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.
Table of Contents 1. INTRODUCTION................................................................................................................................ 1 1.1 Description .............................................................................................................................. 1 1.2 Standard Features .................................................................................................................. 1 2. SAFETY……………………………………………………………………………………………………….2 2.
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. PAY CLOSE ATTENTION TO ANY 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.
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.
2. SAFETY 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: 2.
3. EQUIPMENT INSPECTION Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported immediately to the carrier and your Pulsafeeder representative. 3.1 Storage Instructions The ECA can be successfully stored for extended periods. The key to this success is control of temperature and humidity. 3.1.1 Short Term (0 - 12 months)... The ECA should be stored in a temperature and humidity controlled environment.
4. INSTALLATION 4.1 Location Review the Safety section prior to installing the ECA. It contains important information required to properly install and operate the ECA in industrial environments. The site selected for the installation of your ECA is largely dependent on that of the PULSAR metering pump. Please review the PULSAR Installation Operation Maintenance Instruction Manual (current version) provided with your PULSAR metering pump.
4.3 Housing Access All wiring and programming of the ECA must be accomplished through the removal of the housing cover. Use this procedure for removal and replacement: THIS PROCEDURE REQUIRES REMOVAL OF THE ENCLOSURE COVER. THIS SHOULD BE DONE ONLY IF THE AREA IS KNOWN TO BE NON-HAZARDOUS. Cover Removal 1. Disconnect power at the source. 2. Loosen and remove the 13 Allen screws holding the cover in place (5mm Allen wrench). 3. Grasp both ends of the cover and lift straight up. 4.
3. Verify that the mating surface of the lower half of the ECA is clean. 4. Verify the guide pins are in place in the lower half of the ECA housing. Figure 2 5. Position the housing cover over the lower half and set in place. Do not force the cover as difficulty in assembly indicates mis-alignment. 6. Insert and hand-tighten the 13 Allen screws at first. Figure 3 7. Check the cover joint using a 0.0015in (0.038mm) feeler gage. Clearance should be less than 0.0015in (0.
4.4 Electrical Wiring While the ECA wiring requirements are very simple, always keep in mind that access to these connectors requires the removal of the cover, and as such this procedure should only be performed if the area is known to be non-hazardous. As part of the electrical wiring, a Ferrite core must be used in-line with your connections to meet EMC emission and immunity standards. Figure 4 Connections to be made: 1. AC voltage supply.
4.5 AC Supply THESE PROCEDURES REQUIRES REMOVAL OF THE ENCLOSURE COVER. THIS SHOULD BE DONE ONLY IF THE AREA IS KNOWN TO BE NON-HAZARDOUS. Connect the proper AC voltage supply to power the ECA at connector J7. Neutral, Earth, and Line connection points are indicated on the circuit board. For controllers rated at 220VAC, the two line conductors are wired to the line and neutral inputs.
4.6 Control Input and Output Connections 4.6.1 Motor Status Input The contactor or motor starter controlling the PULSAR motor should be equipped with a normally open auxiliary contact, which closes to indicate the PULSAR motor is on. This auxiliary contact, which must be an un-powered, dry contact only, is to be wired to inputs (J4-5 and J4-6) at the ECA, after removing the factory installed jumper wire.
Figure 7 4.7 System Calibration 4.7.1 Analog Input Signal Calibration The analog input signal should be calibrated to each system. To perform a calibration, the signalgenerating device (e.g., PLC) must be powered up, wired to the ECA and capable of altering its output from the minimum to the maximum signal. Note that the minimum span, or difference between low and high values, is 2.0 mA. The ECA will not actuate to change stroke length during this process.
4.7.3 Analog Output Signal Calibration THIS PROCEDURE REQUIRES REMOVAL OF THE ENCLOSURE COVER. THIS SHOULD BE DONE ONLY IF THE AREA IS KNOWN TO BE NON-HAZARDOUS. To calibrate the analog output, you need to attach an ammeter to the output circuit, or have the ECA wired to the PLC or other device. It is recommended that you calibrate to the actual remote equipment and set the analog output values at whatever is required by that equipment.
4.8 Mechanical Zero Calibration THIS PROCEDURE REQUIRES REMOVAL OF THE ENCLOSURE COVER. THIS SHOULD BE DONE ONLY IF THE AREA IS KNOWN TO BE NON-HAZARDOUS. If the ECA was shipped with a pump attached, the mechanical zero calibration was performed at the factory. Typically this setting will not change during the shipping procedure, but performing a mechanical zero calibration will assure accurate operation of your controller.
5. DIAGNOSTICS 5.1 Trouble Code Reporting The ECA is designed to be as fault tolerant and self-recovering as possible. However, should certain conditions occur which make proper operation impossible, it is important to be able to diagnose the cause of the problem. When the ECA encounters an abnormal condition, a trouble code is indicated using the CAL LED’s as follows: 1. Both LED’s will blink once. 2. The Cal Input LED will blink some number of times to signal the first trouble code digit. 3.
5.3 Self Test Mode The ECA has a diagnostic test mode which can be used to verify performance and troubleshoot problems. To initiate the self-test: 1. Remove power from the ECA, and remove the top cover. 2. Disconnect any field wires attached to J4, and connect Analog Out to Analog In. (jumper J4-1 to J4-3 and J4-2 to J4-4). Figure 11 3. Press and hold the WHITE button. 4. Apply power to the ECA. The ECA will enter the self-test mode and perform the following tests: 1.
6. Specifications Input Power Stroke Length Control Stroke Adjustment response 115 Volt/ 60Hz, 115 Volt/ 50Hz, 220 Volt/ 60 Hz, or 220 Volt/ 50Hz 0 – 100% control range Resolution – 0.0625% increments Approximately 1% per second Analog Input Operating Range Input Impedance Minimum Span Isolation Conditioning 0 to 25.5mA (4-20 mA factory default) 160 ohms 2.0 mA 500V from all other inputs, outputs and ground, optically isolated 8 second running average.
7. Power-Up Options Summary Upon application of input power, the ECA will perform certain functions if the pushbuttons are used, as follows: Pushbuttons pressed at power-up Function Reference Section NONE Normal operation, use all calibration data from memory BLACK key Forces a mechanical zero position calibration 4.8 WHITE key Initiates self-test (with jumpers as per Section 5.3) 5.
Bulletin #: IOM-ECA-0800-Rev G (for s/n 611000-x and higher)
