Pulsafeeder ECA NEMA4X User Manual

PULSAR® ECA

ELECTRONIC CONTROL ASSEMBLY

Installation, Operation &

IOM-CTL-2001-Rev E

Maintenance Instructio n

NEMA Type 4X

ECA FACTORY SERVICE POLICY

Your ECA is a state of the art microprocessor-based stroke length control device for use with PULSAR® Diaphragm Metering Pumps. If you are experiencing a problem with your ECA, consult the

trouble-shooting guide. If the problem is not covered or cannot be solved, please contact your local PULSA Series Sales Organization or our Technical Service Department at (585) 292-8000 for further assistance.

Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include purchasing a replacement unit or returning the ECA to the factory for inspection and repair.

All returns require a Return Material Authorization (R.M.A.) number to be issued by Pulsafeeder. Parts purchased to correct a warranty issue may be credited after examination of the original parts by Pulsafeeder personnel. Parts returned for warranty considerations which are good will be sent back freight collect.

Any field modifications will void the warranty. Out-of-warranty repairs will be subject to Pulsafeeder's standard bench fees and testing costs associated with replacement components.

FCC Warning

This equipment generates and uses radio frequency energy. If not installed and used properly, in strict accordance with the manufacturer’s instructions, it may cause interference to radio communications. Operation of this equipment in a residential area is likely to cause interference in which case the user, at his own expense, will be required to take whatever measures necessary to correct the interference.

reproduced, stored in a retrieval system or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser’s personal use without the written permission of Pulsafeeder.

Table of Contents

1. INTRODUCTION ................................................................................................................................ 1

2. FOREWORD ...................................................................................................................................... 1

2.1 Description ............................................................................................................................... 1

2.2 ECA Standard Features .......................................................................................................... 1

3. SAFETY CONSIDERATIONS ............................................................................................................ 2

3.1 General Safety ......................................................................................................................... 2

3.2 Electrical Safety ....................................................................................................................... 3

3.3 Fire Safety ................................................................................................................................ 3

3.4 Hydraulic Safety ...................................................................................................................... 3

3.5 Liability Exclusion ................................................................................................................... 3

4. TRANSPORT AND STORAGE ................................................................................................................... 5

4.1 Consignment receipt and unpackagin g ................................................................................ 5

4.2 Handling ................................................................................................................................... 5

4.3 Lifting ........................................................................................................................................ 5

4.4 Recycling and end of product life .......................................................................................... 5

5. STORAGE INSTRUCTIONS ...................................................................................................................... 6

5.1 Short Term (0 - 12 months) ..................................................................................................... 6

5.2 Long Term (12 months or more) ............................................................................................ 7

6. INSTALLATION AND WIRING ................................................................................................................... 8

6.1 Location .................................................................................................................................... 8

6.2 Installation Notes ..................................................................................................................... 8

6.3 Installation guidelines for EMC compli ance ......................................................................... 8

6.4 Housing Access ....................................................................................................................... 9

6.5 Electrical Wiring ...................................................................................................................... 11

6.6 Power Wiring Information ....................................................................................................... 11

6.7 Labeling – Nameplate .............................................................................................................. 15

6.8 Control Input and Output Connections ................................................................................. 15

6.8.1 Motor Status Input ........................................................................................................... 15

6.8.2 Analog Input (current loop) ............................................................................................ 15

6.8.3 Analog Output (current loop) ......................................................................................... 16

7. START UP AND OPERATION ................................................................................................................... 17

7.1 Overview ................................................................................................................................... 17

8. INPUT/OUTPUT SETUP ........................................................................................................................... 17

8.1 System User Calibration ......................................................................................................... 17

8.1.1 Analog Input Signal Calibration ..................................................................................... 17

8.1.2 Analog Input Signal Loss................................................................................................ 18

8.1.3 Analog Output Signal Calibration .................................................................................. 18

9. MECHANICAL ZERO CALIBRATION ......................................................................................................... 19

9.1 Factory Re-initialization .......................................................................................................... 20

10. DIAGNOSTICS ................................................................................................................................... 20

10.1 Trouble Code Reporting ......................................................................................................... 20

10.2 Trouble Codes ......................................................................................................................... 22

10.3 Self-Test Mode ......................................................................................................................... 23

10.4 Error Recovery ......................................................................................................................... 24

11. SPECIFICATIONS ................................................................................................................................... 25

12. POWER-UP OPTIONS SUMMARY ............................................................................................................ 26

13. FIELD WIRING SUMMARY ....................................................................................................................... 27

14. TROUBLESHOOTING GUIDE ................................................................................................................... 1

15. MAINTENANCE & SPARE PARTS ............................................................................................................ 2

15.1 Operating Precautions ............................................................................................................ 2

15.2 Cleaning and Decontamination .............................................................................................. 2

15.3 User Replaceable Parts for the ECA ...................................................................................... 3

A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE

Tips have been included within this bulletin to help the operator run the

Conventions

For the remainder of this bulletin, the following conventions are in effect.

EQUIPMENT AND THE PERSONNEL OPERATING IT. THIS MANUAL MUST BE CONSULTED IN ALL CASES WHERE THE NATURE OF THE POTENTIAL HAZARDS AND ANY ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM

WARNING SYMBOL IS MARKED IN ORDER TO FIND OUT THE

CAUTION,

Notes are general information meant to make operating the equipment easier.

equipment in the most efficient manner possible. These “Tips” are drawn from the knowledge and experience of our staff engineers, and input from the field.

Revision History:

Rev E (07-24-2014)

− Updated to reflect requirements of UL 61010-1 3

POSSIBILITY OF ELECTRIC SHOCK

Edition

iii

1. INTRODUCTION

The ECA is a microprocessor based stroke length control device for use with the PULSAR diaphragm-metering pump. It has been designed to operate in a variety of industrial environments. This document describes the ECA controller only. The operation and maintenance of the PULSAR metering pump is covered in the pump IOM. Please refer to this IOM for important safety and operational instructions for your PULSAR pump.

2. FOREWORD

The pumps to which these “instructions” refer to are designed for use in industrial areas and therefore cannot be treated as retail products. The present documentation gives instructions to be used by qualified personnel only. It must be used in compliance with the regulations, laws and technical standards in force and cannot, under any circumstances, take the place of plant standard or additional regulations, including any which are not legally enforceable, which have been issued with the scope of ensuring safety.

Equipment with special manufacturing or constructive variances may differ in details with respect to this description.

In case of any difficulty, please contact PULSAFEEDER, INC. Technical Service.

The ECA is rated for NEMA 4 locations as identified on the controller nameplate.

2.1 Description

The ECA is an electromechanical servo controller dedicated to the PULSAR diaphragm metering pump series. The unit is physically attached and integrated into the pump's design. The controller allows for precise adjustment of output flow of a process media by means of stroke length positioning.

The ECA is designed for the international industrial market. The analog control signals offer flexible remote control. They are fully isolated - from each other as well as earth ground - for improved protection and reliability.

The ECA is designed to simplify and automate the calibration of the analog signals. Analog signal calibratio n is ac c omp lis h ed by simple push button entry. Calibration functions must be completed while the internal circuitry of the unit is accessible, and therefore at a time when the surrounding environment is considered safe for electronic work.

2.2 ECA Standard Features

• Electronic Stroke Length Control

• NEMA Type 4x enclosure

• 4-20mA input and output

• EEPROM storage of calibration data

• Diagnostics and Self-Test mode

The ECA is available for 115 or 230 VAC operation, at either 50 or 60 Hz. Each ECA controller must be operated on the appropriate AC supply as per the nameplate ratings.

SAFETY CONSIDERATIONS

The ECA is a sophisticated microprocessor based controller for use only with PULSAR diaphragm metering pumps. It yields tremendous control capacity -- electrical, mechanical and (in conjunction with the PULSAR pump) hydraulic in nature. In consideration of SAFETY, the user should be mindful of this relative to his/her safety, that of co-workers and of the process environment. Please consider the following prior to the installation and operation of an ECA controlled PULSAR metering pump:

• Read and understand all related instructions and documentation before attempting to install or maintain this equipment

• Observe all special instructions, notes, and cautions.

• Act with care and exercise good common sense and judgment during all installation,

adjustment, and maintenance procedures.

• Ensure that all safety rules, work procedures, and standards that are applicable to your company and facility are followed during the installation, maintenance, and operation of this equipment.

3.1 General Safety

The ECA was designed as a stroke length position actuator for operation solely with the PULSAR metering pump. Use for any other application is considered un-safe and voids all

certification markings and warranties.

3.2 Electrical Safety

The ECA can be considered an industrial process controller. Improper application and use can be hazardous. You are solely responsible for its use.

The ECA’s electr ical installation must conform to all local, state and national relevant electrical codes. Installation and electrical maintenance must be performed by a qualified electrician. Before installing or servicing this device, all power must be disconnected from the source at the main distribution panel.

The ECA emits electro-magnetic energy and may generate radio frequency interference. Its use is restricted to industrial applications. You are responsible for shielding this energy/interference.

Certain wiring procedures may require that the user wear a wrist strap to dissipate static charges.

NSTALLATION AND ELECTRICAL MAINTENANCE MUST BE P E RFORMED BY A QUALIFIED ELECTRICIAN.

Before installing or servicing this device, all power must be disconnected from the source at the main distribution panel. Certain calibration functions must be completed while the electronic section of the unit is exposed and power is applied to the unit, be certain to ensure that proper procedures are followed and that fingers, tools, and wiring do not contact exposed circuitry and components.

The ECA emits electromagnetic energy and generates radio frequency interference. It s use is restricted to industrial applications. The user bears all responsibility for shielding this energy/interference.

3.3 Fire Safety

In case of electrical fire, use a Class C fire extinguisher. Never use water to extinguish a Class C fire.

Class C fires involve electrical equipment, such as appliances, wiring, circuit breakers and outlets. Never use water to extinguish class C fires - the risk of electrical shock is far too great! Class C extinguishers do not have a numerical rating. The C classification means the extinguishing agent is non-conductive. Geometric symbol (blue circle)

3.4 Hydraulic Safety

Thoroughly review and adhere to the contents of the PULSAR Installation, Operation, Maintenance Instruction manual (current version) for hydraulic installation of your PULSAR metering pump.

3.5 Liability Exclusion

Pulsafeeder, Inc. is unable to monitor the observance of the instructions given in this manual, nor verify the actual working conditions and installation of the equipment, the correct operation and maintenance of the equipment and accessories. An incorrect installation, or misuse of the equipment, may cause serious damage and may pose a danger to persons or property. Any anomalies must be reported to the maintenance supervisor. The user is not authorized to tamper with the machine for any reason.

Attempts to disassemble, modify or tamper in general by unauthorized personnel will void the guarantee and will release Pulsafeeder, Inc. from any liability for damage caused to persons or property resulting from such actions.

Pulsafeeder, Inc. is considered released from any liability in the following cases:

- improper installation;

- improper use of the equipment by non-professional or inadequately trained

operators;

- use not in compliance with regulations in the Country of use;

- lack of maintenance or improperly performed;

- use of non-original spare parts or incorrect parts for the model in

question;

- total or partial failure to observe the instructions;

- exceptional environmental events.

DO NOT PERFORM ANY WORK ON THE PUMP, MOTOR OR ECA CONTROL UNIT WITH ELECTRICAL POWER CONNECTED TO THE ECA CONTROL UNIT. DO NOT OPERATE ECA UNIT WITH THE COVER REMOVED. D ANGER OF ELECTRONIC SHOCK AND MECHANICAL PINCH HAZARD!

INSTALLATION AND REPAIRS SHOULD ONLY BE PERFORMED BY AUTHORIZED PERSONNEL!

- FOLLOW ALL SAFETY/ LOCAL LOCK-OUT, TAG-OUT PROCEEDURES!

4. TRANSPORT AND STORAGE

4.1 Consignment receipt and unpackaging

Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation.

Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment.

Each product has a unique serial number. Check that this number corresponds with that advised and always quotes this number in correspondence as well as when ordering spare parts or further accessories.

Shortages or damage should be reported immediately to the carrier and your Pulsafeeder Representative.

4.2 Handling

Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction.

4.3 Lifting

A crane must be used for all controller/pump sets in excess of 25 kg (55 lb). Fully trained personnel must carry out lifting, in accordance with local regulations.

Slings, ropes and other lifting gear should be positioned where they cannot slip and where a balanced lift is obtained.

4.4 Recycling and end of product life

At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and local requirements. If the product contains substances that are harmful to the environment, these should be removed and disposed of in accordance with current regulations. This also includes the liquids and/or gases that may be used in the "seal system" or other utilities.

Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current regulations at all times.

STORAGE INSTRUCTIONS

The ECA can be successfully st ored for extended periods. The key to this success is control of temperature and humidity.

5.1 Short Term (0 - 12 months)

The ECA should be stored in a temperature and humidity controlled environment. It is preferable to keep the temperature constant in the range of -18 to 40° Celsius (0 to 104° Fahrenheit). The relative humidity should be 0 to 90% non-condensing.

If the ECA is installed on the pump, it should not be removed during this period - provided the above conditions can be applied to the pump as well.

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