MURCAL MUNICIPAL
The Series 600 SolutionThe Series 600 controller is the current MURPHYMATIC® control solution for custom municipal pump control systems. It is applied to pumps with electric motor, VFD, Natural Gas Engine and Diesel drives.
The first MURPHYMATIC® controllers were designed in 1958 and were applied to custom projects where a basic auto-start controller would not meet the operator’s needs. The Series 600 control approach is to provide field access to password-protected set points the operator needs to adjust and configure the controls to meet the individual requirements of a specific pumping application.
Our Custom Project Process Ensures that the Control System will meet the End-User’s Needs
Password-Protected Set Points
Seamless Integration of Emission Control Module (AFRC) with Engine Controller and SCADA System for Local and Remote Display of Key Values and Alarms
Status and State of each Controller indicated both Locally and via MODBUS Communication to Central SCADA System
Installation, Service & Training Available from MurCal
The primary feature of the Series 600 controller is the incorporation of years of experience providing solutions to the unique problems found in controlling pumps in municipal applications such as:
a. Controlling Single Well Pumps, Booster Pumps, and Lift Pumps to provide automatic start/stop and speed control.
b. Multi-drive Booster Stations, Lift Stations, Treatment Plant pump control and storm drain pumping stations which are required to operate both independently and frequently on battery power alone when commercial power is not available (e.g. during storms).
• Auto Start and speed control based on local system pressure.
• Speed control based on local pressure and/or discharge flow.
• Remote control/monitoring via SCADA systems using MODBUS RTU communications.
• Special software routines to control Pre-lube, Pump Control Valves, Waste/Discharge Valves.
• Well Pre-Lube Valve control with adjustable delay and fault sensing.
• Engine Pre-lube, Warm-up, Cooldown; Post-lube.
• Speed control for Warm-up, Minimum RPM, Pump-to-waste RPM, Maximum RPM, engine and VFD drives.
• Pump Control Valve control on start and stop where required to control pressure surge.
• Pump to Waste control with valve fault sensing and automatic switch-over to mainline pumping.
• PID Speed control to maintain discharge pressure or flow as required by the application where VFD and Engine Drives are used.
• Fault annunciation both locally and via MODBUS communication to central SCADA system.
• Status and State of the controller indicated both locally and remotely to SCADA system.
• Auto Start and speed control based on local system pressure.
• Remote control/monitoring via SCADA systems using MODBUS RTU communications.
• Special software routines to control Pre-lube and Pump Control Valves.
• Pre-Lube Valve and engine control with adjustable delay and fault sensing.
• Pump Control Valve control on start and stop where required to control pressure surge.
• Speed control for Warm-up, Minimum RPM, Maximum RPM, engine and VFD drives.
• PID Speed control to maintain discharge pressure as required by the application where VFD and Engine Drives are used.
• Fault annunciation both locally and via MODBUS communication to central SCADA system.
• Status and State of the controller indicated both locally and remotely to SCADA system.
• Auto Start and speed control based on local wet well level.
• Remote control/monitoring via SCADA systems using MODBUS RTU communications.
• Special software routines to control Pre-lube, Pump Control Valves.
• Pre-Lube Valve and engine control with adjustable delay and fault sensing.
• Pump Control Valve control on start and stop where required to control pressure surge.
• Speed control for Warm-up, Minimum RPM, Maximum RPM, engine and VFD drives.
• PID Speed control to flow-match varying flow into wet well by maintain a preset level or constant speed operation as required by the application where VFD and Engine Drives are used.
• Fault annunciation both locally and via MODBUS communication to central SCADA system.
• Status and State of the controller indicated both locally and remotely to SCADA system.
Central control and communication with SCADA systems for Booster, Flood Control and Sewage Lift applications. Central controller performs the following:
• Automatic pump substitution on failure with intelligent pump alternation.
• Automatic speed synchronization of pumps as multiple engine and/or VFD drives are added based on demand.
• Control Area Network (CAN) communications between engine controllers to provide instantaneous communication of start commands, speed commands and status between engine controllers and central controller.
• Emergency operation capability with individual engine controllers able to operate independently, if fault is sensed with the central control system.
• PID speed control for variable speed drives such as engines and VFD electrics.
• Central controller can act as a Remote Terminal Unit with direct SCADA connection or can communicate with a separate RTU as required by the application.
The Series 600 control approach is to provide field access to password-protected set points the operator needs to adjust and configure the controls to meet the individual requirements of an application. The following list is an example of some of the standard engine controller set points:
• Start Delay adjustment
• Pre-Lube Delay adjustment
• Crank Delay
• Rest Delay
• Number of Cranks for “Failed to Start” (Overcrank)
• Speed Calibration for speed readings (number of teeth on flywheel for magnetic pickup speed sensor)
• Overspeed shutdown RPM
• Crank Termination RPM
• Warmup RPM
• Minimum Pumping Speed RPM
• Maximum Pumping Speed RPM
Additional set points are included with special alarm and shutdown routines for engine protection devices.
Each control system is supplied with a Sequence of Operation to describe the control features and how they interact to meet the control requirements. An Operation Directions document is created to show which set points are provided and how set points are entered and adjusted.
All custom projects include discussion with the design engineers and the agency representatives to determine the requirements. A submittal package including the Sequence of Operation, Operation Directions, Field Wiring, Drawing and Enclosure Drawing is prepared for approval before work is begun on the final design and fabrication. The submittal process highlights any misunderstanding and stimulates possible changes to be made before the equipment is actually built and delivered. This is a process that dates back to the first MURPHYMATIC® control projects and ensures that the control system will meet the end-user’s needs.
Temperature Range of control platform: -40° C (-40° F) to 85° C (185° F)
Operating Voltage of control platform: 9 VDC to 28 VDC
Current draw of control platform: < 500 ma DC
HMI interface: Graphic Touch Screen with MODBUS interface to control platforms
Memory on Control Platform: 512 KB Flash EEPROM, 4.0 KB EEPROM, 14.0 KB RAM
Analog-to-Digital converters: Two 8-channel
Resolution: 10 bit
Analog inputs scaled to engineering units without requiring special tools or technical experience.
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