Pulsafeeder ABC 50 Manual

ANALOG BOILER
CONTROLLER
MODEL ABC 50
INSTALLATION
OPERATION
MAINTENANCE
INSTRUCTION
®
$5.00 USA $6.25 CANADA
©1997 Pulsafeeder
72-500-06

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ABC™ FACTORY SERVICE POLICY
Your ABC™ controller is a state of the art electronic based unit with on-board diag-
nostics. If you are experiencing a problem with your ABC™ controller, first consult
the troubleshooting guide in your operation and maintenance manual. If the prob-
lem is not covered or cannot be solved, please contact our Technical Services
Department for further assistance. Trained technicians are available to diagnose
your problem and arrange a solution. Solutions may include purchase of replace-
ment parts or returning unit to the factory for inspection and repair. All returns
require a Return Authorization number to be issued by Pulsafeeder. Parts purchased
to correct a warranty issue may be credited after an examination of original parts by
Pulsafeeder. Warranty parts returned as defective which test good will be sent back
freight collect. No credit will be issued on any replacement electronic parts.
Any modifications or out-of-warranty repairs will be subject to bench fees and costs
associated with replacement parts.
ABC™ WARRANTY
Pulsafeeder, Inc. warrants ABC™ control systems of its manufacture to be free of
defects in material or workmanship. Liability under this policy extends for 24
months from date of shipment. The manufacturer's liability is limited to repair or
replacement of any failed equipment or part which is proven defective in material or
workmanship upon manufacturer's examination. This warranty does not include
removal or installation costs and in no event shall the manufacturer's liability
exceed the selling price of such equipment or part. The manufacturer disclaims all
liability for damage to its products through improper installation, maintenance, use,
or attempts to operate such products beyond their functional capacity, intentionally
or otherwise, or any unauthorized repair. The manufacturer is not responsible for
consequential or other damages, injuries, or expense incurred through the use of its
products.
The above warranty is in lieu of any other warranty, whether expressed or implied.
The manufacturer makes no warranty of fitness or merchantability. No agent of
ours is authorized to provide any warranty other than the above.

CONTENTS
1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . 3
2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. ELECTRODE REMOVAL, CLEANING AND REINSTALLATION . . . . . 11
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 12
6. TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . 13
7. ASSEMBLY DIAGRAMS AND PARTS LISTS. . . . . . . . . . . . 14
8. ABC SERIES LINE UP AND OPTIONS . . . . . . . . . . . . . . 16
1. INTRODUCTION
The Pulsafeeder ABC Controllers are used to control total dissolved solids
(TDS) in steam boiler systems, in terms of electrical conductivity measured in
microsiemens per cm (µS/cm). They are designed using the latest technology
with plug-in circuit boards.
The units are very accurate and easy to use. This simplified design provides
automated control at an economic cost.
The ABC Series comes standard with connections for AC power and blow
down activation.
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ANALOG BOILER CONTROLLER
MODEL ABC 50
®

A. LOCATION:
The ABC Series Controllers are designed for ease of installation. Select a
mounting location convenient to electrical and plumbing connections and easily
accessible by the operator for cleaning and maintenance.
The enclosure is corrosion resistant and will stand up to most industrial envi-
ronments. Be sure unit is free from vapors and liquid spills (Refer to Fig. 1,
Typical Installation Diagram). Installation should comply with all national,
state and local codes.
2. INSTALLATION
Fig. 1, Typical Installation Diagram
ABC
ABC
4

B. MOUNTING:
Mount Controller vertically on a wall or a permanent
vertical support with adequate lighting and at a comfort-
able level (Refer to Fig. 2, Controller Dimensions).
C. ACCESSORIES:
(Available through your Pulsafeeder distributor or sales
representative, but not included as standard)
Boiler Conductivity Timed Sample:
1. Blowdown valve, solenoid and strainer or motor oper-
ated ball valve.
2. Needle valve or orifice union and plates for throttling
blowdown.
3. A full-port gate valve for isolation of blowdown
assembly.
4. A flush valve for sensor.
Boiler Conductivity Continuous Sample:
1. Blow down valve, solenoid and strainer or motor
operated ball valve.
2. Two needle valves or two orifice unions and plates for throttling blowdown.
3. A full-port gate valve for isolation of blowdown assembly.
4. A flush valve for sensor.
D. PLUMBING:
A flow rate of at least 1-3 gpm (gallons per minute)
at the electrode is required for proper operation.
Install hand valves on both sides of electrode for easy removal and periodic
maintenance.
Direction of flow should be in line with the arrow on probe assembly. Take
time to review Fig. 1, Typical Installation Diagram, and note locations of hand
valves, etc. for proper operation and maintenance of all components in the sys-
tem loop. The throttling valve must be adjusted so that water flows across the
probe, not steam.
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Fig. 2, Controller Dimensions

E. ELECTRICAL:
The ABC controller has been designed to physically separate the high voltage
connections from low voltage connections. Use only 16 or 18 AWG wire for
conduit power and load connections.
1) High Voltage Connections:
Units must be wired by the customer, refer to Fig. 3 (also see Fig. 10) for
wiring the high voltage connections. The connector JP16 is for the AC input
voltage, JP4 and JP5 are relay driven AC outputs, they change simultaneous-
ly and have a maximum output of 5 amps.
The ABC 50 has two fuses for protection, a 1 amp fuse for the controller
power supply, and a 5 amp fuse for the relay output. Part numbers can be
found in the Trouble Shooting section.
Use the following table when connecting to JP4, JP5, and JP16:
CIRCUIT DESIGNATOR CONNECTION TYPE
BLK or NO/NC Line
WHT Return
GRN Ground
NOTE: Always use caution when making any electrical connection. Follow
all applicable electrical codes. The power supply should be disconnected
at the main before making any (high or low voltage) connections.
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Fig. 3, High Voltage Wiring Diagram

2) Low Voltage Connection:
Please refer to Fig. 4, Low Voltage Connections (located on the front of the
control panel). Generally, low voltage wires are color coded to the designa-
tors printed on the front overlay. Make these connections after making the
high voltage connections and re-
assembling the panel to the front
of the unit.
The insulation on the low voltage
wires is stripped back approxi-
mately .25 inches at the factory.
To attach, push in and hold the
orange tab above the socket while
inserting the stripped lead.
Release the orange tab and pull
gently on the wire to seat it in the
connector and to insure a good
connection.
NOTE: Be careful not to push
the wire too far into the socket
such that the insulation is clamped by the connector.
CIRCUIT DESIGNATOR CONNECTION TYPE PROBE WIRE COLOR
RED Probe + Red
BLK Probe - Black
CLR Probe Temp. Comp. Clear, Green, or White
SHD Probe Wire Shield Silver (no Insulation)
NOTE: Do not connect the ground wire to the Shield (SHD) input. It is for
the shield of the probe cable only.
NOTE: The ABC 50 does not support temperature compensation. A tempera-
ture compensated probe may be used, but will yield non-temperature com-
pensated results.
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Fig. 4, Low Voltage Wiring Diagram
The figure at right illustrates
how an actuated (motorized)
ball valve, which is used for
“blow down”, is connected to
the ABC 50.
It employs a normally open
(NO), a normally closed (NC),
and common (or neutral) con-
nections. In this example, the
first device is connected at JP5.
Location is behind control
panel (see Figure 3).

3. OPERATION
A. CONTROLS:
Refer to Fig. 5, Front Panel Diagram
and familiarize yourself with the con-
trols of your ABC unit.
Control LED: Used for electrode calibra-
tion and to indicate conductivity trip
point has been reached. (Indicates blow
down solenoid relay is active).
Power LED: Indicates unit is plugged in
and power is present on the circuit
board.
Cal: Calibration adjustment knob used to
calibrate unit conductivity.
Test Switch: Activates solenoid relay to confirm proper operation of externally
connected electrical devices (eg. blow down valve).
In Timed Sample Mode, the test switch initiates the blow down cycle.
Trip Point Knob/Scale: Also referred to as “set” or “control” point. Use the Trip
Point knob to set desired “trip” point to activate bleed and feed. This knob and
scale is also used during calibration.
B. CALIBRATION
The ABC 50 controller will require calibration periodically due to changes in
temperature, and the electrodes becoming dirty. Use the test switch to force a
system blow down if necessary for gathering a sample of system water.
NOTE: For best results, calibrate the ABC 50 at a conductivity as near to the
trip point as possible.
1) Make sure unit is mounted properly and all
plumbing and electrical connections are secure
before applying power to the unit.
2) Take a sample of the boiler water and mea-
sure the conductivity with a calibrated hand held
meter (Fig. 6). Take the sample at low pressure.
If your hand held meter is not temperature com-
pensated allow the sample to cool before mea-
suring the conductivity.
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Fig. 6, Water sample reading
Fig. 5, Front Panel Diagram (cover in place)

3) Set the trip point knob to the conductivity measured by the hand held meter
(Fig. 7).
4) Turn the cal knob fully counter clockwise and momentarily activate the test
switch (Fig. 8). If the unit is in continuous mode you will need to wait 10 sec-
onds before slowly turning the cal knob clockwise. If the unit is in the timed
sample mode you will need to wait for the blow down interval to pass, 30 sec.,
1, 2, or 4 minutes before slowly turning the cal knob clockwise. When the con-
trol led turns off stop turning the cal knob, the unit is calibrated.
C. SETTING CONDUCTIVITY TRIP POINT
1) Turn Trip Point Knob to position
pointer on scale to desired trip point.
(See Fig. 9)
NOTE: All standard ABC units have a
differential control that has been
factory set to approximately 6% of
the Trip Point. This important fea-
ture prevents “chattering” (the rapid
on-off switching of the relay when
system conductivity hovers near the
trip point).
The minimum blow down interval in
Continuous Sample Mode is eight
seconds to allow for full movement of
a ball valve.
Fig. 9 Set Trip Point
Fig. 7 Position Trip Point Knob
Fig. 8 Turn Cal Adjust Knob
9

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D. JUMPER SELECTIONS
The ABC controller can be operated in either timed or continuous mode, the
ABC controller has jumpers for selection of the operating mode and the time
intervals (Fig. 10).
CONTINUOUS MODE
For Continuous Mode operation, a jumper should be installed in position JP7.
JP6 should be empty.
NOTE: The minimum blow down interval in Continuous Sample Mode is eight
seconds to allow for full movement of a ball valve.
TIMED SAMPLE MODE
For Timed Mode operation, a jumper should be installed in JP6. JP7 should be empty.
The sample intervals available are 24 hours, 8 hours, 2 hours, and 30 minutes.
A jumper in JP8 selects 24 hours, JP9 selects 8 hours, JP10 selects 2 hours, and
JP11 selects 30 minutes. Jumper only one of the positions JP8 through JP11.
In the Timed Mode, there is a choice of 30 sec., 1, 2, or 4 minute blow down
intervals. A jumper in JP15 selects 30 seconds, JP14 selects 1 minute, JP13
selects 2 minutes, and JP12 selects 4 minutes. Jumper only one of the positions
JP12 through JP15.
NOTE: In the timed mode, the blow down interval will be at least the time
selected. If conductivity is still above the selected trip point (after selected
interval time has expired), blow down will continue until conductivity drops
below the selected trip point.
Fig. 10,
Jumper connection
locations.
Jumper connection
JP6 through JP15
Jumper connection
JP1, 2, 3, 17, and 18
High Voltage connections