MagVFC Variable Frequency Controller

MAGVFC™ VARIABLE
FREQUENCY CONTROLLER

MagVFC Part Number - 5874202800 

 

1     Introduction
       The MagVFC™ variable frequency controller provides control for 2 HP and 4 HP
       variable speed submersible turbine pumps (STPs). The MagVFC™ variable speed
       controller ramps the STPs up and down as-needed to provide optimal flow rates at all
       fueling points. The result is faster, more consistent flow rates than fixed speed systems
       at virtually the same cost of ownership.

TABLE 3.1 – Field Wire Panel

Component	Definition
Field Wire Panel	The right-side panel located under the MagVFC™ cover.
Hook Terminals	Voltage signal from the dispensers to turn pump on. Requires a signal wire and a neutral. No polarity requirements at the Hook Terminal.
Pump Motor Terminals	Labeled GND, BLK, ORG, RED. Connect wires that go to the submersible pump at these terminals. If color codes are not matched at the submersible, the motor may run in reverse.
Input Power Terminals	Labeled GND, L3, L2, L1. Supplies power to MagVFC™ to supply the submersible pump. Minimum 12 AWG wires size.

  MagVFC™ Electrical Specifications

MagVFC™ Incoming Line Draw:

• Single Phase input = 18 A Max.
• Three Phase Input = 20 A Max.

PMA VS4 Motor Draw = 15 A Max.

PMA VS4 Lead-to-Lead winding resistance = 1.2 Ohms ± 1 Ohm

PMA VS2 Motor Draw = 7 A Max.
 

PMA VS2 Lead-to-Lead
Winding resistance = 2.5 Ohms ± 1 Ohm
                                                                 

 NOTE: Optimum performance of the VS4 is achieved with 3-Phase Incoming power.

INPUT Wire Size / Run (Breaker Panel to Drive)
   

Wire Size (AWG)            Maximum Run (Feet)

10                            650
12                            400

 CAUTION: Connecting INPUT POWER to the PUMP MOTOR TERMINALS will damage the MagVFC™.
 WARNING:
•   Do not install in hazardous location. Use only with FE Petro® PMA models VS2 and VS4.
•   Apply power to the controller BEFORE allowing hook signal input. There should be NO hook signal present when applying power to the controller.

NOTE:
•   Use 90° C copper wire rated 300 V minimum. Tighten line and motor terminals to
    8 IN-LBS.
•   Connect wires accurately. Connecting power wires to any other terminals will
    cause irreparable damage to the MagVFC™ controller.
•   The MagVFC™ can only be used with FE Petro® Pump base models IST, IST VS4,
    STP VS4, STP VS2, PMA VS4, or PMA VS2. The MagVFC™ is not compatible
    with competitive makes of variable speed models. The MagVFC™ is compatible
    with the IST-VFC for communication in Primary-Secondary configurations only
    if the MagVFC™ has been upgraded to software revision 1.18 or higher. Refer to
    bulletin TB0106-01 for switch setting information.
•   This drive provides motor overload protection required by the National Electrical
    Code (NEC). This protection limits the motor current to 100% of the drive full
    load current rating.
•   This drive does not provide motor over-temperature sensing.
•   This drive is suitable for use on a circuit capable of delivering not more than
    5000 rms symmetrical amperes, 250 V maximum.
•   This drive requires inverse-time circuit breakers rated 200–250 V, 30 A
    maximum for branch circuit short circuit protection.
•   Integral solid state short circuit protection does not provide branch circuit protection.
    Branch circuit protection must be provided in accordance with the NEC and any
    additional local codes.

                                                                                             
User Interface Panel

Component	Definition
1 - User Interface Panel	The front panel located under the MagVFC™ cover.
2 - Pump Status Display	Displays codes indicating controller or pump status.
3 - Silence Alarm/Fault Readout Button	Push and it will turn off audible alarm. Push and hold button and the Pump status display will show the last three fault conditions the MagVFC™ encountered.
4 - Reset Button	Resets controller of any fault condition.
5 - Communication LED	Used in PRM-SEC controller configurations to indicate communication activity.
6 - RS485 Connection	Used in PRM-SEC controller configurations (frequency connection not used in IST-VFC Mode).
7 - Relay Contact	Normally open. The relay closes when the pump is running.
8 - SW1	Operational Pressure Switch. Adjusts the submersible pump’s operational pressure.
9 - SW2	Address Switches. Used in PRM-SEC controller configurations.
10 - SW3	Configuration Switches.
11 - SW6	Configuration Switches.
12 - Relay	Sold separately.

Installation Instructions

NOTE: Steps 1–3 are also part of the installation instructions for the submersible pump. This is done to make sure all instructions are available if needed during installation. As a result, Steps 1–4 may already be complete.

1. Connect the electrical conduit with approved fittings to the submersible pump junction box.
2. Remove the submersible pump junction box cover and remove the compression seal by loosening the screw (do not remove the screw). The seal has four holes to accommodate a ground wire and three-phase power from the MagVFC.

WARNING: Not installing a ground wire increases the risk of potentially
               lethal electrical shock and equipment failure. All holes of the compression seal
               (contractors plug) must be filled with wires or a Celcon® rod to enable it to seal. 

3. Verify that the power is “OFF” at the supply box. Pull four wires from the spot where the MagVFC™ unit will be mounted into the submersible pump junction box and feed through the compression seal. Slide the compression seal into place and tighten securely. Connect the three wires from the connector assembly to the 3-Phase power wires coming from the MagVFC™. Connect the fourth wire (ground) from inside to the pump junction box ground lug.
                  

   NOTE: All wiring must conform to all applicable guidelines in accordance with all federal, state, and local codes. Failure to comply with all applicable guidelines could result in an unsafe installation. Use the following table for maximum wire length to wire gauge for submersible wiring:
                     

   OUTPUT Wire Size / Run (Drive to Motor)

   
                      Wire Size (AWG)           Maximum Run (Feet)
                               10                           650
                               12                           400
                               14                           250

4. Replace the cover of the pump junction box and securely tighten. 

   WARNING: The compression seal is not a replacement for the vapor explosion seals required by the NEC. All materials used between the power supply box and the submersible pump junction box must be gasoline and oil resistant. All wiring used within the MagVFC™ must be rated 90° C, 300 V minimum. Failure to comply with these, and all applicable NEC guidelines, could result in an unsafe installation.

5. Hang the MagVFC™ on a vertical surface and remove the front panel screw and front cover. Install approved electrical conduits only at factory knockouts on the MagVFC™ enclosure. 

   NOTE: Electrical interference can be created by several types of equipment in a station (fluorescent lighting, compressor, etc.). This interference may affect the operation of sensitive equipment such as tank monitors and electronic line leak detectors. When installing the MagVFC™, Franklin Electric recommends that the power wires from the power source and the power wires to the IST or STP units with VS2 or VS4 suffix (pump) be in their own steel conduit which is not broken or routed through race ways. Franklin Electric also recommends that all equipment be installed per the manufacturer requirements for best results.

   
   NOTE: The MagVFC™ must be mounted indoors in a non-hazardous location with ambient temperatures between 40° F (4° C) and 95° F (35° C).

   
   NOTE: Mount controllers so they have 6" or more of clearance on the top, bottom and right side (cover side), and 3" or more clearance on the left side (heat sink side). Install with the heat sink fins vertical and the knockouts down.

6. Connect the three motor control wires from the pump junction box to labeled terminals observing color coding of wires (BLACK to BLACK, ORANGE to ORANGE, RED to RED). Connect the ground wire from the submersible pump to the ground lug on the MagVFC™ circuit board. 

   
   WARNING: To avoid the risk of potentially lethal electrical shock, fire, or explosion, always tag and lock circuit breakers in the off position before opening the MagVFC™.
   WARNING: After disconnecting power to the MagVFC™, wait one-minute after LED display blanks before opening the cover for servicing. Voltage stored in the capacitor bank of the MagVFC™ presents a risk of potentially lethal electrical shock even after power is disconnected.
   NOTE: If the motor power wires are not connected with the proper polarity, the motor will run in reverse rotation causing output pressures of approximately 17–29 PSI with a PMA VS4 and approximately 10–18 PSI with a PMA VS2 connected.

7. Connect 3-Phase, 200–250 V, 50 or 60 Hz power supply to terminals L1, L2 and L3. 

   
   NOTE: The MagVFC™ may be connected to single phase power only if used with FE Petro® pump motor model PMA VS2 with input power connected to L1 and L2. 
   NOTE: The PMA VS4 model pump motor requires three phase input voltage for optimum performance. Operating on single phase input, the performance of the PMA VS4 will be equivalent to that of a PMA VS2.
   WARNING: Do not connect input power to any terminals other than L1, L2, and L3. Connecting input power to any other terminals will cause failure and permanent damage to the MagVFC™.
   WARNING: There must be NO hook signal present when applying power to the controller.

8. Connect dispenser hook signal to the two-position terminal block on the MagVFC™ board. 
   NOTE: Dispenser hook terminals are capable of accepting voltages from 110 VAC through 240 VAC dispenser signals. The dispenser hook terminals require a signal wire from the dispenser and a neutral/return.

9. Configuration switches are factory set for PMA VS2 in gasoline, mechanical leak detectors, extended run active, and stand-alone operation.

   WARNING: Before making changes to the configuration switches, make sure power supply is locked and tagged out.

10. To access configuration switches SW3 and SW6, remove the two screws from the plastic shield covering the "user interface board".

11. Set all DIP switches as desired.
                                                                                             
         

SW3 Option Select Switch Settings

SW3 Pole	Position	Purpose
1	On	Mechanical Leak Detection Systems or LS500 Electronic Line Leak Detection Systems.
	Off	For Veeder-Root™ PLLD.
2	On	For gasoline (factory setting).
	Off	For diesel product.
3	On	For Primary controller (not for TPI use)
	Off	For Stand-alone operation or SEC configuration (factory setting (for TPI use)).
4	On	Factory Setting
5	On	Factory Setting
6	On	When using PMAVS4 motor. (4HP) Horsepower
	Off	When using PMAVS2 motor (factory setting). (2HP) Horsepower
7	On	For automatic reset of under load fault. An empty tank will cause an under-load fault. The MagVFC™ will automatically reset when the condition is corrected.
	Off	Must push “Reset” button to clear the UL “Under Load” fault (factory setting). Leave in OFF position in IST-VFC “Compatibility” mode.
8	Off	Default (factory setting).

SW6 Option Select Switch Settings

SW6 Pole	Position	Purpose
1	On	Will disable the “Extended Run Alarm” condition.
	Off	The “Extended Run Alarm” is active (factory setting). Not functional in “IST-VFC Compatibility Mode”, leave in “OFF” position.
2	Off	Default (factory setting).
3	On	For “IST-VFC Compatibility Mode”, unit will then ONLY communicate with rev 1.5 software IST-VFCs in “Primary-Secondary” configurations (not for use in communicating “Primary-Secondary” with other MagVFC™s).
	Off	Native MagVFC™ “Primary-Secondary” communication (factory setting).
4	On	When the “Alternating Circuit” configuration is used, this will alternate submersibles every 30 minutes when a hook signal is continuous. This option is used to assist in keeping tanks balanced.
	Off	When “Alternating Circuit” is not needed.
5	On	With software version 1.24, feature “Proportional Alternating Circuit”, allows setting the time each controller runs before it alternates. This feature will help manage tank levels but will not replace a syphon bar or managing levels via EVO™ Series consols or Incon® T5 Series consoles “Leveling” mode.
	Off	When “Proportional Alternating Circuit” is not needed.
6	Off	Not used. Leave in “OFF” position (factory setting).
7	Off	Not used. Leave in “OFF” position (factory setting).
8	Off	Not used. Leave in “OFF” position (factory setting).

12. Replace the cover of the MagVFC™.

13. Insert a 0–100 PSI pressure gauge into the 1/4" line test port of the submerged pump (or other pressurized test location in the piping system). Turn power on to the MagVFC™ at the load center. Turn on the submerged pump at the dispenser and inspect the line and test port for leaks. If there are any leaks, immediately turn off the submerged pump at the dispenser and the load center. Repair the leaks.

14. Begin purging the air from the piping system by activating a dispenser handle and pumping product into an approved container. Verify that with the pump on, no product is dispensed and pressure reading on the gauge is equal to the related pressure from Table 4.12 (step 20), +5 to -7 PSI.

    
        NOTE: If pressure in the piping system is much lower than selected, it is possible
        that the polarity of the motor power wires is not correct. Turn off the pump at
        the power supply, (wait one minute after LED display blanks before opening
        the cover) and change the connection of any two wires at the pump or at the
        MagVFC™ motor terminals. Turn the pump back on and read the pressure gauge.
        The electrical connection which gives the higher reading on the pressure gauge,
        is the correct one.

15. Complete purging the remaining air from the piping system and dispensers. If using “Primary-Secondary” or “Primary-Secondary/Alternating Circuit” configurations.
                                                                                                            

      
   Primary-Secondary Control Configurations

When two IST pumps or STP units with VS4 or VS2 suffix are installed to be run in parallel, (discharging into the same line) three different modes (configurations) of operation are possible.

Configuration	Definition
Primary-Secondary	When a hook voltage is present at the PRM, it will turn on. When demand for product increases (more nozzles open) the PRM will call the SEC controller to turn on. This will maintain the product flow rate in high demand situations. In this configuration, the SEC controllers(s) will run only when requested to do so by the PRM controller.
Alternating Circuit	The controllers will rotate which STP to turn on as the hook voltage turns on and off. Only one controller is on at a time in this configuration. Not available in IST-VFC “Compatibility” mode.
Primary-Secondary/Alternating Circuit	“Primary-Secondary/Alternating Circuit” is a combination of the above two configurations. The first controller to turn on rotates and when the demand for product increases, additional controllers will be called on to assist.

NOTE: For “Primary-Secondary” and “Alternating Circuit” configurations, the MagVFC™ can only be paired with other MagVFC™s. Because of enhanced communication protocols, the MagVFC™ is not capable of communication with the IST-VFC unless SW6 Pole 3 (IST-VFC Compatibility Mode) is switched ON. IST-VFC “Compatibility” mode is available in rev 1.18 software or higher MagVFC™s.

WARNING: To avoid the risk of potentially lethal electrical shock, explosion or fire, always tag and lock circuit breakers in the off position before removing the cover of the MagVFC™.
 

WARNING: After disconnecting power to the MagVFC™, wait one minute after LED display blanks before opening the cover for servicing. Voltage stored in the capacitor bank of the MagVFC™ presents a risk of lethal electrical shock even after power is disconnected.

RS485 Wiring - Primary/Secondary + Dip switch settings

• SW3 poles 4 and 5 on PRM and SEC must match
• SW1 same position for all units

16. Wire the RS485, connecting the Primary controller MagVFC™ to the Secondary controller(s) MagVFC™ as shown in Figure 4. Wire per NFPA 30 A, and NFPA 70. Signal wires require at least 22 AWG (300 V minimum) 4 conductor shielded cable with a drain and within a common jacket. Cut wires to length so there is no excess wiring touching circuit board components.

NOTE: When wiring a “Primary-Secondary” and/or “Alternating Circuit” configuration, connect the signal from the dispenser (hook) to the terminals of the Primary MagVFC™ only. The Primary controller will energize the Secondary controller(s) when needed without a signal from the dispenser.

CAUTION: Line leak detection performance can be affected when using multiple MagVFC™s. Franklin Electric does not recommend using the “Alternating Circuit” feature in conjunction with electronic line leak detection.
Some electronic line leak detector manufacturers require that the Primary controller always turns on first. Please refer to the manufacturer’s requirements.

MagVFC Turbine Pump Interface (TPI) Primary-Secondary Configuration 

• SW3 poles 4 and 5 on PRM and SEC must match

• SW1 same position for all units

  
                                                 

The MagVFC is used to control the 4" variable speed STP’s, which range from 2–4 HP.  When using TPI, a few dip-switch changes are needed on SW2 and SW3.

The SW2 pole should be set for the correct address setting similar to the STP-SCI controllers. The MagVFC™ can be addressed for up to 31 controllers.
If using INCON® ELLD, SW3 settings are:
                                  • SW3 Pole 1 should be in the on position.
                                  • SW3 Pole 2 should be set for the product type, On for Gas off for Diesel.
                                  • SW3 Pole 3 should be left off.
                                  • SW3 Poles 4 and 5 should be set according to piping restriction.
                                  • SW3 Pole 6 should be set to pump horsepower, On for 4 HP Off for 2 HP.
                                  • SW3 Pole 7 can be turned off as TPI will auto reset after a delivery when an
                                    underload occurs.
                                  • SW3 Pole 8 should remain off.

Configuration	Controller	Switch	Pole	Position	Notes
Primary -Secondary	PRM	SW3	3	On
			8	Off
		SW2	All	Off
	SEC	SW3	3	Off
			8	Off	Factory Setting
		SW2	*	*
Alternating Circuit	PRM	SW3	3	Off
			8	On
		SW2	All	Off
	SEC	SW3	3	Off	Factory Setting
			8	Off
		SW2	*	*
		SW6	4	On	To alternate after every 30 minutes of continuous hook signal
Primary-Secondary / Alternating Circuit	PRM	SW3	3	On
			8	On
		SW2	All	Off
	SEC	SW3	3	Off
			8	Off
		SW2	*	*

Not Applicable to IST-VFC Mode

Configuration	Controller	Switch	Pole	Position	Notes
Primary -Secondary	PRM	SW3	3	On
		SW6	3	On
	SEC	SW3	3	Off
		SW2	**	**
Alternating Circuit	PRM	SW3	3	On
		SW6	3	On
	SEC	SW3	3	Off
		SW2	**	**
Primary-Secondary / Alternating Circuit	PRM	SW3	3	On
		SW6	3	On
	SEC	SW3	3	Off
		SW2	**	**

For IST-VFC Compatibility Mode

Another feature of the “Primary-Secondary” and/or “Alternating Circuit” configurations is the ability to have a Secondary controller take command for product delivery if one of the following alarm conditions is present with the Primary controller.
      •    UL – Under Load (Tank Empty).
      •    LI – Low Incoming Voltage.
      •    LU – Locked Rotor in PMA.
      •    HO – High Temperature in MagVFC™.
      •    OS – Over Speed.

Configuration	Controller	Switch	Pole	Position	Notes
Primary - Secondary	PRM	SW6	2	**On ***Off	Required setting for VR PLLD. Factory default.
Alternating Circuit
Primary - Secondary / Alternating Circuit

Secondary in command if alarm active on Primary

               
NOTE: *This option only needs to be selected on the Primary controller.
NOTE: **If “ON”, an alarm condition on any controller (Primary or Secondary) will shut down all controllers. The system will not run until the alarm situation is resolved and the “Reset” button is pushed or the “Fault Shutdown Option” switch is turned “OFF” and the “Reset” button is pushed.
NOTE: ***If “OFF”, an alarm condition will shut down only the controller with the alarm.

17. When all connections are complete, reinstall the MagVFC™ covers and activate supply power. Verify that the front panel status indicator is displaying Id (Idle) for both Primary and Secondary controller(s).
    NOTE: When working with a “Primary-Secondary” or “Primary-Secondary/Alternating Circuit” controller configurations, there can be only one Primary controller and up to 31 Secondary controllers. When connected properly, the yellow Communication LED will flash quickly on the Primary unit and flash in sequence through the Secondary controller(s). See § 3.3 for LED location.

Controller	SW2 Pole 1	SW2 Pole 2	SW2 Pole 3	SW2 Pole 4	SW2 Pole 5
PRIMARY
SECONDARY #1	On
SECONDARY #2		On
SECONDARY #3	On	On
SECONDARY #4			On
SECONDARY #5	On		On
SECONDARY #6		On	On
SECONDARY #7	On	On	On
SECONDARY #8				On
SECONDARY #9	On			On
SECONDARY #10		On		On
SECONDARY #11	On	On		On
SECONDARY #12			On	On
SECONDARY #13	On		On	On
SECONDARY #14		On	On	On
SECONDARY #15	On	On	On	On
SECONDARY #16					On
SECONDARY #17	On				On
SECONDARY #18		On			On
SECONDARY #19	On	On			On
SECONDARY #20			On		On
SECONDARY #21	On		On		On
SECONDARY #22		On	On		On
SECONDARY #23	On	On	On		On
SECONDARY #24				On	On

SW2 Native MagVFC Communication Addressing

Controller	Pole 1	Pole 2	Pole 3	Pole 4	Pole 5
PRM
SEC 1				On	On
SEC 2			On		On
SEC 3			On	On	On
SEC 4		On			On
SEC 5		On		On	On
SEC 6		On	On		On
SEC 7		On	On	On	On
SEC 8	On				On
SEC 9	On			On	On
SEC 10	On		On		On
SEC 11	On		On	On	On
SEC 12	On	On			On
SEC 13	On	On		On	On
SEC 14	On	On	On		On
SEC 15	On	On	On	On	On

SW2 Compatibility Mode Addressing & IST-VFC Primary-Secondary Options

                                                                                  
MagVFC™ Proportional Alternating Circuit Feature (Software Version 1.24)                

To enable the “Proportional Alternating Circuit” feature on the MagVFC™ with software version 1.24 or higher:       

Set SW3 Pole 8 to “ON”.                      
 

Set SW6 Pole 4 to “ON”. This activates the “Timed Alternating Circuit” mode. This switch needs to be enabled on the Primary MagVFC™ only.                        
 

Set SW6 Pole 5 to “ON”. This switch activates the “Proportioning” feature and needs to be enabled on the Primary MagVFC™ only.                                 
 

Set SW2 to the desired address for pump run time. Each MagVFC™ address will be set based on the time it needs to run.                                   
 

NOTE: This is different from the typica Primary MagVFC™ address of “0”. Any address can be set, as long as the addresses are unique between controllers. Typically address and run times will be chosen that are proportional  
to the tank sizes. The example below,  shows three different size tanks and the addresses that run the pumps in proportion to the tank size.
                                                       
           Example:                                     
                                                        
             •   For a Primary controller with a
                 20,000 gallon tank, when set to         
                 address 20 the pump will run for        
                 30 minutes.                             

             •   For an Secondary controller with        
                 a 12,000 gallon tank, when set to       
                 address 12 the pump will run for
                 18 minutes.
             •   For another Secondary controller in an 8,000 gallon tank, when set to address 8,
                 the pump will run for 12 minutes.

MagVFC™ Site Setup

18. Verify rotary switch on MagVFC™ is set to position 4. This will provide approximately 32 PSI (pressure) output from the IST or STP units with VS2 or VS4 suffix,and serves as a good starting point for MagVFC™ calibration.

19. Using a five-gallon capacity minimum approved container, go to the dispense closest to the storage tank and perform a “Flow Rate Test”. If the product being pumped is gasoline, consider following the “U.S. EPA Fuel Dispenser Flow Rate Test Procedure” (for 10 GPM maximum flow rate standard), where applicable. NOTE: It is necessary to perform a “Flow Rate Test” for each product available at the dispenser. This will confirm that all product outputs, including products blended at the dispenser, do not exceed the U.S. EPA 10 GPM maximum, where applicable. 

    NOTE: Use of flow restrictors to control a maximum flow rate of 10 GPM per nozzle (as required by the U.S. EPA) are not required if the variable frequency controller is properly calibrated as defined in § 4.3.4.

20.  If output is above or below the desired range (i.e. 8-10 GPM), turn off the pump at the power supply, wait one minute after LED display blanks before opening the cover, remove the MagVFC™ cover, and adjust the rotary switch (SW1). This switch will increase or decrease the system operating pressure. An increase in pressure will normally yield an increase in flow rate. A decrease in pressure will reduce flow rate. Replace the MagVFC™ cover and re-apply input voltage. Return to step 19 and check GPM with the new settings. Repeat until the output obtained is within the desired range in GPM.
     

Position	Pressure (PSI)
0	24
1	26
2	28
3	30
4	32
5	34
6	36
7	38
8	40
9	42

SW1 Operational Pressure Switch Settings

WARNING: To avoid the risk of potentially lethal electrical shock, explosion or fire, always tag and lock circuit breakers in the off position before removing the cover of the MagVFC™.
WARNING: After disconnecting power to the MagVFC™, wait one minute after LED display blanks before opening the cover for servicing. Voltage stored in the capacitor bank of the MagVFC™ presents a risk of potentially lethal electrical shock even after power is disconnected.
NOTE: Additives in gasoline can change the specific gravity of gasoline, which may cause the pressures to vary.

21. Optimize “Pipe Compensation” settings by doing another “Flow Rate Test”, this time with two other nozzles from the same product open at the same time as your test nozzle. If the flow rate at the test nozzle falls from the desired range with three nozzles open, increase SW3 Pole 4 and Pole 5 to the next highest compensation setting (0 to 1 or 1 to 2 for example). If output exceeds the desired range, decrease to the next lowest compensation setting (2 to 1 or 1 to 0 for example). Repeat this step until compensation setting is optimal for your installation. Factory setting is zero.

Compensation	Pole 4	Pole 5	Notes
0	On	On	Least restrictive. Factory setting.
1	On
2		On
3			Most restrictive.

SW3 - Piping Compensation

NOTE: An example of a “Small Restriction Piping System” would be 2" fiberglass running less than 150'. An example of a “Restrictive Piping System” would be 11/2" convoluted flexible piping greater than 75' in length.
NOTE: When working with a “Primary-Secondary” or “Primary-Secondary/Alternating Circuit” configuration, the “Piping Compensation” must be identical in all controllers.

Display Definitions & Troubleshooting

The MagVFC™ displays the operating status of the controller (normal and abnormal) using reference codes. (error codes) Codes such as “Status”, “Error”, and/or “Alarm” inform the user of the conditions present in the system.
                                   

Code	Definition	Description	Displayed
ID	Idle	No hook signal present, PMA is not running, and no-fault codes present.
xx : yy	Software Revision	Software version of MagVFC™ where numeric value xx displays and then value yy to form the revision xx.yy. Note: If the display stops on yy, there may be an issue of low incoming voltage or loose input power connections.	Immediately after the MagVFC™ has been reset or turned ON.
Pr : NN	Pressure Regulate	Pr is the pressure setting of NN psi that the MagVFC™ is set to maintain. Pr and the numeric value NN of the set pressure will flash alternately on the display when running.	MagVFC™ is running and operating within pressure regulate setting.
PL	Power Limit	Displayed when MagVFC™ is operating at its power limit.	MagVFC™ is running and operating beyond pressure regulate setting.
Sr	Secondary Running	Displayed when an Secondary in a “Primary Secondary” configuration is running.

Display Status Codes

NOTE: The MagVFC™ is equipped with a “Reset” button to clear faults and a “Silence Audible Alarm” button that turns off the audible alarm when depressed. Depressing the “Silence Audible Alarm” button does not clear the fault; it only silences the alarm. Pushing and holding the “Silence Audible Alarm” button will put the “Pump Status Display” in “Fault Readout Mode”, showing the last three fault conditions encountered by the MagVFC™. In example, F0 is followed by the code of the last fault encountered, F1 is second to last fault encountered, F2 is third to last fault encountered. Sequence through the codes by briefly pushing the “Silence Audible Alarm” button after each code is displayed until the “Pump Status Display” returns to normal status.

Code	Condition	Potential Cause	Proposed Action
UL	Under Load, Tank Empty. Incorrect Horsepower Setting	Low fuel level in the storage tank. Obstruction on intake of PMA. SW3 P6 set incorrectly for pump connected.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step.  3. Check SW3 P6 and verify it matches the horsepower of the pump connected. Connecting a VS2 motor with a SW3 P6 “ON” (4 HP), may cause this false indication when operating in SW1 positions 0 - 6.  4. Check fuel level in storage tank. If product is low, schedule fuel delivery. When delivery is complete (fuel level is above PMA end bell), push “Reset” on the MagVFC™. Check for correct system operation.  5. If condition is not corrected, it is possible that there is an obstruction on the inlet of the PMA.
LI	Low Incoming Voltage.	Voltage fluctuations or low input voltage.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step.  3. Use an AC voltmeter to verify incoming voltage is within 200–250 VAC. If voltage is not within this range, contact an electrician to correct.
Er	Extended Run.	Continuous hook signal applied for greater than 60 minutes without change in pumping product flow rate.	1. Disconnect power at load center. Lock and tag out circuit breaker.  2. Check voltage across hook terminals with all dispenser handles off. There should be no voltage applied. If voltage is present, contact an electrician to correct the problem. After the problem has been corrected, turn on input power and verify system is operating correctly.
rI	Voltage Unbalance or Capacitor Bank.	Unbalanced incoming voltage, sudden large load or failed MagVFC™ capacitor bank.	1. Push “Reset” on the MagVFC™.  2. Check incoming voltage and electrical loading.  3. If fault is cleared, observe the MagVFC™ in normal operation for approximately 10 minutes to see if it functions normally.  4. If error recurs, contact FE Technical Support.
OS	Over Speed.	MagVFC™ operating outside of range of operating frequency.	1. Push “Reset” on the MagVFC™.  2. Check for proper operation. If condition is still present, power down unit completely and wait 30 seconds.  3. Turn on power and check for proper operation.  4. If fault recurs, contact FE Technical Support.
HO	High temperature.	Excessive operating temperature in MagVFC™.	1. Verify that the fan is running properly. If not, replace the fan.  2. Check for excessive heat in area where control box is mounted.  3. Verify all louvers for ventilation are free from obstruction. Remove obstruction(s) and cycle power to reset MagVFC™.  4. If the condition persists, contact FE Technical Support.
LU	Locked Rotor Fault at PMA startup.	Foreign material in PMA or defective PMA.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step.  3. Disconnect input voltage at load center, lock and tag circuit breakers.  4. Remove two 9/16" bolts from extractable portion of the manifold. Disengage the 3/4" securing bolt of the electrical connector and swing out of the way.  5. Pull extractable part of the pump.*  6. Remove black end cap from PMA and attempt to spin rotor with a 3/16" Allen wrench to determine if there is any binding. If binding or physical damage, continue with next step. If no binding or physical damage to the PMA, and it is a new installation, reinstall extractable.  7. Turn power on to the MagVFC™ unit and verify correct system operation. If condition is corrected, do not continue to the next step. If condition is still present, remove the extractable (repeat steps 3, 4, and 5) and continue to the next step. NOTE: PMA can have a locked rotor during startups if it has been exposed to a corrosive environment, such as a tank ballasted in water.  8. Remove four cap screws connecting the PMA with ¼" Allen wrench and remove the PMA from the motor discharge head. NOTE: Prior to mounting a new PMA, check lead assembly (wires inside the extractable portion to PMA) for shorted wires which may have caused the condition.  9. Replace with a new variable speed pump motor (PMAMVS4 or PMAVS2).*  10. Reinstall extractable by following reverse order of disassembly.  11. Turn on power to the MagVFC™ unit and verify correct system operation.  NOTE: *PMA shell can be damaged by blows from hard surfaces; use care when removing or replacing.  NOTE: Where motor wiring runs are extremely long and/ or of a small wire diameter, a false LU (locked up) may be displayed on the MagVFC™.
SU	Upper Rail Short.	Short Circuit condition in field wiring or component failure internal to the MagVFC™.	1. Push “Reset” on the MagVFC™.  2. Check for proper operation.  3. If fault re-occurs turn off power to MagVFC™, lock out and tag circuit breaker. Disconnect the wires to the STP at the controller terminals marked BLACK, ORANGE and RED.  4. Use wire nuts and cap each wire off to prevent any possible shorts in the controller. Turn power on to the MagVFC™ and observe the display. If the controller indicates an OC (Open Circuit) condition, follow the troubleshooting steps for a short circuit.  5. If controller display indicates the SU (Upper Rail Short) condition, then contact FE Technical Support.
OC	Open circuit from MagVFC™ to motor. (See note).	Connection broken from MagVFC™ to PMA.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step. MagVFC™/PMA Connections  1. Disconnect power at load center, lock and tag circuit breakers.  2. Remove the three motor control outputs from the MagVFC™ unit.  3. Using an ohmmeter on 200 setting, place leads between these three wires from the pump motor (this is the first step in determining where the open circuit has occurred). Correct reading between any two of the three wires should be 1.2 +/-1 ohms (VS4) and 2.5 +/-1 ohms (VS2).  4. Continue conductivity tests on the remaining combinations of wires (three total). Results, e.g. BLACK to RED = 2 ohms. Readings between any of the three motor control wires and ground should be an open circuit. If readings in this step are incorrect go to step 7. If readings are correct, contact FE Technical Support for assistance.  5. Go to the submerged turbine and remove the cover at the top of the extractable manifold; remove the three wire nuts.  6. Place an ohmmeter between the three wires leading to the pump motor as above. If readings are incorrect go to PMA replacement in 3 flashes section. If readings are correct, there is problem with the wiring between the MagVFC™ and this point.  7. Remove the junction box cover and do conductivity test on the wires from junction box to the extractable discharge head. If wires are not conducting, replace the male and female connectors of the submerged turbine. If there is no problem with these connections,d the wires from the MagVFC™ to the submerged turbine are suspect. Contact an electrician to correct the problem.  8. After the problem has been corrected turn on power to MagVFC™ and verify system is operating correctly. Note: Where motor wiring runs are extremely long and/or of a small wire diameter, a false OC (open circuit) may be displayed on the MagVFC™.
SC	Short Circuit. Incorrect Horsepower Setting.	Short in connections from MagVFC™ to PMA. SW3 P6 set incorrectly for pump connected.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step.  3. Check SW3 P6 setting and verify that it matches the horsepower of the pump connected. Connecting VS4 motor with a SW3 P6 “OFF” (2 HP) setting, may cause this false indication. MagVFC™/PMA Connections  1. Disconnect power at load center, lock and tag circuit breakers.  2. Remove the three motor control outputs from the MagVFC™ unit.  3. Using an ohmmeter on 200 setting, place leads across any two of the three wires from the pump motor. Correct reading between any two of the three wires should be 1.2 +/-1 ohms (VS4) and 2.5 +/-1 ohms (VS2).  4. Continue conductivity tests on the remaining combinations (three total). Readings between any of the three motor control wires and ground should be greater than 80k ohms. If readings are incorrect proceed to step 8. If readings are correct, the possibility of a short circuit in the connections between the MagVFC™ and the PMA still exist. Contact FE Technical Support for additional troubleshooting assistance.  5. Go to the submerged turbine and remove the cover at the top of the extractable; remove the three wire nuts.  6. Place an ohmmeter between the three wires leading to the pump motor as above. If wires are shorted, go to PMA replacement in 3 flashes section. If readings are correct there is problem with the wiring between the MagVFC™ and this point.  7. Remove the junction box cover and do conductivity tests on wires from junction box to extractable discharge head. If wires are shorted to ground or each other, replace the male and female connectors of the submerged turbine. If there is no problem with these connections, the wires from the MagVFC™ to the submerged turbine are suspect. Contact an electrician to diagnose and correct the problem.  8. After the problem has been corrected turn on power to the MagVFC™ and verify system is operating correctly.
Lr	Locked rotor fault with PMA running. (See note.)	Foreign material in PMA or defective PMA.	1. Push “Reset” on the MagVFC™.  2. If condition is corrected, check for proper operation of system. If operating correctly do not continue to next step. If condition is still present continue to next step. PMA Inspection.  3. Disconnect input voltage at load center, lock and tag circuit breakers.  4. Remove two 9/16" bolts from extractable portion of the manifold. Disengage the 3/4" securing bolt of the electrical connector and swing out of the way.  5. Pull extractable part of the pump.*  6. Remove black end cap from PMA and attempt to spin rotor with a 3/16" Allen wrench to determine if there is any binding. If binding or physical damage, continue with next step. If no binding or physical damage to the PMA, and it is a new installation, reinstall extractable.  7. Turn power on to the MagVFC™ unit and verify correct system operation. If condition is corrected, do not continue to the next step. If condition is still present, remove the extractable (repeat steps 3, 4, and 5) and continue to the next step. NOTE: PMA can have a locked rotor during startups if it has been exposed to a corrosive environment, such as a tank ballasted in water.  8. Remove four cap screws connecting the PMA with ¼” Allen wrench and remove the PMA from the motor discharge head. NOTE: Prior to mounting a new PMA, check lead assembly (wires inside the extractable portion to PMA) for shorted wires which may have caused the condition.  9. Replace with a new variable speed (VS4 or VS2) pump motor.*  10. Reinstall extractable by following reverse order of disassembly.  11. Turn on power to the MagVFC™ unit and verify correct system operation.  NOTE: *PMA shell can be damaged by blows from hard surfaces; use care when removing or replacing.

Troubleshooting Codes (error codes)

                                                                                                              23