Installation, Operation &

Maintenance Instruction

Stroke Length Controller

PULSAmatic®
Bulletin #: IOM-CTL-AE-2006 REV A CONTROLLER
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PULSA SERIES GUARANTEE
Should you experience a problem with your Pulsafeeder pump, first consult the
troubleshooting guide in your operation and maintenance manual. If the problem is not
covered or cannot be solved, please contact your local Pulsafeeder Sales Representative,
or our Technical Services Department for further assistance.
Trained technicians are available to diagnose your problem and arrange a solution.
Solutions may include purchase of replacement parts or returning the 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.
In addition, Pulsafeeder guarantees its PULSA Series drive assemblies for a period of two
years from the date of shipment. All other material and workmanship are fully covered for a
period of one year. Any parts found to be defective within the above time span will be
replaced free of charge, F.O.B. factory.
Equipment or accessories manufactured by others but purchased through Pulsafeeder, such
as electric motors, are guaranteed only to the extent of the original manufacturer.
Damages incurred from misuse, abuse, and/or improper protection during storage will be
cause to void the guarantee. Erosion, corrosion, or improper application of the equipment or
related piping by the buyer or any third party is also excluded from the guarantee.
The above guarantee is in lieu of any other guarantee, either expressed or implied. We
make no warranty of fitness or merchantability. No agent of ours is authorized to make any
warranty other than the above.

Safety Considerations:
1. Read and understand all related instructions and documentation before attempting to install
or maintain this equipment
2. Observe all special instructions, notes, and cautions.
3. Act with care and exercise good common sense and judgment during all installation,
adjustment, and maintenance procedures.
4. Ensure that all safety and work procedures and standards that are applicable to your
company and facility are followed during the installation, maintenance, and operation of this
equipment.

Information in this document is subject to change without notice. No part of this publication may be
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, Inc.

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 Table of Contents
1. INTRODUCTION ..................................................................................................................................... 1
1.1 General Description ................................................................................................................ 1
1.2 Options ..................................................................................................................................... 3
1.3 Input Signals ............................................................................................................................ 3
1.4 Control Modes ......................................................................................................................... 4
1.5 Current Output Signals ........................................................................................................... 4
2. EQUIPMENT INSPECTION ....................................................................................................................... 4
3. PROCEDURAL NOTES ............................................................................................................................ 4
4. INSTALLATION ................................................................................................................................. 5
4.1 Wiring Up .................................................................................................................................. 5
4.2 Start Up ..................................................................................................................................... 6
5. CALIBRATION ....................................................................................................................................... 6
5.1 Deadband Adjustment ............................................................................................................ 6
5.2 Circuit Board Calibration ........................................................................................................ 7
5.3 Meter Readout Calibration ...................................................................................................... 9
5.4 Auto-Manual Calibration ......................................................................................................... 9
6. REPAIRS............................................................................................................................................... 10
6.1 Limit Switch Adjustment......................................................................................................... 10
6.2 Potentiometer .......................................................................................................................... 10
6.3 Zero Alignment ........................................................................................................................ 11
6.4 Brake Air Gap ........................................................................................................................... 12
6.5 Jammed Slider Block .............................................................................................................. 13
7. ORDERING PARTS ................................................................................................................................. 13
8. CONVERSION (MANUAL TO PULSAMATIC) ............................................................................................ 13
9. TROUBLESHOOTING .............................................................................................................................. 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. 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. These
“Tips” are drawn from the knowledge and experience of our staff
engineers, and input from the field.

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1. Introduction
1.1 General Description
The PULSAmatic actuator converts reciprocating motion of the pump into rotary motion to
turn the pump’s stroke adjustment screw. By selectively engaging either of the two
oppositely oriented, one-way clutches, one of two corresponding nuts hat ordinarily rotate
freely on a “diamond” actuator shaft is blocked form rotation when the shaft moves
longitudinally in one direction. Thus locked, the nut compels the shaft to rotate, thereby
turning the adjustment screw to which it is connected.
The actuator assembly consists of the following major components: the actuator shaft (a
major portion of which is in the form of a diamond screw), tow brake housings, two one-
way clutches, and two helix nuts. Mounted side-by-side, the two brake housings are
concentric to the axis of the actuator shaft. The helix nuts are located between the inner
walls of the brake housings and the surface of the shaft. One nut engages the right-hand
thread of the shaft and other engages the left-hand thread. Each nut rotates within a one-
way clutch.
In operation, the actuator shaft reciprocates along its axis. When the brakes are de-
energized, each nut, along with its respective clutch, is free to rotate in alternation
clockwise and counterclockwise directions as it is driven by grooves in the shaft. Under
this condition, the shaft and adjustment screw do not rotate.
Upon energizing one of the brakes, the corresponding one-way clutch is utilized allowing
the nut to rotate only in one direction, while the shaft is moving longitudinally during the e
discharge stroke of the pump (linear motion of the shaft is now in the opposite direction),
the clutch prevents the nut from rotating, causing the shaft to rotate. This rotation is
transmitted by a mechanism inside the gearbox housing to the pump adjustment screw
so that the piston stroke length is changed. By energizing the other brake, the adjustment
screw is rotated in the opposite direction. To increase or decrease pump output, it is only
necessary to selectively energize either brake.

Rotary motion of the actuator shaft also rotates a sleeve which in turn drives a gear train
through a spur gear pressed on one end of the sleeve. The gear train transfers outputs
for a positional feedback potentiometer and limit switches. A bevel gear mounted on the
opposite side of the drive sleeve is meshed with a hand wheel bevel gear and mechanical
stroke position indicator.

A printed circuit board contains standard and optional control circuits. The incoming
command signal is compared with the internal feedback signal. If the two are equal or
nearly so, no action occurs. If the command signal is greater, one brake is energized,
resulting in a corresponding change in pump output (stroke length) and feedback signal.
If the feedback signal is greater than the command signal, the other brake is energized,
changing the pump output and feedback signal in the reverse direction. When the
feedback signal matches the command signal, stroke length is properly positioned and
adjustment is halted.

The override switch, operable from outside the actuator assembly, disconnects the
brakes from the circuit board to permit manual adjustment using the hand wheel. The
“out” position is for manual operation and the “in” position is for automatic operation.
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1.2 Options
The PULSAmatic actuator is configured at the factory for a variety of options, both singly
and in various combinations. The appropriate wiring diagrams external to the circuit board
are included with each pump shipment.

1.3 Input Signals

.
Standard signals are:
1-5 mA DC @ 2000 ohm Impedance
4-20 mA DC @ 470 ohm Impedance
10-50 mA DC @ 180 ohm Impedance
0-10 V DC @ Greater than 270,000 ohm Impedance

Slide wire (Remote, 1000-ohm manual control potentiometer, user-supplied).

Actions
Direct Acting- minimum and maximum input signal levels correspond directly to
minimum and maximum stroke settings respectively. For example, a 4-20 mA signal
ranges stroke from zero at 4mA to full at 20 mA. This is the standard mode of action.
Reverse Acting- Signal response is inverted relative to direct acting. For example, a 4-
20 mA signal ranges stroke from full at 4 mA to zero at 20 mA. This is an optional mode
of action.

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1.4 Control Modes
Ratio Control- When ratio control is applied, the range of stroke adjustment is
proportionally reduced to a level equal to the ratio setting. For example, at a ratio setting
of 60%, the full span of the input signal commands the pump to operate between zero
and 60% of full stroke rather than over the full range of the stroke. The ratio is manually
set between zero and 100% using a remote potentiometer.
Split Ranging- A single control signal command s two pumps, each pump responding
only to a portion of the total range of the signal. The PULSAmatic controller operates
specifically as follows: One pump is commanded from zero to full stroke over the lower
half of the input signal, and a second pump is commanded, in the reverse-acting mode,
from full to zero stroke over the higher half of the input signal. For example, a 4-20 mA
input signal controls the first pump between zero stroke at 4mA to full stroke at 12 mA
and controls the second pump between full stroke at 12 mA and zero stroke at 20 mA
Manual- Remote manual stroke adjustment potentiometer.
Auto-Manual- Remote switch selection between automatic and remote manual
operation.

1.5 Current Output Signals

0-10 mA DC – 500 ohm Impedance max.
4-20 mA DC – 250 ohm Impedance max.

2. Equipment Inspection
1. Check all equipment for completeness against the order and for shipping damage.
Shortages or damage should be reported immediately to your PULSA Series
representative.
2. Check pump and PULSAmatic stroke control identification tags for serial and model
numbers. There are two tags: one on the pump gearbox which includes the pump
model number and another on the PULSAmatic enclosure. The pump gearbox serial
number identifies the PULSAmatic actuator as well as any separately mounted control
stations. Each should correspond to the information on the parts lists. Use these
reference numbers whenever corresponding with the factory.
3. Check the envelope containing this bulletin for service parts list and special drawings
and wiring diagrams for specified control options.

3. Procedural Notes
Electrical repairs and calibrations should be undertaken only by an electronic technician
q2ualified in the maintenance and repair of linear (analog) industrial process control
equipment.
A digital voltmeter and a process control signal generator are required for electronic
calibrations.
Troubleshooting and repair may require access to the mechanism linking the actuator
control to the oscillating housing inside the pump gearbox. This requires removal and

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 replacement of the rear gearbox cover assembly. Refer to the pump operations manual
for the description of these operations.
Detailed circuit board schematics, containing component identifications, are available
from the factory to facilitate electronic circuit troubleshooting and repair at the board level.
The following conventions and procedures apply throughout this bulletin.
1. “Zero Stroke” refers to a zero, or (000) setting on the mechanical stroke counter.
“Full Stroke” refers to a full or (100) setting on the mechanical stroke counter.
2. A “low end” input control signal is one that commands the pump to zero stroke
A “high end” input control signal is one that commands the pump to full stroke.
Note that the signal values are inverted in the reverse acting option so that, for
example, a 4-20 mA signal commands full to zero stroke. In this case, 4 mA is the
high end signal. See “Options” under “principals of Operation” above for signal
definitions.
3. Pump stroke can be manually or automatically set as required for calibrations and
adjustments. References to the disable switch (“out” for manual, “in” for automatic)
may be omitted. Manual, or hand wheel adjustments made while the pump is not
operating, require that pressures be relieved from both the suction and discharge
lines.
4. Wiring terminals are indentified on the circuit board and referred to directly. For
example TB2-3 refers to terminal No. 3 on Terminal Board No. 2, (reference Figure
4).

CAUTION: When troubleshooting, always remove signal potential prior to

disconnecting AC power. This will help protect integrated circuits on the circuit
board.

4. INSTALLATION
4.1 Wiring Up
(Refer to any special wiring diagrams and installation drawings supplied by Pulsafeeder).
AC power lines should be routed to the actuator via a separate conduit from the control
signal and any optional accessory wiring. A separate switched and protected circuit is
recommended for the actuator power supply.
Remove the PULSAmatic actuator cover, which is secured by two screws, or screwed on,
in the case of an explosion proof enclosure. The two power transformers should be wired
as described by wiring diagrams. Power and ground wire should be No. 18 AWG wire
size or larger. A power ground screw is provided on the backing plate near the conduit
openings. Terminal TB1-4 is also provided as an optional circuit board ground. This
terminal is connected to the circuit board ground through a 4700 ohm resistor.
Run the signal and accessory wiring using the alternative conduit opening. No. 22 AWG
wire size or larger is recommended. Make all connections per the diagram that apply to
the combination of signal and accessories provided.
Explosion proof actuators are Underwriters Laboratories (UL) listed and are labeled with
the hazardous environments for which they are rated, along with any special installation
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 specifications required in support of UL listing. They must be installed, wired, operated,
and maintained in accordance with local electrical codes.
CAUTION: To help protect the integrated circuits in the servo amplifier, always
energize AC power prior to connecting the signal leads.

4.2 Start Up
Ever actuator is adjusted and calibrated at the factory. However, due to variations in input
signals RECALIBRATION IS REQUIRED. Prior to performing this procedure (as outlined
in the next section) it is recommended that the following steps be followed in order to
verify proper mechanical operation and limit switch adjustment.

Mechanical Operation- Before applying electrical power, remove the coupling guard
between pump and motor and manually rotate the motor shaft through several
revolutions. The thin metal brake armatures should rotate in alternate directions as the
actuator shaft moves first in one direction and then the other. (If they do not, the actuator
linkage may be disconnected from the oscillating housing under the main cover). Replace
the motor coupling guard.

Limit Switch Verification- with the counter indicating 090 or less, pull out the handwheel
and rotate to increase the count. As a value of 200 is approached (from 099 to 100) a
faint click should be heard from one of the limit switches. If an audible indication of the
limit switch operation cannot be obtained, operation may be verified electrically. Turn the
handwheel back to a counter indication of 090 and pull out the override switch. Continuity
should exist between the terminals of the limit switch mounted on a double switch
bracket, farthest from the printed circuit board. Pull out and slowly rotate the handwheel
so that the counter indication increases. The switch should open, indicated by loss of
continuity, when the stroke indicator reads between 097 and 100.

Operation of the second limit switch (the one closest to the circuit board) may be checked
in a similar manner. The limit switch should be open at a stroke indicator reading between
001 and 000.
If either of the limit switches appears to be out of adjustment refer to “repairs- Limit
Switch Adjustment”.
Barring any problems proceed with “Calibrations and Adjustments”.
Refer also to the “Equipment Startup” section of the pump Installation, Operation, and
Maintenance Instructions.

5. Calibration
As stated previously, field recalibration is required upon startup. The following procures
are to be performed in sequence as presented. Refer to Figure 4 as required for circuit
component locations.

5.1 Deadband Adjustment

With pump stroke positioned exactly as commanded by the input signal, a certain change
in signal must occur in either direction (increase or decrease) in order to cause the
actuator to respond.

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 For example, if a pump is operating at 50% stroke in response to a 50% input signal, the
signal must typically increase to 51% or decrease to 49% before the actuator does not
respond, or is “dead”, is called “deadband”. If deadband is too narrow, the actuator will
frequently make slight adjustments in response o small signal variations. In the extreme
case, the actuator will continually “hunt” back and forth over a small range of adjustment.
If deadband is too broad, response will lag and accuracy will suffer. The “Null”
potentiometer near the center of the circuit board adjusts deadband. Clockwise
movement decreases deadband, increasing sensitivity. Counterclockwise movement
increases deadband, decreasing sensitivity.
Deadband adjustment for response to a 1% change in signal (depicted in the example
above) is appropriate to most installations. This can be set approximately by setting the
“Null” potentiometer in the six o’clock position shown in Figure 4. To check deadband
adjustment, cycle the pump automatically, by input signal command, to an approximately
midrange stroke setting. Leaving the override switch in the “in” or automatic position,
slowly adjust the handwheel in either direction until the actuator responds to return the
stroke to the original set point. Care must be taken during this operation, as the
handwheel will move without warning. Deadband is observed on the mechanical stroke
indicator as the difference between the original stroke setting and that at which the
actuator responds.

5.2 Circuit Board Calibration

The PULSAmatic circuit senses all control signals in terms of voltage. A current signal is
converted to a voltage signal measured across a resistor, provided in the circuit board,
through which the current passes. For example, the most commons signal, 4-20 mA DC,
passes through a 470 ohm resistor to generate a 1.88-9.40 volt DC signal, (0-6.3 v with
Ratio Control).
This procedure trims the actuator circuits to the low and high ends of the actual input
control signal.

Without Ratio Control – Coarse Adjustment

1. Place the override switch in the “out” or manual position. The pump need not be
running for coarse adjustment.
2. Set up a voltmeter to read a full scale DC voltage of 10.
3. Connect the positive lead of the voltmeter to TB2-2 and the negative lead to TB2-1.
4. Set the control signal at the low end (0%) and record the voltage.
5. Set the control signal at the high end (100%) and record the voltage.
6. Set up a voltmeter for DC voltage measurement between TB2-5 (positive) and TB2-1
(common).
7. Adjust the “LO” trim potentiometer on the circuit board to the voltage recorded in step
4.
8. Set up the voltmeter for DC voltage measurement between TB2-4 (positive) and
TB201 (common).
9. Adjust the “HI” trim potentiometer on the circuit board to the voltage recorded in step
5.

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10. The above adjustments are interactive. It may be necessary to repeat steps (2)
through (5) several times until the voltages stabilize. This completes coarse
adjustment.

Without Ratio Control – Fine Adjustment

11. With the override switch still in the “out” or manual position start the pump.
12. Set up a voltmeter for DC voltage measurement between TB2-3 (positive) and TB2-1
(common).
13. Set the control signal at the low end (0%). Move the override switch to the “in” or auto
position. The LO” drive LED will light and the pump with automatically adjust to the
0% stroke.
14. Adjust the “LO” trim potentiometer on the circuit board to the voltage recorded in step
(4). The stroke indicator should now read 000-001 and both LED drive lights should
be off.
15. Apply a high end (100%) control signal. Allow the pump to adjust to 100% stroke.
16. With the voltmeter remaining as set up in step (12) above, adjust the “HI” trim
potentiometer to the voltage recorded in step (5). The stroke indicator should now
read 099-100 and again both drive lights should be off.
17. The above adjustments are interactive. It may be necessary to repeat steps (12)
through (16) several times until the voltages stabilize. This completes fine adjustment.

With Ratio Control (Optional Feature) – Coarse Adjustment

1. With the override switch in the “out” or manual position, start the pump.
2. Set the controls signal at the low end (0%). Move the override switch “in” to the auto
position and allow the pump to adjust to 0%.
3. Place the override switch back in the “out” or manual position. Check the stroke
indicator; if it does not read 000-001 use the handwheel to manually adjust it to this
point.
4. Set the remote ratio control potentiometer at 100%.
5. Set up the voltmeter for DC voltage measurement between TB3-4 (positive) and TB3-
6 (common).
6. Adjust the “Ratio Zero” potentiometer on the circuit board (to the right of TB3) to +/-
0.0 volts.
7. With the voltmeter remaining as set up in step (5) above, set the control signal at the
high end (100%) and record the voltage.
8. Set up a voltmeter for CD voltage measurement between TB2-5 (positive) and TB2-1
(common).
9. Adjust the “LO” trim potentiometer on the circuit board to +/-0.0 volts.
10. Set up a voltmeter for DC voltage measurement between TB2-4 (positive) and TB2-1
(common).
11. Adjust the “HI” trim potentiometer on the circuit board to the high end voltage
recorded in setup (7) above.

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 12. The above adjustments are interactive. It may be necessary to repeat steps (8)
through (12) several times until the voltages stabilize. This completes coarse
adjustment

With Ratio Control (Optional Feature) – Fine Adjustment

13. With the override switch still in the “out” or manual position start the pump.
14. Set up a voltmeter for DC voltage measurement between TB2-3 (positive) and TB2-1
(common).
15. Set the control signal at the low end (0%). Move the override switch to the “in” or auto
position. The “LO” drive LED will light and the pump will automatically adjust to 0%
stroke.
16. Adjust the “LO” trim potentiometer on the circuit board to the voltage recorded in step
(6). The stroke indicator should now read 000-001 and both LED drive lights should
be off.
17. Apply a high end (100%) control signal. Allow the pump to adjust to 100% stroke.
18. With the voltmeter remaining as set up in step (14) above, adjust the “HI” trim
potentiometer to the voltage recorded in step (7). The stroke indicator should now
read 099-100 and again both drive lights should be off.
19. The above adjustments are interactive. It may be necessary to repeat steps (12)
through (16) several times until the voltages stabilize. This completes fine adjustment.

5.3 Meter Readout Calibration

This procedure trims the current output to the calibrated range of pump capacity or
stroke. Because the output is based on position of the feedback potentiometer, an input
signal is not required for adjustment.
Depending on the options ordered an analog meter will have been supplied for signal
indication. If not, an amp meter will be required to measure the output, 0-10 mA standard,
4-20 mA optional.
1. With the pump set a zero stroke, adjust the “Meter Zero” potentiometer on the circuit
board (to the left of TB-3, as shown in Figure 4) for zero (0%) meter indication or 0%
current level as applicable. Note that with 4-20 mA output the “Meter Zero” and
“Range” potentiometers will be reversed.
2. Will the pump set at full stroke; adjust the “Range” potentiometer on the circuit board
for 100% meter indication or 100% current level as applicable.
3. The above adjustments are interactive. Repeat steps (1) through (2) several times
until the meter accurately indicates both zero and full stroke settings.

5.4 Auto-Manual Calibration

This procedure trims the manual control potentiometer to the low and high ends o the
actual input control signal.
The main circuit board must be calibrated prior to this procedure.
For current type control signals, a resistor is installed across terminals of the auto-manual
switch. If present, this resistor must remain in place.

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 This procedure can be performed with the pump on-line and operating, in the manual
(handwheel) control mode, with the override switch in the “out” position.
1. All voltages in this procedure are DC and are measured between TB2-2 (positive) and
TB2-1 (common).
2. Set the remote auto-manual selector switch to the “Auto” position.
3. Set the control signal to the low end and record voltage.
4. Set the control signal to the high end and record voltage.
5. Set the remote selector switch to the “manual” position.
6. Set the remote “percent stroke” control potentiometer at zero percent.
7. Adjust the “LO” trim potentiometer on the small circuit board mounted on the back of
the “percent stroke’ potentiometer for the low end voltage recorded in step (3) above.
Verify that both LEDS on the main circuit board are off.
8. Set “percent stroke” potentiometer at 100%.
9. Adjust the “HI” trim potentiometer on the small circuit board on back of “percent
stroke” potentiometer for high end voltage recorded in step (4) above. Verify that both
LEDS on main circuit boards are off.
10. The above adjustments are interactive. It may be necessary to repeat steps 6 through
9 several times, until the voltages stabilize.

6. Repairs
6.1 Limit Switch Adjustment
This procedure adjust the limit switches to prevent the pump mechanism from jamming
due to over travel, without significantly restricting the range of stroke length settings.
The limit switches disable the actuator from operating below zero strokes or above full
stroke, either of which can cause jamming. For this reason, correct limit switch
adjustment is very important.
The procedure for checking limit switch adjustment is given under “Installation- Start Up”.
As stroke length is manually decreased, the switch closest to the circuit board should
open (disabling decrease clutch voltage) at as stroke indicator reading between (001) and
(000). This reading must not be below (000). As stroke length is manually increased, the
switch farthest from the circuit board should open (disabling increase clutch voltage) at a
stroke indicator reading between 099 and 100. This reading must not be above 100.
To adjust a limit switch, loosen its two mounting screws, slide it in the required direction
and tighten the screws. Verify the adjustment as described under “Installation- Start Up”.

6.2 Potentiometer
1. Record the color codes of the potentiometer leads to TB2-3, 4, and 5, and disconnect
them from TB2.
2. Verify full potentiometer resistance of approximately 1000 ohms between the leads
removed from pins 4 and 5.
3. A needle type (analog) meter is recommended for checking potentiometer operation.
As the potentiometer gear is turned counterclockwise, the resistance between leads
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 removed from pins 5 and 3 should vary uniformly from zero to approximately 1000
ohms.
As the potentiometer gear is turned clockwise, the resistance should vary uniformly
from approximately 1000 ohms to zero.
4. If the extreme readings vary significantly from zero and 1000 ohms respectively or if
the resistance variation with rotation is not smooth at any point, the potentiometer
should be replaced. If the directions of rotation are the reverse of those stated above,
then the potentiometer has been wired for reverse acting operation.
5. To replace the potentiometer assembly, assure that pump has been turned manually
to the “000” indicator setting. Turn the potentiometer gear full clockwise (see from the
gear end) then back counterclockwise ¼ turn.
6. Install the potentiometer and reconnect leads to the circuit board.

6.3 Zero Alignment

The actuator mechanism must be aligned relative to the pump drive in order to permit the
full range of stroke adjustment.

Preliminary Check
1. Set up a multimeter for resistance measurement across the limit switch (in
subassembly #635, Figure 6 or 7) closest to the circuit board.
2. Turn the handwheel clockwise to decrease pump stroke length until the meter
indicates an open switch. Record the mechanical stroke indicator reading at this point.
Continue decreasing stroke length until resistance is encountered. Record stroke
indication at this point as well. If the stroke can be decreased to the resistance point
without opening the switch, jump to Step 4. Otherwise proceed with Step 3.
3. If resistance was felt at 000 on the stroke indicator and if the switch opened at a
stroke higher than 000 but not above 003, zero alignment is correct and no further
action is required. If not, proceed with re-alignment as outlined below.

Re-alignment –Non-explosion Proof

1. Disconnect the power source to the drive motor and actuator.
2. Remove the screws to the rear gearbox cover, Item #526A. Refer to Figures 8 and 9.
3. Lift the cover slightly and hold the diamond screw shaft Item #657, horizontal to
prevent binding. Pull the cover back towards the motor until the shaft is disengaged
from the actuator drive sleeve, Item #621.
4. Check to see that the block, Item #352, inside the oscillating housing, Item #358 is at
the top by turning the miter gear Item #357 clockwise. Refer to Figure 5.
5. Set the stroke indicator two digits lower than the setting at which the limit switch
opened (see Step 2 of “Preliminary Check”).
6. If he diamond shaft is dry, lightly coat it with grease.
7. Hold the cover over the pump and carefully insert the shaft into the actuator drive
sleeve as you lower the cover in place. Be sure that the stroke indicator remains as
set in Step 5.
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 8. Replace the cover screws.
9. With the handwheel fully clockwise, the stroke position indicator show read (000). If
not, remove the handwheel assembly form the cover assembly, turn to the (000)
setting and replace.
10. Align the potentiometer as described under “Repairs”.
11. Confirm free operation of mechanism and limit switch setup, as described under
“Installation”.

Re-alignment –Explosion Proof

1. Disconnect the power source to the drive motor and actuator.
2. Remove the screws to the rear gearbox subcover, Item #529A. Refer to Figures 8 and
9.
3. Manually rotate the motor coupling until the oscillating housing is vertical. It may be
necessary to remove pressure from the piping system.
4. Remove the cotter pin, Item #539, nut, Item # 535, and washer, Item #534 from the
end of the diamond screw shaft on top of the housing.
5. Remove the screws to the rear gearbox cover, Item #526A.
6. Lift the cover slightly and pull it back towards the motor. As the shaft disengages, the
miter gear, Item #533, bushing, Item #532, and bushing pin, Item #538, will come
loose. Don’t allow them to fall into the gear box.
7. Check to see that the block Item #352, inside he oscillating housing, Item #358, is at
the top by turning the miter gear, Item #357, clockwise. Ref to Figure 5.
8. Set the stroke indicator two digits lowers than the setting at which the limit switch
opened (See Step 2 of “Preliminary Check”).
9. If the diamond shaft is dry, lightly coat it with grease.
10. Hold the cover of the pump and insert the shaft into the housing bore as you lower the
cover in place. Make sure that the miter gear, bushing and bushing pin are in place
and that the stroke remains as set in Step 8.
11. Replace the washer and nut on the shaft. Snug the nut and then back it off to the
nearest hole for insertion of the cotter pin.
12. Replace the cover screws, subcover and coupling guard.
13. With the handwheel fully clockwise, the stroke position indicator should read (000. If
not, remove the handwheel assembly from the cover assembly, turn to the (000)
setting and replace.
14. Align the potentiometer as described under “Repairs”.
15. Confirm free operation of mechanism and limit switch setup, as described under
“Installation”.

6.4 Brake Air Gap

1. Check the axial air gaps between the mating halves of the brake and clutch
assemblies, Items #638 and #646 on Figures 6 and 7. The gap specifications are
0.010-0.040 inches.

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 2. If either brake drags without being energized and the gap is less than 10 mils, equally
shim all three spacer sleeves, Items #608, to increase the air gap to the specified
range. Refer to Figures 6 and 7. Item 607 denotes shim location on the illustrations, but
as a spare part. It consists of a pack of six 20-mil shims and twelve 5-mil shims.
NOTE: Care must be taken in this adjustment as permanent damage can result. We
recommend that all other possible causes listed under “Troubleshooting-Brake
Slipping” be investigated first.

6.5 Jammed Slider Block

1. The slider block is probably jammed if the stroke cannot be freely adjusted using the
handwheel with the override switch pulled out and no pressure load on the pump. To
confirm the problem, remove the cover (Item #529A, Figures 8 and 9) over the
oscillating housing and observe the position of the front connecting rod, Item #353,
where it enters the housing, Item #351 where Figure 5 refers. If the slider block is
jammed, the connecting rod will be at the extreme top or bottom position.

2. Two free a jam, turn the slotted nut, Item #535, with the cotter pin, Item #539,
remaining in place, using a wrench. (Refer to Figures 8 and 9). If the connecting rod is
in the top position, rotate the nut counterclockwise. If the connecting rod is in the
bottom position, rotate the nut clockwise.

3. Replace the cover.

7. Ordering Parts
When ordering replacement parts, always specify:

1. Pump model and serial number (stamped on the pump nameplate, e.g. 7120-S-AE with
S/N 8604146-1)
2. The part name and part number from the parts lists.

8. Conversion (Manual to PULSAmatic)

Follow these instructions when converting from manual to PULSAmatic stroke adjustment.
Numbers in parentheses refer to items as appropriate in Figures 5 through 9, except as
noted.
Removal of the Existing Manual Control Assembly
1. Disconnect the power supply going to the pump drive motor. Remove the motor
coupling guard.
2. Drain out the pump oil into a clean container if it is to be reused or into a suitable
container for disposal.
3. Remove the cover screws (530). Pull the cover back toward the motor and lift it off.
4. Inspect the gearbox internal components for broken, missing or worn parts at this time
it is advisable to flush any sediment or foreign material from the gearbox, using a
suitable solvent.
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5. Remove the rear connecting rod cotter pin (#545) and wrist pin (#544).
6. Remove the housing pivot pins (#547).

Models 7120 and 7440

Remove the retainer set screws (#546) located directly above the housing pins in the
opt surface of the gearbox.
NOTE: If slight heat is applied to the pivot pins to loosen paint, or sealant, ensure that
no cleaning or combustible fumes or materials are present.

Models 7660 and 8480

Remove the housing pin flange bolts and thread them into the tapped holes in the
flange. Tighten all bolts equally to remove the pins.
7. Pull the housing assembly (#540) rearward until the cross head wrist pin (#550) is
exposed. Loosen the set screw (#549) located on the rear of the crosshead (#551), and
slide the wrist pin out. Complete removal of the housing assembly is now possible.
8. If a new crosshead is to be used, the existing crosshead can be left on the front
connecting rod (#353) and the piston rod unscrewed from the crosshead by placing a
wrench on the front connecting rod and the piston rod. One some models it may be
necessary to remove the reagent and pump head assemblies in order to remove the
piston from the crosshead. If the head assemblies must be removed, refer to the pump
“Installation, Operation, and Maintenance Instructions” for proper repriming
instructions, etc. The pump head assemblies are held on to the gearbox by two socket
head capscrews located at the 3:00 and 9:00 positions inside the gearbox.

Installation of the PULSAmatic Control Assembly

1. Adjust the new oscillating housing assembly (#540) to zero stroke. This is done by
turning the miter gear (#357) on the top of the housing assembly until the sliding block
(#352) is all the way to the top.
2. Position the new housing assembly in the gearbox.
3. Connect the front connecting rod (#353) into the existing cross head (#551). Ensure
that the wrist pin (#550) is centered so that it does not protrude out the sides of the
cross head. Secure with the set screw (#549).
OR
4. Attach the rear connecting rod onto the housing assembly.
5. Ensure that the pivot pin gaskets are in good condition. Apply a thin coat of sealant.
6. Align the housing to the pivot pin holes and install the pins (#547). On the 7120 and
the 7440 pumps, make sure the small reliefs machined into the pins are positioned
directly under the set screw holes.
7. Secure by tightening set screws (#546) or flange bolts depending on the model.
8. Adjust the handwheel (#501) on the cover until the stroke indicator (#503) reads 000.
9. Lightly grease the drive shaft (Item #531, Figure 8 or 9) in the diamond groove area.
10. On non-explosion proof models, install the drive shaft assembly onto the housing cap
(#358). Hand-tighten the slotted nut (#535), loosen 1 ½ turn to the nearest hole-slot
alignment, and insert cotter pin (#539). Assembly cover assembly to pump by carefully
threading the drive shaft assembly onto the PULSAmatic control while lowering the
cover into place.
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 On explosion proof models, the diamond shaft is retained in the PULSAmatic unit and
does not come out so the drive shaft assembly must be fed into the housing cap as
the cover assembly is lowered onto the pump. The slotted nut (#535) should be
adjusted as above. Access to this nut is provided through small subcover (#529A).
11. Fasten cover to the gearbox making sure cover gaskets (#526B) are positioned
properly.

Refer to the “Installation” section for more detailed set-up and wiring information.

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9. Troubleshooting

PROBLEM PROBABLE CAUSE

1. No AC power to actuator.
2. Pump not running.
3. Override switch not pushed in.
4. Control signal off, incorrect, or of inverted polarity.
5. Ratio control (if so equipped) set at or very near zero percent.
6. Blown fuse (see Figure 4 for location).
Actuator Does Not Adjust
7. Wiring discontinuity.
8. Brake slipping (see “Troubleshooting”).
9. Defective feedback potentiometer (see “Repairs”).
10. Circuit board malfunction.
11. Broken actuator linkage.
12. Brake drive nut damaged.
1. Control signal incorrect or of inverted polarity.
2. Incorrect ratio control setting (if so equipped).
3. Circuit board out of calibration (if so equipped). (See “Calibration”).
4. Actuator misaligned to pump (see “Repairs”).
Actuator Adjusts to
5. Defective feedback potentiometer (see “Repairs”).
Incorrect Setting
6. Defective feedback potentiometer (see “Repairs”).
7. Limit switch out of adjustment (see “Repairs”).
8. Circuit board malfunction.
1. Control signal incorrect or of inverted polarity.
2. Incorrect ratio control setting (if so equipped).
3. Wiring discontinuity.
Actuator Adjusts in One 4. Brake slipping (see “Troubleshooting”).
Direction Only 5. Defective feedback potentiometer (see “Repairs”).
6. Limit switch out of adjustment (see “Repairs”).
7. Circuit board malfunction.
8. Defective brake.
1. Jammed slider block (see “Repairs”).
2. Circuit board malfunction (inadequate power to the brake).
Brake Slipping 3. Brakes misaligned.
4. Improper brake air gap (see “Repairs”).
5. Brake friction surface contaminated with oil or other foreign material.
1. Wiring discontinuity.
2. Narrow deadband (see “Calibration”).
3. Erratic control signal.
4. Noisy controls signal (check grounding and shielding of controls
signal leads).
Erratic Operation
5. Defective feedback potentiometer (see “Repairs”).
6. Brake slipping (see “Troubleshooting”).
7. Brake dragging (check brake alignment and air gap, see “Repairs”).
8. Circuit board malfunction.

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 Figure 5

17
AP00229
 MODEL 7120/7440 AE HOUSING ASSEMBLY
PULSAMATIC CONTROL
(Reference Figure 5)

ITEM PART NAME QUANTITY

351 Housing 1

352 Housing Block 1

353 Connecting Rod-Front 1

354 Pin 1

355 Pin 1

356 Adjustment Screw 1

357 Miter Gear 1

358 Housing Cap Assembly 1

359 Cap Screw 3

360 Washer 3

361 Washer 1

362 Nut 2
Housing Assembly: Consists of all
300 the above components pre- 1
assembled

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 MODEL 7660/8480 AE HOUSING ASSEMBLY
PULSAMATIC CONTROL
(Reference Figure 5)

ITEM PART NAME QUANTITY

351 Housing 1
352 Housing Block 1

353 Connecting Rod-Front 1

354 Pin 1

355 Pin 1

356 Adjustment Screw 1

357 Miter Gear 1

358 Housing Cap Assembly 1

359 Cap Screw 4

360 Washer 4

361 Washer 1

362 Nut 2
Housing Assembly: Consists of all
300 the above components pre- 1
assembled

19
 Figure 6
Standard NEMA 4 ENCLOSURE

20
 MODEL 7120/7440/7660/8480
NEMA 4 ACTUATOR ASSEMBLY
PULSAMATIC CONTROL AP00332
(Reference Figure 6)

21
 AP00333

Figure 7
EXPLOSION PROOF ENCLOSURE

AP00334
22
 MODEL 7120/7440/7660/8480
NEMA 7 ACTUATOR ASSEMBLY
PULSAMATIC CONTROL
(Reference Figure 7)

23
AP00335
 Figure 8
MODELS 7120 AND 7440

24
AP00330
 MODEL 7120/7440 -AE
CONTROL ASSEMBLY
PULSAMATIC CONTROL
(Reference Figure 8)

ITEM PART NAME QUANTITY

501 Handwheel 1
502 Set Screw 1

503 Counter 1

504 Round Head Screw 2

505 Counter Gasket 1

506 Bushing 1

507 Set Screw 1

508 Mounting Plate 1

509 Cap Screw 4

510 Gasket 5

511 Gear 48T 1

512 Gear 16T 1

513 Set Screw 1

514 Gear 22T 1

515 Spacer 1

516 Washer 1

517 Washer 1

518 Cap Screw 1

519 Insert 1

520 Miter Gear 1

521 Set Screw 1

522 Spring 1

523 o-Ring 1

524 Pin 1

525 Roll Pin 1

526A Cover 1

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526B Cover Gasket 1

527 Dip Stick Assembly 1

529A Breather Cover 1

529B Diaphragm 1

530 Fillister Head Screw 6

531 Drive Shaft Assembly 1

532 Bushing 1

533 Miter Gear 1

534 Washer 1

535 Slotted Nut 1

536 Actuator Assembly 1

537 Spacer 1

538 Pin 1

539 Cotter Pin 1

540 Housing Assembly 1

541 Warning Plate 1

542 Drive Screw 4

543 Cap Screw 4

544 Pin 1

545 Cotter Pin 1

546 Set Screw 2

547 Housing Bolt 2

548 o-Ring 2

549 Set Screw 1

550 Pin 1

551 Crosshead 1

552 Fillister Head Screw 4

553 Tube Fitting 1

7120/7440 PULSAmatic Control
500 consists of all the above components 1
pre-assembled

26
 Figure 9
MODELS 7660 AND 8480

27
 MODEL 7660/8480 -AE
CONTROL ASSEMBLY
PULSAMATIC CONTROL
(Reference Figure 9)

ITEM PART NAME QUANTITY

501 Handwheel 1
502 Set Screw 1

503 Counter 1

504 Round Head Screw 2

505 Counter Gasket 1

506 Bushing 1

507 Set Screw 1

508 Mounting Plate 1

509 Cap Screw 4

510 Gasket 5

511 Gear 48T 1

512 Gear 16T 1

513 Set Screw 1

514 Gear 22T 1

515 Spacer 1

516 Washer 1

517 Washer 1

18 Cap Screw 1

519 Insert 1

520 Miter Gear 1

521 Set Screw 1

522 Spring 1

523 o-Ring 1

524 Pin 1

525 Roll Pin 1

526A Cover 1

526B Cover Gasket 1

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527 Dip Stick Assembly 1

528A Front Cover 1

528B Diaphragm 1

529A Cover Plate 1

529B Gasket 1

530 Fillister Head Screw 10

531 Drive Shaft Assembly 1

532 Bushing 1

533 Miter Gear 1

534 Washer 1

535 Slotted Nut 1

536 Actuator Assembly 1

537 Spacer 1

538 Pin 1

539 Cotter Pin 1

540 Housing Assembly 1

541 Warning Plate 1

542 Drive Screw 4

543 Cap Screw 4

544 Pin 1

545 Cotter Pin 1

546 Hex Head Bolt 3

547 Housing Bolt 2

548 Gasket 2

549 Set Screw 1

550 Pin 1

551 Crosshead 1

552 Fillister Head Screw 4

7660/8480 PULSAmatic Control
500 consists of all the above components 1
pre-assembled

29
30
PULSAmatic®
CONTROLLER
Bulletin #: IOM-CTL-AE-2006 REV A Stroke Length Controller

A unit of IDEX Corporation

2883 Brighton Henrietta Town Line Road
Rochester NY 14623
+1 (585) 292-8000
www.pulsa.com
[email protected]

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