Accudyne Industries Milton Roy Milroyal Series User manual

Electronic Capacity
Control IOM Manual
MAXROY®B, MACROY®, mRoy®, and
Milroyal®Product Family Pumps
Manual No : 53870
Rev. : 00
Rev. Date : 10/2015

iInstallation, Operations & Maintenance Manual
PRECAUTIONS
The following precautions should be taken when working with metering pumps.
Please read this section carefully prior to installation.
Protective Clothing
ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or
near your metering pump. Additional precautions should be taken depending on the solution
being pumped. Refer to Safety Data Sheets for the solution being pumped.
Hearing Protection
It is recommended that hearing protection be used if the pump is in an environment where the
time weighted average sound level (TWA) of 85 decibels is exceeded (as measured on the A
scale slow response).
Electrical Safety
• Remove power and ensure that it remains off while maintaining pump.
• DO NOT FORGET TO CONNECT THE PUMP TO EARTH.
• Electric protection of the motor (Thermal protection or by means of fuses) is to correspond
to the rated current indicated on the motor data plate.
Liquid Compatibility
Verify if the materials of construction of the wetted components of your pump are
recommended for the solution (chemical) to be pumped.
Pumps Water “Primed”
All pumps are tested with water at the factory. If your process solution is not compatible with
water, ush the Pump Head Assembly with an appropriate solution before introducing the
process solution.
Plumbing and Electrical Connections
Always adhere to your local plumbing and electrical codes.
Line Depressurization
To reduce the risk of chemical contact during disassembly or maintenance, the suction and
discharge lines should be depressurized before servicing.
Over Pressure Protection
To ensure safe operation of the system it is recommended that some type of safety/pressure -
relief valve be installed to protect the piping and other system components from damage due
to over-pressure.
Lifting
This manual should be used as a guide only - Follow your company’s recommended lifting
procedures. It is not intended to replace or take precedence over recommendations, policies
and procedures judged as safe due to the local environment than what is contained herein.
Use lifting equipment that is rated for the weight of the equipment to be lifted.

ii Installation, Operations & Maintenance Manual
IMPORTANT SAFETY INSTRUCTIONS
WHEN INSTALLING, CALIBRATING, OR OPERATING THIS ACTUATOR, BASIC SAFETY PRECAUTIONS
SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE, ELECTRIC SHOCK, AND PERSONAL
INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY.
Read all instructions before installation, calibration, or operation.
GENERAL SAFETY CONSIDERATIONS
• Read this manual carefully.
• Installation, calibration, and maintenance should be performed by trained and qualied personnel.
Personnel should be familiar with the precautions required in working with hazardous voltages which
exist inside the actuator. Personnel should also be adequately trained on any hazards inherent in the
chemicals used in the metering pump.
• Always wear protective clothing including gloves and safety glasses when working on or near chemical
metering pumps.
• Follow directions and warnings provided with the chemicals from the chemical manufacturer. User is
responsible for determining the hazards associated with the chemicals being pumped and using the
proper safety gear and procedures.
• Hazardous voltages are present when cover is removed. Disconnect power when installing or servicing
this unit.
• Unit must be properly grounded.
• Conform to local codes in wiring this equipment.
• Actuator must be adequately rated if it is to be used in a hazardous location. See product data plate
for rating information. This rating must not be exceeded under any circumstances. To prevent ignition
of hazardous atmospheres, cover must be tight while circuits are energized.
• In order to comply with the requirements of agency approvals (see data plate), specications for
conduits connections, wire gauge and type, fastener torque ratings, and operating condition must be
adhered to.

iiiInstallation, Operations & Maintenance Manual
GENERAL SAFETY CONSIDERATIONS FOR IECEx RATED APPLICATIONS
• Actuator is to be cleaned regularly to prevent a buildup of dust on the enclosure.
DO NOT OPEN THE ACTUATOR WHEN AN EXPLOSIVE ATMOSPHERE IS PRESENT.
ACTUATOR MUST BE GROUNDED.
POTENTIAL ELECTROSTATIC CHARGING HAZARD – GROUNDING EQUIPMENT WILL NOT PREVENT
PROPAGATING BRUSH CHARGES. THE EQUIPMENT SHOULD NOT BE SUBJECTED TO CHARGING
MECHANISMS STRONGER THAN MANUAL RUBBING.
• Earthing (protective) conductor is to be ≥ the size of the phase conductors and equipotential bonding
conductors are to be minimum 4mm2(10 AWG) cross sectional area.
• The ground lug shall be tightened to the earthing connector so that contact pressure on the electrical
connections shall be maintained and not loosen due to temperature or humidity.
• Only suitable rated IECEx approved Ex d cable glands are to be employed that also maintain the IP6X
rating.
• Only suitable cable and cable glands or conductors in conduits rated to 100°C are to be employed to
maintain the temperature rating.
• Only suitable rated IECEx approved Ex d blanking elements are to be employed that also maintain
the IP6X rating.
• If required, only IECEx approved blanking elements are to be employed and shall not be used with
an adaptor.
• Only suitable rated IECEx approved Ex d thread adaptors are to be employed that also maintain the
IP6X rating.
• If required, only IECEx approved devices are to be employed.

iv Installation, Operations & Maintenance Manual
QUICK START GUIDE
NOTE:
Read and understand safety instruction before proceeding.
READ
• Read and comply with all safety instructions presented in this manual. In order to comply with the
requirements of agency approvals (see data plate), specications for conduit connections, wire gauge
and type, fastener torque ratings, and operating conditions must be adhered to.
CONNECT
• Connect AC power. Use conduit connections or cable glands.
• Ground unit.
• Connect command signal.
• Connect feedback signal.
VERIFY
• Voltage selector switch is set to the required voltage (115 or 230 VAC).
• DIP switches are set for desired operation.
• Command input signal is set to desired operation 4-20 mA or (-5 VDC). Factory set at 4-20 mA.
• Feedback signal output is set to desired operation 4-20mA or (1-5 VDC). Factory set at 4-20 mA.
• Loss of command signal action (unit moves to low signal position or hold last position). Factory setting
moves unit to low signal position.
• If reverse action is required (optional, visit factory website).
HAZARDOUS VOLTAGES ARE PRESENT ON THE CIRCUIT BOARD. TO PREVENT IGNITION OF
HAZARDOUS ATMOSPHERES, COVER MUST BE TIGHT WHILE CIRCUITS ARE ENERGIZED.
APPLY POWER
• Apply command signal.
• Apply AC power.
OBSERVE
• Actuator should run to command position and stop.
• Full range of command signal should result in desired range of actuator travel (factory setting is for
full travel of 0% to 100%).
CALIBRATE
• If actuator was installed on the pump at the factory, it has been factory calibrated.
• If actuator is retrot or a non-standard range is desired, follow the calibration instructions in this
manual.
FINISH
• Install cover. Observe torque requirements of 15 ft-lb (20 N-m) in hazardous location.
• If the unit is IECEX/ATEX certied, tighten the set screw in the base to lock the cover to maintain the
rating and prevent tampering.

vInstallation, Operations & Maintenance Manual
IMPORTANT SAFETY INSTRUCTIONS ........................................................ ii
QUICK START GUIDE ......................................................................iv
SECTION 1 - GENERAL DESCRIPTION ....................................................... 1
1.1 GENERAL INFORMATION ......................................................... 1
1.2 PRINCIPLE OF OPERATION ....................................................... 1
1.3 SPECIFICATIONS ................................................................ 2
1.4 PRODUCT MODEL CODING ....................................................... 2
1.5 AGENCY APPROVALS ............................................................ 5
SECTION 2 - INSTALLATION ................................................................ 7
2.1 GENERAL INFORMATION ......................................................... 7
2.1.1 Field Installation of ECC .......................................................... 7
2.1.2 ECC Circuit Board Replacement.................................................... 7
2.1.3 Circuit Board Replacement For ECC(s) Built After January 2000 and/or After A Circuit Board
Retrot Kit is Replaced ........................................................... 7
2.2 UNPACKING .................................................................... 8
2.3 STORAGE/IDLE SERVICE ......................................................... 8
2.4 SAFETY PRECAUTIONS .......................................................... 8
2.5 MOUNTING ..................................................................... 8
2.6 WORKING WITH THE COVER ...................................................... 9
2.7 ELECTRICAL CONNECTIONS ...................................................... 9
2.7.1 Installation of Input/Output Command Signal Wiring..................................... 9
2.7.2 Input Signal ................................................................... 10
2.7.3 Feedback Output Signal ......................................................... 10
2.7.3.1 Feedback Output Signal 4-20 mA ................................................ 10
2.7.3.2 Feedback Output Signal 1-5 VDC................................................. 10
2.7.4 Installation of Primary Power Wiring ................................................ 11
2.8 CIRCUIT BOARD RETROFIT KIT INSTALLATION ...................................... 11
2.8.1 Remove Old Circuit Board ....................................................... 11
2.8.2 Required Modications .......................................................... 11
2.8.2.1 ECC Part Number 0152226XXX, 0152195XXX ...................................... 12
2.8.3 Install New Circuit Board ........................................................ 12
SECTION 3 - OPERATION ................................................................. 14
3.1 CONTROLS.................................................................... 14
3.2 INITIAL START-UP............................................................... 14
3.2.1 Operating Modes .............................................................. 14
3.2.2 Input Signal................................................................... 15
3.3 CONTROL RANGE ADJUSTMENT ................................................. 16
TABLE OF CONTENTS

vi Installation, Operations & Maintenance Manual
SECTION 4 – MAINTENANCE .............................................................. 18
4.1 SPARE PARTS ................................................................. 18
4.2 RETURNING UNITS TO THE FACTORY ............................................. 18
4.3 MAINTENANCE ................................................................ 18
4.4 PRINTED CIRCUIT BOARD (PCB) REPLACEMENT.................................... 19
4.4.1 Removal of PCB ............................................................... 19
4.4.2 Installation of PCB ............................................................. 19
4.5 FEEDBACK POTENTIOMETER REPLACEMENT ...................................... 19
4.5.1 Removal of Feedback Potentiometer ............................................... 19
4.5.2 Installation of Feedback Potentiometer.............................................. 20
4.6 NYLON WORM GEAR REPLACEMENT.............................................. 20
4.6.1 Removal of Nylon Worm Gear .................................................... 20
4.6.2 Installation of Nylon Worm Gear................................................... 20
4.7 MOTOR REPLACEMENT ......................................................... 20
4.7.1 Removal of Motor .............................................................. 20
4.7.2 Installation of Motor ............................................................. 21
4.8 ECC CALIBRATION.............................................................. 22
4.8.1 Calibration Routines ............................................................ 22
4.8.1.1 Calibration A................................................................. 22
4.8.1.2 Calibration B................................................................. 24
4.8.1.3 Calibration C ................................................................ 25
SECTION 5 - TROUBLESHOOTING .......................................................... 28
SECTION 6 - PARTS LIST .................................................................. 29
6.1 GENERAL ..................................................................... 29
6.2 ILLUSTRATED PARTS LIST ....................................................... 29
6.3 ELECTRONIC CAPACITY CONTROL PARTS LIST ..................................... 33
6.4 PARTS LIST FOR mROY®ECC MOUNTING ADAPTER (mROY®“A” ) ....................... 37
6.5 PARTS LIST FOR mROY®ECC MOUNTING ADAPTER (mROY®“B”) ....................... 39
6.6 PARTS LIST FOR MACROY®ECC MOUNTING ADAPTER (MACROY®“G”, “D” AND
MILROYAL®G).................................................................. 42
6.7 PARTS LIST FOR MAXROY®ECC MOUNTING ADAPTER (MAXROY®“B”) .................. 45
6.8 PARTS LIST FOR MILROYAL®ECC MOUNTING ADAPTER AND MOUNTING ADAPTER
GUARD ASSEMBLY (MILROYAL®“B”) ............................................... 48
6.9 PARTS LIST FOR MILROYAL®ECC MOUNTING ADAPTER AND GEAR DRIVE
(MILROYAL®“C”) ................................................................ 50
6.10 PARTS LIST FOR MILROYAL®ECC MOUNTING (MILROYAL®D) ......................... 52
APPENDIX A MAXROY®B PUMP ECC INSTALLATION (RETROFIT) .......................... 53
APPENDIX B MILROYAL®B PUMP FIELD INSTALLATION (RETROFIT) ....................... 54
APPENDIX C MILROYAL®C PUMP FIELD INSTALLATION (RETROFIT) ....................... 56

viiInstallation, Operations & Maintenance Manual
LIST OF ILLUSTRATIONS
FIGURE 1. Nema 4 Electronic Capacity Control Data Plate......................................... 5
FIGURE 2. Nema 7 Electronic Capacity Control Data Plate......................................... 5
FIGURE 3. IECEX/ATEX Certied Electronic Capacity Control Data Plate ............................. 5
FIGURE 4. Declaration of Conformity.......................................................... 6
FIGURE 5. Circuit Board Connectors J4 and J5................................................. 10
FIGURE 6. Circuit Board, 30033 ............................................................ 13
FIGURE 7. Circuit Board, 0152226XXX, 0152195XXX ............................................ 13
FIGURE 8. Conversion Detail ............................................................... 13
FIGURE 9. Jumper Plugs/Action Mode Conversion .............................................. 14
FIGURE 10. Effect of Zero & Span Controls..................................................... 15
FIGURE 11. Split Range Operation with Two Pumps (Typical pH Control System) ....................... 15
FIGURE 12. Circuit Board, Top............................................................... 17
FIGURE 13. Circuit Board, Bottom ............................................................ 17
FIGURE 14. Circuit Board Removed .......................................................... 19
FIGURE 15. Potentiometer Connector P2 Pins 1 and 2 ............................................ 23
FIGURE 16A. Electronic Capacity Control (DWG 1022483000)...................................... 30
FIGURE 16B. Electronic Capacity Control with Setscrew........................................... 31
FIGURE 16C. Electronic Capacity Control (DWG 1022483000)...................................... 32
FIGURE 17. mRoy®“A” ECC Mounting Adapter (DWG. 1021971000) .................................. 36
FIGURE 18. mRoy®“B” ECC Mounting Adapter (DWG. 10221460003) ................................ 38
FIGURE 19A. MACROY®“G” ECC Mounting Adapter (DWG. 1022118000) Design through
“September 2004” and Milroyal®“G”. ............................................... 40
FIGURE 19B. MACROY®“D” ECC Mounting (DWG. 1021572000) ................................... 41
FIGURE 20. MAXROY®B ECC Mounting Adapter (DWG. 1021572000) ............................... 44
FIGURE 21A. Milroyal®B ECC Mounting Adapter (DWG 1022095000) ................................ 46
FIGURE 21B. Milroyal®B ECC Mounting Adapter Guard Assy (DWG 1022095000) ...................... 47
FIGURE 22. Milroyal®C ECC Mounting Adapter (DWG. 10222850002)................................ 49
FIGURE 23. Milroyal®D ECC Mounting Adapter (DWG. 1022906000)................................. 51

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