PCM Series INSTALLATION AND MAINTENANCE MANUAL

RELIABLE CHEMICAL FEED PUMPS SINCE 1957

OPERATING REQUIREMENTS

2

SAFETY INSTRUCTIONS

GENERAL SAFETY HAZARDS AND NOTICES

This is the safety alert symbol. When displayed in thismanual or on the equipment, look for one of the followingsignal words alerting you to the potential for personal injury orproperty damage.

Warns about hazards that CAN causedeath, serious personal injury, or property damage if ignored.

NOTICE: Indicates special instructions or generalmandatory action.

READ AND FOLLOW ALL SAFETY INSTRUCTIONS!

ELECTRIC SHOCK HAZARD: Equipment is supplied with grounding power cord and attachedplug. To reduce risk of electrical shock, connect only to a properlygrounded, grounding type receptacle.

DO NOT alter the power cord or plug end.

DO NOT use receptacle adapters.

DO NOT use PCM with a damaged or altered power cord or plug. Contact the factory or an authorized service facility for repair.

PCM IS INTENDED FOR INDOOR USE.

Electrical installation should adhere to all national and local codes. Consult a licensed professional for assistance with proper electrical installation.

HAZARDOUS VOLTAGE:DISCONNECT power cord before removing cover for service.Electrical service by trained personnel only.

EXPLOSION HAZARD: This equipment is not explosion proof. DO NOT install or operatein an explosive environment.

RISK OF FIRE HAZARD:DO NOT install or operate on any flammable surface.

DO check supply voltage prior to connecting power cord to prevent damage.

DO mount PCM in a dry location to avoid water intrusion and damage.

DO install PCM so that it is in compliance with all national and local codes.

DO use all required personal protective equipment when working on or near chemical metering pumps.

DO use PCM ONLY with a dry contact, reed switch style water meter.

ADDITIONAL PRECAUTIONS AND NOTICES

DO NOT attempt installation or service prior to reading and understanding all safety hazards. This equipment is designed for installation and service by trained personnel.

DO NOT connect PCM input signal cord to any AC voltage supply.

DO NOT connect PCM input signal cord to any hall effect 4-20mA or voltage carrying signal source.

DO NOT adjust the PCM time to a longer duration than the minimum time duration between water meter contacts.

DO NOT use pump adjustment to control dosage. An adjustable metering pump must be used at the maximum pump setting.

ELECTRIC SHOCK HAZARD

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The knob on the PCM providesadjustment of the on-time,required per input signal. Supplyvoltage is transformed to lowvoltage for control circuits and theinput signal for safety duringoperation and installation.

3.75''

Top

4.50''

3.00'' 4.50''

2.00''

Front Side

3.50''

0.1 – 1.0 second setting

0.5 – 5.0 second setting

1.0 – 10.0 second setting

HAZARDOUS VOLTAGE: DISCONNECT power cord before removing cover for service.

The PCM time range is factory set according to the specific model. The time range can be changed to convert a PCM to any of three available timeranges without purchasing another model.

The time range is converted by changing the position of the shunt on the printed circuit board located under the PCM’s cover. To change the time range:

• Unplug the PCM power cord from the input power supply.

• Remove the cover (four screws) and reposition the shunt to correspondwith the desired time range.

• Replace the PCM cover and secure with the four screws.

• Document the PCM conversion, so the correct tables are used during calculations.

PCM Model Time Setting

PCM1 0.1 - 1.0 seconds

PCM5 0.5 - 5.0 seconds

PCM10 1.0 - 10.0 seconds

Microcontroller Timer . . . . . . . . . . . . With triac output

Input Signal Specifications:Type. . . . . . . . . . . . . . . . . . . . . . . Nonvoltage dry contact . . . . . . . . . . . . . . . . . . . . . . . . . . . reed switch meter signal

Reset Time . . . . . . . . . . . . . . . . . Immediate

Minimum Signal Duration. . . . . 10 milliseconds

Input Electrical Specifications:Voltage . . . . . . . . . . . . . . . . . . . . 120VAC 60Hz

No Load Current . . . . . . . . . . . . 0.45 mA AC maximum

Output Electrical:Maximum Device Load . . . . . . . 8 amps resistive at 120VAC

Turndown Ratio . . . . . . . . . . . . . . . . . 10:1

Housing . . . . . . . . . . . . . . . . . . . . . . . . ABS plastic

Shipping Weight . . . . . . . . . . . . . . . . 2 lbs

TECHNICAL SPECIFICATIONS

PCM MODEL CONVERSION

PCM/MP PUMP SIZING GUIDE

P1

P1

P1

INSTALLATION

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1. Position the PCM within 6 feet of the Stenner fixed outputmetering pump in a protected environment to prevent anypotential water intrusion.

2. Mount the PCM to a suitable surface using adequatefasteners through the mounting holes.

3. Verify the supply voltage to prevent damage to the unit.The use of a GFIC circuit is recommended.

4. Uncoil the input signal cable and remove approximately 2 inches of the outer cable jacket.

5. Strip the ends of the two wires within the cableapproximately one-half inch.

6. Attach the two wires to the contact output water meter or relay switch.

7. Adjust the knob to the desired on-time duration. Refer tothe Section “PCM/MP Pump Sizing Guide” for assistance.

8. Plug the fixed output chemical feed pump power cord intothe PCM’s receptacle.

9. Plug the PCM power cord into a properly installed,grounded, 120VAC receptacle.

The PCM is now set to deliver the desired amount of solution per gallon of water flowing through the meter. Once installed, thesystem may need to be fine-tuned by adjusting the on-time duration and solution concentration according to the application needs.Verify the final PCM settings through analytical testing of the water.

TROUBLESHOOTING

The typical cause of an apparent failure of the PCM is usually:

1. Lack of input supply voltage (120VAC)

Plug the fixed output chemical metering pump directly into the 120VAC receptacle into which the PCM was originallyplugged; this will bypass the PCM. If the pump does not run, the power source or pump is defective. If the metering pumpoperates, proceed to #2.

2. Lack of proper input signal

Plug the metering pump into the PCM and the PCM into the receptacle tested in #1. Remove the PCM input signal cablefrom the water meter or relay and touch the two wires together. The pump should run for the pre-determined on-time andthen stop.

If the metering pump runs, the failure is in the water meter contacts.If the metering pump does not run, the failure is in the PCM.Contact the factory for information on service and repair.

Point ofInjection

PCM PowerCord

Pump Control Module

MeteringPump Power Cord

DryContactWaterMeter

Tank SystemMetering PumpDischarge Line

Refer to themetering pumpmanual forinstallationinstructions.

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PCM/MP PUMP SIZING GUIDE

PCM Pump Control Module

MP Stenner fixed output metering pump

cpg contacts per gallon (ppg pulse per gallon)

ppm parts per million(mg/l milligramsper liter)

gpm gallons per minute

gpd gallons per day

gps gallons per second

spg seconds per gallon

• Maximum flow rate (of the water system) in gallons per minute (gpm)

• Required dose amount in parts per million (ppm)

• Solution strength in parts per million (ppm)

• Water meter contacts per gallon (cpg or ppg)

• Stenner fixed output metering pump

PRE-SIZING REQUIREMENTSGLOSSARY

STEP 1. AVAILABLE DOSE TIME

The available dose time is the minimum time interval (in seconds) between the water meter contact closures (or input signalsto the PCM) at the maximum system flow rate. (Note: The PCM on-time cannot be longer than the available dose time.)

The available dose time is calculated using two equations:

1a) Divide 60 seconds by the (maximum system flow rate in gpm) to convert into seconds per gallon.

60 seconds ÷ gpm = spg

1b) Divide the seconds per gallon by the water meter contacts per gallon to determine the minimum time interval in seconds between meter contact closures.

spg ÷ cpg = dose time in seconds

STEP 2. DOSE AMOUNT or FEED PUMP OUTPUT

NOTICE: Use a PCM and pump model combination that prevents the PCM time setting (Step 4, next page) frombeing greater than the available dose time (Step 1). The available dose time is the minimum time durationbetween water meter contacts (or input signals to the PCM). DO NOT adjust the PCM to a setting greater than theavailable dose time. Failure to maintain this relationship will result in chemical feed errors. The PCM is designedfor use with fixed output metering pumps. Adjustable pumps MUST be used at maximum output.

Calculate the dose amount (of chemical feed) in gallons per day, based on the maximum system flow rate in gallons per minute. In steps 3 and 4 (next page), you will use this value to determine which feed pump model and PCMcombination is best suited for the application.

Dose amount (pump output) is calculated using two equations. The first equation is the standard feed pump sizing formula:

2a) well pump output OR flow rate in gpm x required dose in ppm x 1440

solution strength in ppm

OR

gpm x ppm x 1440 ÷ solution strength (ppm) = dose amount (feed pump output) in gpd

2b) The pump model to use is based on the dose amount (calculated above) in gallons per day.Convert the gallons per day to gallons per second. (86,400 seconds = 24 hours).

gpd ÷ 86,400 = gpscontinued on page 6

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PCM/MP PUMP SIZING GUIDE

The PCM setting is the amount of time (in seconds) that the selected pump (step 3) will need to run to deliver the dose amount.

PCM setting is calculated using two equations:

4a) Divide the dose amount (step 2) by the MP pump output (step 3) to determine the PCM setting.

dose amount (gps) ÷ MP pump output (gps) = PCM setting (seconds)

The calculated feed pump run time in seconds (PCM setting) will determine the PCM model. The pump run time must fall within thePCM model’s time range.

STEP 4. ESTABLISH PCM SETTING/FINALIZE PCM MODEL REQUIRED

PCM Model Time Setting

PCM1 .1 - 1 seconds

PCM5 .5 - 5 seconds

PCM10 1 - 10 seconds

4b) The PCM has a 10:1 turndown ratio and to set the PCM knob, convert the PCM setting from seconds into a percentage. Divide the PCM setting (seconds) determined above by the PCM model maximum time range.

PCM setting (seconds) ÷ PCM model max. time range (seconds) = PCM setting (Convert the decimal to a percentage by moving the decimal two places to the right.)

STEP 3. FEED PUMP MODEL

Choose a pump model that closely matches the required dose amount in gallons per second (step 2, previous page).

Model No. gpd gph gpm gps ml/min ml/sec oz/min oz/sec

45mphp2 3 0.1250 0.002 .00004 7.884 0.1314 0.2665 0.0044

45mphp10 10 0.4167 0.007 .00012 26.28 0.4380 0.8880 0.0148

45mphp22 22 0.9167 0.015 .00026 57.82 0.9676 1.9540 0.0326

85mphp5 5 0.2083 0.0035 .00006 13.14 0.2190 0.4440 0.0074

85mphp17 17 0.7083 0.0118 .00020 44.68 0.7446 1.5100 0.0251

85mphp40 40 1.6666 0.0277 .00046 105.12 1.7520 3.5530 0.0592

NOTICE: These figures are approximate estimates and actual output may vary. These values are intended as a guide only. Final testing and field calibration is recommended.

APPROXIMATE OUTPUTS BY STENNER MODEL IN GPD/GPM/GPS/ML/OZ

NOTICE: FINAL PCM SETTINGS must be determined through analytical testing of the water. The procedure andformulas contained herein are intended solely as a guide to be used to assist in the proper application of Stenner’sPCM (Pump Control Module). G. H. Stenner & Co., Inc. makes no guarantee as to the accuracy of the informationcontained herein. User assumes all risk and liability from use of the information contained in this manual.

continued from page 5

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REFERENCE CHARTS/FORMULAS

COMMON CHEMICAL SOLUTION STRENGTHS

The most popular water meter andthe easiest for calculation purposesis the 1 contact (cpg) or 1 pulse pergallon (ppg) dry contact water meter.

Common Name Chemical Name Strength % Strength ppm

Bleach Sodium Hypochlorite NaOCl 5.25 52,500

Bleach Sodium Hypochlorite NaOCl 6.125 61,250

Bleach Sodium Hypochlorite NaOCl 12.5 125,000

Potassium Potassium Permanganate as 3 30,000

Permanganate KMnO4 dissolved 1/4 lb per Gal

Peroxide Hydrogen Peroxide 8 80,000

Polyphosphate Polyphosphate dissolved 1 lb per 10 Gals 1.2 12,000

• Gallons per day (gpd) to gallons per minute

gpd ÷ 1440 = gpm

• Gallons per day (gpd) to milliliters per minute

gpd x 2.628 = ml/min

• Gallons to milliliters

gals x 3785 = ml

CONVERSION FORMULAS

• Ounces to milliliters

oz x 29.57 = ml

• Milliliters to ounces

ml x .0338 = oz

• Solution Strength % to ppm

% x 10,000 = ppm

Meter Size Max Flow Rate (gpm) Meter cpg/ppg

3/4" 20 10

3/4" 20 5

3/4" 20 2.5

3/4" 20 1

1" 50 1

1" 50 2

1" 50 4

1" 50 5

1 1/2" 100 1

1 1/2" 100 2

1 1/2" 100 4

TYPICAL WATER METER CPG/PPG (Partial List)

3174 DeSalvo RoadJacksonville, Florida 32246sales@stenner.com

www.stenner.comPhone: 904-641-1666US Toll Free: 800-683-2378Fax: 904-642-1012

Hours of Operation (EST):Mon. – Thu. 7 AM – 5 PM Friday 7 AM – Noon

LIMITED WARRANTY AND SERVICE POLICYDamaged or Lost ShipmentsUPS and prepaid truck shipments: Check your order immediately upon arrival. Alldamage must be noted on the delivery receipt. Call Stenner Customer Service at800-683-2378 for all shortages and damages within seven (7) days of receipt.

ReturnsStenner offers a 30-day return policy. Except as otherwise provided, no material willbe accepted for return after 30 days from purchase. To return merchandise at anytime, call Stenner at 800-683-2378 for a Returned Goods Authorization (RGA)number. A 15% re-stocking fee will be applied. Include a copy of your invoice orpacking slip with your return.

Limited WarrantyG. H. Stenner & Co., Inc. will for a period of one (1) year from the date of purchase(proof of purchase required) repair or replace – at our option – all defective parts.G. H. Stenner & Co., Inc. is not responsible for any removal or installation costs. G. H. Stenner & Co., Inc. will incur shipping costs for warranty products shippedfrom our factory in Jacksonville, Florida. Any tampering with major components,chemical damage, faulty wiring, weather conditions, power surges, or productsnot used with reasonable care and maintained in accordance with the instructionswill void the warranty. G. H. Stenner & Co., Inc. limits its liability solely to the costof the original product. We make no other warranty expressed or implied.

DisclaimerThe information contained in this manual is not intended for specific applicationpurposes. G. H. Stenner & Co., Inc. reserves the right to make changes to prices,products and specifications at any time without prior notice.

PCMINST