MCI Pumps and Pump Packages are CSA certified for use in Class 1/ Division 2 environments. Optionally we can provide Class 1/ Division 1 Pumps.

Our solar array includes two Sharp 123W (17.21V, 7.14A) CSA certified Class 1, Division 2 solar panels. It is wired in series to produce the 24V dc voltage required by our Stepper Motor. For summertime applications the MCI power system is extremely over powered. However the measure of these Pump packages is winter performance. We have designed our system to operate without interruption on the coldest days with the least Peak Sunlight Hours, 1.5 hours per day. The Winter Solstice (December 21st) may not be the coldest day of the year but it is the day with the least sunlight.

We use four Power-Sonic 100AH absorbed glass mat (AGM) batteries. The batteries are wired in a series/ parallel configuration to develop the 24V dc required by the Stepper Motor.

Yes, as an option. There are two optional low voltage cut-outs available. One is built into the charging regulator/ controller. The other is a separate module that is wired directly into the charging circuit. “Excessive discharge reduces battery life and can cause batteries to freeze and crack at low temperatures.” (ECO-ENERGY)

We use the industry standard Texsteam style fluid end. We selected this style for its proven service, reliability, maintenance ease and seal variety. Every operator, maintenance provider and service technician is completely familiar with this design. However we DO NOT USE CONVENTIONAL PACKING. We have developed a patented plunger seal technology we call N-Seal. Designed to eliminate packing and the associated plunger friction N-Seal secondary containment technology reintroduces any high pressure seal chemical bypass to the suction side of the fluid end. Our pumps include a standard carbon steel fluid end with the option of stainless steel.

During regular visual inspections production or maintenance staff can isolate the sight glass from the storage tank and watch the liquid level during the injection stroke. If the liquid rises in the site glass the seal kit should be replaced. Alternatively the seal kit replacement can be included in the regular maintenance schedule.

MCI pumps have four seal groups:

• i) Fluid end seals are Fluorosilicone.
• ii) Static seals on the high and low pressure glands are Teflon.
• iii) Static secondary containment seals are Buna.
• iv) Dynamic seals for the plunger are UHMW Polyethylene.

NOTE: Seal material options exist for items i), ii) and iii) above including Kalrez and Viton.

We have tested a number of options but selected Tungsten Carbide for its combination of material compatibility and cost effectiveness.

We use 316L Stainless Steel for all high pressure wetted parts. The atmospheric pressure containment system is hard anodized 6061 Aluminum.

Maximum injection pressures and rate are dependent on plunger diameter:

Yes the controller has Reverse Polarity Check. If the positive and negative wires are switched the controller will not energize. Simply swap the power wires and the controller will start up without any damage to the system.

No, MCI does not offer a dual headed pump. MCI pumps are designed to provide both volume accuracy and volume reliability (repeatability). Not only can you set our injection volume at very low rates (0.12 L/ day) but you can be assured of that flow rate no matter how the line pressure varies. When one motor drives two fluid ends with independently variable injection volumes some kind of highly accurate independent flow control mechanism is required. Without this control there is a high likelihood that the pump will over inject chemical resulting in much higher than normal operating cost. 1L of inhibitor at $5/L results in the waste of $1,825.00 per year.

The pump has two main operating modes:

• i) Cold Start - designed to assist in extreme cold temperature motor starting. The motor controller automatically runs through the Cold Start subroutine each time the motor is started. This function consumes 800mA, operates for 10 minutes and is automatically transitioned to normal operation. During Cold Start the plunger stroke length, normally 1 inch, is shortened. Once Cold Start ends the “strokes per minute” setting selected prior to cycling the power will be resumed.

  NOTE: DURING COLD START THE POWER BUTTON IS DISABLED. TO EXIT COLD START AND REACTIVATE THE POWER BUTTON SIMPLY PRESS EITHER ARROW BUTTON.

• ii) Normal Operation – the maximum power consumption is 600mA on the injection stroke at maximum speed (15 SPM) and 300mA on the suction stroke. As the stroke rate decreases the power consumption is reduced. Maximum average power consumption is 450mA at 15 SPM (600mA + 300mA / 2).

  NOTE: THE SUCTION STROKE RATE REMAINS CONSTANT OVER THE ENTIRE RANGE OF THE INJECTION STROKE RATE.

Battery life and the associated pump runtimes, without recharging the batteries, are complete dependent on the battery charge going prior to the “blackout” and the ambient temperature. We estimate the following runtime with zero recharging during the blackout period:

Yes. The MCI pump requires 24V DC and less the 1 Amp. A Thermal Electric Generator (TEG) can be used to power the MCI pump. If you have a TEG with 120V AC power on sight you can use a rectifier (example: SOLA SCP 100S24X-DVN) to produce 24V dc.

Yes. MCI offers an option analogue input. Using this module an analogue output, by other, can remotely control the pump - “on,” “off” and scaled over the full Strokes Per Minute range (0 – 15 SPM), with infinite steps.

No. MCI consciously chose to not include analogue or discrete feedback. Any output from the pump controller would tell an automated system that the pump is running. However this does not guarantee that the chemical is flowing to the pipeline due to chemical line damage, fluid end leaks or other unforeseen mechanical events. For this reason we recommend an inline flow switch or meter positioned at the injection point.

MCI pumps operate continuously. As the plunger stroke rate is varied manually by the operator or remotely by the analogue input the variable speed controller alters the motor RPM accordingly and, in turn, changes the plunger injection speed. The suction stroke rate remains constant, approximately 3 seconds. As a result at lower stroke rates the MCI pump injection duty cycle is nearly constant (95% @ 1L / day, 90% @ 2L / day).

Not as a standard part of any package. However we do offer Through-wall Battery Enclosures as an option. These enclosures are flange mounted with a 12” x 20” through-wall cutout required. Heat is transferred through the non-insulated, sealed steel wall of the battery enclosure. The insulated portion of the enclosure, sitting outside the building, is 24”h x 20”w x 17”d.

MCI pumps employ a Variable Speed Controlled DC Stepper Motor. These motors give MCI pumps unique qualities that set them apart from other pumps in the market. There are two reasons for the ratcheting sound:

• i) Power Interruption: DC stepper motors are used in both “closed” and “open” loop configurations. Where precise control is paramount the dc stepper motor controller receives “feedback” from a device like a digital encoder. This closed loop condition gives positional information to the controller at all times. Optionally, in “task” oriented applications like displacement pumping, were the injection plunger travels over a known range, the need for precise feedback can be omitted in the interest of cost reduction - open loop. However if power is cycled to the dc stepper motor it can lose its place and needs to “zero” or “position locate” itself. This function is accomplished automatically but it does require the motor to travel to its fully retracted position and then confirm that it is in the retracted position, the ratcheting or chattering you hear, before it automatically resumes its pumping duty.
• ii) Power Reduction: In this case the dc stepper motor requires 24V DC to operate effectively. If this voltage drops the controller will attempt to continue operating the motor because the electronic controller functions in voltage ranges well below the effective operating voltage of the motor. However there will not be sufficient power to run the motor. The ratcheting sound is the result of the stepper motor trying unsuccessfully to rotate.

  NOTE: IF THE RATCHETING SOUND OCCURS FROM THE INITIAL COMMISSIONING OF THE PUMP PLEASE CHECK THE BATTERY SYSTEM TO ENSURE IT IS PRODUCING 24V DC. IF THE RATCHETING PERSISTS DECOMMISSION THE DRIVE AND CONTACT THE FACTORY.

Winter brings many challenges for maintenance and operations personnel as they work to keep the product flowing. Solar Power systems are pushed to their maximum. In an effort to maintain a healthy knowledge of the products we implement I am forwarding the following information from the Kyocera website - http://www.kyocerasolar.com/solar/modules.html.

MCI uses Sharp solar panels with a 36 cell configuration. While they may not be Kyocera panels we are confident that the technology is similar enough to add merit to this information.

Solar Electric Modules - Shading:
PV modules are very sensitive to shading. Unlike a solar thermal panel which can tolerate some shading, many brands of PV modules cannot even be shaded by the branch of a leafless tree.

Shading obstructions can be defined as soft or hard sources. If a tree branch, roof vent, chimney or other item is shading from a distance, the shadow is diffuse or dispersed. These soft sources significantly reduce the amount of light reaching the cell(s) of a module. Hard sources are defined as those that stop light from reaching the cell(s), such as a blanket, tree branch, bird dropping, or the like, sitting directly on top of the glass. If even one full cell is hard shaded the voltage of that module will drop to half of its un-shaded value in order to protect itself. If enough cells are hard shaded, the module will not convert any energy and will, in fact, become a tiny drain of energy on the entire system.

Partial-shading even one cell of a 36-cell module, such as the KC120, will reduce its power output. Because all cells are connected in a series string, the weakest cell will bring the others down to its reduced power level. Therefore, whether ½ of one cell is shaded, or ½ a row of cells is shaded as shown above, the power decrease will be the same and proportional to the percentage of area shaded, in this case 50%.

When a full cell is shaded, it can act as a consumer of energy produced by the remainder of the cells, and trigger the module to protect itself .The module will route the power around that series string. If even one full cell in a series string is shaded, as seen on the right, it will likely cause the module to reduce its power level to ½ of its full available value. If a row of cells at the bottom of a module is fully shaded the power output may drop to zero. The best way to avoid a drop in output power is to avoid shading whenever possible.