Regal ECS401 Training manual

REGAL Series ECS400 single and dual cylinder electronic scales
are designed for use in multiple water treatment applications
to monitor the chemical weight of Chlorine, Sulfur Dioxide and
Ammonia supplied in 150 lb. cylinders. The scales are an
essential part of all REGAL Gas Feed Systems, providing the
user with instantaneous Gross and Net weight readings. The
two models available are the ECS401 for single cylinder
applications and the ECS402 for dual cylinders.
REGAL™ ELECTRONIC CYLINDER SCALES
odels ECS401 Single Cylinder Scales
and ECS402 Dual Cylinder Scales
INTRODUCTION
1. All software including design, appearance, algorithms, and source
codes are copyrighted and owned by Chlorinators Incorporated.
2. The entire contents of this manual UST be read and under-
stood prior to installing and operating this equipment.
3. DO NOT discard this instruction manual upon completion of the
installa tion as this manual contains information essential to the
safe handling, operation, and maintenance of this equipment.
4. Additional instruction manuals are available at nominal cost from
Chlorinators Incorporated.
5. Plastic pipe or tubing connector fittings may be broken or
damaged if tightened excessively. HAND TIGHTEN ONLY.
6. or optimum operation, the installation should be indoors so that
the minimum and maximum temperature limitations as listed in
the “TECHNICAL SPECI ICATIONS” section of this manual are
not exceeded.
I PORTANT NOTES
WARNINGS
INSTRUCTION BULLETIN ECS 401/402
1044 SE Dixie Cutoff Road, Stuart, lorida 34994 USA
Phone: [phone] ax: [phone]
www.regalchlorinators.com Email: [email protected]
1. This equipment is suitable for use only with the gases specified.
DO NOT USE THIS EQUIP ENT WITH OTHER GASES. Such
use can result in failures having hazardous consequences.
2. This equipment is designed OR VACUUM SERVICE ONLY.
3. To insure proper and safe operation of this equipment, use only
REGAL parts. The use of non-REGAL parts can result in equip-
ment failures having hazardous consequences and voids the
REGAL warranty and insurance coverage.
4. Maintenance should be performed by competent personnel
familiar with this type of equipment, such as Chlorinators
Incorporated themselves.
5. It is essential that all external wiring be done exactly as shown
on the wiring diagrams depicted in this manual. Incorrect wiring
or improper grounding of this equipment WILL cause improper
operation and presents a safety hazard.
6. ield wiring UST conform to national and local electrical codes.
7. DISCONNECT POWER BEFORE removing the cover or
servicing this equipment.
8. ALWAYS make sure that the cover is in place and securely
fastened to prevent the entry of moisture, water, or corrosive
gases and also to eliminate the potential for electric shock.
9. Any equipment powered by AC line voltage presents a potential
shock hazard. Installation and servicing of this equipment
should only be attempted by qualified electronics technicians.
10. This non-metallic enclosure DOES NOT automatically provide
grounding between the conduit connections. Grounding UST
be provided as part of the installation.
11. Damage to the circuit boards or internal components incurred
by drilling the enclosure for field wiring or connecting power
lines to low voltage signal terminals voids the warranty.
12. Changing parameter settings and selections WILL affect the
operation of this equipment. If unsure, consult Chlorinators
Incorporated BEFORE changing parameters or selections.

2
CHLORINATORS INCORPORATED ONE (1)
YEAR LIMITED WARRANTY
Chlor nators Incorporated (here nafter called “C.I.”) sets forth
the follow ng warrant es w th respect to ts REGAL Model ECS
Electron c Cyl nder Scales. Th s war ranty does not apply to the
purchase of spare parts or other serv ces performed by C.I. or ts
author zed dealers. Th s represents the ent re agreement between
C.I. and Buyer (also referred to as “end-user”) and shall apply
unless mod f ed n wr t ng and s gned by a C.I. Off cer, and th s
warranty and ts ntended terms shall supersede any pr or negot -
at ons, correspondence, understand ngs, or agreements, wr tten or
oral. The Buyer agrees to and accepts all terms of th s warranty
by ts contract ng for or acceptance of C.I.’s prod ucts, and forms
or other documents or statements ssued by Buyer or any other
person shall not mod fy or otherw se affect any of the follow ng
terms. Buyer should be aware that reseller must rely ent rely
upon Chlo r nators Incorporated’s warrant es, or assume the r
own respons b l ty.
Th following stat s C.I.’s ntir warranty and
r pr s nts Buy r’s xclu siv r m dy with r sp ct
to its product. Such warranti s ar xpr ssly
giv n in li u of any oth r warranty, xpr ss d or
impli d, including but not limit d to thos of
m rchantability and fitn ss for a particular
purpos . This xpr ss d warranty or any oth r
warranty impli d by law shall not cov r d f cts
du to accid nt, improp r us , or non-complianc
with C.I.’s op rating and main t nanc , ass mbly,
installation manual and instructions.
Recommendat ons and adv ce as to spec f cat ons, capab l t es,
des gn, n stallat on, eng neer ng, appl cat on, and use of products
are prov ded as an accommodat on and are ntended only as
suggest ons. C.I. assumes no l a b l ty for such recommendat ons
and adv ce and they are not to be con strued as const tut ng any
warranty, expressed or mpl ed.
TERMS OF WARRANTY
C.I. warrants ts REGAL Model ECS Scales for a per od of one
(1) year from date of sh pment from C.I. Date of sh pment from
the factory shall be determ ned solely on the bas s of the ser al
code st cker ns de the mon tor enclosure. The ser al number
conta ns a date code. All ser al numbers are also reg stered by
Chlor nators Incorporated as to date of sh pment, model number
and b ll ng name. If the ser al number s m ss ng, defaced,
changed, or n any way ren dered un readable, Chlor nators
Incorporated shall, at ts opt on, have the r ght to declare the
warranty vo d. If the ser al number does not match the reg s tered
model number as to, but not l m ted to, such tems as max mum
chlor ne feed rate, the same opt on shall be appl cable.
The warranty shall apply aga nst mater al defects n components
and work mansh p occurr ng n the course of manufacture.
Buyer’s sole remedy for breach of sa d warranty shall be, at
C.I.’s opt on, e ther repa r or replace ment of any un t wh ch s
rece ved by C.I. at ts plant n Stuart, Flor da (sh pp ng charges
prepa d by buyer), w th n the t me per od set forth above and
wh ch s found by C.I. to be defect ve by reason of manufacture.
Not withstanding th for going, C.I. shall not b
liabl to Buy r for damag s, including p rsonal
injury or d ath to any p rson or p rsons, or claims
of any kind by a third party or prop rty damag ,
loss of busin ss or profits. In no v nt shall C.I.
b liabl to Buy r for cons qu ntial or accid n-
tal damag s of any kind, v n if C.I. was awar
of th possibility of such damag s. Th r ar no
r m di s xc pt thos s t forth. Furth r, that
th r ar no oth r authoriz d warranty r pair
faciliti s oth r than thos at th Chlorinators
Incorporat d factory in Stuart, Florida.
EXCLUSIONS
The following are considered external environmental factors beyond the
control of C.I., and which may cause damage and/or need for service which
will be specifically excluded from this warranty (i.e., not a material defect in
components and workmanship occurring in the course of manufacture).
1. Damage by extraneous causes such as fire, water, lightning, chemical
or galvanic attack, etc.
2. Damage to the circuit boards or internal components incurred by
drilling the enclosure for field wiring.
3. Damage due to the connection of power lines to low voltage signal
terminals.
4. Physical damage due to force, dropping, misuse or other abuse.
5. Use other than that as described in this Instruction Manual
(misapplication).
6. Repair by someone other than Chlorinators Incorporated.
7. Improperly installed.
8. This warranty DOES NOT cover wear items subject to periodic
replacement such as o-rings, gaskets, seals and packing.
The exclusions listed above are provided for purposes of clarification,
and are not intended to, in any way, limit or eliminate other possible
exclu sions.
NO OTHER WARRANTIES
Unless otherwise explicitly agreed in writing, and signed by a C.I. officer,
it is understood that this is the only written warranty given by C.I. for the
systems and components stated.
Th d al rs or r pr s ntativ s of C.I. may not mak
v rbal r pr s ntations that add, modify or chang
th writt n warranti s contain d h r in or chang
th xt nt and natur of C.I.’s liability. In no
v nt shall C.I. b liabl for dir ct, cons qu ntial,
sp cial, incid ntal or punitiv damag s of any
kind with r sp ct to th product, including but
not limit d to thos which may all g dly aris out
of br ach of warran ty, br ach of contract, n glig nc ,
strict liability, or any oth r law, gov rnm ntal
r gulation, or court d cision, xc pt as
provid d h r in.

The REGAL Single Cylinder (ECS401) and Dual Cylinder
(ECS402) Electronic Scales come equipped with the following
standard features:
• Easy to read LCD digital display(s).
• LED indicators for low and empty weight conditions.
• Auto Zero feature with back-up pushbutton.
• 4-20 milliamp analog output circuits for data recording
and SCADA interface.
• Stainless steel electronic strain gage load cells.
• Low profile base(s) for easy changing of cylinders.
• Solid PVC platforms and stainless steel hardware.
• Cylinder Stop(s) for proper positioning of cylinders.
• Accommodates Chlorine, Sulfur Dioxide and Ammonia
cylinders.
• Wall mount brackets with cylinder restraining chains.
• Low weight alarm relay circuits.
• Displays "Gross" or "Net" cylinder weight with the
push of a button.
GENERAL INFORMATION
Capacity: 300 lbs./base
Cylinder Size: 14" Dia. Max.
Overload Capacity: 150%
Temperature Rating: 32° to 122°
Resolution: 0.2 lbs.
Accuracy: ±1% ull Scale
Pushbuttons: 3 or 4 tactile-dome
Updates/second: our
Display
Indicators: LED (three per channel)
Digital Display: LCD
Auto Zero Maintenance: ±4 Graduations
Load Cell Excitation: 5 VDC
Power: 115V/230V AC
Power Consumption: 10 Watts
Milliamp Output: 4-20mA (500 Ohms)
use: 1/4 Amp (115V), 1/8 Amp (230V)
Low Level Alarm Relays (5 Amp or Better)
orm: C (N/O & N/C)
unction: Low Weight Alarm
SPECIFICATIONS
3

4
A) SCALE PLATFOR (S)
The Scale Platform(s) should be installed near a wall in a clean and
dry area. A hard, smooth and LEVEL floor surface is necessary to
ensure accuracy and help prevent damage.
1) After inspection, position each base 1 to 3 inches from
the wall. See Drawing No. 1C. DO NOT allow the base to
touch the wall.
2) Before anchoring the angle brackets to the floor, make
sure they rotate freely around the bolts that attach them
to the platform. If necessary, loosen the bolts SLIGHTLY
to allow for easy rotation. This will allow the platform to
properly hinge and provide even distribution of weight to
the load cell. The hinge also allows the platform to be
lifted for easy access to the floor surface when cleaning.
3) After anchoring the angle ("L") brackets to the floor,
mount the cylinder restraining wall bracket at a height of
38 to 40 inches above the floor. See Drawing No. 1A.
B) ONITOR
The monitor enclosure is designed to mount on an inside wall, at
eye level, to allow easy access while ensuring that temperature
limitations (32° to 122° ) are not exceeded.
1) With the AC power* off (unplugged), remove the front
cover from the monitor enclosure by loosening the four
corner screws. Carefully lift the cover and unplug the
ribbon cable from inside the main enclosure.
2) Mount the main enclosure to the wall with the proper
length pan head screws (#12 minimum) inserted into the
four corner openings that are visible once the cover is
removed. See Drawing No. 3C.
NOTE: When determining the screw length, figure an additional
1 1/8" to compensate for the amount recessed into the enclosure.
3) Using Drawing No. 3B as a guide, route the cable from
each scale base into the monitor enclosure through the
cable grip fittings. Connect the five cable leads to
Terminal Block 10 (TB10) of the CPU/Display Circuit
Board(s) as follows:
a) Black and Yellow leads to -E
b) Red lead to -S
c) White lead to +S
d) Green lead to +E
NOTE: On a dual cylinder scale, there is a left and a right
display board. Viewing the monitor with the cover in place,
make sure the leads from the left platform are connected to
the left display board and likewise for the right side. Also, be
sure to tighten the cable grip fittings once a sufficient amount
of wire is fed into the enclosure to make connections.
*I PORTANT: If the AC power is to be directly wired, an
experienced, licensed technician is required. Also, it is
essential to install external power conditioning equipment
(surge suppressors, filters) to protect electronic circuitry,
regardless of the power source.
4) If the 4-20mA output circuit(s) is to be used, connect the
leads (supplied by others) to Terminal Block 2 (TB2) of
the Power Supply Circuit Board. See Drawing No. 3C.
5) If the Low Weight Alarm Relays (K1 and K2) are to be
used, see Drawing No. 3C for proper connections to
Terminal Block 1 (TB1) of the Power Supply Circuit Board.
6) After all wiring is completed, re-connect the ribbon cable
to the Power Supply Circuit Board, replace the front
cover and proceed to Calibration.
1) With NO WEIGHT on the scale platform(s), plug in the
power cord OR switch the AC power on if the unit is wired
directly. The monitor(s) will most likely display a weight
reading other than zero. Simply press the GROSS/NET
(ZERO) keypad button to change the reading to zero.
NOTE: Based on how it applies, the GROSS/NET (ZERO) key-
pad button will be referred to as either GROSS/NET or ZERO.
NOTE: On a Dual Cylinder Scale ( odel ECS402), each platform
requires separate calibration. Press the TOGGLE button a
few times and take note of the alternating Green LED which
indicates which platform is activated. Press ZERO and the
active indicator will respond. TOGGLE over to the second
platform and press ZERO again. Both platforms (one at a
time) are now ready for calibration.
2) Place a ULL cylinder on the platform making sure it is
centered and pressed firmly against the stop(s). Place the
restraining chain around the cylinder and attach it to the
wall bracket to help prevent the cylinder from being tipped
over.
3) Mount the vacuum regulator to the cylinder valve using a
new lead gasket. With the cylinder wrench in place,
calculate the GROSS weight of the cylinder as follows:
Cylinder Tare Weight + Chemical (Net) Weight (150 lbs.)
+ 4.5 lbs. (Vacuum Regulator) + 0.8 lbs (Cylinder Wrench)
= GROSS WEIGHT
CALIBRATION
INSTALLATION

5
4) Allow time for the chemical to stop moving around in the
cylinder until you have a constant reading. Press and HOLD
the GROSS/NET keypad button for ~10 seconds until CAL
(calibrate) appears on the display. Release the button and
a numerical display with a blinking triangle will appear. The
number shown represents the GROSS weight and the blinking
triangle designates that you have entered the calibration mode.
5) Use the Up and DOWN (arrow) buttons to change the
displayed value to match the calculated GROSS WEIGHT.
6) Once the correct Gross Weight value is set, EXIT the
Calibration mode by Pressing and HOLDING the GROSS/NET
keypad button for ~10 seconds. After exiting, the Gross
weight will remain displayed with no blinking triangle.
7) Now Press and Release the GROSS/NET keypad button
to display the NET weight. A triangle (non-blinking) will
appear just left of the numerical display to confirm that
the Net Weight is being shown. Use the UP and DOWN
(arrow) buttons to adjust the displayed value to read
150 lbs. When changing the NET weight, it is necessary
to Press and Hold ONE of the arrow keys for ~5 seconds
before the monitor responds. Once activated, the keys will
respond accordingly. The delay is incorporated to help prevent
inadvertent changes from being made while the system is
in operation.
8) After the NET value is set, wait ~5 seconds and the
displayed value will flash as it "locks in". The scale is now
ready for operation.
NOTE: On a Dual Cylinder Scale, remember to switch (toggle)
to the second platform and proceed to complete the
calibration process.
When calibrating the scales for weight measures in kilograms (kg)
versus pounds (lbs.), simply enter the equivalent numerical value
for the Gross and Net weights when performing steps 3 through
7. or example, the Net weight for a standard 150 lb. cylinder
would be entered as 68 (kg). Entering these values simply sets
the range that will measure within, therefore, the true weight value
is automatically understood.
The analog output, representing the Net weight, will also need to
be changed from 150 (lbs.) to 68 (kg). The Low weight (10 lbs.)
and Cylinder Empty (2 lbs.) alarm settings should be changed as
well. Approximate values are sufficient. or example, 5 (kg) for
Low weight and 1 (kg) for Empty. To make all of these changes,
refer to steps 1, 3 and 4 under SWITCH SETTINGS on page 5.
1) To ensure accuracy, the scale should be calibrated each
time a cylinder is replaced. Once calibrated, simply press
the GROSS/NET keypad button to alternately display the
weight readings.
2) On a Dual Cylinder Scale, be sure to activate (toggle) each
platform separately to check the weight readings.
The main DIP switch (S1) with twelve settings is located on the
back side of the Display Circuit Board(s). See Drawing No. 3B. or
most applications, none of these settings need to be changed from
the factory settings. More specifically, Switches No. 1, 2, 5, 8, 9, 10,
11 and 12 should NEVER be changed. Switches No. 3, 4, 6 and 7
are explained below and should be changed only if necessary.
NOTE: The AC power supply must remain on when making
the following changes. Therefore, an experienced, licensed
technician is required.
1) Switch No. 3 is used to change the ull Scale of the 4-20
milliamp output. This applies when cylinders with a Net
Weight LESS than the factory set standard (150 lb.) are
going to be used on a regular basis. To change this
setting, turn switch No. 3 ON (closed). Then use the UP
and DOWN arrow buttons to adjust to the new (lower)
weight setting. Once the proper setting is displayed, turn
switch No. 3 O (open) to lock in the value.
I PORTANT: When the Full Scale is changed, remember to
use the New Net Weight when performing Calibration Steps
No. 3 and 7.
2) Switch No. 4 is used to calibrate the 4-20 milliamp output
circuits for remote indication, data recording and SCADA
interface. Simply turn Switch No. 4 ON (closed) and use
the ZERO button to alternately display the 4 & 20 milliamp
points. Use a milliamp meter to check the readings for the
Channel(s)* located on the Power Supply Circuit Board
(See Drawing No. 3C). To make any necessary changes,
use potentiometers VR1 (span) and VR2 (zero) for
Channel #1. Use VR3 (span) and VR4 (zero) for Channel
#2. When the points are properly set, turn Switch No. 4
O (open) to lock in the new settings.
* On a Single Cylinder Scale (ECS401), only Channel #1 is
active.
3) Switch No. 6 is used if it is necessary to change the point
at which the Cylinder Empty LED (and Alarm Relay)
will turn on. The factory setting is 2.00 lbs. To change
this setting, turn Switch No. 6 ON (closed) and adjust
the value using the UP and DOWN arrow buttons. Once
the preferred setting is displayed, turn Switch No. 6 O
(open) to lock in the new value.
4) Switch No. 7 is used if it is necessary to change the point
at which the Low Weight LED (and Alarm Relay) will turn
on. The factory setting is 10.00 lbs. To change this setting,
turn Switch No. 7 ON (closed) and adjust the value using
the UP and DOWN arrow buttons. Once the preferred
setting is displayed, turn Switch No. 7 O (open) to
lock in the new value.
OPERATION
SWITCH SETTINGS
Only Needed for Custom Applications

6
DRAWING NO. 1
A) REGAL odel ECS401
Single Cylinder Electronic Scale
B) REGAL odel ECS402
Dual Cylinder Electronic Scale
C) Scale Base Installation
TOP VIEW SIDE VIEW
DI ENSIONS = INCHES ( ILLI ETERS)
REGAL SERIES 400 SCALE BASE
REGAL SERIES 400
SCALE BASE
CYLINDER STOP
"L" BRACKET
2.00 (50.8) ROM WALL
13.50 (342.9)
13.00
(330.2)
38 (965.2) -
40 (1016.0)
16.00
(406.4)
2.00
(50.8)
ROM
WALL
REGAL
A-816
SWITCHOVER
GAS
REGULATOR
HEAD
AC POWER SOURCE
4-20 mA OUTPUT(S)
AND/OR ALARM RELAYS
AC POWER SOURCE
4-20 mA OUTPUT(S)
AND/OR
ALARM RELAYS SA ETY
CHAIN
WALL
BRACKET
REGAL A-820
GAS REGULATOR
HEAD
SA ETY CHAIN
WALL BRACKET

7
DRAWING NO. 2 - ODEL ECS4011 AND ECS402 ONITORS
A) Single Cylinder ( odel ECS401) Electronic Scale onitor
B) Dual Cylinder ( odel ECS402) Electronic Scale onitor
3.63 (92.202)
5.20 (132.08)
7.06 (179.324)
7.87 (199.898)
4.25 (107.95)
4.75 (120.65)
7.06
(179.324)
7.87
(199.898)
5.80
(147.32)
6.30
(160.02)
DI ENSIONS = INCHES ( ILLI ETERS)
ELECTRONIC SCALE
ELECTRONIC SCALE

Copyright 2013 Chlorinators Incorporated Printed in U.S.A.
Pub. No. 0813-1
1044 SE Dixie Cutoff Road, Stuart, lorida 34994 USA
Phone: [phone] • ax: [phone] • www.regalchlorinators.com • Email: [email protected]
DRAWING NO. 3 - CIRCUIT BOARDS FOR ECS SERIES ELECTRONIC CYLINDER SCALES
A) Front Side of Display Board B) Back Side of Display Board
C) Power Supply Circuit Board in ECS-402 (Dual Cylinder) Enclosure
KEYPAD
RIBBON
CONNECTOR
RIBBON CABLE CONNECTOR
SCREW HOLES OR
MOUNTING TO WALL
MAIN ENCLOSURE
4-20 mA OUTPUTS
OPTIONAL
LOW WEIGHT
ALARM RELAYS
IMPORTANT
On a Dual Cylinder Scale
(ECS-402), switch No. 5 is
factory set in the ON position
for one display board and in
the O position for the
second board. DO NOT
change this setting.
RIBBON
CABLE
CONNECTOR
or the scale
base(s)
wiring guide,
see page 4,
step B3
under
Installation.
TB10
S1
J1