ELECTRIC FIRE PUMP CONTROLLER

INSTRUCTION MANUAL
SERIAL NO.

MODEL NO.

MCA / MCP / MCR / MCO

MCY / MCS / MCT

FOR VERSION

23

MASTER CONTROL SYSTEMS, INC.

P.O. BOX 276 • 910 NORTH SHORE DRIVE • LAKE BLUFF, ILLINOIS 60044, USA
TELEPHONE: 847-295-1010 • FAX: 847-295-0704
www.mastercontrols.com
 Table of Contents
Page 2: MC* Controller Labeled – Diagram

Page 3: General Description and Application

Page 4: Included Options

: Installation

Page 5: Connections

Page 6: Control Wiring, Jumper Connections and Typical Options

Page 8: Jumper Settings

Page 9: Selector Switch / Pressure Switch Settings

Page 10: Pressure Settings and Examples

Page 11: Weekly Test Procedure

Page 12: Startup Procedures

• Preliminary Checks
• Startup Checklist

Page 15: BEFORE YOU LEAVE!

Page 16: Operating Procedures

Page 17: Replacement Parts - Electric Fire Pump Controllers

Page 18: Maintenance

Page 19: Model DR Digital Pressure and Alarm Recorder

Drawings:
-External Wiring Diagram
-Schematic Diagram
-Piping Connection

Option and Modification Drawings

Master Control Systems, Inc. -1- Lake Bluff, Illinois

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 Visual Indicators and MC* Series Controller
Digital Display -Labeled Diagram-

Visual Indicators and

Digital Display

Isolating Switch
2
Selector Switch

Circuit Breaker
3 (Disconnecting Means)

Start (Pushbutton)

Stop (Pushbutton)

Emergency Manual Operator

Latch
-Our display shows three sections of
information: Pump Alarms1 on Emergency Manual Operator
the top section, Pump Status LEDs2
are shown just below this, and a digital Pressure Sense Line
read-out3 is shown on the bottom. Piping Connections.

Line Chassis

Instruction Manual

Control Unit

Pressure Switch Settings

Display box

Isolating Switch

Circuit Breaker

Current Transformers

Contactor

Emergency Manual Operator Bar

Master Control Systems, Inc. -2- Lake Bluff, Illinois

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 GENERAL DESCRIPTION and APPLICATION

Master combined Manual and Automatic Electric Fire Pump Controllers meet all of the requirements of NFPA-20,
Standard for the Installation of Centrifugal Fire Pumps. Their purpose is to automatically start an electric motor
driven fire pump to provide the required water pressure and volume for proper operation of an automatic sprinkler
system in the event of a fire.

-Model MCA controllers provide full voltage (across-the-line) direct-on-line starting for three phase motor
driven fire pumps. These controllers are used where local power limitations do not restrict the motor starting
in-rush (locked rotor) current.

-Model MCP controllers provide part winding reduced inrush (partial voltage) starting for three phase motor
driven fire pumps. These controllers are used where local power limitations restrict the motor starting in-rush
(locked rotor) current.

-Model MCR controllers provide primary reactor reduced inrush (reduced voltage) starting for three phase
motor driven fire pumps. These controllers are used where local power limitations restrict the motor starting
in-rush (locked rotor) current.

-Model MCO controllers provide wye-delta (star-delta) open transition reduced inrush (reduced voltage)
starting for three phase motor driven fire pumps. These controllers are used where local power limitations
restrict the motor starting in-rush (locked rotor) current.

-Model MCY controllers provide wye-delta (star-delta) closed transition reduced inrush (reduced voltage)
starting for three phase motor driven fire pumps. These controllers are used where local power limitations
restrict the motor starting in-rush (locked rotor) current.

-Model MCS controllers provide reduced inrush (reduced voltage) ramp starting and ramp stopping (soft
start/soft stop) for three phase motor driven fire pumps. These controllers are used where local power
limitations restrict the motor starting in-rush (locked rotor) current, and/or where hydraulic conditions
warrant. They utilize a solid state motor starter for the start and stop ramp functions which is bypassed with a
motor contactor for normal or emergency full voltage running. A mode switch selects between normal
operation or full voltage (across the line) starting operation.

-Model MCT controllers provide autotransformer reduced inrush (reduced voltage) starting for three phase
motor driven fire pumps. These controllers are used where local power limitations restrict the motor starting
in-rush (locked rotor) current.

WARNING - DANGER OF LETHAL ELECTRICAL SHOCK AND ARC FLASH

HAZARD - USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE) IN
ACCORDANCE WITH NFPA 70E.
Do NOT defeat any Interlocks or Safety Features or Equipment or Circuitry
LETHAL voltages are NORMALLY present
-This equipment is LIKELY to be SERVICE ENTRANCE equipment.
-Foreign Voltages (Supervisory Power) may be present.
-Very high SHORT CIRCUIT (Fault) Currents are NORMALLY present.
This equipment MUST be serviced ONLY by QUALIFIED PERSONNEL.
-Obtain and wear Proper Level of Personal Protection Equipment (PPE) BEFORE attempting to open
equipment; including panels, covers, or doors; and BEFORE attempting to service this equipment.
-Follow ALL Safety and Personal Protection Equipment (PPE) requirements of NFPA-70E.

Master Control Systems, Inc. -3- Lake Bluff, Illinois

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 Included Options (G3)

Option Name Description

A Minimum Run Timer: Factory set for 10 minutes. Automatic and manual capabilities.
D Sequence start: 1 – 99 seconds
F Pump Running light
H Withstand Rating of 100,000 Amps with voltage between 200 – 480, full service
I Instrumentation (adds digital readout)
J Failure to Start light and SPDT contacts
DR Digital Pressure and Alarm Recorder with USB port
P Digital pressure display
R Remote and Deluge Valve Start
SP Single Phase Protection in accordance with NFPA 20
T Weekly Test
Mod 21 Lockout Circuit (external contact required – Not FM Approved)

INSTALLATION
The fire pump controller and all of its wiring and plumbing should be installed in accordance with the requirements
given below and the external wiring diagram(s) near the end of this manual. It should also be installed in accordance
with the requirements of NFPA-20, Standard for the Installation of Centrifugal Fire Pumps, and the requirements of
NFPA-70, the National Electric Code, as well as any local requirements. Incoming routing, protection and wiring
must meet service entrance requirements, if applicable.

LOCATION - Controllers should be located as close as practical to the motors they control. This location should be
within sight of the motor and in an area free from dripping and spraying water.

RATINGS - Check that the system voltage and the motor nameplate voltage and horsepower ratings agree with the
controller nameplate voltages and horsepower ratings before beginning installation.

MOUNTING - Controllers should be securely mounted and bolted to noncombustible surface or structure. The use
of a (3 inch) housekeeping pad is recommended when needed to keep the bottom of the controller dry.

CONDUIT ENTRANCE - Conduit entrance can be made either through the top or bottom of the enclosure.

WARNING - FOREIGN METALLIC DEBRIS, SUCH AS DRILLING CHIPS OR DEBRIS, CAN CAUSE
A DANGEROUS AND/OR DAMAGING ELECTRICAL FAULT WHEN THE EQUIPMENT
IS ENERGIZED. BE SURE TO PROTECT ALL ELECTRICAL PARTS FROM
METALLIC DEBRIS DURING INSTALLATION.

Use appropriate waterproof conduit hubs to keep water out of controller. Use the same type hubs as shown on the
controller nameplate "Enclosure Type". When controllers suitable for outside installation are used, be sure the
appropriate weatherproof conduit hub is used. Provide a sun roof, if required, to avoid excessive temperature
build-up within the controller.

PIPING CONNECTIONS - A 1/2 inch nominal (trade size) metallic corrosion resistant (brass or 300 series stainless
steel) Pressure Sense Line with two 3/32" orifices should be connected from the fire protection system to the
bulkhead fitting located on the side of the controller. Secure this sense line as needed to prevent vibration or damage.
For further installation details, consult NFPA-20 or see Piping Diagram drawing located in the drawing section of
this manual.

Master Control Systems, Inc. -4- Lake Bluff, Illinois

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 CONNECTIONS
POWER CONNECTIONS –

MCA - The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2 & L3. The output motor wiring is connected to the bottom of the Main Contactor "M" load side terminal
lugs T1, T2, and T3. Refer to the External Wiring diagram for details.

MCP – The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2 & L3. The output motor wiring is connected to the bottom of the Main Contactors “M1” and “M2” load
side lugs T1-T2-T3 and to T7-T8-T9. Refer to the External Wiring diagram for details.

MCR - The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2 & L3. The output motor wiring is connected to the bottom of the Main Contactor “M” load side terminal
lugs T1, T2, and T3. Refer to the External Wiring diagram for details.

MCO - The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2 & L3. The output motor wiring is connected to the bottom of the Main Contactor M1 & M2 load side
terminal lugs T1-T2-T3 and to T6-T4-T5 or T12-T10-T11. Refer to the External Wiring diagram for details.

MCY – The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2, & L3. The output motor wiring is connected to the bottom of the Main Contactors “M1” & “M2” load
side terminal lugs T1-T2-T3 and to T6-T4-T5 or T12-T10-T11. Refer to the External Wiring diagram for
details.

MCS – The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2 & L3. The output motor wiring is connected to the bottom of the Main Contactor “M” load side terminal
lugs T1, T2, and T3. Refer to the External Wiring diagram for details.

MCT – The three phase input power conductors are connected to the Isolating Switch (IS) line terminals L1,
L2, & L3. The output motor wiring is connected to the bottom of the Main Contactor “M” load side terminal
lugs T1, T2, and T3. Refer to the External Wiring diagram for details.

MOTOR CIRCUIT CONDUCTORS - All motor circuit conductors must be sized according to the National Electric
Code (NFPA-70) on a continuous duty basis. Insulation for these conductors should be chosen so it will not be
affected by the surrounding environment and have an insulation temperature rating at least 90 degrees C.

The ampacity of the wire is based on 125% of the motor full load current (FLA) using the 60 or 75 degree C wiring
table. The outgoing motor wiring is reduced to:

-58% of this value for wye-delta (MCO or MCY) controllers.

OR
-50% of this value for part winding (MCP) controllers.

The outgoing terminals are rated for copper conductors only.

NOTE: Be sure to secure conductors in such a manner so they will not move or interfere or rub against any
components or mechanisms in the controller. Protect against contact with sharp edges or corners.

Note that the controller is Service Entrance Rated. A dual grounding lug is provided for service entrance grounds or
for enclosure bonding. No neutral connection is provided or needed. The controller is suitable for use on either three
wire or four wire systems without the use of a neutral.

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 Control Wiring, Jumper Connections and Typical Options
REMOTE ALARM CONNECTIONS - Observe the contact rating limitations shown on the wiring diagram.

1. Pump Running Signal - Terminals numbered 5, 6, and 7 provide a form "C" set of contacts which transfer
when the motor current is detected. Contacts on terminals 5 and 6 close in the alarm (motor running) state,
while contacts on terminals 6 and 7 open in the alarm (motor running) state.

2. A.C. Power Failure Signal - Terminals numbered 8, 9, and 10 provide a form "C" set of contacts which
transfer when any phase of the incoming normal power fails. Contacts on terminals 8 and 9 close in the
alarm state, while contacts on terminals 9 and 10 open in the alarm state.

3. Phase Reversal Signal - Terminals numbered 11, 12, and 13 provide a form "C" set of contacts which
transfer when any two phases of the incoming power are reversed. Contacts on terminals 11 and 12 close in
the alarm state, while contacts on terminals 12 and 13 open in the alarm state.

4. Option "A" (G3) - Automatic Stop - Controllers are normally equipped for Manual Stop. Plug-in a MC-OM
module for Automatic Stop operation. Standard modules have a fixed 10 minute minimum running
shut-down delay time. Press the miniature pushbutton, when present on the MC-OM module, to shorten the
minimum running delay time for test purposes.

NOTE: The minimum run timer (Automatic Stop Operation) should not be used on sole supply pumps (see
NFPA-20). Sole supply pumps should be set Manual Stop operation.

5. Option “G” – Supervisory Power Failure Start. Terminals numbered 23 and 24 are provided for connection
of Supervisory Power. See “Supervisory Power Input” above.

6. Option “H” (G3) -100,000 Amp Short Circuit Rating - Controller rated for 100,000 Amps at 480 Volts.

7. Option “J” (G3) Failure To Start – Terminals 14,15 and 16 provide a form C set of contacts which transfer
after a start demand is received and the water has yet to start. Contacts on terminals 14 and 15 close in the
alarm state, while contacts on terminals 15 and 16 open in the alarm state.

8. Option “K” – Built-in Alarm System. Terminals numbered 23 and 24 are provided for connection of
Supervisory Power. See “Supervisory Power Input” above.

9. Option "R” (G3) - Remote Momentary Start (Pushbutton) - Controllers so equipped are shipped with a
jumper wired between terminals numbered 1 and 3 to prevent the controller from automatically starting when
this feature is not used or not wired. To use the remote start feature, remove the jumper and wire the
normally closed (momentary) contacts from the remote switch(s). Several may be wired in series.

Deluge Valve Start - Controllers so equipped are also shipped with a jumper wired between terminals
numbered 1 and 2 to prevent the controller from automatically starting when this feature is not used or not
wired. To use the deluge valve start feature, remove the jumper and wire the normally closed (maintained)
contacts from the deluge valve switch(s). Several may be wired in series.

10. Option “T” – Weekly Test (G3) - Provides a weekly test circuit and drain valve solenoid to automatically test
the fire pump once a week by pressure drop. See Weekly Test Procedure for further instructions.

11. Mod. DR (G3) – Digital Recorder with 4000 pressure and alarm points, USB and RS232

Master Control Systems, Inc. -6- Lake Bluff, Illinois

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12. Mod. 21 - Lockout Contacts (G3) - To use this feature, wire normally open contact(s) to terminals 1 and 4.
These contact(s) close to lockout or shutdown the fire pump. Closing these external contacts will lockout or
shutdown all start conditions (demands) except the Local START pushbutton. Jumper must be enabled.

NOTE: This option is not allowed on FM sites. Contact your FM agent for special use applications!

13. Mod. “SP” (G3) - Single-Phase Protection per NFPA 20

Master Control Systems, Inc. -7- Lake Bluff, Illinois

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 JUMPER SETTINGS:

Minimum Run LED:

-Indicates that the Minimum Run
Timer is timing when flashing.
Minimum Run Timer Short Cycle:
-Overrides the 10 minute stop
timer, stops the controller when
held down for 8 seconds.
Auto / Manual Stop Jumper:
-Determines if the controller
stops automatically after the 10
minute Minimum Run Timer or
manually by pressing the Stop
Pushbutton. Place the Jumper
In DIS for Manual Stop.
Lockout Jumper:
-To enable this option place the
jumper in the ENA position.
Remote Jumper:
-To enable this option place the
jumper in the ENA position.
Deluge Jumper:
-To enable this option place the
jumper in the ENA position.
Sequence Start:
-Set the amount of time (3s/div)
Sequence Start LED:
-Blinks while timing the
Sequence Start setting.

Deluge Valve: Remote Start:

-Wire in the Normally Closed -Wire in the Normally Closed
contacts on the Deluge Valve pushbutton for Remote Start operation
for start operation between between terminals 1 and 3.
terminals 1 and 2.

Master Control Systems, Inc. -8- Lake Bluff, Illinois

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 SELECTOR SWITCH / PRESSURE SWITCH SETTINGS:

Selector Switch
Digital Display

START Pressure setting

SYSTEM Pressure

RESET Pressure setting

Pressure Switch Settings:

RESET Setting

START Setting

Digital Recorder Functions:

DR TIME Pushbutton
-Will send the current
time set in the Digital
Recorder.

USB Reset Pushbutton

RS232 Serial Port

USB Connection

RESET Pushbutton

Master Control Systems, Inc. -9- Lake Bluff, Illinois

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 PRESSURE SETTINGS:

NOTE: If you need to adjust the Start Setting, simply adjust the Start Setting and the Reset Setting will automatically
adjust to maintain the differential. When adjusting the Reset Setting you will change the pressure differential; the
Start Setting will remain the same. These two functions will not overlap at any point.

Changing the Start Setting

Original Reset Setting: 80 Auto-Adjusted Reset Setting: 110

New Start Setting: 100 Goal Met!

Original Start Setting: 70 Goal: 100

Notice how the original 10 psi pressure differential between the Start and Reset Setting remained the same!

* * *

Example 2

Desired Differential Setting: 5 psi

Another example – Your Reset Setting is at 80, and your Start Setting is at 70. You wish to adjust the Reset Setting to
obtain a 5 psi differential. Simply adjust the Reset Setting to 75 psi as shown below:

Goal: 5 psi
Reset Setting: 80
Differential
Reset Setting: 75 Goal Met!
Start Setting: 70 Start Setting: 70

Master Control Systems, Inc. - 10 - Lake Bluff, Illinois

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 WEEKLY TEST PROCEDURE:
WEEKLY TEST MODEL A:
If you have Weekly Test part number 647999 OR 618248 use the following instructions, otherwise see below.

+ / - Pushbutton Menu OK

1. Press the “Menu” button to begin

2. Set the current time using the + / - pushbuttons (hour, minute, day) then hit OK to proceed
3. Select which program mode you will be setting, P01 or P02 – begin with P01
a. P01 corresponds to the START time for your weekly test
b. P02 corresponds to the STOP time for your weekly test
4. Set the start time for your weekly test first by hour, minute, then day. Press OK.
5. Repeat steps 1-4 for P02.

NOTE: Make sure to set the interval between P01 and P02 appropriately to ensure your weekly test does not run
for an incorrect amount of time.
WEEKLY TEST MODEL B:
For part number 650915

START pushbutton

1. Press the START pushbutton to initiate a weekly cycle at that precise

moment every week.
a. For example: if you press the start button Sunday at noon, every
proceeding Sunday at noon the weekly test will self-initiate.

b. Note: be sure enable jumper J8 is in the On position

c. If you wish to change the weekly test time and date, simply press
the START push button at the new time.

2. To disable, unlatch and unplug white connector.

Part Number White Connector Latch

Master Control Systems, Inc. - 11 - Lake Bluff, Illinois

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 START-UP PROCEDURE
WARNING - LETHAL SHOCK AND ARC FLASH HAZARD, USE APPROPRIATE PERSONAL
PROTECTIVE EQUIPMENT (PPE) IN ACCORDANCE WITH NFPA 70E.

WARNING - BOTH HIGH VOLTAGES AND HIGH CURRENTS ARE PRESENT - TO AVOID THE
POSSIBILITY OF ELECTROCUTION OR INJURY, DO NOT TOUCH ANY CIRCUIT
CONDUCTOR UNTIL IT HAS BEEN DETERMINED BY MEASUREMENT TO BE DEAD.
USE EXTREME CAUTION TO AVOID TOUCHING OR SHORTING LIVE TERMINALS.

WARNING - TO PREVENT THE POSSIBILITY OF SERIOUS PERSONAL INJURY DUE TO AN

ELECTRICAL FAULT, BE SURE THE DOOR IS CLOSED AND LATCHED BEFORE
CLOSING THE ISOLATING SWITCH OR OPERATING THE CONTROLLER.

WARNING - FOREIGN VOLTAGE MAY BE PRESENT. CONTROLLERS EQUEPPED WITH OPTION

“K” OR “G” UTILIZE AUXILIARY BRANCH CIRCUIT POWER (120 Vac / 60 Hz OR 220
Vac / 50 Hz) WHICH IS NOT SWITCHED OR CONTROLLED. ALWAYS TURN OFF OR
DISCONNECT THE EXTERNAL SOURCE OF POWER BEFORE ATTEMPTING TO
SERVICE THE CONTROLLER.

PRELIMINARY CHECKS (Prior to Start-up)

CAUTION - Perform these preliminary checks BEFORE Energizing the controller.

1. Make absolutely sure that the system (power supply) voltage, motor nameplate voltage and horsepower
ratings correspond to the controller nameplate voltages and horsepower ratings.

2. Inspect for and remove any metal chips which may have fallen in the controller during installation.

3. Remove all shipping ties and packing material that may not yet have been removed. In particular, check the
contactor or contactors for full movement of the plunger.

4. Check all control wires for tightness.

5. Check that all connectors are seated and latched.

6. Check that all printed circuit boards in the black card cage (MC-CU) are fully seated.

7. Check all connections in the power path of the motor and any Ground or Grounded conductors for tightness.
Re-torque any loose connections to the component manufacturers specifications. Contact Master Control
Systems for any that are not marked.

8. Check the motor contactor for proper seating. Hold a thin piece of paper against one of the contactor pole
faces and operate the Manual Mechanical Operator mechanism. The paper should be tightly held.

9. Make final adjustment on the circuit breaker Trip Unit setting. Check the range chart inside the door to see
that the range setting of the MC-TM Trip Monitor module is correct for the motor nameplate full load current
(FLA or FLC). The trip setting should be at the motor FLA or the next higher setting.

10. Set the accelerate time for the desired amount:

a. Does not apply for MCA
b. MCP, MCR, MCT set zero to ten seconds. The factory setting is 3 seconds.
c. MCY, MCO set zero to ten seconds. The factory setting is 7 seconds.
d. MCS is factory set to 9 seconds. See Soft Starter instructions for other settings.

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 START-UP PROCEDURE

START-UP CHECKLIST
I. ENERGIZING CONTROLLER
A. Close and Latch the controller door.

B. With the controller door closed, close the Isolating Switch (IS), then close the Circuit Breaker (CB).

C. Check that the Power On indicating lamp is lit.

D. Check Phase Reversal alarm lamp. If lit, open the Circuit Breaker and Isolating Switch and open the door.
Set the Phase Sequence Toggle Switch on the MC-CU chassis to the opposite position.

E. Re-Close and latch the controller door, Isolating Switch (IS), and Circuit Breaker (CB).

F. Pump Rotation Check: Check for motor rotation by jogging (bumping) the motor. Do this by pressing and
holding the Stop pushbutton, then, the Start pushbutton. Momentarily release the Stop pushbutton. Finally,
release the Start pushbutton, then release the Stop pushbutton. If the pump runs backwards, open the Circuit
Breaker (CB), the Isolating Switch (IS), and have the electrician reverse two of the three motor leads at the
contactor output ("T") terminals to change rotation, if required. Re-close the door(s), Isolating Switch (IS),
and the Circuit Breaker (CB).

G. Running Voltage Check: Push the Start pushbutton to start and run the motor. On units equipped with
Option "I" (Built-in Digital Meter), use the Meter Selector Switch to measure all three line to line voltages.

_H. Running Current Check: Measure the three motor currents. Check to see that they do not exceed the motor's
nameplate full load running current multiplied by the service factor. Check that the motor currents are within
5% of each other.

II. MANUAL MECHANICAL OPERATOR START

A. Pull up on the Manual Operator. Check that the Main contactor actuates electrically about half way thru the
handle travel and that the motor starts.
B. Slide spring latch under Manual Operator handle, not in it. The entire Emergency Manual Operator
should be resting on the latch. Check that the motor remains running.
C. Lift up on the Manual Operator handle to unlatch, then release it. Check for any binding or friction. Check
that the contactor drops out about half way thru the handle travel and that the motor stops.

III. ENERGIZING THE CONTROLLER FOR STAND-BY OPERATION

A. Pressurize the system using the Jockey Pump or by Running the Fire Pump. This is to avoid pump starting
while setting the Pressure Switch Start and Reset set points.

B. Close the Circuit Breaker and Isolating Switch. Set the METER SELECTOR SWITCH to the SYSTEM PRESSURE
position. The digital meter display is the system pressure in psig (pounds per square inch, gauge).

C. To check the pump Start set point, place the METER SELECTOR SWITCH to the START PRESSURE position and
observe the reading on the digital display. The value displayed is the pump Start pressure set point. The
pump will start whenever the system pressure is at or below this value.

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 START-UP PROCEDURE
START-UP CHECKLIST (continued)

D. To check the pump Reset set point, METER SELECTOR SWITCH to the RESET PRESSURE position and observe
the reading on the digital display. The value displayed is the pump Reset pressure point. On controllers set
for Automatic Stop, the controller will stop the pump whenever the system pressure is at or above this value
if the Minimum Run Timer has timed out.

E. Use the test valve to drop pressure to check for pump pressure loss starting. Use the Stop pushbutton to stop
the pump to leave it in service.

F. Make sure the pump discharge valve is open and that any other valves are properly set.

Master Control Systems, Inc. - 14 - Lake Bluff, Illinois

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 CONFIGURATION CHECKLIST:
Fill in the blanks or circle the chosen settings:

1. Minimum Run Timer Setting: ________ minutes.

2. Sequence Start Setting: __________ seconds.

3. Lockout Jumper Setting: ENABLED / DISABLED.

4. Remote Start Jumper: ENABLED / DISABLED.

5. Deluge Start Jumper: ENABLED / DISABLED.

6. Pressure Setting -

i. Start Setting: _________ psi.

ii. Reset Setting: _________ psi.

BEFORE YOU LEAVE!

1. Place the Isolating Switch (IS) in the ON position.

2. Place the Circuit Breaker (CB) in the ON position.

3. Drop the pressure at the side of the controller. The motor will start.

4. Press the STOP pushbutton. The motor will stop.

5. The Controller is now ready to operate.

Master Control Systems, Inc. - 15 - Lake Bluff, Illinois

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 OPERATING PROCEDURES:
EMERGENCY STOPPING - Pull the Circuit Breaker handle down to open the breaker and stop the motor.

WARNING: OPEN THE ISOLATING SWITCH BEFORE ATTEMPTING TO OPEN THE DOOR OR
SERVICE THE UNIT.

Energizing Controller: When energizing the controller for the first time after installation or after any service to the
controller, the motor, or motor wiring follow the "Start-up and Test Procedure" found earlier in this manual. For
other cases, follow the Operating Instructions on the instruction plates on the controller door.

Stand-by (Fire Protection) Service: The normal stand-by (automatic start) configuration for the controller is for both
the Isolating Switch and the Circuit Breaker to be in the closed (on) position. The green Power On, and Supervisory
Power On (if present) indicators should be lit. The motor should be off and no other indicators lit. The Audible
Alarm (if so equipped) should be silent.

De-energizing Controller: To de-energize the controller, make sure the manual operator is off. Operate the STOP
pushbutton to ensure the main contactor is open, then open the Circuit Breaker and then the Isolating Switch. All
lights should be off. Complete operating instructions are posted on the controller door.

CAUTION: DISCONNECT SUPERVISORY POWER IF PRESENT (USED WITH EITHER OPTIONS "G"
OR "K") AT ITS SOURCE BEFORE SERVICING THE CONTROLLER.

Manual Electric Starting: Momentarily press the START pushbutton. Note, this is not a latching pushbutton.

Manual Mechanical (Emergency) Starting: Pull up on the MANUAL OPERATOR handle and slide the latch bolt
knob under the operator to the right to engage and hold the handle lever. To stop the fire pump motor, pull up on
MANUAL OPERATOR to release the latch bolt and then release the operator handle quickly.

NOTE: In most cases, an electrical assist will engage or drop-out at around one half of the handle travel.

Stopping the Motor: If the motor is running under Manual Mechanical start, follow the above directions to
disengage the manual mechanical operator. In all other cases, press the STOP pushbutton to stop the motor.

CAUTION: IF THE MOTOR RESTARTS AFTER THE STOP pushbutton IS RELEASED, THERE IS AN
ACTIVE PRESSURE OR REMOTE DEMAND FOR THE FIRE PUMP. THE PUMP WILL
HAVE TO BE TAKEN OUT OF SERVICE TO STOP THE MOTOR. MAKE SURE THE PUMP
IS NOT NEEDED BEFORE THE NEXT STEP.

To take the PUMP OUT OF SERVICE, press and hold the STOP pushbutton and open (turn off) the Circuit
Breaker(s) then both Isolating Switches. Note that both of the Isolating Switches and Circuit Breaker(s) are load
break rated.

WARNING: THIS LEAVES THE FIRE PUMP OUT OF SERVICE RESULTING IN EITHER
REDUCED FIRE PROTECTION OR NO FIRE PROTECTION.

Master Control Systems, Inc. - 16 - Lake Bluff, Illinois

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 ELECTRIC FIRE PUMP CONTROLLERS – REPLACEMENT PARTS:
DESIGNATION DESCRIPTION MCS PART NUMBER
Complete Chassis Assemblies
MC-LC Line Voltage Transformer and Relay Chassis 586XXX
MC-CU Control Unit Chassis and Module Card Cage 647XXX
MC-OP Aux. Relay & Option Chassis 647XXX
(Supplied only with certain options)
Plug-In Control Module Board Assemblies
MC-PM Power Supply, Voltage & Phase Sequence Monitor 647111
MC-PM Power Supply, Voltage & Phase Sequence (1 Phase) 647112
MC-TM Current & Circuit Breaker Trip Monitor 537XXX
MC-TC Control Logic & Timing Module w/o Mod. 85 647131
MC-TC Control Logic & Timing Module – Reduced Voltage 647135
MC-OM Option Module (Opt. A,D,R,21) 595439
MC-ATB Accelerate Timer Daughter Board Module 647201
Door Mtd. Digital Readout & Display Board
MC-MD Meter & LED Display Panel (13 LEDS) 64977X
MC-MD Meter & LED Display Panel (16 LEDS) 64977X
MC-PAB Pressure Transducer Amp. Board 647XXX
MC-MIB Meter Interface Daughter Board 647XXX
Cabinet Mounted Control Components
MC-ALS Kit Audible Alarm - Silence 400875
MC-ALS Kit Audible Alarm - Buzzer 402618
START “START” Pushbutton Switch 400875
STOP “STOP” Pushbutton Switch 400875
IS Isolating Sw. Operating Handle w/ Door Interlock 400654
CB Circuit Breaker Operating Handle (w/o Door Interlock) 800685
MC-MO Manual Mechanical Emergency Operator Handle 800685
MOLS Manual Operator Limit Switch 801110
S.A. Surge Arrester 208 thru 480 Vac Controllers 303481
S.A. Surge Arrester 600 Vac Controllers 303482
F1,F2,F3 Fuse, Surge Arrester, 480 Vac, 100kA, Standard 204219
F1,F2,F3 Fuse, Surge Arrester, 600 Vac, 200kA, Controllers 204319
Plug-In Relays
RY1 1 form “X”, 24 VDC, Standard MC-LC 617020
RY2 1 form “X”, 24 VDC, Models O,Y,T MC-LC 617020
RY3 1 form “X”, 24 VDC, Models Y MC-LC 617020
RY4 1 form “X”, 24 VDC, Models P,R,O,Y,T MC-LC 617020

NOTE: When ordering replacement parts, you MUST supply the SERIAL NUMBER and MODEL NUMBER of
the Controller in which parts are to be used.

Master Control Systems, Inc. - 17 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 MAINTENANCE

WARNING - LETHAL SHOCK AND ARC FLASH HAZARD, USE APPROPRIATE PERSONAL
PROTECTIVE EQUIPMENT (PPE) IN ACCORDANCE WITH NFPA 70E.

WARNING - BOTH HIGH VOLTAGES AND HIGH CURRENTS ARE PRESENT - TO AVOID THE
POSSIBILITY OF ELECTROCUTION OR INJURY, DO NOT TOUCH ANY CIRCUIT
CONDUCTOR UNTIL IT HAS BEEN DETERMINED BY MEASUREMENT TO BE
DEAD. USE EXTREME CAUTION TO AVOID TOUCHING OR SHORTING LIVE
TERMINALS.

WARNING - TO PREVENT THE POSSIBILITY OF SERIOUS PERSONAL INJURY DUE TO AN

ELECTRICAL FAULT, BE SURE THE DOOR IS CLOSED AND LATCHED BEFORE
CLOSING THE ISOLATING SWITCH OR OPERATING THE CONTROLLER.

WARNING - FOREIGN VOLTAGE MAY BE PRESENT. CONTROLLERS EQUEPPED WITH

OPTION “K” OR “G” UTILIZE AUXILIARY BRANCH CIRCUIT POWER (120 Vac / 60
Hz OR 220 Vac / 50 Hz) WHICH IS NOT SWITCHED OR CONTROLLED. ALWAYS
TURN OFF OR DISCONNECT THE EXTERNAL SOURCE OF POWER BEFORE
ATTEMPTING TO SERVICE THE CONTROLLER.

On a weekly basis with the door(s) closed and latched, perform a test of the controller by dropping the pressure at
the pressure sensing line next to the controller or by using the Weekly Test function provided with this controller.
In addition to the pressure drop test, remote starting or deluge valve starting should be tested if used.

On an annual basis, a complete Start-up and Test Procedure outlined in the previous section of this manual should
be performed.

During the annual testing, qualified personnel should be present to inspect the inside of the controller and check:

• All control wires for tightness

• That all connectors are seated and latched

• That all printed circuit boards in the black card cage (MC-CU) are fully seated

• All connections in the power path for tightness. Re-torque any loose connections to the component
manufactures’ specifications. Contact Master Control Systems, Inc. for any that are not marked.

• For any indication of water marks on any of the components. Replace every component that has water
marks on it.

• For any indication that the wire insulation is cracking.

If any operation of the controller does not function correctly, or the inspection reveals any of the above problems, contact
Master Control Systems, Inc. at mastercontrols.com for service recommendations.

Master Control Systems, Inc. - 18 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 Model DR
Digital Pressure and Alarm Recorder

Modification “XDR” (G3) in Fire Pump Controller

Installation and Instruction Manual

Table of Contents

Page 20: General

Page 21: Initial Connection

- USB Flash Drive
- RS232 Connectivity

Page 25: Setting the Date and Time

Page 26: Normal Operation

Page 27: System Commands

Page 28: Hyperterm for Vista

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MC_ Issue 23-v02 2012.1.13
 GENERAL

Overview: The Master Control Systems, Inc. Model DR Digital Recorders is specifically designed to
communicate through an RS-232 serial port directly to a lap-top computer, USB Flashdrive or, if Modification
DRT is installed, a network server. This recorder constantly monitors the system pressure, at a rate of three times
per second, and records it into permanent non-volatile solid state memory (NVSRAM or EEPROM) every hour or
when the pressure changes by more the 5 psi (default setting) from the last saved value. The DR recorder also
monitors and records all alarm and status change events into memory. All recorded alarm and pressure data are
time stamped with the date and time of the event recorded. Alarm & Pressure data is recorded in to separate data
buffers and do not interact with each other. These recorders are completely independent of the fire pump
controller and vice versa. Failure of one does not impede the function of the other.

Fire Pump Controller Option Designations: The model DR digital pressure and alarm recorder is included in
modification code (G3).

Equipment Provided: The system consists of:

1) Solid State Pressure transducer
2) Operator push button to control unit reset, USB reset, and time function.
3) RS-232 customer serial port for data access and control.
4) USB Flash Drive accessibility

Connectivity: Controllers equipped with Mod. Code DRT are network enabled. This allows direct connection to
an Ethernet hub or server for connection to a Local Area Network (LAN) or a Wide Area Network (WAN) or
Internet Access. It uses TCP/IP protocol and is assigned an IP address which can be changed in the field. A work
sheet is supplied with the appropriate network parameters. A customer supplied IP address and sub-net mask can
be pre-programmed by the factory upon notification.

Master Control Systems, Inc. - 20 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 INITIAL CONNECTION

Using the USB Flash Drive:

CPY RST

CPY Light

RS232 port

USB port

1) Plug in your USB Flash Drive to the USB Port - the CPY light will turn solid orange, signaling the
transfer of data has begun.

2) When the CPY light turns green, remove your USB Flash Drive.

3) If the USB Flash Drive is removed too quickly, the CPY light will flash red and no data will be
saved. Remove the USB Flash Drive and press the CPY RST button, then repeat step 1

4) Connect your USB Flash Drive to your computer and look for an excel file with the extension
“.csv.” The file name will be coded in the following fashion:

10F28P34.csv, where: 10 = year 2010

F = 06 = June
28 = Day
P = 16th hour = 4PM
34 = minute

Master Control Systems, Inc. - 21 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 INITIAL CONNECTION – Continued

5) The following are sample screenshots of both electric and diesel recordings:

Electric Diesel

6) Save the file as an excel file to avoid any formatting errors

Using the RS232 Port:

1) Plug in the RS232 cable from your computer to the Display Box (cable not included)

2) Open up Hyperterm. If you use Vista, see P. 38 before continuing on to step 3.

Master Control Systems, Inc. - 22 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 INITIAL CONNECTION - Continued

3) Enter a name for your new connection to the Master Digital Pressure Recorder as shown here.

4) Change the Connect Using: to COM1 (or as appropriate to your computer).

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MC_ Issue 23-v02 2012.1.13
 INITIAL CONNECTION - Continued

5) Change the following information:

a. Bits per second: 9600
b. Data bits: 8
c. Parity: None
d. Stop Bits: 1
e. Flow Control: Xon / Xoff

6) Press OK. Wait approximately 5 seconds for the next screen to load, which should look like this:

Master Control Systems, Inc. - 24 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 INITIAL CONNECTION - Continued

7) You can now find a shortcut to your connection for future references by going to Start Æ All
Programs Æ Accessories Æ Communications Æ HyperTerminal Æ Name Of Connection.

Setting the Time and Date (if necessary):

At the Welcome Screen shown in step 6 above, type the following:
a. “H3” <RETURN>
b. T=Day number followed by month/day/year hour:min:sec in 2-digit numeric form then
<RETURN>. This sets the time in a 24 hour format.
c. To verify you have input the correct date, type “T” then <RETURN>
d. For Example: T=01 1/20/09 15:22:00
i. This will input a time of Monday (01) January 20th, 2009 (1/20/09) at 3:22:00PM (15:22:00)

Downloading Data:
1) Click on the Transfer tab at the top and click Start Capture.

2) At the Welcome screen shown in step 5, you may now type C6 for Alarm data (Digital Recorder
only), C7 for Pressure Data or C8 for Current Pressure. Press <RETURN> and the data will begin
to be captured, as shown in the following picture.

3) After the data is done downloading, click the Transfer tab Æ Capture Text Æ Stop. You can now
save the file as whichever name you wish to a file specified by you.

Master Control Systems, Inc. - 25 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 NORMAL OPERATION (default constants)

Switches and LEDs - The back of the display box provides a Security switch, a Send Status push button, and a
Reset push button along with system and diagnostic LEDs.

The TM pushbutton sends the present time to the connected lap-top or network adapter.

The Reset pushbutton resets all the hardware and software to their initial states.

The USB reset pushbutton clears all USB faults.

The following status LEDs are provided on the display back box:
CPY – Solid yellow light indicates the unit is copying data, solid green light indicates completion of data
transfer,
red light indicates failed transfer.
INIT - Indicates that the unit is going through initialize operations.
PROC - Indicates that the unit is running in the general program. It should always be flashing.
XMT - Indicates the unit is transmitting data through the RS232 port
RCV - Indicates the unit is receiving data from the RS232 port
CONN -Indicates that the unit is properly connected and ready to communicate. This connection may be made
by a lap top computer, network server or an external modem.
+5V - Indicates that +5 VDC power is available.

Master Control Systems, Inc. - 26 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 SYSTEM COMMANDS

(H1) CONTROL CODES USED

C0 Hardware reset (same as power up reset)
C6 Send alarm data buffer
Add ",MM/DD/YY" for starting date
C6- Reverse order of information for download
C7 Send pressure data buffer
Add ",MM/DD/YY" for starting date
C7- Reverse order of information for download
C9 Toggle display between PSI and Bar

(H3) TIME & DATE ENTRY

Type "T=" followed by the day number
followed by month/date/year hour:min:sec
in 2-digit numeric form then <RETURN>.
Set time in 24-hr format. To check type
"T" then <RETURN>.

EXAMPLE: Type "T=07 10/19/96 16:04:00"

<RETURN>. This enters Sunday, October 19, 1996
at 4:04:00 in the afternoon.
The last character in the time message before
the "+" sign is the daylight savings setting.
A "0" for OFF or a "1" for ON. To change this
setting, do a time set as above ending with a
"0" or "1" as required, factory default is 1.
See manual for more detailed information.

Master Control Systems, Inc. - 27 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 Hyperterm and Microsoft Vista:

NOTE: Microsoft Vista no longer contains Hyperterm by default. There is, however, a way to get Hyperterm to
work on your Vista computer provided that you have an old XP computer:

1) Make sure your computer has a serial port. If not, you need to purchase a USB to Serial Port Adapter.

2) Search for the following files on your old XP computer:

-htrn_jis.dll
-hypertrm.exe
-HYPERTRM (this file is of the type “DL_File”)
-Hypertrm.dll

This was a
separate search.

3) Once you have the above files, copy them into a single folder on your new Vista computer.

Open Hyperterm through the Hypertrm.exe file, and continue with Step 3 on P.21.

Master Control Systems, Inc. - 28 - Lake Bluff, Illinois

MC_ Issue 23-v02 2012.1.13
 OPTION AND MODIFICATION DRAWINGS

NOTE: The following drawings are applicable to controllers with model numbers which indicate that
they are equipped with the following. See controller nameplate for complete model number.

OPTION DESCRIPTION DRAWING

O Auxiliary Alarm & Option Chassis 16350, 16450

K Built-in Alarm Panel 16659

MODIFICATION

X (FOLLOWED BY)

17A or 17B Aux. Motor Run Contacts 16423

17C or 17D Aux. Power Failure Contacts 16426

17E or 17F Aux. Phase Reversal Contacts 16429

19 Strip Heater 16430

20 Strip Heater w/Thermostat 16430

20A Strip Heater w/Humidistat 16430

33 Auxiliary 115 VAC Output 16484

LSC Low Suction Cut-Off Chassis 16691