Pulsafeeder ECA NEMA7 User Manual

Installation Operation Maintenance Instruction

Bulletin #: IOM-ECA-0800-Rev G

(s/n 611000-x and higher)

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.

This document describes product features controlled by ATEX requirements. Those features, and this document, can not be changed without notification or approval of the appropriate agency.

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

1.1 Description .............................................................................................................................. 1

1.2 Standard Features .................................................................................................................. 1

2. SAFETY……………………………………………………………………………………………………….2

2.1 General Safety ......................................................................................................................... 2

2.2 Explosive Atmosphere Safety ............................................................................................... 2

2.3 Electrical Safety ...................................................................................................................... 2

2.4 Hydraulic Safety ...................................................................................................................... 2

3. EQUIPMENT INSPECTION ............................................................................................................... 3

3.1 Storage Instructions ............................................................................................................... 3

3.1.1 Short Term (0 - 12 months)............................................................................................. 3

3.1.2 Long Term (12 months or more)... ................................................................................. 3

4. INSTALLATION ................................................................................................................................. 4

4.1 Location ................................................................................................................................... 4

4.2 Installation Notes .................................................................................................................... 4

4.3 Housing Access ...................................................................................................................... 5

4.4 Electrical Wiring ...................................................................................................................... 7

4.5 AC Supply ................................................................................................................................ 8

4.6 Control Input and Output Connections ................................................................................ 9

4.6.1 Motor Status Input ........................................................................................................... 9

4.6.2 Analog Current Input ...................................................................................................... 9

4.6.3 Analog Current Output ................................................................................................... 9

4.7 System Calibration ................................................................................................................. 10

4.7.1 Analog Input Signal Calibration ..................................................................................... 10

4.7.2 Analog Input Signal Loss ............................................................................................... 10

4.7.3 Analog Output Signal Calibration .................................................................................. 11

4.8 Mechanical Zero Calibration .................................................................................................. 12

4.9 Factory Re-initialization ......................................................................................................... 12

5. DIAGNOSTICS .................................................................................................................................. 13

5.1 Trouble Code Reporting ......................................................................................................... 13

5.2 Trouble Codes ......................................................................................................................... 13

5.3 Self Test Mode ......................................................................................................................... 14

5.4 Error Recovery ........................................................................................................................ 14

6. SPECIFICATIONS ................................................................................................................................... 15

7. POWER-UP OPTIONS SUMMARY ........................................................................................................... 16

8. FIELD WIRING SUMMARY ...................................................................................................................... 16

Conventions

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

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

EQUIPMENT AND THE PERSONNEL OPERATING IT WARNING

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

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

. PAY CLOSE ATTENTION TO ANY

Rev E (4-20-06)

All sections updated to reflect new circuit board design and operation of new software

on ECA controllers with serial numbers 577000 and higher. Rev F (10-20-06) All sections and illustrations updated to reflect new wiring terminal blocks for power

and control for serial numbers 61100 and higher. Rev G (9-26-07) Added ATEX control statement, inside front cover

iii

1. INTRODUCTION

The ECA is a microprocessor based stroke length control device for use with the PULSAR diaphragmmetering 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.

1.1 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 calibration is accomplished 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 non-hazardous.

1.2 Standard Features

 NEMA 7 enclosure  4-20mA input and output  EEPROM storage of calibration data.  Diagnostics and Self-Test mode

The ECA is available for 120 or 240 VAC operation, at either 50 or 60 Hz. Each ECA controller must be operated on the appropriate AC supply as per the nameplate ratings.

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