displayed.
ANALOG OUTPUT
STROKE POSITION
THE STROKE OUTPUT ACTUALLY REPRESENTS CALIBRATED STROKE POSITION
WHERE 0% ANALOG OUTPUT MAY NOT CORRELATE TO THE MECHANICAL 0% STROKE
POSITION.
Press [ENTER] to accept your selection. You are then returned to the {–MENU– / ANALOG
OUTPUT} screen.
3. If the desired mode is {MOTOR SPEED}, press [UP] until the {MOTOR SPEED} screen is
displayed.
ANALOG OUTPUT
MOTOR SPEED
THE MOTOR SPEED OUTPUT REPRESENTS THE TARGET MOTOR SPEED.
Press [ENTER] to accept your selection. You are then returned to the {–MENU– / ANALOG
OUTPUT} screen.
7.2.7 Motor Speed Display
This sub-menu allows you to view the target and actual averaged motor speed. The average
value represents the last 30 pump strokes or less.
MOTOR SPEED DISPLAY PROCEDURE
1. Press [MENU] to enter the {–MENU–} sub-system. Press [UP] or [DOWN] until {–MENU– /
MOTOR SPEED} is displayed.
- MENU MOTOR SPEED
2. Press [ENTER] to display the {TARGET RPM / ACTUAL RPM} screen.
TARGET RPM XXXX
ACTUAL RPM XXXX
PRESSING [UP] OR [DOWN] RESETS THE {ACTUAL RPM} AVERAGE TO 0. THE PUMP
MUST COMPLETE 1 STROKE BEFORE AN ACTUAL RPM IS DISPLAYED.
3. Press [ENTER] to return to the {–MENU– / MOTOR SPEED} screen.
7.2.8 End-Point Setup
The End-Point Setup menu is a powerful tool that allows you to modify the performance of your
DLCM. The term 'End Points' refers to the operating limits of the control elements. The DLCM has
two control elements: the mechanical stroke adjustment and the motor speed adjustment. These
elements have limits to their operation. The stroke adjustment can control from 0% stroke to
100% stroke. The motor speed adjustment can control from 5% speed (87.5 RPM) to 100%
speed (1750 RPM). These settings are referred to as 'End Points'. You can adjust these End51
Point values to affect the way the DLCM operates. For example, you can limit the operating range
of the stroke adjustment by setting its End Points to 0% and 50%. Thus, in normal operation, the
DLCM will not adjust its stroke setting above 50% stroke.
Another aspect of the End-Points menu is the term 'Priority'. The DLCM has influence over two
control elements. It needs to adjust these elements to produce a desired flow rate. Thus, if you
desire the pump's output to be 0.1LPH, the DLCM must adjust the stroke length and motor speed
to produce the desired flow. In most cases, there are an infinite variety of stroke length and motor
speed combinations that will produce a desired flow rate. For example, if the desired flow output
is 25%, it can be achieved by setting the stroke length to 100% and the motor speed to 25% (1.00
* 0.25 = 0.25). Or, the stroke length can be set to 50% and the motor speed set to 50% (0.50 *
0.50 = 0.25). The DLCM uses one rule when deciding how to adjust stroke and speed to obtain a
given flow rate. This rule is as follows:
When adjusting from 100% flow to 0% flow, the 'Priority' control element (e.g., motor
speed) will be adjusted first from its maximum End Point to its minimum End Point. When
the 'Priority' control element's (e.g., motor speed) minimum End Point is achieved the
second element (e.g., stroke length) will be adjusted from its maximum end point until it
achieves its minimum.
The term 'Priority' refers to the element that is adjusted first or has 'Priority' when adjusting from
100% to 0%. The DLCM uses the following defaults for 'Priority' and 'End Points':
Type
Motor Speed
Stroke Length
Default Value
Minimum End Point
Maximum End Point
Minimum End Point
Maximum End Point
10%
100%
0%
100%
The following is a graphical representation of the Priority and End-Point operation. The x-axis
represents Adjustment (e.g., the value you enter at the front panel). The y-axis represents flow.
Figure 14 – Priority and End-Point Operation
At the 100% Adjustment (maximum value on the x-axis), the DLCM is operating at 100% stroke
length and 100% motor speed. This results in a 100% flow output. As the Adjustment is
decreased to 50% for example, the motor speed is adjusted to 50% (motor speed has 'Priority')
and the stroke length remains at 100%. As we continue to decrease the Adjustment value, the
DLCM continues to decrease motor speed until it reaches its minimum End-Point value (10%). At
the 10% adjustment, the DLCM's motor speed will be 10% and the stroke length will be 100%. As
the Adjustment is set below 10%, the motor speed setting will remain at its minimum End Point
value of 10% and the stroke length will be adjusted. Thus, as the Adjustment is reduced to 5%,
the DLCM will keep the motor speed at its minimum End Point value of 10% and adjust the
Stroke Length to 50% (0.10 * 0.50 = 0.05). Finally, when the DLCM is at its minimum Adjustment
52
value (i.e., 0%), the motor speed will be at its minimum End Point value of 10% and the Stroke
Length will be at its minimum End Point value of 0% (0.10 * 0.00 = 0.00). When increasing the
adjustment value, the same rule system is followed in the opposite order. Thus, stroke length is
increased until it reaches its maximum End Point, then speed is increased until it reaches its
maximum End Point.
Looking at this graph, you will notice that 90% of the pump's flow output is covered by motor
speed while 10% is covered by stroke length. The End Point and Priority settings allow you to
change characteristics such as this. For example, if you set the 'Priority' value to Stroke Length,
then 100% of the pump's flow is covered by stroke length (when the stroke length has a 0%
Minimum End point, the motor speed will also be set to its Minimum End Point as the Adjustment
value will be 0%).
WHEN CONTROLLING FROM A SINGLE ANALOG INPUT (1-CHANNEL), THE ABOVE
STATED RULE APPLIES. WHEN CONTROLLING FROM TWO ANALOG INPUTS (2CHANNEL), THE END POINT VALUES ARE ENFORCED, BUT THE PRIORITY IS NOT.
DURING PUMP FLOW CALIBRATION AND ZERO CALIBRATION, THE SELECTED END
POINTS MAY BE VIOLATED.
YOU CAN FIX THE OPERATING POINT OF STROKE LENGTH OR MOTOR SPEED BY
SETTING THE MINIMUM AND MAXIMUM END POINT VALUES EQUAL (E.G., YOU CAN FIX
THE STROKE LENGTH AT 50% BY SETTING THE MINIMUM END POINT TO 50% AND THE
MAXIMUM END POINT TO 50%).
7.2.8.1 End-Point Example
A PULSAR pump is purchased with the DLCM option. Due to anticipated future capacity growth,
the pump is twice as large as currently required. The process will require the pump to typically
operate between 5% and 35% flow. In addition, it is critical that the pump not operate above the
50% flow output. The pump will be controlled by a single analog signal.
There are a number of ways to assure that the pump does not exceed the 50% flow output. For
example, the 4-20mA input calibration could be ratioed 50% to limit the output. But, this technique
would not prevent someone from walking up to the pump and manually adjusting it above 50%. A
better way is to adjust the End Point values. Using the default End Point and Priority values, the
DLCM will typically operate the motor speed from 50% to 10% and the stroke length from 100%
to 0%. Unfortunately, this means that in the 5% to 25% anticipated flow range, the DLCM will
transition between stroke length and motor speed control (at the 10% flow point).
Figure 15 – Typical End Point Example
A better way to accomplish this is to modify the Maximum End Point for Stroke Length. If we
53
change the Maximum End Point value to 50% stroke length, then the maximum pump output will
be limited to 50% (50% Length and 100% motor speed yields 50% output). This improves the
control characteristics as 5% to 35% flow range is now covered fully with motor speed.
Figure 16 – Modified End Point Example
END POINT SETUP PROCEDURE
1. Press [MENU] to enter the {– MENU –} sub-system. Press [UP] or [DOWN] until {–MENU– /
END POINT} is displayed.
2. Press [ENTER] to display the {STROKE END POINT / MINIMUM = XXX%} screen.
STROKE END POINT
MINIMUM = XXX%
Press [UP] or [DOWN] to set the value. Press [ENTER] to accept your setting.
3. The {STROKE END POINT / MAXIMUM = XXX%} screen is displayed.
STROKE END POINT
MAXIMUM = XXX%
Press [UP] or [DOWN] to set the value. Press [ENTER] to accept the setting.
4. The {SPEED END POINT / MINIMUM = XXX%} screen is displayed.
SPEED END POINT
MINIMUM = XXX%
Press [UP] or [DOWN] to set the value. Press [ENTER] to accept the setting.
5. The {SPEED END POINT / MAXIMUM = XXX%} screen is displayed.
SPEED END POINT
MAXIMUM = XXX%
Press [UP] or [DOWN] to set the value. Press [ENTER] to accept the setting.
6. The {PRIORITY SPEED} screen is displayed.
54
7. Press [UP] or [DOWN] to set the priority to either {SPEED} or {STROKE}.
PRIORITY
SPEED
- Or -
PRIORITY
STROKE
Press [ENTER] to accept your selection.
8. The {FLOW RANGE} screen is displayed. This represents the available Flow Range based
on your settings. Press [ENTER]
FLOW RANGE
1.0% - 90%
9. The {CONFIRM CHANGE} screen is displayed.
CONFIRM CHANGE
YES
If you do not want to confirm these changes, press [DOWN] to display the {CONFIRM
CHANGE = NO} screen.
CONFIRM CHANGE
NO
In either case, confirming or not confirming, press [ENTER] to complete the action. At this
point, you are returned to the {–MENU– / END POINT} screen.
7.2.9 Leak-Detection Failure Setup
This sub-menu allows you to configure the DLCM to interact with a PULSAlarm Leak-Detection
Diaphragm. You can modify the way the DLCM responds to a diaphragm rupture. The following
responses are available:




Shut the motor off,
Trigger an alarm relay,
Shut the motor off and trigger an alarm relay,
Have no interaction with the Pump Motor or Alarm Relay other than log the diaphragm
failure and display a message on the LCD display (this message is displayed until a key
on the keypad is pressed).
THE LEAK SENSOR SWITCH MUST BE A DRY CONTACTING TYPE. REFER TO SECTION
5: INSTALLATION, LOW-VOLTAGE INPUT CONNECTIONS FOR WIRING INFORMATION.
IF YOU SELECT THE 'MOTOR OFF' OPTION, THE MOTOR WILL HAVE TO BE MANUALLY
RE-STARTED IF A LEAK-DETECTION FAILURE IS DETECTED (I.E., PRESS [MOTOR] TO
START THE PUMP MOTOR).
LEAK-DETECTION FAILURE SETUP PROCEDURE
1. Press [MENU] to enter the { –MENU– } sub-system. Press [UP] or [DOWN] until {–MENU– /
LEAK DETECTION} is displayed.
- MENU LEAK DETECTION
Press [ENTER] to continue to program the Leak-Detection options.
2. The Leak-Detection Input can be configured as {INACTIVE}. If the pump is not supplied with
55
a PULSAlarm Leak-Detection Diaphragm, it should be set as {INACTIVE}.
LEAK DET INPUT
INACTIVE
Press [ENTER] to accept your selection. The {–MENU– / LEAK-DETECTION} screen is
displayed.
3. If your pump is supplied with a PULSAlarm Leak-Detection Diaphragm, press [UP] to select
the type of switch. The Leak-Detection Input switch can be configured as {NORMALLY
OPEN},
LEAK DET INPUT
NORMALLY OPEN
Or press [UP] to configure the switch as {NORMALLY CLOSED}.
LEAK DET INPUT
NORMALLY CLOSED
Press [ENTER] to accept the desired configuration.
4. The display prompts you to configure the motor state (ON/OFF) should a diaphragm rupture
occur (i.e., a leak is detected).
LEAK DETECTION
MOTOR OFF? NO
If you do not want the pump's motor to turn off when a leak is detected, press [ENTER] to
accept the default value. If you want the motor to shut off if a leak is detected, press [UP] to
scroll to {YES} and press [ENTER].
5. The display prompts you to configure the alarm relay status (triggered or not triggered).
LEAK DETECTION
ALARM RELAY? NO
If you do not want the Alarm Relay activated when a leak is detected, press [ENTER] to
accept the default of {NO}. If you want the alarm relay to be active if a leak is detected, press
[UP] to scroll to {YES} and press [ENTER]. The display returns to the { –MENU– / LEAKDETECTION} screen.
56
7.2.10
Level / Remote Start-Stop Setup
This sub-menu allows you to configure the DLCM to interact with a level input. You can program
the DLCM to have one of the following responses:

Shut the motor off,

Trigger the alarm relay,

Shut the motor off and trigger the alarm relay,

Shut the motor OFF when the level input is in one state (e.g. CLOSED) and turn the motor
ON when the level input is in the other state (e.g. OPEN).
THE LEVEL SENSOR OR START/STOP SWITCH MUST BE A DRY CONTACTING TYPE.
REFER TO SECTION 5: INSTALLATION, LOW-VOLTAGE INPUT CONNECTIONS.
IF YOU SELECT THE 'MOTOR OFF' OPTION, THE MOTOR WILL HAVE TO BE MANUALLY
RE-STARTED WHEN A LEVEL FAILURE IS DETECTED (I.E., PRESS [MOTOR] TO START
THE PUMP MOTOR).
LEVEL/START-STOP SETUP PROCEDURE
1. Press [MENU] to enter the { –MENU – } sub-system. Press [UP] or [DOWN] until { –MENU–
/ LEVEL SWITCH} screen is displayed.
- MENU LEVEL SWITCH
Press [ENTER] to continue to program the Level Switch sub-menu.
2. The level input can be configured as {INACTIVE}, if it will not be used.
LEVEL SWITCH
INACTIVE
Pressing [ENTER] when {LEVEL SWITCH / INACTIVE} is displayed will cause the screen to
return to the { –MENU– / LEVEL SWITCH} screen.
3. Press [UP] to scroll to the next option {LEVEL SWITCH / ACTIVE}.
LEVEL SWITCH
ACTIVE
4. Press [ENTER] when {LEVEL SWITCH / ACTIVE} is displayed and the following screen is
displayed.
LEVEL SWITCH
DRUM LEVEL
Select this option if the level input is to be connected to a drum level switch. Press [ENTER]
to select. Go to step 7.
THE NORMAL STATE FOR DRUM LEVEL REFERS TO THE CONDITION THAT EXISTS
WHEN THE DRUM LEVEL IS OK AND THE PUMP SHOULD BE RUNNING. FOR EXAMPLE,
IF THE DRUM LEVEL SWITCH CLOSES WHEN THE DRUM IS FULL (AND THE PUMP
SHOULD BE RUNNING) THEN THE NORMAL STATE IS CLOSED.
5. Pressing [UP] when the {LEVEL SWITCH / DRUM LEVEL} screen is displayed will open the
{LEVEL SWITCH / START/STOP} screen.
LEVEL SWITCH
START/STOP
57
THE NORMAL STATE FOR START/STOP, REFERS TO THE CONDITION THAT EXISTS
WHEN THE START/STOP (CALL TO RUN) SIGNAL IS OK AND THE PUMP SHOULD BE
RUNNING. FOR EXAMPLE, IF THE START/STOP SWITCH CLOSES WHEN THE PUMP IS
EXPECTED TO RUN THEN THE NORMAL STATE IS CLOSED.
6. Pressing [ENTER] from {LEVEL SWITCH / START/STOP} screen to configure the LEVEL
SWITCH input for use with a remote motor On/Off switch.
7. The Level Switch Configuration screen is displayed:
LEVEL SWITCH
NORMALLY CLOSED
8. Press [ENTER] to configure the switching device as {NORMALLY CLOSED}, or press [UP]
and then press [ENTER] to configure the switching device as {NORMALLY OPEN}.
WHEN {LEVEL SWITCH / START/STOP} HAS BEEN SELECTED, YOU ARE RETURNED TO
THE {–MENU– / LEVEL SWITCH} SCREEN. THIS SETTING USES THE DEFAULT SETTINGS
OF {MOTOR OFF? / YES} AND {ALARM RELAY / NO}. THESE SETTINGS CANNOT BE
MODIFIED.
9. The display prompts for the motor status when the Level Input trips:
LEVEL SWITCH
MOTOR OFF? YES
Press [ENTER] if you want the PULSAR motor to turn off when the Drum Level input is
sensed. Go to step 11.
10. 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 SWITCH
MOTOR OFF? NO
11. The display prompts you for the alarm relay status should the Drum Level Input trigger the
alarm relay.
LEVEL SWITCH
ALARM RELAY? YES
Press [ENTER] if you want the Alarm Relay to activate with the Drum Level Input. The
display returns to the {–MENU– / LEVEL SWITCH} screen.
12. If you do not want the Alarm Relay to activate with the Level Switch Input, press [UP] to
scroll to {NO}.
LEVEL SWITCH
ALARM RELAY? NO
Press [ENTER] to accept the setting. The display returns to the {–MENU– / LEVEL SWITCH}
screen.
58
7.2.11
Digital Output Setup
This sub-menu allows you to determine if the Digital Output is to be used as a counter for pump
strokes, as a remote motor on/off indicator, or for Mode indication.
For example: If the Digital Output is set up as {RUN/STOP STATUS}, and {DIGITAL OUTPUT /
NORMALLY OPEN} it will activate when the motor is on and deactivate when the motor is off.
Figure 17 – Run/Stop Status
If the Digital Output is set up as {PUMP STROKE}, it will activate for 50% of each stroke and
deactivate for 50% of each stroke.
Figure 18 – Pump Stroke Status
If the Digital Output is set up as {MODE INDICATION / ANALOG MODE}, and {DIGITAL
OUTPUT / NORMALLY OPEN} it will activate when the mode is set to {ANALOG} and deactivate
in any other (e.g., {MANUAL MODE}) mode.
Figure 19 – Mode Indication
59
DIGITAL OUTPUT SETUP PROCEDURE
1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– /
DIGITAL OUTPUT}.
- MENU DIGITAL OUTPUT
2. Press [DOWN]. The {DIGITAL OUTPUT / RUN/STOP STATUS} screen is displayed.
DIGITAL OUTPUT
RUN/STOP STATUS
To use the DIGITAL OUTPUT function as a remote On/Off indication, press [ENTER]. Go to
step 5.
3. Press [ENTER] to continue to program the Digital Output sub-menu. The {DIGITAL OUTPUT
/ PUMP STROKE} screen is displayed.
DIGITAL OUTPUT
PUMP STROKE
To use the DIGITAL OUTPUT to indicate pump strokes, press [ENTER]. Go to step 5.
4. Press [DOWN]. The {DIGITAL OUTPUT / MODE INDICATION} screen is displayed.
DIGITAL OUTPUT
MODE INDICATION
To use the DIGITAL OUTPUT function as a Mode Indicator press [ENTER]. The following
screens are displayed:
MODE INDICATION
MANUAL MODE
Press
[UP]
MODE INDICATION
ANALOG MODE
Press
[UP]
MODE INDICATION
MODBUS MODE
Press [UP] or [DOWN] to scroll through the screens shown above. Press [ENTER] to select
the desired option.
5. The {DIGITAL OUTPUT / NORMALLY OPEN} screen is displayed.
In this mode, the output is open (non-conducting) when the motor is off or the Mode is
wrong.
DIGITAL OUTPUT
NORMALLY OPEN
The output is closed (conducting) when the motor is on or the Mode is correct. Configure the
output as {NORMALLY OPEN} by pressing [ENTER]. Go to step 7.
6. Press [UP] to open the {DIGITAL OUTPUT / NORMALLY CLOSED} screen.
In this mode, the output is open (non-conducting) when the motor is on or the Mode is
correct.
DIGITAL OUTPUT
NORMALLY CLOSED
The output is closed (conducting) when the motor is off or the Mode is wrong. Press
[ENTER] to configure the output as {NORMALLY CLOSED}.
7. The {–MENU– / DIGITAL OUTPUT} screen is displayed.
60
7.2.12
Motor Thermostat Setup
This sub-menu allows you to configure the DLCM to interact with the pump motor thermostat.
Depending on the application, it is possible for the fan cooled pump motor to run at low RPM and
high torque, which degrades the effectiveness of the fan and can cause heat buildup.
For equipment safety, the DLCM can be programmed to have one of the following responses if
the Motor Thermostat activates:






Shut the motor off (no alarm) (no restart)
Trigger the alarm relay (motor stays on)
Shut the motor off and trigger the alarm relay (no restart)
Shut the motor off, trigger the alarm relay, and then restart the motor when the Motor
Thermostat resets
Shut the motor off and then restart the motor when the Motor Thermostat resets (No
alarm)
Ignore the thermostat input (not recommended)
MOTOR THERMOSTAT SETUP PROCEDURE
1. Press [MENU] once and then press [UP] or [DOWN] until the display reads {–MENU– /
MOTOR THERMOSTAT}.
- MENU MOTOR THERMOSTAT
2. Press [ENTER] and the {MOTOR THERMOSTAT / NORMALLY CLOSED} screen is
displayed.
MOTOR THERMOSTAT
NORMALLY CLOSED
Press [ENTER] to accept the {NORMALLY CLOSED} configuration. Go to step 3.
Or
Press [UP] and the {MOTOR THERMOSTAT / INACTIVE} screen is displayed.
MOTOR THERMOSTAT
INACTIVE
If the {MOTOR THERMOSTAT} is to be configured as {INACTIVE}, press [ENTER] and
you are returned to the {–MENU– / MOTOR THERMOSTAT} screen.
IF YOU SET {MOTOR THERMOSTAT} TO {INACTIVE} IT IS POSSIBLE FOR THE MOTOR
WINDINGS TO OVERHEAT LEADING TO PREMATURE MOTOR FAILURE AND POSSIBLE
HAZARDOUS CONDITIONS (E.G., FIRE).
3. Pressing [UP] from the {MOTOR THERMOSTAT / INACTIVE} screen will display the
{MOTOR THERMOSTAT / NORMALLY OPEN} screen.
MOTOR THERMOSTAT
NORMALLY OPEN
Press [ENTER] to accept the {NORMALLY OPEN} configuration.
4. The {MOTOR THERMOSTAT / MOTOR OFF? YES} screen is displayed.
MOTOR THERMOSTAT
MOTOR OFF? YES
61
Press [UP] to select between {YES} or {NO}.
If you want the motor to turn off when the thermostat activates, (recommended), set
{MOTOR OFF?} to {YES}.
Press [ENTER] to accept the desired configuration.
IF YOU SET {MOTOR OFF?} TO {NO} IT IS POSSIBLE FOR THE MOTOR WINDINGS TO
OVERHEAT LEADING TO PREMATURE MOTOR FAILURE AND POSSIBLE HAZARDOUS
CONDITIONS (E.G., FIRE).
5. The {MOTOR THERMOSTAT / ALARM RELAY? YES} screen is displayed.
MOTOR THERMOSTAT
ALARM RELAY? YES
Press [UP] to select between {YES} and {NO}.
MOTOR THERMOSTAT
ALARM RELAY? NO
Press [ENTER] to accept the desired configuration.
6. If {MOTOR THERMOSTAT / MOTOR OFF? YES} is selected in step 4, the {RESTORE
TO: / MOTOR ON} screen is displayed.
RESTORE TO:
MOTOR ON
If you want the DLCM to turn the motor back on when the thermostat deactivates, set
{RESTORE TO:} to {MOTOR ON}. Press [UP] to select between {MOTOR ON} and
{MOTOR OFF}. Press [ENTER] to accept your setting.
RESTORE TO:
MOTOR OFF
7. The display will return to the {–MENU– / MOTOR THERMOSTAT} screen.
7.2.13
Over Temperature Setup
This sub-menu allows you to disable the warning message when the DLCM’s internal
temperature approaches its operating limit of 70˚C / 158˚F. The error condition will not reset until
the temperature drops below 65˚C / 149˚F. The difference between the trip and release point is
5˚C / 9˚F.
RUNNING THE DLCM AT ELEVATED TEMPERATURES COULD RESULT IN IMPROPER
AND DANGEROUS OPERATION.
THIS WARNING DOES NOT AFFECT THE OPERATION OF THE DLCM, IT IS FOR YOUR
INFORMATION ONLY. DISABLING THIS FLASHING WARNING MESSAGE DOES NOT
INHIBIT THE LOGGING OF THE DIAGNOSTIC TIME AND DATE OF THE EVENT.
OVER TEMPERATURE SETUP PROCEDURE
1. Press [MENU] once and then [UP] or [DOWN] until the display reads {–MENU– / OVER
TEMPERATURE}.
- MENU OVER TEMPERATURE
62
Press [ENTER] to go to the Over Temperature response sub-menu.
2. The {OVER TEMPERATURE / ENABLED} (system default) screen is displayed.
OVER TEMPERATURE
ENABLED
3. Press [ENTER} to accept the {ENABLED} setting and you are returned to the {–MENU– /
OVER TEMPERATURE} screen. or
Press [UP] to display the {OVER TEMPERATURE / DISABLED} screen.
OVER TEMPERATURE
DISABLED
Press [ENTER} to accept the {DISABLED} setting. The display will return to the {–MENU– /
OVER TEMPERATURE} screen.
- MENU OVER TEMPERATURE
7.2.14
Power Failure Setup
This sub-menu allows you to configure the way the DLCM reacts when power is restored after a
power outage. Additionally this sub-menu allows setting the action to take if improper voltage is
applied.
During the power up stage, the DLCM can either:

Return to settings that were active when the pump lost power.

Shut the motor off.
A POWER OUTAGE IS DEFINED AS THE LOSS OF POWER WHENEVER THE DLCM IS NOT
IN THE {MOTOR OFF} STATE.
POWER FAILURE SETUP PROCEDURE
1. Press [MENU] once and then [UP] or [DOWN] until the display reads {–MENU– / POWER
FAILURE}.
- MENU POWER FAILURE
Press [ENTER] to go the power failure response sub-menu.
2. The display prompts you for the {Power-up} status. To shut the motor off when the power is
returned to the unit (after a power failure), select the {MOTOR OFF} option (factory default).
DURING POWER UP
MOTOR OFF
Press [ENTER] to accept. Go to step 4.
3. If you want to return to the prior settings, press [UP] and scroll to {DURING POWER UP /
PRIOR SETTINGS}.
DURING POWER UP
PRIOR SETTINGS
Press [ENTER] to accept.
63
4. The display prompts you for an action to take when the wrong voltage is detected.
WRONG VOLTAGE
HARD SHUT DOWN
The following options are available:
SELECTION
Hard Shutdown
Motor Off
Message Only
Ignore Error
ACTION
Display under/over voltage message
Turn motor off
Inhibit motor operation (Motor Key Disabled)
Voltage correction and power cycle required to reset
alarm.
Display under/over voltage message
Turn motor off
Display under/over voltage message
None
Press [UP] or [DOWN] to make your selection. Press [ENTER] to accept your selection.
5. The display will return to the {–MENU– / POWER FAILURE} screen.
7.2.15
Alarm Relay
This sub-menu sets up the alarm relay outputs as normally open or normally closed.
THESE SCREENS CONFIGURE BOTH THE HIGH-VOLTAGE OUTPUT AND LOW-VOLTAGE
SWITCH (TRANSISTOR).
ALARM RELAY SETUP PROCEDURE
1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / ALARM RELAY} is displayed. Press
[ENTER] to continue to program the Alarm Relay sub-menu.
- MENU ALARM RELAY
2. The alarm relay can be configured as {NORMALLY OPEN}. With this setting the relay will
CLOSE when the alarm output is activated.
RELAY OUTPUT
NORMALLY OPEN
If you would rather have the relay OPEN when the output is activated, press [UP] to change
the configuration to {NORMALLY CLOSED}.
RELAY OUTPUT
NORMALLY CLOSED
When you have finished making your selection, press [ENTER] to accept.
3. The display returns to the {–MENU– / ALARM RELAY} screen.
7.2.16
Analog Mode
Use the Analog Mode setting to activate or de-activate the analog mode and set the number of
active signals. If deactivated, the analog mode will not appear when the [MODE] key is pressed. If
you are not using the analog input (i.e., you have made no connections to J4-1, J4-2, and J4-7,
J4-8) but have the Analog Mode set to ACTIVE then any time you press [MODE], by default the
DLCM will generate an {ANALOG SIG FAIL} alarm. De-activating Analog Mode prevents this.
64
If Analog Mode is active, you must also configure the number of active signals. If you will be
adjusting the stroke setting with one signal and the motor speed with a second signal, you must
set the DLCM to the 2-signal operating mode.
You can also modify the way the DLCM responds to a signal. You can set the number of samples
to be averaged (within a range of 1 to 100 samples), and you can set the interval, in number of
samples, that the DLCM should adjust the stroke setting to the specified average (within a range
of 1 to 100 samples). The DLCM samples the Analog Input every 0.25 seconds. The default
value for the number of samples is 20 and the default value for the sample interval is 20.
Therefore, the DLCM will average the last 20 samples and make an adjustment every 5 seconds
(20*.25=5.0). Here are some general guidelines to assist you when adjusting these values:

Increase the {SAMPLE SIZE} value to reduce the effect of electrical noise on the
Analog Input.

Decrease the {SAMPLE SIZE} value to increase sensitivity to changes in the
Analog Input.

Increase the {UPDATE EVERY / XX SAMPLES} value if the DLCM is constantly
adjusting the stroke setting (often resulting in a {DUTY CYCLE} alarm).

Decrease the {UPDATE EVERY / XX SAMPLES} value to increase tracking
response.
IN MOST SITUATIONS, THE DEFAULT VALUES WILL BE ADEQUATE.
ANALOG MODE SETUP PROCEDURE
1. Press [MENU] once and then [UP] or [DOWN] until the screen {–MENU– / ANALOG MODE}
is displayed.
- MENU ANALOG MODE
Press [ENTER] to continue to program the Analog Mode sub-menu.
2. The {ANALOG MODE / ACTIVE} screen is displayed.
ANALOG MODE
ACTIVE
Press [ENTER] to accept the default value.
If you want the analog mode to be inactive and {ACTIVE} is displayed, press [UP] to change
the display to {INACTIVE}. Press [ENTER] to accept your selection. Go to step 12.
The {STROKE & SPEED / 1 – SIGNAL} screen is displayed.
STROKE & SPEED
1 – SIGNAL
3. To accept the default value of 1 – SIGNAL, press [ENTER]. To select the 2-signal mode, go
to step 7.
4. The {SAMPLE SIZE / XXX} screen is displayed.
SAMPLE SIZE
XXX
Press [UP] or [DOWN] to set the number of samples taken from the 4-20mA input to
average. The DLCM will adjust its output in accordance with the average of the number of
65
samples you set here. Enter a value in the range of 1 to 100 samples using the [UP] or
[DOWN] key(s).
Press [ENTER] to accept the entry.
INCREASE THE NUMBER OF SAMPLES TO SMOOTH OUT A NOISY INPUT. DECREASE
THE NUMBER OF SAMPLES TO CAUSE THE DLCM TO TRACK A RAPIDLY CHANGING
SIGNAL MORE CLOSELY.
5. The {UPDATE EVERY / XXX SAMPLES} screen is displayed. Press [UP] or [DOWN] to set
how often the DLCM will adjust to the current average value. The default value (20) causes
the DLCM to adjust every 20 samples or every 5 seconds (20 * 0.25 = 5). You may enter a
value in the range of 1 to 100 using the [UP] or [DOWN] key(s).
DECREASE THE VALUE TO BETTER FOLLOW A RAPIDLY CHANGING SIGNAL.
UPDATE EVERY
XXX SAMPLES
6. Press [ENTER] to accept your selection. Skip to step 12.
7. From the {STROKE & SPEED / 1 – SIGNAL} screen press [UP] to select the {2-SIGNALS}
mode.
STROKE & SPEED
2 - SIGNALS
Press [ENTER] to accept your selection.
8. The {#1 SAMPLE SIZE / XXX} screen is displayed.
#1 SAMPLE SIZE
XXX
Press [UP] or [DOWN] to set the {#1 SAMPLE SIZE}. The ‘#1’ refers to the signal that
controls the STROKE adjustment.
INCREASE THE NUMBER OF SAMPLES TO SMOOTH OUT A NOISY INPUT. DECREASE
THE NUMBER OF SAMPLES TO CAUSE THE DLCM TO TRACK A RAPIDLY CHANGING
SIGNAL MORE CLOSELY.
Press [ENTER] to accept your selection.
9. The {#1 UPDATE EVERY / XXX SAMPLES} screen is displayed.
#1 UPDATED EVERY
XXX SAMPLES
Press [UP] and [DOWN] to set the {#1 UPDATE EVERY / XXX SAMPLES}. Press [ENTER]
to accept your selection.
DECREASE THE VALUE TO BETTER FOLLOW A RAPIDLY CHANGING SIGNAL.
10. The {#2 SAMPLE SIZE / XXX} screen is displayed.
#2 SAMPLE SIZE
XXX
Press [UP] or [DOWN] to set the #2 SAMPLE SIZE. The ‘#2’ refers to the signal that controls
the MOTOR SPEED adjustment.
Press [ENTER] to accept your selection.
66
11. The {#2 UPDATE EVERY / XXX SAMPLES} screen is displayed.
#2 UPDATE EVERY
XXX SAMPLES
Press [UP] or [DOWN] to set the {#2 UPDATE EVERY / XXX SAMPLES}. Press [ENTER] to
accept your selection.
12. The {–MENU– / ANALOG MODE} screen is displayed.
7.2.17
MODBUS Mode
Use the MODBUS mode setting to activate or de-activate the DLCM’s ability to follow a MODBUS
serial signal. If deactivated, the MODBUS mode will not appear when [MODE] is pressed. If you
are not using the serial input (i.e., you have made no connections to J7 or J8) but have the
MODBUS mode set to active, then any time you mistakenly press [MODE], by default the DLC
will generate a{MODBUS SIGNAL FAILURE} alarm. De-activating MODBUS mode prevents this.
THE [MODE] KEY ALLOWS YOU TO SELECT AN OPERATING MODE. IT ACTS AS A
MASTER SWITCH ALLOWING YOU TO SELECT THE SIGNAL THAT CONTROLS THE
DLCM. IT DOES NOT INHIBIT MODBUS COMMUNICATIONS. IT ONLY INHIBITS MODBUS
COMMANDS THAT PERTAIN TO THE OPERATION (E.G., YOU CANNOT TURN THE PUMP
MOTOR ON USING MODBUS UNLESS THE MODE IS SET TO MODBUS).
MODBUS MODE SETUP PROCEDURE:
TO ACCESS THE {MODBUS MODE} MENU YOU MUST HAVE SERIAL COMM ENABLED
AND THE CLASS SET TO SLAVE. REFER TO THE SERIAL COMMUNICATIONS SECTION
LATER IN THIS CHAPTER.
1. Press [MENU]. Press [UP] or [DOWN] until the {–MENU– / MODBUS MODE} screen is
displayed.
- MENU MODBUS MODE
Press [ENTER] to continue to program the MODBUS mode. The {MODBUS MODE /
INACTIVE} screen is displayed.
MODBUS MODE
INACTIVE
{MODBUS MODE / INACTIVE} would be selected if you do not intend to control the DLCM
using the MODBUS protocol. Pressing [ENTER] when {INACTIVE} is displayed will cause the
screen to return to the {–MENU– / MODBUS MODE} menu.
2. {MODBUS MODE / ACTIVE} would be selected if you are going to control the DLCM using the
MODBUS protocol.
With the {MODBUS MODE / INACTIVE} screen displayed, press [UP] to display the {MODBUS
MODE / ACTIVE} screen.
MODBUS MODE
INACTIVE
Press
[UP]
MODBUS MODE
ACTIVE
3. While in the {ACTIVE} mode there are two options to select from: {STROKE & SPEED / 1 –
SIGNAL} and {STROKE & SPEED / 2 – SIGNALS}.
STROKE & SPEED
1 – SIGNAL
- Or -
67
STROKE & SPEED
2 - SIGNALS
4. While the {STROKE & SPEED / 1 – SIGNAL} is displayed, press [ENTER] to select this option.
The {INPUT RATIO / 100%} screen is displayed.
5. Use the {INPUT RATIO} setting to scale the serial input value to meet your needs. Press [UP]
or [DOWN] to set the ratio value between 20% and 100%.
INPUT RATIO
100%
Press [ENTER] to accept your changes. The {ACTION / FORWARD} screen is displayed.
6. You can also instruct the DLCM to act on the MODBUS signal in a forward or reverse
direction. When {ACTION / FORWARD} is selected, the DLCM “acts” in the same direction as
the signal. If the signal changes from 25% to 75%, the DLCM will adjust its output from 25% to
75% (assuming the ratio is set to 100%). When {ACTION / REVERSE} is selected the DLCM
will “act” in the opposite direction. If the signal changes from 25% to 75% the DLCM will adjust
its output from 75% to 25% (assuming the ratio is set to 100%).
Press [UP] or [DOWN] to switch between {ACTION / FORWARD} and {ACTION / REVERSE}.
ACTION
FORWARD
Press
[UP]
ACTION
REVERSE
Press [ENTER] to accept your selection.
7. The {–MENU– / MODBUS MODE} screen is displayed. (Skip to 13.)
8. With the {STROKE & SPEED / 1 – SIGNAL} screen displayed (refer to step 3), press [UP] to
display the {STROKE & SPEED / 2 – SIGNALS} screen.
STROKE & SPEED
2 - SIGNALS
Press [ENTER] to accept your selection. The {STROKE RATIO / 100%} screen is displayed.
9. Use the {STROKE RATIO} setting to scale the serial input value to meet your needs. Press
[UP] or [DOWN] to set the ratio value between 20% and 100%.
STROKE RATIO
100%
Press [ENTER] to accept your changes. The {STROKE ACTION / FORWARD} screen is
displayed.
10. Use the {STROKE ACTION} setting to determine the stroke direction to meet your needs.
When {STROKE ACTION / FORWARD} is selected, the DLCM “acts” in the same direction as
the signal. When {STROKE ACTION / REVERSE} is selected the DLCM will “act” in the
opposite direction as the signal. Press [UP] or [DOWN] to select between {STROKE ACTION /
FORWARD} and {STROKE ACTION / REVERSE}.
STROKE ACTION
FORWARD
Press
[UP]
STROKE ACTION
REVERSE
Press [ENTER] to accept your changes. The {SPEED RATIO / 100%} screen is displayed.
11. Use the {SPEED RATIO} setting to scale the pump speed to meet your needs. Press [UP] or
[DOWN] to set the ratio value between 20% and 100%.
SPEED RATIO
100%
68
Press [ENTER] to accept your changes. The {SPEED ACTION / FORWARD} screen is
displayed.
12. Use the {SPEED ACTION} setting to determine the pump speed reaction to meet your needs.
When
{SPEED ACTION / FORWARD} is selected pump speed will “act” in the same direction, and if
the signal changes from 25% to 75%, the pump speed will adjust its output from 25% to 75%
(assuming the ratio is set to 100%). When {SPEED ACTION / REVERSE} is selected pump
speed will “act” in the opposite direction. If the signal changes from 25% to 75% pump speed
will adjust its output from 75% to 25% (assuming the ratio is set to 100%).
Press [UP] or [DOWN] to switch between {SPEED ACTION / FORWARD} and {SPEED
ACTION / REVERSE}.
SPEED ACTION
FORWARD
Press
[UP]
SPEED ACTION
REVERSE
Press [ENTER] to accept your changes.
13. The {–MENU– / MODBUS MODE} screen is displayed.
7.2.18
Security
The DLCM has three modes of security:
1. None (OFF)
2. Tamper Proof
3. Calibration
With Tamper Proof security active, the DLCM will lockout all of the front panel keys with the
exception of [MOTOR]. To use any other key you will be prompted to enter a four digit Personal
Identification Number (PIN). Successful entry of a PIN allows you to access all DLCM functions
without PIN re-entry. With Calibration security set, the DLCM will lockout access to the [CAL] submenu, Pin Setup and Factory Reset Ability. To use [CAL] you must first enter your PIN.
Successful entry of a PIN allows you to access the {CALIBRATE} menu.
THE SECURITY MODE RE-SETS AFTER 5-MINUTES OF KEYPAD IN-ACTIVITY.
SECURITY SETUP PROCEDURE
1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / SECURITY} is displayed. Press
[ENTER] to continue to program the Security sub-menu.
- MENU SECURITY
2. The type of security available appears flashing on the display. If no password security
protection is desired, press [ENTER] and go to step 8.
SECURITY TYPE
OFF
3. Press [UP] and the {TAMPER PROOF} option is displayed. If complete tamper proof security
of all settings is required, press [ENTER] and go to step 5.
SECURITY TYPE
TAMPER PROOF
69
4. Press [UP] and the {CAL SETTINGS} option is displayed. If security protection of only the
calibration settings is desired, press [ENTER].
SECURITY TYPE
CAL SETTINGS
5. The display prompts you to enter a four digit pin number. A line under the first digit indicates
the character to be changed. Press [UP] and [DOWN] to scroll through the numbers 0-9.
Press [ENTER] to accept the desired number. The line then moves to beneath the second
digit. Continue to press [UP], [DOWN] and [ENTER] to set the four digit password.
THE VALUES YOU ENTER ARE VISIBLE TO BOTH YOURSELF AND ANYONE ELSE WHO
MAY BE WATCHING YOU. SAFE GUARD THE SECURITY OF YOUR PASSWORD.
NEW PIN #
0000
6. After the four digit PIN has been entered, the display prompts you to confirm the new
number:
CONFIRM CHANGE?
YES
Press [ENTER] to accept the pin number and go to step 8.
7. If the pin number is not correct or you don’t want the selected security level, press [UP] to
change the display to {CONFIRM CHANGE? / NO}
CONFIRM CHANGE?
NO
Press [ENTER] to reject the security changes.
8. The menu display returns to {–MENU– / SECURITY} screen.
REMEMBERING THE PIN # YOU SET, IS PROBABLY ONE OF THE MOST IMPORTANT
FUNCTIONS OF SETTING SECURITY.
70
7.2.19
Number Format
The meaning of the comma and decimal point can be interchanged in the number format menu.
You can also change the number of significant decimal places.
REFER TO THE TABLE IN SECTION 10: FACTORY DEFAULTS FOR FACTORY DECIMAL
POSITION SETTINGS.
NUMBER FORMAT SETUP PROCEDURE
1. Press [MENU]. Press [UP] or [DOWN] until the display reads {–MENU– / NUMBER
FORMAT}. Press [ENTER] to continue into the number format sub-menu.
2. The display shows the English numerical format of 9,999.99. Press [UP] to change to the
European format of 9.999,99.
E.G.: 9,999.99
DECIMAL OR COMMA
Press
[UP]
E.G.: 9.999,99
DECIMAL OR COMMA
Press [ENTER] to accept the displayed format.
3. The decimal position screen is displayed. Press [DOWN] to move the decimal position one
place to the left. Press [UP] to move the decimal position one place to the right. For example,
the screen displays 9.99999, pressing [DOWN] causes the display to change to 0.999999.
The valid range is 999.999 to 0.0999999. When the decimal position satisfies your needs
press [ENTER] to accept.
E.G.: 9.99999
DECIMAL POSITION
Press
(DOWN)
E.G.: 0.999999
DECIMAL POSITION
4. The display returns to {–MENU– / DECIMAL FORMAT} screen.
PERFORM A PUMP FLOW CALIBRATION AFTER CHANGING THE DECIMAL POSITION.
7.2.20
Contrast Adjust
The DLCM display contrast can be adjusted to a desired setting.
CONTRAST ADJUSTMENT PROCEDURE
1. Press [MENU]. Press [UP] or [DOWN] until the display reads {–MENU– / CONTRAST
ADJUST}. Press [ENTER] to continue in the contrast adjust sub-menu.
- MENU CONTRAST ADJUST
2. Press and hold [UP] to darken the characters on the display. Press and hold [DOWN] to
lighten the characters.
USE ARROWS TO
ADJUST CONTRAST
BY GOING TOO FAR IN EITHER DIRECTION THE SCREEN CAN BE EXTREMELY
DIFFICULT TO READ. PRESS AND HOLD THE OPPOSITE ARROW TO CORRECT THE
DISPLAY OR YOU CAN RETURN TO THE FACTORY SETTING BY PRESSING [UP] AND
[DOWN] SIMULTANEOUSLY WHILE IN THIS MENU.
3. Press [ENTER] to accept the desired contrast setting.
4. The display returns to {–MENU– / CONTRAST ADJUST} screen.
YOU CAN ADJUST THE CONTRAST AT ANY TIME BY PRESSING AND HOLDING [MENU]
AND [UP] OR [DOWN] SIMULTANEOUSLY.
71
7.2.21
Serial Communications
Use {–MENU– / SERIAL COMM} to configure the serial communications port for operation using
the MODBUS protocol (refer to Section 14: Pulsanet Specification section at the back of this
manual for further information).
By using the serial communications port you can communicate digitally with your DLCM. This
allows a PC/PLC or another DLC or DLCM to send and receive exact values. This eliminates
inaccuracies typically associated with analog signal conversion.
In order for two or more devices to communicate using serial communications they must:







Be electrically connected (refer to Section 5: Instrumentation, Electrical Wiring).
Enabled.
Speak the same language (protocol).
Speak at the same speed (baud rate).
Use the same error detection protocol.
Have unique addressing in the network.
Have only one master on a given network.
The {SERIAL COMM} menu allows the setting of these communication parameters.
If you are installing this DLCM into an existing network, retrieve the following parameters (bold
indicates default DLCM values not network defaults).
COMMUNICATION PARAMETERS WORKSHEET
MODBUS Type
Baud Rate
Data Parity
Slave Address
(Mark one or
more)
RTU
300
Even
1
9
17
25
ASCII
600
Odd
2
10
18
26
1200
None
3
11
19
27
2400
4800
9600
19,200
38,400
4
12
20
28
5
13
21
29
6
14
22
30
7
15
23
31
8
16
24
32
COMMUNICATIONS SETTINGS FOR DLCM’S OPERATING IN A MULTIPLEXED
ENVIRONMENT (I.E., ONE MOTOR DRIVING ONE OR MORE PUMP HEADS) ARE PRECONFIGURED.
COMMUNICATIONS SETUP PROCEDURE
1. To access the Serial Communications menu press [MENU] and then press [UP] or [DOWN]
until the {–MENU– / SERIAL COMM} screen is displayed.
- MENU SERIAL COMM
Press [ENTER] to view/modify the settings.
2. The display prompts you to enable or disable the DLCM’s communications function.
SERIAL COMM
DISABLED
Press
[UP]
SERIAL COMM
ENABLED
Press [UP] or [DOWN] to reveal your selection. Press [ENTER] to accept your setting.
72
3. The display prompts you for the type of communications. The DLCM supports the standard
MODBUS protocol. This standard defines two ways for devices to format the data they
exchange:


“RTU” is a binary format that offers improved data throughput.
“ASCII” is a format based on the ANSI character standard. It has larger message
blocks that yield reduced data throughput.
If you are installing a DLCM into an existing network, you must match the setting you marked
on the worksheet.
If this is a new DLC/DLCM only installation, choose “RTU”. Press [UP] or [DOWN] to select
your choice.
TYPE
RTU
Press
[UP]
TYPE
ASCII
Press [ENTER] to accept.
4. The display prompts you to set the baud rate. The baud rate must be common for the
network (i.e., all devices must be set at the same baud rate).
Set this value to that recorded on your worksheet previously or use the default setting of
9600.
BAUD RATE
9600
Press [UP] or [DOWN] to select your choice. Press [ENTER] to accept.
5. The data parity display instructs the DLCM on the use of the parity bit for error checking
transferred data. This setting must match that of the existing network (refer to the selection
you made on the work sheet). Otherwise, select the default value of EVEN.
DATA PARITY
EVEN
Press
[UP]
DATA PARITY
ODD
Press
[UP]
DATA PARITY
NONE
Press [UP] or [DOWN] to set the parity type.
6. The Class setting defines how the DLCM will operate in the network. If Class is set to
Master, then the DLCM tells other equipment (e.g., other DLCM’s) that are configured as
slaves what to do (e.g., adjust stroke percent to 50%). If the Class setting is set for Slave,
then the DLCM is expecting a command from a Master unit.
YOU CAN ONLY HAVE ONE MASTER IN A NETWORK. THUS, THE CLASS SETTING WILL
TYPICALLY BE SLAVE.
Press [UP] or [DOWN] to set the Class setting.
CLASS
SLAVE
Press
[UP]
CLASS
MASTER
Press [ENTER] to accept your setting.
THE MASTER DOES NOT HAVE A NETWORK ADDRESS. SKIP TO STEP 8.
7. Every slave attached to a MODBUS network must have a unique address. Use the {NET
ADDRESS} menu to set the address for this DLCM.
If this is a new installation, check your worksheet for an available address.
NET ADDRESS
1
Press [UP] or [DOWN] to set the address. Press [ENTER] to accept your setting.
73
8. If you selected Master in step 6, you must also set the amount of time the DLCM should wait
for a response from a Slave. If the Slave fails to respond within this time period, the Master
will attempt to communicate with the next Slave on its list.
RESPONSE TIME
1.5 SECONDS
Press [UP] or [DOWN] to set the response time value (refer to the beginning of this section
for tips on making this setting).
9. If you selected Master in step 6, then you will be presented with a menu that allows you to
identify Slaves. Otherwise go to step 10.
You can use the {IDENTIFY SLAVES} menu in one of two ways:
1. Set the Slave addresses manually
2. Use the Auto Detect feature
To use the Auto Detect feature, press [UP] or [DOWN] to change the setting to Auto
Detect. Press [ENTER] to accept your selection.
IDENTIFY SLAVES
AUTO DETECT
The DLCM will then display a status screen as it scans the 32 addresses for slave devices.
The address under test is indicated to the right of AUTO DETECT.
PLEASE WAIT
AUTO DETECT #
YOU CAN USE THE AUTO DETECT FEATURE TO VALIDATE COMMUNICATIONS BETWEEN
A MASTER DLCM AND ONE OR MORE SLAVES. YOU CAN ALSO USE THE SERIAL
DIAGNOSTIC MENU (REFER TO THE NEXT SECTION).
10. After the AUTO DETECT completes, you are returned to the {–MENU– / SERIAL COMM}
screen. Repeat steps 1 through 9 without selecting AUTO DETECT to return to this menu.
7.2.22
Serial Diagnostics
The Serial Diagnostics menus are designed to assist you in the troubleshooting of the
communications system.
SERIAL DIAGNOSTIC PROCEDURE
1. To access the Serial Diagnostics menu press [UP] or [DOWN] until the {–MENU– / SERIAL
DIAG.} is displayed.
- MENU SERIAL DIAG
.
Press [ENTER].
2. The first menu shows the number of MODBUS messages exchanged by this node while the
menu is displayed.
RECEIVE: 640
TRANSMIT: 640
3. Press either [UP] or [DOWN] to reset the count value. Press [ENTER] to proceed to the next
screen.
LOOPBACK TEST
NO
- Or -
74
LOOPBACK TEST
YES
Selecting {YES} will start the test (skip to Step 6), or if {NO} is selected you are sent to the
{ECHO TEST / NO} screen.
4. The {ECHO TEST / NO} screen is displayed.
ECHO TEST
NO
The Echo test causes the DLCM to echo back all characters it received, much like the
Loopback Device. You can then use another piece of equipment (e.g., PC) to originate
characters.
5. Press [ENTER] to skip the echo test or press [UP] and then [ENTER] to set {ECHO TEST /
NO} to {ECHO TEST / YES} and initiate the test. The following screen is displayed:
ECHO CHARACTERS
TEST IN PROGRESS
When the Echo Test is complete, the following screen is displayed:
GOOD
BAD
XXXX
XXXX
6. Press [ENTER] to exit the Echo Test and return to the {–MENU– / SERIAL COMM} screen.
Loopback Test Procedure
7. The Loopback test is helpful in the identification of wiring errors and the possible need for
line terminators at the ends of the network. While this menu is displayed the DLCM
transmits and expects to receive characters back. The display shows the percent (%) of
successful characters exchanged.
The Loopback test requires the installation of a Loopback device at the end of the cable
segment under test. This can be constructed according to Figure 20 below:
Figure 20 – Loopback Device Wiring Diagram
75
8. Install the cable under test in the second port. (J7 or J8)
9. Install the loop back device at the far end of the cable under test.
Figure 20.1 – Loop Back Circuit (Line Terminator Optional)
10. With the {LOOPBACK TEST YES} screen displayed, press [ENTER].
LOOPBACK TEST
YES
11. While the LOOPBACK test is being conducted, the following screen is displayed:
PLEASE WAIT
TEST IN PROGRESS
When the test is completed, a result screen is displayed:
100.0% SUCCESS
RETRY? YES
12. If the indicated percent of success is 100%, the cable segment is good and no further action
is required. Skip to the end of this procedure.
13. If the indicated percent of success is less than 100% then double check the connections.
Repeat the test by pressing [ENTER]. Refer to Section 8: Installation/Component for further
details wiring details.
14. If the indicated percent of success persists network termination at the far ends of the
network may be required. Install the line terminator in one port of the DLCM in J7 or J8.
15. Figure 20.2 - Line Terminator
76
Alternatively, it may be possible to lower the baud rate on the network or use an ASCII
message format instead of the RTU default. See Section 7 General Operations, Menu,
Serial Communications for further details.
16. To exit the diagnostic menu press [UP] and then press [ENTER]. The {–MENU– / SERIAL
COMM} screen is displayed.
7.2.23
Language
All displayed text can be displayed in English, Spanish, French or German.
LANGUAGE SETUP PROCEDURE
1. Press [MENU]. Press [UP] or [DOWN] until {–MENU– / LANGUAGE} is displayed.
- MENU –
LANGUAGE
Press [ENTER] to continue through the language sub-menu.
2. The language type appears on the display. Press [UP] to scroll through the available
languages.
LANGUAGE TYPE
ENGLISH
Press
[UP]
LANGUAGE TYPE
FRANCAIS
LANGUAGE TYPE
DEUTSCH
Press
[UP]
LANGUAGE TYPE
ESPANOL
Press
[UP]
When the correct language is displayed, press [ENTER] to activate. All text will be displayed
in the selected language.
3.
The display returns to {–MENU– / LANGUAGE}.
7.2.24
Factory Defaults Reset Procedure
All of the DLCM settings can be returned to factory defaults.
FACTORY DEFAULTS RESET PROCEDURE
1. Press [MENU, then [UP] or [DOWN] until the {–MENU– / FACTORY DEFAULTS} screen is
displayed.
- MENU FACTORY DEFAULTS
Press [ENTER] to continue through the factory defaults sub-menu.
2. The display prompts you to not reset all the settings to the factory defaults.
FACTORY RESET?
NO
If a Factory Reset is not desired, press [ENTER] to go back to the {–MENU– / FACTORY
DEFAULTS} screen.
3. If the DLCM is to be reset to the factory defaults, press [UP] to scroll the value to {YES}.
FACTORY RESET?
YES
Press [ENTER] to accept your selection.
77
4. The display prompts you to verify your action.
RESETTING FACTORY DEFAULTS WILL DESTROY ALL USER CALIBRATION
INFORMATION.
ARE YOU SURE?
NO
Press [UP] to change the value to {YES}. Press [ENTER] to accept your selection. The
following message is displayed:
PLEASE WAIT
5. The first screen displayed during the Re-Set procedure prompts you to turn the motor on.
TURN MOTOR ON
TESTING ENCODER
6. Press [MOTOR]. You will hear the pump motor spin up, and the DLCM will perform an
Encoder test (displaying the following message):
PLEASE WAIT
TESTING ENCODER
7. When the Encoder test is complete, (usually takes about 2 or 3 seconds) the DLCM
performs a Zero Calibration (displaying the following message):
PLEASE WAIT
CALIBRATING ZERO
8. When the Zero Calibration is complete, you are returned to the {–MENU– / FACTORY
DEFAULTS} screen.
9. Press [MENU] and the next screen displayed is:
MOTOR STOPPED
10. Re-establish any Menu and Calibration settings that are non-standard at this time.
7.3 Units
By pressing [UNITS] with the motor on, the display will scroll through the CMH, GPH, LPH, CCH,
CMM, GPM, LPM, CCM, % flow, % stroke length or % motor speed. The DLCM will automatically
convert the motor and stroke settings based on the calibrated flow, to the above referenced units.
The accuracy of the flow rate display is dependent on the pump flow calibration accuracy.
7.4 Varying the Flow Rate - Manually
When the DLCM is in Manual Mode, pump flow rate can be increased by pressing [UP]. The flow
rate is decreased by pressing [DOWN]. The DLCM will display the corresponding value of the
flow adjustment.
If you attempt to adjust the DLCM’s hand-wheel while it is under power, the DLCM will re-adjust
back to the position specified by its programming. The hand-wheel is for emergency manual
override only. Refer to Section 13: General Repairs, Emergency Manual Pulsar Operation.
78
DO NOT ADJUST THE DLCM'S HAND-WHEEL WHILE THE POWER IS OFF. THIS WILL
CAUSE THE DLCM TO LOSE ITS ZERO POINT AND FORCE A {ZERO CALIBRATION} AT
STARTUP.
7.5 Mode
Pressing [MODE], switches the DLCM’s operating mode. If the ANALOG MODE is set to
ACTIVE, then pressing [MODE] will switch between {MANUAL MODE} and {ANALOG MODE}.
When MODBUS MODE is set to ACTIVE, pressing [MODE] will switch between {MANUAL
MODE} and {MODBUS MODE}. In essence, this key acts like a local auto/manual switch.
7.6 Batch
The DLCM is capable of following up to three (3) different batch programs. The batches operate
in two modes: One Time Only and Repeating.
WHEN DAYLIGHT SAVINGS IS SET TO AUTO CHANGE, USE CAUTION WHEN SETTING UP
BATCHES THAT RUN THROUGH OR START OR STOP IN THE TIME CHANGE OVER
PERIODS WHERE ONE FULL HOUR EITHER DOESN’T EXIST AT ALL OR OCCURS TWICE
CONSECUTIVELY. IF YOU ARE IN DOUBT, SET THE {DAYLIGHT SAVINGS} OPTION TO
[NO]. (REFER TO SECTION 7: GENERAL OPERATION, SET TIME AND DATE)
7.6.1 One-Time Only
The One Time Only batch will start at a specified time and run for a specified duration at a
specified flow rate that you define (refer to Figure 21).
Figure 21 – One Time Only Batch
79
7.6.2 Repeating
A Repeating Batch will start at a specified time and run for a specified duration. It will stop for a
specified period of time and then repeat the run time. This will continue indefinitely (refer to
Figure 22).
ANY OF THE THREE BATCHES CAN BE SPECIFIED AS ONE TIME ONLY OR REPEATING.
Figure 22 - Repeating Batch.
7.6.3 Overlapped
The batches can also be overlapped (refer to Figure 23 below).
Figure 23 – Overlapping Batch.
WHEN THE BATCHES ARE OVERLAPPED, THE FLOW RATES ARE NOT ADDITIVE. THE
HIGHEST OF THE TWO OR THREE FLOW RATES IS USED.
THE DLCM CAN MAKE A 1% PER SECOND ADJUSTMENT OF PUMP STROKE LENGTH.
REMEMBER THAT WHEN A BATCH STARTS, THE DLCM WILL REQUIRE SOME AMOUNT
OF TIME TO ACHIEVE THE NEW STROKE SETTING. THE ADJUSTMENT TIME IS TAKEN
AS A PORTION OF THE BATCH RUNNING TIME. THIS WILL CAUSE THE OUTPUT OF THE
PUMP TO BE SKEWED.
80
BATCHING SYSTEM SETUP PROCEDURE
1. Press [BATCH], to enter the batch setup menu.
2. The display will come up as {BATCHES / ACTIVE} or {BATCHES / INACTIVE}. Press
[UP] to change the batch system to {ACTIVE}.
SETTING THE BATCH SYSTEM TO ACTIVE WILL CAUSE ANY PRE-CONFIGURED BATCHES
THAT ARE SCHEDULED TO START AT THIS TIME, TO START IMMEDIATELY, SO YOU
MIGHT WANT TO DO THIS LAST.
BATCHES
ACTIVE
Press
[UP]
BATCHES
INACTIVE
Press [ENTER] to continue on to the batch sub-menu.
3. The display shows {EDIT / BATCH #1}. Press [UP] to {EDIT / BATCH #2} and [UP] again
to {EDIT / BATCH #3}.
EDIT
BATCH #1
Press
[UP]
EDIT
BATCH #2
Press
[UP]
EDIT
BATCH #3
The DLCM is supplied with three user programmable batches. Press [ENTER] to select
the desired batch to edit.
4. The display shows {BATCH #1 RATE / 92.5%} (the value and unit of flow will depend on
previous programming). The {RATE} text will be flashing. You can press [UP] or [DOWN]
to view/change the other menu items related to this batch (e.g., RATE / DURATION /
TYPE / START, etc.). Pressing [ENTER] causes the {RATE} value to stop flashing and
allows you to program the batch flow rate. Press [UP] or [DOWN] to set the value.
IF A VALUE HAS BEEN SET PREVIOUSLY IT WILL BE USED AS A STARTING POINT FOR
THE NEW SETTING.
YOU CAN CHANGE THE DISPLAY UNITS AT ANY TIME BY PRESSING [UNITS].
BATCH #1 RATE
92.5%
Press [ENTER] to accept your setting.
5. The display shows {BATCH #1 DURATION / XX HRS, XX MIN} with the word DURATION
flashing. Press [ENTER] to set the duration (i.e., pump on time) of the batch.
BATCH #1 DURATION
12 HRS 30 MIN
6. The hours value should now be flashing on the display. A line (cursor) under the second
digit indicates the field to be changed. Press [UP] or [DOWN] to scroll through the
numbers 0-99. Press [ENTER] to accept the desired hour setting.
BATCH #1 DURATION
12 HRS 30 MIN
7. The cursor then moves to minutes field. Use [UP] or [DOWN] to scroll through the
numbers 0-5. Set the first digit of the minute value one position at a time and press
[ENTER] to accept it.
BATCH #1 DURATION
12 HRS 30 MIN
81
8. The cursor then moves to the second digit of the minutes field. Use [UP] or [DOWN] to
scroll through the numbers 0-9. Set the second digit of the minute value. Press [ENTER]
to accept the desired second digit of the minute setting which completes the batch
duration entry and exits the Batch duration screen.
BATCH #1 DURATION
12 HRS 30 MIN
9. The display shows {BATCH #1 TYPE / ONE TIME ONLY}. Press [ENTER] to program the
type of batch.
BATCH #1 TYPE
ONE TIME ONLY
10. You can select from one of two types of batches: either a one-time only batch or a
repeating batch. A one-time only batch executes the batch only once. A repeating batch
repeats an on/off cycle indefinitely. Press [UP] to scroll between the different batch types.
BATCH #1 TYPE
ONE TIME ONLY
Press
[UP]
BATCH #1 TYPE
REPEATING
Press [ENTER] to select the type of batch desired. If you select {ONE TIME ONLY} skip to
step 12.
11. If a Repeating batch is selected, the display prompts you to enter the off duration time of
the batch.
BATCH #1 OFF TIME
10 HRS 23 MIN
12. The display shows {BATCH #1 START TIME / XX:XX XX/XX/XX}. Press [ENTER] to edit
the batch start time. Press [UP] or [DOWN] to set the time and date value one character at
a time. Press [ENTER] to accept your setting.
BATCH #1 START
8:01a
2/3/01
13. The display shows {BATCH #1 CONFIRM? / YES}. Press [ENTER] to confirm the batch or
press [UP] to scroll to the {NO} value and then press [ENTER] to disregard the changes to
the batch.
BATCH #1 CONFIRM?
YES
Follow the procedure outlined in steps 3 through 13 for the Remaining Batches if desired.
14. If the batch was made active, the display changes to let you know the batch is now
pending and displays the time and date the batch will begin.
BATCH #1 PENDING
8:01a 2/3/01
15. When the clock reaches the start time and date for the batch, the display automatically
changes to indicate that the batch is running. The pump will then operate at the specified
rate, for the specified time.
YOU CAN PRESS [UNITS] TO CHANGE THE DISPLAYED UNITS WHILE THE BATCH IS
RUNNING.
82
BATCH #1 RUNNING
92.5%
While a batch is running you can display the time left in HH:MM:SS format by pressing
either [UP], [DOWN] or [ENTER].
BATCH #1 RUNNING
REMAIN
11:59:58
16. When the batch has operated for the specified time period, it will automatically shut off the
pump's motor.
17. If this a One Time Only batch, the display will show the batch completed message and the
operating mode will be set to manual.
BATCH #1 COMPLETED
PRESS ANY KEY
Press any key to clear the display.
MOTOR OFF
18. If this was a repeating batch, the display will return to {BATCH #X PENDING / HH:MM
MM/DD/YY} and the DLCM will wait until its internal clock matches the displayed
Time/Date. At that time, the batch will recycle.
BATCH #1 PENDING
6:45a
2/4/01
7.6.4 Inactivating the Batches
If the batch operation is not required to operate over a certain period of time, for instance the
weekend, the batches should be inactivated.
BATCH INACTIVATION
Press [BATCH]. The screen will show the batch status: {BATCHES / ACTIVE}. Press [UP] to
change the display to {BATCH / INACTIVE}. Press [BATCH] to accept and inactivate the batches
and return to Manual Mode.
83
8 Diagrams: Installation / Component
DIAGRAM 1 – DLCM Wiring Diagram
84
Diagram 2 – Serial Communications – RS 485 Connections
85
9
Specifications
Overview
The DLCM controller for Pulsar Pumps is an upgrade from the DLC stroke length controller, which
provides all of the same functions, but adds the capability of motor speed control using SCR
control of the armature voltage applied to a permanent magnet DC motor.
STROKE LENGTH CONTROL
0-100% control range (Software programmable, 0% – 100% factory default)
0.1% resolution
10:1 turndown for accuracy specification
MOTOR SPEED CONTROL
5-100% control range. (Software programmable, 10% – 100% factory default)
0.1% resolution
20:1 turndown for accuracy specification
COMBINED CALIBRATED FLOW
50:1 total turndown for accuracy specification.
6 significant digits for displayed units of flow
PUMP ACCURACY
Accuracy
Diaphragm
Standard
With Leak
Diaphragm
Detection
Single
Solid
Capacity
Teflon
Reference
Diaphragm
Turndown Range
Stroke
Length
Motor
Speed
Combined
Turndown
Steady State
±0.5%
±0.5%
±0.5%
Set Point
10:1
20:1
50:1
Repeatability
±0.5%
±1.0%
±1.0%
Full Rating
10:1
20:1
50:1
Linearity
±1.0%
±3.0%
±3.0%
Full Rating
10:1
20:1
50:1
ADJUSTMENT RESPONSE
1% per second on stroke length
1% per second on steady state speed
TEMPERATURE
–18˚C to 40˚C (0˚F to 104˚F) Operation
–18˚C to 60˚C (0˚F to 140˚F) Storage
LOW-VOLTAGE INPUTS
Inputs
Analog Input Channel 1
Field Wiring
Specification / Description
Location
J4 Pin 1 is +
J4 Pin 2 is –
Any signal within the range of 0 to 25mA (e.g.: 4-20) or
0 to 5 volts (e.g., 1-5v) Minimum span of 2mA or 0.4 volts.
Note: No jumpers used. Displayed in mA.
Split Ranging, Reverse Acting and Ratio Control standard on
all units; accessible via calibration.
Fused at 50mA. Protected against mis-wiring.
Surge Protection: 7.4 Joules
Isolation: 500 volts from all other inputs, outputs, and ground.
86
LOW-VOLTAGE INPUTS (continued)
Inputs
Field Wiring
Location
Specification / Description
Analog Input
Channel 2
J4 Pin 7 is +
J4 Pin 8 is –
Specifications same as Channel 1.
J4 Pin 3 is +
J4 Pin 4 is –
Dry Contact. (Optically Isolated) – Do not apply powered
signal.
Isolation: Not isolated from Digital Input or Motor Thermostat,
500 volts from all other inputs, outputs and ground.
May be software configured as Normally Open or Normally
Closed. May be software configured to operate the Alarm
Relay.
May be configured to turn the Pump Motor off.
J4 Pin 5 is +
J4 Pin 6 is –
Dry Contact. (Optically Isolated) – Do not apply powered
signal.
Isolation: Not isolated from PULSAlarm or Motor Thermostat,
500 volts from all other inputs, outputs and ground.
May be software configured as Normally Open or Normally
Closed. May be software configured to operate the Alarm
Relay (Level Input Only).
May be configured to turn the Pump Motor off. (Level Input
Only)
PULSAlarm (Leak
Detection)
Digital Input
Programmable as
Level Input
Or
Remote Run / Stop
LOW-VOLTAGE OUTPUTS
Outputs
Field Wiring
Location
Specification / Description
J5 Pin 1 is +
J5 Pin 2 is –
Any signal within the range of 0 – 20mA (e.g.: 4-20). Minimum
span of 2mA.
Maximum load: 700 ohms.
Reverse Acting standard on all units, which is accessible via
calibration.
Fused at 50mA protected against mis-wiring.
Surge Protection: 7.4 Joules
Isolation: 500 volts from all inputs and outputs.
J5 Pin 3 is +
J5 Pin 4 is –
Dry Contact (Transistor Type) VCE (SAT): 0.3 volts
Max forward current: 50mA Maximum 32VDC
On-state resistance: 100 ohms
Isolation: 5000 volts from all inputs, outputs and ground.
Follows the state of High-Voltage Alarm Output, which may
be software configured as Normally Open or Normally
Closed.
Analog Output
Channel
Programmable
to output either
Calibrated stroke
length, percent
speed, Or
Calibrated flow
Alarm Status
87
LOW-VOLTAGE OUTPUTS (continued)
Outputs
Field Wiring
Location
Specification / Description
J5 Pin 5 is +
J5 Pin 6 is –
Dry Contact (Transistor Type) VCE (SAT): 0.3 volts
Max forward current: 50mA Maximum 32VDC
On-state resistance: 100 ohms
Isolation: 5000 volts from all inputs, outputs and ground.
May be software configured as Normally Open or Normally
Closed. (Remote Run Status and Mode Indication only).
Digital Output
Programmable as
Remote Run Status
Or
Stroke Counter
Or
Mode Indication
HIGH-VOLTAGE INPUTS
Inputs
Line Power:
Field Wiring
Location
Specification / Description
J1
Factory configured to one of the following:
115VAC ±10%, 50/60 Hz, 10 Amp max (with 90 volt armature
motors only)
230VAC ±10%, 50/60 Hz, 5 Amp max (with 180 volt armature
motors only)
Surge Protection: 7.4 Joules
Software protected against Over/Under voltage. (user
selectable)
HIGH-VOLTAGE OUTPUTS
Inputs
Field Wiring
Location
Specification / Description
Alarm Relay
J2
Fused at 1 amp at rated Line voltage.
May be software configured as Normally Open or Normally
Closed.
J3
Permanent Magnet SCR Drive DC Motors with thermostat.
Base Speed: 1750 RPM, NEMA 56C Frame, Class F or
better insulation. 90 Volt armature, 5.0 amps max. at 115
VAC Input Power.
180 Volt armature, 5.0 amps max at 230 VAC Input Power.
Pump Motor
SERIAL COMMUNICATIONS
Inputs
RS–485
Field Wiring
Location
Specification / Description
J7 & J8
Max Cable length: 1219 meters (4000 feet) Max Address
sites: 32
See Section 8: Diagrams Installation/Component for further
line termination when required.
Isolation: 500 volts from ground and all other inputs and
outputs.
88
CONTROL INPUTS
Control
Inputs
Field Wiring
Location
Tachometer
Sensor
J10 Pin 1 is
Connection point for Tach Sensor. Used for sensing Motor Speed.
VDC J10 Pin 2
is Tach
Motor
Thermostat
J10 Pin 3 is +
J10 Pin 4 is –
10
Specification / Description
Dry Contact (Optically Isolated) – Do not apply powered signal.
Isolation: Not isolated from PULSAlarm or Digital Input, 500 volts
from all other inputs, outputs, and ground.
May be software configured as Normally Open or Normally Closed
(default). May be software configured to operate the Alarm Relay
(default is YES).
May be software configured to turn the Pump Motor OFF (default).
If MOTOR OFF is selected may optionally restart the Pump Motor
when the thermostat resets (default).
Factory Default Values
CALIBRATION
Pump Flow
1-Point Calibration on PULSAR at Rated
Flow and Pressure.
Analog Input
Analog Output
DIAGNOSTICS
4.0 - 20.0mA @ 100% Ratio
4.0 - 20.0mA @ 100% Ratio
Alarms
Cleared
DATE/TIME
Date Format
MM/DD/YY
Time Format
24:00
Daylight Savings Time
No
ANALOG INPUT
Enabled – Number of input channels enabled
is one.
Freeze at last signal / Restore to Analog
Mode/ Error message enabled
20 Samples
Failure Mode channel #n
Sample Average channel #n
Sample Update channel #n
ANALOG OUTPUT
20 Samples (5.0 Seconds)
Stroke and Speed setting
Calibrated Stroke and Speed combined
END POINT & PRIORITY
Stroke Minimum
Stroke Maximum
0%
100%
Speed Minimum
10%
Speed Maximum
100%
Priority
LEAK DETECTION
Speed
89
Failure Mode
Inactive
LEVEL INPUT
Failure Mode
Inactive
DIGITAL OUTPUT
Run/Stop
MOTOR THERMOSTAT
Normally Open
Input
Enabled
Switch
Normally Closed
Motor
Off
Alarm
On
Restore to
Motor On
OVER TEMPERATURE
Error Message
Enabled
POWER FAILURE
Failure Mode
During power up – Motor Off
During power up – Motor Off
Wrong Voltage
ALARM RELAY
Relay Output
Normally Open
SECURITY
NUMBER FORMAT
Remains as previously set
Separators
X , XXX . XX (Comma / Decimal)
Position
PULSAR dependent (e.g., 9.99999, 0.999999, etc.)
Factory set to match pump head size. Refer to
Factory Decimal Position Settings below.
CONTRAST
Restored to initial Factory setting
SERIAL COMM
Net Address
LANGUAGE
Disabled
English
MODE
Manual – Motor Off
UNITS
Percent (%)
BATCH
Inactive
Batch #n Rate
0%
Batch #n Duration
0 H 00 M
Batch #n Type
One Time Only
Batch #n Start
Current Date and Time for first setting
FLOW RATE
0%
Stroke Position
0%
Motor Speed
10%
90
FACTORY DECIMAL POSITION SETTINGS
RATED CAPACITY RANGE
5.99999
to 59.9999
1,585.03
to 15,850.3
5,999.99
to 59,999.9
5,999,990
to 59,999,990
0.0999999
to 0.999999
26.4172
to 246.172
99.9999
to 999.999
99,999.9
to 999,999
0.599999
to 5.99999
158.503
to 1,585.03
599.999
to 5,999.99
599,999
to 5,999,990
0.00999999
to 0.0999999
2.64172
to 26.4172
9.99999
to 99.9999
9,999.99
to 99,999.9
0.0599999
to 0.599999
15.8503
to 158.503
59.9999
to 599.999
59,999.9
to 599,999
0.000999999
to 0.00999999
0.264172
to 2.64172
0.999999
to 9.99999
999.999
to 9,999.99
0.00599999
to 0.0599999
1.58503
to 15.8503
5.99999
to 59.9999
5,999.99
to 59,999.9
0.0000999999
to 0.0009999999
0.0264172
to 0.264172
0.0999999
to 0.999999
99.9999
to 999.999
0.000000001
to 0.00599999
0.000001
to 1.58503
0.000001
to 5.99999
0.001
to 5,999.99
0.00000000001 to 0.0000999999
0.00000001
to 0.264172
0.00000001
0.0999999
0.00001
99.9999
UNITS
cmh
gph
lph
cch
cmm
gpm
lpm
ccm
cmh
gph
lph
cch
cmm
gpm
lpm
ccm
cmh
gph
lph
cch
cmm
gpm
lpm
ccm
chm
gph
lph
cch
cmm
gpm
lpm
ccm
cmh
gph
lph
cch
cmm
gpm
lpm
ccm
91
-MENU- / DECIMAL POSITION
999.999
999.999
999.999
999.999
999.999
999.999
999.999
999.999
99.9999
99.9999
99.9999
99.9999
99.9999
99.9999
99.9999
99.9999
9.99999 (default size)
9.99999 (default size)
9.99999 (default size)
Actual flow is
9.99999 (default size)
usually slightly
9.99999 (default size)
larger than the rated
9.99999 (default size)
flow.
9.99999 (default size)
9.99999 (default size)
0.999999
0.999999
0.999999
0.999999
0.999999
0.999999
0.999999
0.999999
0.0999999
0.0999999
0.0999999
0.0999999
0.0999999
0.0999999
0.0999999
0.0999999
11 Troubleshooting Guide
11.1 System Diagnostics
Your DLCM contains extensive diagnostics that allow it to determine the source of common
problems. If your DLCM is not operating properly, your first course of action should be to review
the {DIAGNOSTICS} sub-menu. To access this menu from the standard operating mode follow
this procedure (provided your user interface – keypad and display – is functioning):
1. Press [MOTOR] repeatedly until the display reads {MOTOR OFF}.
2. Cycle power to the DLCM (turn the main OFF then ON). This will cause the self-test routine to
re- execute.
3. Press [MENU]. The screen {–MENU– / DIAGNOSTICS-1} is displayed. The value, in this case
'1' indicates how many failures were detected.
4. Press [ENTER] to enter the Diagnostics Menu. The screen {DIAG MENU 1/11 / POWER IN:
OK} is displayed.
5. Repeatedly press [UP] to cycle through all nine Diagnostic screens.
6. If a screen displays a FAIL message, press [ENTER] to display the time and date the failure
occurred. Press [ENTER] again to display the clear screen. Press [UP] and then [ENTER] to
clear the message. (This paragraph does not apply should you encounter a Battery Fail or
Circuit Fail situation).
Make a note of any failures reported in the Diagnostics Menu. Using this information, proceed
with the troubleshooting instructions below:
OTHER ACTIONS MAY BE NECESSARY TO BRING THE PROCESS BACK TO NORMAL
CONDITIONS BEFORE CLEARING A FAILURE.
SYMPTOM
DIAG 1/11
POWER IN: FAIL
DIAG 2/11
ANALOG IN: FAIL
DIAG 3/11
MODBUS FAIL
DIAG 4/11
LEAK DETECTION: FAIL
MENU (DIAGNOSTICS)
PROBABLE CAUSE
The power to the DLCM failed
while the pump motor was
running.
The Analog Input signal fail under
the calibrated range, or fell to 0
within 0.25 seconds (i.e., the
signal was changing by more than
8.8 mA per second and was less
than 0.3 mA).
A properly formatted and addressed MODBUS message was
not received in the allotted time.
The Leak-Detection Switch
closure activated according to its
configuration.
92
POSSIBLE SOLUTION
Place DLCM in {MOTOR OFF}
operating mode before
disconnection power. Refer to
POWER Troubleshooting.
Place DLCM in {MANUAL MODE}
or OFF before the signal loss
occurs. Recalibrate Analog Input.
Condition Analog Input Signal.
Refer to ANALOG INPUT
troubleshooting.
Increase the Response Time
setting.
Diaphragm may have failed.
Refer to Pump IOM or review
Section 7: General Operation,
Leak-Detection Failure Setup.
Refer to PULSAlarm LeakDetection Troubleshooting.
SYMPTOM
MENU (DIAGNOSTICS)
PROBABLE CAUSE
DIAG 5/11
LEVEL INPUT: FAIL
The Level Input Switch closure
activated according to its
configuration.
DIAG 6/11
MOTOR TEMP
The motor exceeded its maximum
internal temperature.
DIAG 7/11
DRIVE TEMP: FAIL
The DLCM internal temperature
has exceeded the rating.
DIAG 8/11
BATTERY: FAIL
The DLCM clock is backed by a
Lithium Battery with a 10 year life.
The Random Access Memory
(RAM) on the mother board
cannot be reliably read and/or
written to.
The Electronically Erasable
Programmable Read Only
Memory (EEPROM) on the
mother board cannot be read
and/or written to.
DIAG 9/11
CIRCUIT: FAIL *RAM*
DIAG 9/11
CIRCUIT: FAIL *EEPROM*
DIAG 9/11
CIRCUIT: FAIL *MOTOR*
The DLCM’s internal motor failed
to respond when given a
command to do so.
DIAG 9/11
CIRCUIT: FAIL *MOTOR*
The DLCM’s internal motor has
achieved its Duty Cycle limit: 50%
over a 20 minute interval.
SYMPTOM
DISPLAY
PROBABLE CAUSE
No power supplied
No display back-lighting
No display back-lighting
Supply power wired incorrectly
Supply power outside of
specification
Low-voltage I/O wired incorrectly
Display ribbon cable loose
Low-voltage power supply failed
The DLCM internal temperature
has exceeded the rating.
Contrast out of adjustment
Software did not initiate properly
No text on display
Memory corrupted
Environment exceeds 40˚C
(104˚F)
93
POSSIBLE SOLUTION
If abnormal, review Section 7:
General Operation, Level Input
Failure Setup. Refer to LEVEL
INPUT troubleshooting.
Relocate to a cooler area and/or
out of direct sunlight. Increase
minimum motor speed setting.
Re-locate the DLCM to an
environment with lower ambient
temperatures. Refer to Section 9:
Specifications.
The life expectancy is over.
Contact Technical Service.
Cycle Power on unit to double
check error. Contact Technical
Services.
Cycle Power on unit to double
check error. Contact Technical
Services.
Cycle Power on unit to double
check error. Review MANUAL
KNOB / DLCM INTERNAL DRIVE
MOTOR troubleshooting. Contact
Technical Services.
Cycle Power to clear. Reduce
motor run time by changing batch
or conditioning analog input or
Averaging Parameters.
POSSIBLE SOLUTION
Check power source. Plug &
Circuit Breaker
Check wiring
Check voltage/frequency against
specification
Check wiring
Contact Technical Service
Contact Technical Service
Relocate the DLCM to an
environment with lower ambient
temperatures. Refer to Section 9:
Specifications.
Adjust with [MENU] + [UP] or
[MENU] + [DOWN]
Cycle power
Cycle power. Perform Factory Reinitialize
Relocate to another area
SYMPTOM
POWER
PROBABLE CAUSE
No power supplied
No power indicators
SYMPTOM
Supply power wired incorrectly
Supply power outside of
specification
Low-voltage I/O wired incorrectly
Low-voltage power supply failed
PULSAR DC MOTOR
PROBABLE CAUSE
No power supplied
Motor wired incorrectly
Supply power outside of
specification
Motor key not pressed. Keypad
problem
Motor will not start
Remote Motor Switch is off
Software did not initiate properly
Alarm or Level input set with
option MOTOR OFF? Set to YES.
PULSAR mechanicals locked
Motor Thermostat not connected
or programmed
Solid-state relay failed
MODBUS in control
94
POSSIBLE SOLUTION
Check power source. Plug &
Circuit Breaker
Check wiring
Check voltage/frequency against
specification
Check wiring
Contact Technical Service
POSSIBLE SOLUTION
Check power source to DLCM
Check wiring
Check voltage/frequency against
name plate
Press [MOTOR] to start motor.
Refer to Keypad Troubleshooting
section.
Turn switch on
Cycle power
Correct Alarm or Level condition.
Set MOTOR OFF? To NO.
Check pump, reference PULSAR
IOM.
Connect or program the Motor
Thermostat
Contact Technical Service
Check MODBUS Control
Application
PULSAR DC MOTOR (continued)
SYMPTOM
PROBABLE CAUSE
POSSIBLE SOLUTION
Motor wired incorrectly
Check wiring
Software did not initiate properly
Cycle power
Press [MOTOR] to stop motor.
Motor will not stop
Motor key not pressed. Keypad
Refer to the Keypad Troubleproblem.
shooting section
Solid-state relay failed
Contact Technical Services
Refer to Tachometer Troubleshooting or contact Technical
Tachometer not adjusted properly
Services for readjustment
Motor running too fast (run-away).
procedures.
Display may show {OVER
Refer to Section 5: Installation,
SPEED! / SHUTDOWN!}
Tachometer input is not wired
Tachometer Input for wiring
correctly
instructions.
Solid-state relay failed
Contact Technical Services
At high discharge pressures and
low motor speeds, the motor will
cog during the discharge portion
Normal operation
of the stroke. This is only a
problem if it causes excessive
heat in the motor, or stalls for long
periods of time.
Torque too high
Reduce discharge pressure
Motor stepping. Typically
Increase speed setting. If the
associated with running at
standard pump operating
extremely low speeds (<10%)
conditions call for the pump motor
to operate at high turndowns
(<10%), it is wise to change the
Speed setting too low
stroke End Point to reduce the
Maximum End Point value. Refer
to Section 7: General Operation,
End Point Setup for more
information.
Refer to Section 11: Troubleshooting, Tachometer TroubleTachometer not adjusted properly
shooting for readjustment
procedures.
Motor stalled. Display may show
Refer to Section 5: Installation,
{TACHOMETER FAILURE}
Tachometer Input for wiring
Tachometer input is not wired
instructions or Section 11:
correctly
Troubleshooting, Tachometer
Troubleshooting
Solid-state relay failed
Contact Technical Services
SYMPTOM
Alarm Relay will not activate
ALARM RELAY (High-Voltage J2)
PROBABLE CAUSE
POSSIBLE SOLUTION
Relay wired incorrectly
Check wiring
Relay fuse blown
Replace with 1A@250 VAC fuse
Refer to Section 7: General
Software not configured properly
Operation, Menu
95
SYMPTOM
ANALOG INPUT
PROBABLE CAUSE
Input wired incorrectly
Input not wired to correct channel
Not responding to Analog (mA)
Input
Input fuse(s) blown
Not in Analog Operation Mode
Input not calibrated properly
Signal failure message displayed
with no signal loss
Lo Analog Input point (e.g., 4.0
mA) does not equate to 0% unit
reading
Break in wiring
Input outside of specification
Process fluctuates too rapidly:
less than 0.3 mA and changing by
more than 8.8 mA/s
Miss-calibrated
0% calibration value misinterpreted
Jitters or slow response
SYMPTOM
Not responding to PULSAlarm
Input
PULSAlarm (Leak Detection)
PROBABLE CAUSE
Relay wired incorrectly
Input not configured properly
Solid-state device used
SYMPTOM
LEVEL
PROBABLE CAUSE
Input wired incorrectly
Input not configured properly
Not responding to Level Input
Solid-state device used
96
POSSIBLE SOLUTION
Check wiring
Refer to Section 5: Installation,
Analog Input for wiring
instructions.
Replace F4 & F5 w/ 50 mA@250
VAC for channel #1 and F6 & F7
for channel #2
Press [MODE] or configure
Active. Refer to Section 7:
General Operation, Analog Mode
Review Section 7: General
Operation, Analog Input Signal
Calibration
Check wiring
Boost/Condition signal
Condition signal. Change failure
mode. Recalibrate.
Recalibrate
The “0% = 4.0 mA” calibration
screen refers to 0% flow. Not 0%
stroke.
Change averaging parameters.
Refer to Section 7: General
Operation, Analog Mode.
POSSIBLE SOLUTION
Check wiring
Review Section 7: General
Operation: Menu, Leak-Detection
Failure Setup
Remove and replace with dry
contact. If no change, contact
Technical Service.
POSSIBLE SOLUTION
Check wiring
Review Section 7: General
Operation: Menu, Level Input
Failure Setup
Remove and replace with dry
contact. If no change, contact
Technical Service.
SYMPTOM
No Analog (mA) signal present
Not tracking
SYMPTOM
No Output
ANALOG OUTPUT
PROBABLE CAUSE
Output wired incorrectly
Output fuse(s) blown
Output not calibrated properly
POSSIBLE SOLUTION
Check wiring
Replace F2 & F3 with 50
mA@250 VAC.
Review Section 7: General
Operation: Analog Output
Calibration
ALARM RELAY OUTPUT (Low-Voltage J5)
PROBABLE CAUSE
POSSIBLE SOLUTION
Output wired incorrectly
Check wiring
Refer to Section 8: Diagram 1,
External device not powering
DLCM Wiring Diagram. External
output
device must supply voltage to
solid-state switch.
Review Section 7: General
Alarm options not set
Operation, Leak-Detection/LevelInput Setup/Alarm Relay.
MANUAL ADJUSTMENT KNOB/DLCM INTERNAL DRIVE MOTOR
PROBABLE CAUSE
POSSIBLE SOLUTION
Eliminate batches that are cycling
too rapidly (e.g., changing stroke
Internal DLCM Synchronous
from 0 to 100% one minute and
motor has achieved its duty cycle
100 to 0% the next – the internal
Knob will not turn under DLCM
limit of 50% ON time (based on a
drive motor runs all the time).
control. Display shows {DUTY
20 minute interval). Rapidly
Condition analog input signal.
CYCLE}
cycling batches and wildly
Cycle Power. Wait for ‘cool-down’
swinging analog inputs will cause
period. Refer to Section 5:
this motor to run continuously.
Installation, High-Voltage
Connections, PULSAR Motor.
Normal Zero Calibration. Display
Do not turn knob by hand while
Knob turns at power-up
should read {PLEASE WAIT /
DLCM’s power is off.
CALIBRATING ZERO}
Note that the Stroke doesn’t always adjust. Most of the DLCM flow adjustment is made by varying the
motor speed. Also check Section 7: General Operation, End-Point Setup for equal MIN & MAX stroke
settings.
SYMPTOM
SYMPTOM
Display does not respond to
keypad entry
KEYPAD
PROBABLE CAUSE
Display contrast out of
adjustment. See Display
Troubleshooting. Software did not
initiate properly
Memory corrupted
Keypad connector loose
97
POSSIBLE SOLUTION
Cycle power
Cycle power. Perform factory reinitialize.
Contact Technical Services
SYMPTOM
Activated batch appears to be
running through batches rapidly
Repeating Batch will not start
BATCH OPERATION
PROBABLE CAUSE
Repeating Batch activated with
Old Start Date. For example,
today is 1/22/16, you have a
repeating batch programmed to
start on 1/5/16. The display will
show the ‘run-through’ of all
batches between the start day
and time and today.
Batch duration is set to 0 hours
and 0 minutes
SYMPTOM
CALIBRATION
PROBABLE CAUSE
Message: {Terminated/Press any
key} appears during Calibration
Manual Knob adjusted while
Calibration session was active
SYMPTOM
UNITS
PROBABLE CAUSE
Units do not increment with
change in %
Unit not properly calibrated.
Calibration beyond display
resolution.
Displayed units read – 000000
High pressure pump. Due to
compressibility, the pump will not
discharge fluid until the Stroke
Adjustment is above a non-zero
value (e.g., set the adjustment to
3% and the pump discharges
fluid. Set the adjustment below
3% and no fluid will be
discharged). When the stroke is
set below the zero point, the
display shows -000000.
SYMPTOM
SERIAL COMMUNICATIONS
PROBABLE CAUSE
Wiring
No response to Master
Communications setting mismatch between Master & Slave
Master not receiving
98
POSSIBLE SOLUTION
Change Batch start-time/date to
current or future date/time.
Duration must be greater than 0
minutes for batch to activate.
POSSIBLE SOLUTION
Do not touch the Manual
adjustment knob while a
Calibration session is active.
Press any key to clear message.
POSSIBLE SOLUTION
Re-calibrate to value within
display range. Change number
format to give additional
precision.
Display is normal. Increase the
stroke setting until the unit reads
properly. Re-calibrate.
POSSIBLE SOLUTION
Master / Slave wiring incorrect.
Refer to Section 5: Installation,
Serial Communications Input.
Check Communications Settings.
Refer to Section 7: General
Operation, Serial
Communications.
Use serial diagnostics to check
receipt and transmission of
characters. Refer to Section 7.
SYMPTOM
SERIAL COMMUNICATIONS
PROBABLE CAUSE
Wiring/interference
Poor performance
Communication Settings
Frequent message {MODBUS
SIG. FAIL}
SYMPTOM
Over voltage or under voltage
message displayed
Time out setting
MISCELLANEOUS
PROBABLE CAUSE
Incoming Power un-reliable
Note: you must power off and
then power back up to clear
DLCM factory configured for
operating voltage other than input
Power failure message displayed
PULSAR motor running at time of
power loss
Tachometer Sensor wiring
incorrect
Failed or mis-adjusted sensor
Motor over speed
Motor stalled
Tachometer failure message
displayed
Failed to detect shaft rotation with
the motor turned on
99
POSSIBLE SOLUTION
Use proper wire type. Limit total
network length to 1200M (4000 ft)
Do not run communication wire in
the same conduit with the power
wire. Avoid runs near large
motors. Add Termination.
Refer to the guidelines in Section
7: General Operation: Serial
Communications.
Refer to Section 7: General
Operation, MODBUS Signal
Failure Setup for guidelines on
time out settings.
POSSIBLE SOLUTION
DLCM should have separate
branch circuit taken from main.
Re-wire. Consider surgesuppression.
DLCM must run under Factory
configured operating voltage.
Locate source of correct voltage
and re-wire
Turn PULSAR motor off before
powering DLCM down.
Check wiring
Contact Technical Services
Failed solid state relay
Check pump pressure
Note: you must power off and
then power back up to clear
The tachometer has failed.
Remove power to the DLCM and
pump motor. Turn the power back
on and repeat the startup
procedure. If the TACHOMETER
FAILURE message is displayed
again, remove all power from the
DLCM.
Refer to Section 5: Installation,
Tachometer Input for information
on how to access the Tachometer
Sensor wiring connections,
located on the Field Wiring Board.
Verify the condition of the
TACHOMETER SENSOR
connections (refer to Tachometer
Troubleshooting). If these
connections are correct, contact
Technical Services.
ENCODER ERROR
PROBABLE CAUSE
SYMPTOM
Encoder defective
Message: {ENCODER
ERROR/PRESS ENTER}
displays during encoder test.
Internal Motor unable to turn
adjustment knob
POSSIBLE SOLUTION
Refer to Section 11:
Troubleshooting, Encoder
Diagnostics.
Broken or jammed gears – refer
to Section 11: Troubleshooting,
Encoder Diagnostics.
Defective motor – refer to Section
11: Troubleshooting, Encoder
Diagnostics.
Defective Drive circuits – refer to
Section 11: Troubleshooting,
Encoder Diagnostics.
Defective encoder or wiring
11.2 Encoder Diagnostics
Pulsafeeder supplies the DLCM electronic controllers on the PULSAR line of metering pumps.
This controller utilizes a common drive system to actuate the stroke length mechanism within the
pump. This drive system consists of a motor, gear train, and a digital encoder, which allows the
controller to track the position of the stroke mechanism. The encoder produces digital pulses as
the adjustment shaft rotates. By tracking these pulses, the controller can adjust the stroke
position with a very high level of accuracy.
Gear Train
Encoder Gear
Encoder
Figure 24 – Encoder position within the enclosure
If, at any time during this process the DLCM detects an error the following screen is displayed:
ENCODER ERROR
PRESS ENTER
- Or -
POSITION ERROR
PRESS ENTER
NOTE: THERE COULD BE INTERNAL DAMAGE TO THE ENCODER OR GEAR TRAIN –
POSSIBLY AN OBSTRUCTION OR A BROKEN GEAR.
There can be a number of reasons for this failure; the following will guide you through several
possibilities.
100
Gear Train
Encoder Gear
Encoder
Motor
Figure 25 – Encoder and Gear Train layout
11.2.1
Troubleshooting
11.2.1.1
First Steps
1. Remove AC power from the controller.
2. Rotate the stroke adjustment knob several turns manually to increase the setting (Counter
Clockwise). The knob can be turned 25 turns. The mechanism includes hard stops at 0% and
100% that prevent over rotation. Do not force the knob – try turning in the opposite direction.
3. Ensure that the knob rotates smoothly for several full revolutions in BOTH directions. Skip to
step 5.
4. A majority of encoder issues with the DLC are associated with mis-alignment of the DLC’s
output coupling with the pumps stroke adjustment mechanism. To eliminate this condition,
loosen but do not remove the 4 screws that hold the controller to the top of the pump.
See Figure 26, Controller Pump Interface
5. Replace covers if necessary and re-apply power to the controller. Use [UP] or [DOWN] to cause
the DLC to adjust the stroke setting.
6. If the cause of the error was a mechanical jam, it may be necessary to perform a Zero
Calibration. See Section 6: Startup Instructions, Overview, Performing a Factory Reinitialization.
If the cause was a mis-alignment issue, the control should start adjusting properly.
7. If the hold down screws were loosened in step 4, retighten evenly while the unit is adjusting.
8. Monitor the unit as necessary for further faults.
11.2.1.2
Mechanical Problem
A primary cause of encoder errors is a mechanical problem within the pump or the controller. In
these cases, it may or may not be possible to rotate the knob as described above. Suggested
troubleshooting sequence:
1. Remove the controller from the pump to separate the mechanisms
2. Rotate the stroke adjustment mechanism in the pump and then the controller by hand to
determine which part may not be functioning correctly
3. If the trouble appears isolated to the pump, see 11.2.1.3 for further information
4. If the trouble appears to be within the controller, see 11.2.1.4 for access to the interior of the
controller
101
Pump shaft and controller
shaft join here
Remove these (4)
screws to separate
controller and pump
Figure 26 – Controller/Pump interface
11.2.1.3
Gear Train Problem
The internal motor and gear train used for stroke length adjustment may be damaged or worn.
Some potential problems include:
1. Jammed or damaged motor
2. Broken or fractured gears
3. Gears with broken or missing teeth
11.2.1.4
Encoder Setscrew Problem
A number of encoder issues have been related to the setscrew that secures the encoder gear to
the encoder shaft coming loose. Carefully check this gear by hand to ensure it is securely attached
to the encoder shaft. Take care to avoid applying excessive force to the encoder shaft as this can
damage it.
11.2.1.5
Electrical Problem
Electrical problems can affect both the circuit boards within the controller, and the encoder itself.
The circuits within the controller cannot be tested without specialized fixtures and test equipment.
If no mechanical cause for an encoder error is located the next most likely cause is a malfunction
of the encoder itself.
11.2.1.6
Pump Interface
The Pulsafeeder DLCM controller connects mechanically to the PULSAR pump using a twosection shaft. The lower section is mounted within the pump, and drives the stroke adjustment
mechanism, regulating the stroke length and therefore the flow output of the pump. The upper
section is mounted within the controller. This allows the controller to regulate the stroke length of
the pump.
102
Pump Stroke Length Mechanism Troubleshooting
The PULSAR metering pump utilizes a screw and slider cam system to regulate the stroke length
of the pump. The screw shaft is rotated by the electronic controller. The rotation drives the wedgeshaped slider cam up or down on the shaft. As the cam moves up or down, it actuates a follower
pin, which limits the rearward travel of the piston:
a) Slider cam moves up, follower pin is moved forward for shorter strokes and lower flow rates
b) Slider cam moves down, follower pin is moved back for longer strokes and higher flow rates
Figure 27 – Pulsar pump stoke adjustment mechanism
11.2.1.7
Possible Mechanical Malfunction Causes
1. Damage to the threads on the screw shaft, which do not allow the cam to travel smoothly
2. A bent or warped screw shaft
3. Damage to the threads on the cam
4. Damage to the face of the cam, which does not allow the follower pin to slide smoothly
5. Damage or rotation of the follower pin, which does not allow it to extend or retract smoothly
11.2.2
Encoder/Gear Train Access
FOLLOW ALL APPROPRIATE SAFTEY PROCEDURE WHEN OPENING ANY ELECTRICAL
ENCLOSURE TO PROTECT PERSONEL AND PROCESES.
One screw under label on knob (not shown)
Note: For certain motor
frame sizes, the DLCM may
have to be lifted slightly
from the pump to allow
access to all screws.
Figure 28 – Upper cover assembly removal
103
PROCEDURE:
1. Remove 6 retaining screws and the washers as shown in Figure 28.
2. Lift the top cover straight up.
FOR DLC CONTROLLERS THE KEYPAD AND DISPLAY MODULE IS ATTACHED TO THE
UPPER COVER. USE CARE WHEN REMOVING THIS COVER, AS THERE IS A RIBBON
CABLE THAT CONNECTS FROM THE INTERNAL CIRCUIT BOARDS TO THE UPPER
COVER ASSEMBLY. RAISE THE COVER SLOWLY, UNTIL THIS WIRING CAN BE
IDENTIFIED AND SECURED. THE WIRING MAY BE CAREFULLY UNPLUGGED FROM THE
CIRCUIT BOARD SO THAT THE UPPER COVER ASSEMBLY CAN BE SET ASIDE FOR
SERVICE.
11.2.3
Encoder Replacement
Encoders for the DLCM controller come complete with the ribbon cable and plug attached. The
current Pulsafeeder part number for this assembly is NP530100-000. Encoders are kept as a
stock item at the factory.
To replace the encoder:
1. Disconnect power to the controller and follow all applicable procedures to ensure personal and
process safety.
2. Remove the top cover from the controller as described previously in this document.
2.1 Inspect the gear train for broken, worn or missing teeth. See Figure 29. If these conditions
exist, contact the factory for replacement gear train.
3. Unplug the encoder cable from the circuit board.
4. Loosen the setscrew and remove the drive gear from the encoder shaft.
5. Remove the nut and lock washer (if present), and remove the encoder from the mounting plate.
CAUTION: WHEN HANDLING THE NEW ENCODER, DO NOT LOAD THE SHAFT RADIALLY
(TO THE SIDE), FOR EXAMPLE WHEN ADJUSTING ITS POSITION OR TIGHTENING THE
SETSCREW.
6. Install the new encoder carefully, replace the lock washer (as per the original configuration) and
nut onto the shaft, but do not completely tighten them at this time.
7. Re-install the gear, aligning the height of the encoder gear to match the mating gear.
8. Apply a small drop of non-permanent locking compound to the setscrew and tighten gently,
following the caution mentioned.
9. Adjust the position of the encoder as per the photographs in Figure 29. Allow for a small
amount of backlash between the gears. There should be no radial loading of the encoder shaft.
Off axis loads on this shaft will cause premature encoder failure.
10. Once position is established, tighten the encoder mounting nut to secure it to the plate.
104
Note spacing
Figure 29 – Encoder positioning for proper gear engagement for proper gear engagement
11.2.4
Tachometer Troubleshooting
The DLCM utilizes the Tachometer sensor installed in the gear box to determine motor speed.
This sensor detects the passage of 24 gear teeth per motor shaft revolution. If this device is not
working properly, the DLCM will malfunction. This typically results in the display of the
{TACHOMETER / FAILURE} or {OVER SPEED / SHUT-DOWN} message. If your DLCM displays
either of these messages, use the following procedure to trouble shoot the device:
Required Tools:



Phillips head screw driver
Adjustable Wrench
Multi-meter
11.2.4.1
Motor Rotation
If the drive motor is not rotating, a tach failure is displayed. Potential issues are as follows:
1. Drive motor brushes dirty – clean out brush area
2. Drive motor brushes not contacting commutator – clean area, check springs
3
Drive motor brushes worn – replace (brush part number is on the motor nameplate and these
can be sourced from your local motor shop).
4. Motor coupling loose or damaged – repair or replace
5. Motor failed – replace
105
11.2.4.2
Tach Sensor Wiring
If any recent work has been done within the DLCM control, the wiring from the tach sensor may
have been damaged or come loose from the terminals. The tach sensor wires enter the junction
box at the back of the controller through a small diameter black conduit on the back surface. Check
that the blue and black leads are secure in their terminals as in Figure 30. Make sure the terminals
are making good contact with the stripped portion of each wire.
Figure 30 – Field wiring of Tach Sensor
11.2.4.3
Tach Sensor Adjustment and Testing
Key:
2. Mounting busing
3. Sealing O-ring
4. Tach Sensor
5. Locking Nut
5
Figure 31 – Tach Sensor
106
11.2.4.4
Basic tach sensor adjustment procedure:
1. Unscrew and gently pull back the black plastic conduit connector (not shown on the diagram
above), this will reveal the threaded tach body (#4) surrounded by a locking jam-nut (#5).
2. Loosen the jam nut. This will allow the tachometer sensor itself to be rotated, which
moves it in and out of the gearbox.
3. Turn the body of the tachometer sensor clockwise until it goes all the way inwards and
(gently) bottoms in the fitting, this means it has contacted the gear teeth as illustrated in
Figure 31.
4. Retract the sensor approximately ½ to ¾ of a turn counter-clockwise (outwards), and then
hold it in place and re-tighten the jam nut (#5).
5. Replace the plastic conduit connector and re-wire the tach.
To electrically test and adjust the tach sensor:
1. Apply power to the DLCM.
2. Note the following terminals:
J 5-8 signal ground (VDC -)
J10-1 voltage output (12 VDC +)
J10-2 tachometer signal (VDC variable +)
3. Measure voltage between J5-8 and J10-1, it should read 12VDC (see note below).
4. Remove the top cover of your drive motor so that you can access the shaft.
5. Measure the voltage between terminals J5-8 and J10-2, and rotate the motor shaft until you
have the lowest voltage reading.
6. Loosen the locknut on the tachometer body, and adjust the position of the tachometer sensor
until the voltage reads 1.0 VDC.
7. Rotate the motor shaft again, and observe the voltage, the highest voltage observed should be
5.5 – 6.0 VDC.
8. As the motor shaft is rotated, the voltage should vary between 1.0 and 5.5 to 6.0 VDC.
9. Make necessary adjustments to achieve this range, and then tighten the locknut on the
tachometer body.
10. Secure all wiring, replace all covers, and prepare the pump for operation as per normal
procedures.
NOTE: Some older controllers utilized a 5 volt control system. If you read 5 volts during
step # 3 above, you have an older system. Older systems should be factory upgraded to
the new 12 volt design for more reliable tachometer operation. Consider contacting your
local Pulsafeeder Representative about arranging for a factory update on your controller.
For some older models, depending on age and condition, replacement of the complete
controller is a more cost effective solution.
11.2.4.5
Tach Sensor Replacement
If none of the above restores proper operation, and the electrical tests do not result in the proper
voltage readings, then the tach sensor may be bad. The Pulsafeeder part number for a
replacement sensor is:
NP530052-000
Inductive Sensor, DLCM
Contact your local Pulsafeeder Representative for price and delivery information.
107
12 Conversion (Manual to DLCM)
Your PULSAR can be converted from a Manual Stroke Adjustment Mechanism to the DLCM. The
DLCM effectively replaces the Manual Cover Assembly. Use the following procedure for
conversion:
1. While running the pump motor, adjust the stroke setting to approximately 50%.
2. Disconnect the power supply going to the PULSAR drive motor. Remove AC motor and
replace with DC motor. Refer to Section 5: Installation, Pulsar Pump Motor for motor
specifications.
3. Remove the six Phillips Head screws that hold the Manual Cover Assembly to the Eccentric
Box (refer to Figure 32).
Figure 32 – Manual Cover Assembly
4. Remove the Manual Cover vertically from the Eccentric Box.
5. Visually inspect the Cam Pocket cover.
If the Cam Pocket cover is constructed out of plastic, refer to and perform the procedure
defined in Bulletin No. PMP-DLC-FCM-98 Cam Pocket Cover Replacement.
If the Cam Pocket cover is constructed out of metal continue to step 6.
6. Note the position of the adjustment shaft 'flats'. They mate with a slot in the DLCM output
shaft. Familiarize yourself with these mating components prior to installation (refer to Figure
33).
108
Figure 33 – DLCM/Eccentric mating components
7. Locate the face on the bottom of the DLCM that mates with the face of the lip of the eccentric
box. The DLCM is oriented such that the control pad and display sit to the left of the pump's
reagent head (as viewed standing in front of the reagent head looking at the motor). The
conduit connections and access panel (with Serial Tag) reside at the rear of the pump near
the gear box.
8. Orient the DLCM properly at a comfortable height above the pump and align the slot in the
DLCM coupling with the 'flats' on the adjustment shaft by turning the black hand knob on the
DLCM. Do not turn the adjustment shaft!
9. Lower the DLCM onto the eccentric box. It may be necessary to tip the DLCM slightly
towards the motor to clear the motor adapter. With the DLCM approximately 25mm (1 inch)
above the eccentric box, make a fine adjustment to align the slot in the DLCM coupling with
the adjustment shaft 'flats'. Once aligned, lower the DLCM to mate with the eccentric box. Do
not force the cover! When the coupling is properly aligned, the DLCM will seat properly under
its own weight.
10. Install the 4 DLCM mounting screws and washers provided.
11. Remove the 4 wiring access panel screws.
12. Follow the instructions in Section 5: Installation, Electrical Wiring of this manual for
electrical connections of pump DC motor and tachometer.
13. Perform the steps detailed in Section 6: Startup Instructions.
14. Review Section 7: General Operation for detailed information on configuring your DLCM
and its advanced features.
109
13 General Repairs
In the unlikely event that your DLCM needs service, it can be returned to Pulsafeeder for
evaluation and repair. Contact PULSAFEEDER Customer Service at (585) 292-8000 for a return
material authorization number and further instructions.
13.1 Emergency Manual Pulsar Operation
If your DLCM is not functioning, you can operate your PULSAR manually without removing the
DLCM. Follow this procedure:
1. Remove power from the DLCM.
2. Replace the DC motor with an AC motor or drive the DC motor with an external SCR drive.
3. Start the motor.
THE PULSAR MOTOR WILL START IMMEDIATELY! TAKE ALL NECESSARY SAFETY
PRECAUTIONS.
4. Rotate the manual adjustment knob on the DLCM clockwise to zero the pump. It will be
difficult to rotate as you are back-driving the DLCM stroke adjustment motor. Be careful! Do
not force the knob. Try to turn it in both directions to get a feel for the back-drive torque. As
you approach zero the knocking will diminish.
5. Once you have found zero, mark the knob and the DLCM cover with pieces of tape to use as
a position reference.
6. You can set the stroke adjustment to a specific value by calculating the number of knob
turns. To do this, divide the desired setting (%) by a factor of 4 (%/rotation). For example, say
your desired setting was 67%. You would divide 67 by 4 which equals 16.75. So you would
turn the knob 16 and 3/4 revolutions in a counter-clockwise direction from the zero position.
13.2 DLCM Removal and Replacement
THE FOLLOWING PROCEDURE ASSUMES THAT YOU HAVE RECEIVED YOUR DLCM AND
ARE READY TO PERFORM THE REPLACEMENT.
1. If possible, activate the PULSAR motor and adjust the stroke setting in the range of 10 to
90%. Avoid 0 and 100% stroke settings on the PULSAR when replacing a DLCM. If
necessary, use the Manual Adjustment knob. It should be easier to adjust the stroke
manually in the (+) counter clockwise direction.
DO NOT ADJUST THE STROKE SETTING BEYOND THE 100% (25 TURNS FROM 0%)
SETTING.
2. Disconnect the power to the DLCM at the main. Power down all attached equipment (e.g.,
PLC's).
3. Remove the four screws and Teflon Gaskets that hold the wiring access cover to the DLCM
(refer to Figure 34).
110
Figure 34 – Wiring Cover Access
4. Remove the Wiring Access Cover.
5. Remove the Tachometer Sensor Input Cable on the Field Wiring Board.
a) Disconnect the wire (typically brown) connected to Pin 1 of J10.
b) Disconnect the wire (typically blue) connected to Pin 2 of J10.
6. Disconnect the Tachometer Sensor Conduit Assembly nut from the Tachometer Sensor
Conduit Assembly and remove the Conduit Assembly and Tachometer Sensor wire from the
DLCM housing.
Figure 35 – Accessing the Tachometer Sensor Conduit
111
7. Remove the four screws and Teflon Gaskets that retain the conduit adapter (refer to Figure
36).
Figure 36 – Conduit Adapter Screw Removal
When removing the DLCM in Step 8, the conduit adapter will stay with the wire and conduit.
It plugs into the bottom of the DLCM. When lifting the DLCM off the Conduit Adapter, it may
be necessary to have a second person hold the Adapter and associated conduit while the
DLCM is 'un-plugged' from it.
8. Remove the four screws that hold the DLCM to the PULSAR gearbox (refer to Figure 37).
Figure 37 – DLCM Removal for Replacement
9. Remove the DLCM from the gear box by lifting vertically.
10. Bring the replacement DLCM to the installation site.
If you are planning to re-wire the DLCM during replacement, skip to step 12.
11. Remove the Conduit Adapter from the replacement DLCM by performing step 7. Attach the
conduit adapter to the unit being returned.
112
12. Note the position of the PULSAR adjustment shaft 'flats'. They mate with a slot in the DLCM
drive coupling of the output shaft. The output shaft is connected to the adjustment knob.
Familiarize yourself with these mating components prior to installation (refer to Figure 38).
Figure 38 – DLCM/Eccentric Mating Components
13. Locate the face on the bottom of the DLCM that mates with the face of the lip of the gear
box.
The DLCM is normally oriented such that the control pad and display sit to the left of the
pump's reagent head (as viewed standing in front of the reagent head looking at the motor).
The conduit connections and access panel (with Serial Tag) reside at the rear of the pump
near the gear box (refer to Figure 39).
Figure 39 – Installation Orientation
Orient the DLCM properly at a comfortable height above the pump and align the slot in the
DLCM coupling with the 'flats' on the adjustment shaft by turning the Manual Control knob
on the DLCM.
DO NOT TURN THE PULSAR GEAR BOX ADJUSTMENT SHAFT!
113
14. Lower the DLCM onto the gear box.
Figure 40 – Positioning the DLCM
It may be necessary to tip the DLCM slightly towards the motor to clear the Motor adapter.
a) With the DLCM approximately 25mm (1 inch) above the gear box, make a fine
adjustment to align the slot in the DLCM coupling with the adjustment shaft 'flats'.
b) Once aligned, lower the DLCM to mate with the gear box.
DO NOT FORCE THE COVER! WHEN THE COUPLING IS PROPERLY ALIGNED, THE DLCM
WILL SEAT ITSELF UNDER ITS OWN WEIGHT
114
Figure 41 – Shaft Alignment
15. 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 Adapter.
Once properly aligned, the units will mate with moderate force (approximately 20 Newtons or
4.5 pounds of force).
a) Install the four screws and Teflon Gaskets that hold the Conduit Adapter to the DLCM
(refer to Figure 36).
FAILURE TO INSTALL THE TEFLON GASKETS WILL CAUSE YOU TO LOSE THE NEMA-4X
RATING ON YOUR ENCLOSURE AND WILL VOID THE PRODUCT WARRANTY.
16. Install the 4 DLCM to gearbox mounting screws (refer to Figure 37).
17. Remove the 4 wiring access cover screws and cover (refer to Figure 34).
115
18. Insert the Tachometer Sensor Conduit Assembly and wires (removed in step 6) in the hole
provided in the back of the DLCM housing.
19. Slide the Tachometer Sensor Assembly nut over the wires, and re-attach the Tachometer
Sensor Conduit assembly.
YOU ARE ATTACHING A PLASTIC CONDUIT ASSEMBLY WITH A STEEL NUT. DO NOT
OVER TIGHTEN OR DAMAGE WILL OCCUR TO THE CONDUIT ASSEMBLY.
20. On the Field Wiring Board, attach the wire labeled VDC (typically brown) in J10 Pin 1
(removed in step 5.a).
21. On the Field Wiring Board, attach the wire labeled TACH (typically blue) in J10 Pin 2
(removed in step 5.b).
22. Follow the instructions in Section 5: Installation: Electrical Wiring for electrical connections.
23. Perform the steps detailed in Section 6: Startup.
24. Review Section 7-General Operation for detailed information on configuring your DLCM
and its advanced features.
14 PULSAnet Specification
14.1 Introduction
FOR SIMPLICITY, THE DLC AND DLCM VARIATIONS WILL ALL BE REFERRED TO AS THE
DLC UNLESS OTHERWISE NOTED
The DLC PulsaNet communication system is an implementation of the industry standard
MODBUS® protocol. The physical layer uses an RS-485 four-wire multi-drop scheme. Up to 32
slave units can be connected to a single master on the same set of wires. They can share those
wires with PLC’s and PC’s that use the same method of communication.
The MODBUS protocol was created in 1978 by Modicon as a simple way for transferring data
between controllers. Since its creation it has become a de-facto industry standard used by
multiple control and sensor companies. Today the MODBUS® protocol is the single, most
supported protocol amongst automation devices.
The MODBUS protocol is both a trademark and a fully owned product of Schneider Automation.
The specification is freely distributed on the Schneider Automation home page on the World Wide
Web.
With the few noted exceptions in this document, PulsaNet complies with the Schneider MODBUS
protocol specification. If you are interested in developing a MODBUS application to interface with
PulsaNet, please obtain the MODBUS specification from the Schneider Automation web site.
14.2 Operational Overview
The DLC has several different methods of operation when it comes to Serial Communications and
MODBUS Mode.
1. A PC or PLC MASTER can Monitor Information in the DLC while it is in any mode of
operation.
2. A PC or PLC MASTER can also WRITE certain information when the DLC is in
MODBUS MODE.
3. A DLC MASTER can control up to 32 DLC SLAVES in a similar way that Analog signals
can be used to daisy chain units together. Additional features that are available are:
a)
The DLC SLAVE can follow the on/off motor state of the master and,
b)
The DLCM SLAVE can follow the STROKE and SPEED separately of a DLCM
MASTER.
116
4. A DLC MULTIPLEX MASTER can control MULTIPLEX slaves permitting better
integration of the ‘motor-less’ DLC’s.
14.3 MODBUS Messaging
The MODBUS protocol was written for use with PLC’s. Programmable Logic Controllers (PLC’s)
typically have relay outputs, digital inputs, analog inputs, analog outputs and general system
settings (e.g., setpoints, alarm points, etc.). To access this data the MODBUS protocol uses the
following basic message structure (ASCII shown):
Start
1 Char
Address
2 Char
Function
2 Char
Data
N Char
Check
2 Char
End
2 Char
Start identifies the start of a message, Address contains the slave’s address, Function identifies
the function to perform, Data contains the data required by the Function, Check is the LRC or
CRC checksum of the message and End identifies the end of the message.
The FUNCTION CODE is the defining element in the message. It serves two purposes, 1) it
defines an operation, and 2) it identifies an optional block of data as the operand. When the
FUNCTION CODE operates on a block of data the ADDRESS of that data is transmitted in the
DATA portion of the message. For example to read the Digital Level Input from the DLC we would
use FUNCTION CODE 0x02 and ADDRESS 0x000A. To read the analog input #1 we would use
FUNCTION CODE 0x04 and ADDRESS 0x0000.
These FUNCTION CODEs and associated data are organized into categories as follows:
MODBUS
Category
COIL
Function
Code(s)
0x01 (Read)
INPUT BITS
0x02 (Read)
INPUT
REGISTER
HOLDING
REGISTER
0x04 (Read)
0x03 (Read)
0x06 (Write)
0x10 (Write
Multiple)
Description
PulsaNet Application
A relay output with either a 1
(ON) or 0 (OFF) status.
A dry contact or open
collector input with either a
1 (ON) or 0 (OFF) status.
A16-bit Analog input.
Digital output, Alarm Relay
Status.
Keyboard KEYS, LEAK,
LEVEL and THERMOSTAT
switch inputs.
4-20mA, Internal
Temperatures.
Display contents,
keyboard, counters and
various status and process
variables.
A 16-bit multipurpose register
value.
Each MODBUS Category constitutes a block of data with ADDRESSES of 0x0000 to 0xFFFF.
The MODBUS protocol also supports FUNCTION CODEs that do not apply to data. For example,
FUNCTION CODE 0x11, REPORT SLAVE ID, returns identifying information about the SLAVE
(e.g., gives Run Status, Prom Version and Serial Number).
14.4 PULSAnet DDE Server Messaging
Up to this point, this discussion is related specifically to MODBUS messaging. It would typically
concern someone developing an application that would communicate directly with the DLC. Most
users will access data through a Data Server like the PulsaNet DDE Server. To use such a
program you specify a data REFERENCE value. The server interprets the REFERENCE value to
determine what FUNCTION CODE and ADDRESS should be used. In the following Data
Category tables, you will find the FUNCTION CODE, ADDRESS and DDE REFERENCE
relationships.
117
14.5 Coils
Coils are discrete, single bit outputs like the ALARM OUTPUT and DIGITAL OUTPUT.
Notes:
1.
2.
3.
4.
Read only.
The coil information is packed as 8 coils per byte.
Coils are accessible through Function Code 0x01.
The requested value is returned in the least significant bit.
Function
Address
Read (0x01) 0x0000
Read (0x01) 0x0001
DDE Ref.
000001
000002
Purpose
Alarm Output
Digital Output
Data Format
Bit(0x01 = On)
Bit(0x01 = On)
14.6 Input Bits (1X References)
Input Bits are discrete, single bit inputs such as the keyboard KEYS, LEAK DETECTION, LEVEL
INPUT and THERMOSTAT inputs.
Notes:
1.
2.
3.
4.
Read only.
The input information is packed as 8 input bits per message byte.
Input Bits are accessible through Function Code 0x02.
The requested value is returned in the least significant bit.
Function
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
READ (0x02)
Address
0x0000
0x0001
0x0002
0x0003
0x0004
0x0005
0x0006
0x0007
0x0008
0x0009
DDE Ref.
100001
100002
100003
100004
100005
100006
100007
100008
100009
100010
READ (0x02)
0x000A
100011
READ (0x02)
0x000B
100012
READ (0x02)
READ (0x02)
READ (0x02)
0x000C
0x000D
0x000E
100013
100014
100015
Purpose
Key Pad Input: START/STOP
Key Pad Input: BATCH
Key Pad Input: UP
Key Pad Input: MENU
Key Pad Input: CALIBRATE
Key Pad Input: DOWN
Key Pad Input: UNITS
Key Pad Input: MODE
Key Pad Input: ENTER
Digital Input: LEAK DETECT
(J4-3, J4-4)
Digital Input: LEVEL INPUT
(J4-5, J4-6)
Digital Input: MOTOR
THERMOSTAT (J10-3, J10-4)
Encoder: Channel B
Encoder: Channel A
Digital Input: Tachometer
(J10-1, J10-2)
118
Data Format
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
Bit(0x01=On)
14.7 Input Registers
These 16-bit input registers contain Analog (4-20mA) and Thermistor input readings.
Notes:
1.
The input information is returned as 16-bit integers.
2.
Input Registers are accessible through Function Code 0x04.
Function
Read (0x04)
Address DDE Ref.
0x0000
300001
Read (0x04)
0x0001
300002
Read (0x04)
0x0002
300003
Read (0x04)
0x0003
300004
Purpose
Raw Analog Input #1 (4-20mA):
STROKE (J4-1, J4-2)
Raw Analog Input #2 (4-20mA):
SPEED (J4-7, J4-8)
Raw Analog Input: MOTHER
BOARD TEMPERATURE
Raw Analog Input: DRIVE
BOARD TEMPERATURE
Data Format
WORD (0x0 –
0xFFFF) [NOTE#1]
WORD (0x0 –
0xFFFF) [NOTE#1]
WORD (0x0 –
0xFFFF) [NOTE#2]
WORD (0x0 –
0xFFFF) [NOTE#2]
Notes:
1. This is the Raw analog value returned by the 10-bit Analog to Digital Converter. Use the
following formula to yield approximate 4-20mA values:
a)
Analog(mA) = Raw Value*0.025
2. This is the raw analog value returned by the 10-bit Analog to Digital Converter. Use the
following formula to yield approximate temperature:
a) Temperature (C) = (Raw Value * 0.116538952) - 8.480204328
b) Temperature (F) = (Raw Value * 0.209770114) + 16.73563219
14.8 Holding Registers
These 16-bit holding registers contain display, keyboard, counters and various status and process
variables. Holding Registers are accessible through several Function Codes:
Function Code = 0x03 Read Holding Registers.
a) Function Code = 0x06 Preset Single Holding Register.
b) Function Code = 0x10 Preset Multiple Holding Registers.
Notes:
1. The input information is returned as 16-bit integers.
2. Reading a write-only HOLDING REGISTER will return the value that was written previously.
3. Writing to a read-only HOLDING REGISTER will NOT write and will NOT return an error.
Function
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Address DDE Ref.
0x0000
400001
0x0001
400002
0x0002
400003
0x0003
400004
0x0004
400005
0x0005
400006
0x0006
400007
0x0007
400008
Purpose
Screen Character: Row 1, Column 1
Screen Character: Row 1, Column 2
Screen Character: Row 1, Column 3
Screen Character: Row 1, Column 4
Screen Character: Row 1, Column 5
Screen Character: Row 1, Column 6
Screen Character: Row 1, Column 7
Screen Character: Row 1, Column 8
119
Data Format
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Function
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Address DDE Ref.
0x0008
400009
0x0009
400010
0x000A
400011
0x000B
400012
0x000C 400013
0x000D 400014
0x000E
400015
0x000F
400016
0x0010
400017
0x0011
400018
0x0012
400019
0x0013
400020
0x0014
400021
0x0015
400022
0x0016
400023
0x0017
400024
0x0018
400025
0x0019
400026
0x001A
400027
0x001B
400028
0x001C 400029
0x001D 400030
0x001E
400031
0x001F
400032
0x0020
400033
0x0021
400034
0x0022
400035
0x0023
400036
0x0024
400037
0x0025
400038
0x0026
400039
0x0027
400040
0x0028
400041
0x0029
400042
0x002A
400043
0x002B
400044
0x002C 400045
0x002D 400046
0x002E
400047
0x002F
400048
0x0030
400049
0x0031
400050
0x0032
400051
0x0033
400052
0x0034
400053
0x0035
400054
0x0036
400055
0x0037
400056
0x0038
400057
0x0039
400058
Purpose
Screen Character: Row 1, Column 9
Screen Character: Row 1, Column 10
Screen Character: Row 1, Column 11
Screen Character: Row 1, Column 12
Screen Character: Row 1, Column 13
Screen Character: Row 1, Column 14
Screen Character: Row 1, Column 15
Screen Character: Row 1, Column 16
Screen Character: Row 2, Column 1
Screen Character: Row 2, Column 2
Screen Character: Row 2, Column 3
Screen Character: Row 2, Column 4
Screen Character: Row 2, Column 5
Screen Character: Row 2, Column 6
Screen Character: Row 2, Column 7
Screen Character: Row 2, Column 8
Screen Character: Row 2, Column 9
Screen Character: Row 2, Column 10
Screen Character: Row 2, Column 11
Screen Character: Row 2, Column 12
Screen Character: Row 2, Column 13
Screen Character: Row 2, Column 14
Screen Character: Row 2, Column 15
Screen Character: Row 2, Column 16
Flash Character: Row 2, Column 1
Flash Character: Row 1, Column 2
Flash Character: Row 1, Column 3
Flash Character: Row 1, Column 4
Flash Character: Row 1, Column 5
Flash Character: Row 2, Column 6
Flash Character: Row 2, Column 7
Flash Character: Row 1, Column 8
Flash Character: Row 1, Column 9
Flash Character: Row 1, Column 10
Flash Character: Row 1, Column 11
Flash Character: Row 1, Column 12
Flash Character: Row 1, Column 13
Flash Character: Row 1, Column 14
Flash Character: Row 1, Column 15
Flash Character: Row 1, Column 16
Flash Character: Row 2, Column 1
Flash Character: Row 2, Column 2
Flash Character: Row 2, Column 3
Flash Character: Row 2, Column 4
Flash Character: Row 2, Column 5
Flash Character: Row 2, Column 6
Flash Character: Row 2, Column 7
Flash Character: Row 2, Column 8
Flash Character: Row 2, Column 9
Flash Character: Row 2, Column 10
120
Data Format
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Function
Addres DDE
s0x003A Ref.
Read (0x03)
400059
Read (0x03)
0x003B 400060
Read (0x03)
0x003C 400061
Read (0x03)
0x003D 400062
Read (0x03)
0x003E 400063
Read (0x03)
0x003F 400064
Read (0x03)
0x0040 400065
Write (0x06)
0x0041 400066
Write Mult. (0x10)
Read (0x03)
0x0042 400067
Write (0x06)
Write Mult. (0x10)
Read (0x03)
0x0043 400068
Write (0x06)
Write Mult. (0x10)
Read (0x03)
0x0044 400069
Write (0x06)
Write Mult. (0x10)
Read (0x03)
0x0045 400070
Write (0x06)
Write Mult. (0x10)
Read (0x03)
0x0046 400071
Write (0x06)
Write Mult. (0x10)
Read (0x03)
0x0047 400072
Read (0x03)
0x0048 400073
Read (0x03)
Write (0x06)
Write Mult. (0x10)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Read (0x03)
Purpose
Flash Character: Row 2, Column 11
Flash Character: Row 2, Column 12
Flash Character: Row 2, Column 13
Flash Character: Row 2, Column 14
Flash Character: Row 2, Column 15
Flash Character: Row 2, Column 16
Cursor: Flag & Position
Key-press
Data Format
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #1]
Word (0x0 – 0xFFFF) [Note #2]
Word (0x0 – 0xFFFF) [Note #3]
Pump Motor Status
Word (0x0 – 0xFFFF) [Note #4]
Desired Percent Stroke
(hundredths %)
Word (0x0 – 0xFFFF) [Note #5]
Desired Percent Speed (hundredths %) Word (0x0 – 0xFFFF) [Note #6]
Stroke Counter High 16 Bits
Word (0x0 – 0xFFFF) [Note #7]
Stroke Counter Low 16 Bits
Word (0x0 – 0xFFFF) [Note #7]
Under/Over Voltage Error Flag
Actual Stroke Position (hundredths %)
Word (0x0 – 0xFFFF) [Note #8]
Word (0x0 – 0xFFFF) [Note #9]
0x0049 400074 Actual Average Motor Speed
(hundredths %)
Word (0x0 – 0xFFFF) [Note #9]
0x004A
0x004B
0x004C
0x004D
0x004E
0x004F
0x0050
0x0051
0x0052
0x0053
0x0054
0x0055
(0000-9999) [Note #10]
(0,1,2) [Note #11]
(0,1,2,3) [Note #12]
(0,1) [Note #13]
(00-99)
(1-12)
(1-31)
(1-7, 1 = Sunday)
(0-23)
(0-59)
(0-59)
(0=AC, 1=DC, 2=None)
400075
400076
400077
400078
400079
400080
400081
400082
400083
400084
400085
400086
Security PIN #
Security Type
Current Mode
Find Zero Calibration
Year of Century
Month of Year
Day of Month
Day of Week
Hour of Day
Minute of Hour
Second of Minute
Motor Type
Notes:
1. There is one character per 16-bit value, which resides in the least significant byte.
2. The most significant byte contains the cursor status (0 = cursor off, 1 = cursor on). The least
significant byte contains the cursor position offset (0-15 for the first line and 16-31 for the second).
3. Used to invoke Key-presses. The key value must be sent in the least significant byte (the most
significant byte is unused).
121
THIS REGISTER (0X0041 – KEY PRESS) MUST NOT BE USED FOR AUTOMATION
PURPOSES. IT CAN PRESENT HAZARDOUS CONDITIONS TO THE OPERATOR.
ACTIVATING CODE 0X01 (STOP_START_KEY) WILL OVERRIDE LOCAL KEYPAD
CONTROL! USE REGISTER 0X0042 – PUMP MOTOR STATUS FOR AUTOMATED MOTOR
CONTROL.
Note that the UP Key and Down Key are inhibited from modifying the stroke length and motor
speed. Use 0x0043 and 0x0044 for that purpose. The following codes are assigned:
0 = 0x00 =
1 = 0x01 =
2 = 0x02 =
3 = 0x03 =
4 = 0x04 =
5 = 0x05 =
6 = 0x06 =
7 = 0x07 =
8 = 0x08 =
9 = 0x09 =
NO_KEY
STOP_START_KEY (motor
key)
MENU_KEY
UNITS_KEY
BATCH_KEY
CALIBRATE_KEY
MODE_KEY
ENTER_KEY
UP_KEY
UP_REPEAT_KEY
10 = 0x0A =
11 = 0x0B =
12 = 0x0C =
13 = 0x0D =
14 = 0x0E =
15 = 0x0F =
16 = 0x10 =
17 = 0x11 =
18 = 0x12 =
UP_ENTER_KEY
DOWN_KEY
DN_REPEAT_KEY
DN_ENTER_KEY
UP_DOWN_KEY
SECRET_1_KEY
SECRET_2_KEY
SECRET_3_KEY
TIMEOUT_KEY
4. The most significant byte contains the desired condition (0 = user desires pump off, 1 = user desires
pump on). The least significant byte contains the actual motor status ( 0 = pump motor off, 1 = pump
motor on). When writing, only write to the Most Significant byte. The Least Significant byte must be
set to 0x00 or an error will be returned.
5. Percent-Stroke value is expressed in hundredths of percent i.e. 0x01F4 = 500 = 5.00%. The 0-10,000
value range may be modified by Ratio and Reverse Acting and further limited by end-points.
6. Percent-Speed value is expressed as hundredths of percent i.e. 0x2710 = 10000 = 100.00%. The 010,000 value range may be modified by Ratio and Reverse Acting and further limited by end-points.
This value is write-able only in a DLCM. A DLC will always return 100.00%.
7. Stroke Counter 16-bits (Most significant or Least significant depending on register). The combination
of these addresses constitutes a 32-bit unsigned LONG value. It is useful only if the tachometer
option is installed (e.g., DLCM).
8. The least significant bit contains the Under/Over Voltage Flag (0=False[No Error], 1=True[Error]).
9. The Actual Stroke Position value is expressed in hundredths of percent i.e. 0x01F4 = 500 = 5.00%.
10. The Actual Average Motor Speed value is expressed in hundredths of percent i.e. 0x01F4 = 500 =
5.00%. The Average Interval is 10 pump strokes. Writing any value will reset the Average.
11. Writing while security is disabled sets a new PIN #. Writing while security is enabled compares to the
old PIN #.
12. Reading returns the current condition from RAM that can be either 0=Security Off, 1=Tamper Proof,
2=Calibration Settings. Writing while security is disabled, enables the chosen security type. NOTE
that you should write the PIN # before enabling security here.
13. This is provided because you can only write items while in MODBUS MODE. 0=MANUAL MODE,
1=ANALOG MODE, 2=MODBUS MODE, 3=BATCH MODE.
14. Reading determines if we are currently performing a Find Zero Calibration. (0=no, 1=in progress) This
register can be written with a ‘1’ to force a Find Zero Calibration to occur.
122
SUPPORTED FUNCTION CODES and SUB-FUNCTION CODES
0x01
0x02
READ COIL STATUS (bits)
READ INPUT STATUS (bits).
0x03
READ HOLDING REGISTERS (16-bit integers)
0x04
0x05
0x06
0x07
0x08
READ INPUT REGISTERS (16-bit integers)
0x09
0x0A
0x0B
0x0C
0x0D
0x0E
0x0F
0x10
0x11
SUPPORTED
SUPPORTED
SUPPORTED
SUPPORTED
NOT supported
SUPPORTED
NOT supported
PARTIALLY
supported
SUPPORTED
SUPPORTED
NOT supported
SUPPORTED
SUPPORTED
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
NOT supported
SUPPORTED
SUPPORTED
FORCE SINGLE COIL (bits)
PRESET SINGLE HOLDING REGISTER (16-bit integer)
READ EXCEPTION STATUS (8-bits only)
DIAGNOSTIC FUNCTIONS
0x0000
RETURN QUERY DATA (ECHO)
0x0001
RESTART COMMUNICATIONS PORT
0x0002
RETURN DIAGNOSTIC REGISTER
0x0003
CHANGE ASCII INPUT DELIMITER <LF>
0x0004
SET LISTEN ONLY MODE
0x0005 - 0x0009 reserved
0x000A
CLEAR CTRS AND DIAGNOSTIC REGISTER
0x000B
RETURN BUS MESSAGE COUNT
0x000C
RETURN BUS COMM. ERROR COUNT
0x000D
RETURN BUS EXCEPTION ERROR COUNT
0x000E
RETURN SLAVE MESSAGE COUNT
0x000F
RETURN SLAVE NO RESPONSE COUNT
0x0010
RETURN SLAVE NAK COUNT
0x0011
RETURN SLAVE BUSY COUNT
0x0012
RETURN BUS CHAR. OVERRUN COUNT
0x0013
RETURN OVERRUN ERROR COUNT
0x0014
CLEAR OVERRUN COUNTER AND FLAG
0x0015
GET/CLEAR MODBUS® PLUS STATISTICS
0x0016 - 0xFFFF reserved
PROGRAM MODICON 484 CONTROLLER
POLL MODICON 484 CONTROLLER
FETCH COMMUNICATIONS EVENT COUNTER
FETCH COMMUNICATIONS EVENT LOG
PROGRAM CONTROLLER
POLL CONTROLLER
FORCE MULTIPLE COILS.
PRESET MULTIPLE HOLDING REGISTERS
REPORT SLAVE ID
-------------------------------------- Return Message Contains --------------------------------------
0x22 = Byte Count (length of data field to follow) (34 decimal)
0x99 = Slave ID
0x## = Run Status (of the pump motor)
16 characters from prom_ver[] string like: "
0x00=off, 0xFF=on
1.24
"
16 characters from Serial Number string entered at Factory Setup
Example: "B156045-D10
"
0x12
PROGRAM 884/M84
NOT Supported
0x13
RESET COMMUNICATIONS LINK
NOT supported
0x14
READ GENERAL REFERENCE
NOT supported
0x15
NOT supported
WRITE GENERAL REFERENCE
0x16
MASK WRITE 4X REGISTERS.
NOT supported
0x17
READ/WRITE 4X REGISTERS.
NOT supported
0x18
READ FIFO QUEUE
NOT supported
0x19 to 0x7f UNUSED
NOT assigned
Exception: 0x6f is used ONLY for the DLC to DLC MODBUS Mode.
123
Notes:
1.
Function codes that are NOT SUPPORTED or NOT ASSIGNED return an ILLEGAL
FUNCTION CODE response.
2.
Unsupported SUB-FUNCTION CODES under DIAGNOSTIC FUNCTIONS return INVALID
DATA.MODBUS Mode
14.9 MODBUS Mode
14.9.1
Introduction
The serial communications supplied with the DLC/M is similar in operation to that with the 4-20mA
signal. The [MODE] key controls the current operating mode: MANUAL, ANALOG (4-20mA) or
MODBUS. Serial communications can occur with the DLC/M regardless of the mode setting.
Never the less, only when the DLC/M is in the MODBUS MODE can a value be written –
changing the operation of the device. In any other mode, values can only be read. Note that even
in MODBUS MODE, the arrow keys cannot be used to adjust the flow, stroke or speed.
14.9.2
General Discussion
A PC or PLC MASTER controls a DLC SLAVE by writing to the Holding Registers for Percent
Stroke, Percent Speed and Motor Status values. When the MASTER READS from the Stroke
and Speed, it retrieves the User Desired Position and User Desired Speed. When the MASTER
WRITES to the Stroke and Speed, it changes the Digital-Stroke and Digital-Speed values. This
allows the application of the RATIO and REVERSE ACTING factors and checking of the end
points limits. The written values must be in the range of 0.00% – 100.00% (0-10000). In addition,
if this is NOT a DLCM, writing anything at all to the Motor Speed will return an error. The FLOW
RATE cannot be set directly by the MASTER, it is calculated from the Stroke and Speed settings.
WARNING: FOR SAFETY, IF AN OPERATOR WANTS TO DISABLE THE MODBUS REMOTE
CONTROL OF THE DLCM, THEN THEY MUST SWITCH THE DLCM OUT OF MODBUS
MODE. TURNING OFF THE MOTOR WILL NOT PROTECT THEM AGAINST THE PUMP
BEING TURNED BACK ON BY THE PC/PLC. WHENEVER PERFORMING MAINTENANCE,
THE POWER SHOULD BE REMOVED COMPLETELY FROM THE DLCM.
To prevent operators from modifying the operation of the DLC (e.g., changing the MODE from
MODBUS to MANUAL), Tamper Proof Security should be invoked. When doing this, carefully
select options in the {MODBUS SIG. FAIL} menu. If the DLC/DLCM is configured to restore to
MANUAL MODE, and a MODBUS signal failure is detected, the PC/PLC will no longer be in
control of the DLC. If Security is enabled, then operators will not be able to control the DLC/DLCM
either (except for the motor key, which is never protected by security).
15 Spare Parts
User replaceable parts for the DLCM.
Table 4: Miscellaneous Replacement Parts
Pulsafeeder P/N
NP250012-000
NP991209-003
NP260003-GPC
NP550003-DLC
NP992207-STL
NP992208-STL
NP992205-STL
NP460016-TFE
NP530314-000
Description
Clear Lexan Keypad / Display Cover
Cover Pins
Manual Adjustment Knob
Manual Adjustment Knob Decal
Connector Board Assembly Screw (short)
Connector Board Assembly Screw (long)
Wiring Access Cover Screw
Teflon Screw Gasket
CE Filter Kit (Required for CE only)
124
Qty
1
2
1
1
2
2
4
8
1
Installation, Operation &
Maintenance Instruction Manual
PULSAR® DLCM
NEMA TYPE 4x
DIGITAL STROKE LENGTH & MOTOR
SPEED CONTROLLER
Bulletin No.: IOM-CTL-DLCM-2004
Pulsafeeder, Inc.
A unit of IDEX Corporation
2883 Brighton Henrietta Town Line Road
Rochester NY 14623
+1 (585) 292-8000
www.pulsa.com
pulsa@idexcorp.com
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