Milton Roy MAXROY B User manual

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Tag Number(s): _____________________________________
Model Number: _____________________________________
Serial Number: _____________________________________
Installation Date: ____________________________________
Installation Location: ________________________________
Electronic
Capacity Control
maxRoy®B, MacRoy®, mRoy®, and Milroyal®
Product Family Pumps
339-0083-000
ISSUED 01/2012
This manual supersedes the following manuals:
339-0002-000, 339-0006-000, 339-0016-000,
339-0018-000, 339-0051-000, 339-0067-000, and 339-
0083-000 Dated 08/2005 & 09/2009
INSTALLATION,
OPERATION, AND
MAINTENANCE
MANUAL
mRoy
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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 Material Safety Data Sheets for the solution being pumped.
Hearing Protection
! It is re commended that h earing p rotection be used if the pu mp is in an environment where the time -
weighted average sound level (TWA) of 85 deci bels is exceeded. (as measured on the A scale -- slo w
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 material s 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, flush
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 che mical contact during disassembly or maintenance, the su ction 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.
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IMPORTANT SAFETY INSTRUCTIONS
WARNING
WHEN INSTALLING, CALIBRATING, O R OP ERATING THIS ACTUATOR, BASIC
SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDU CE RISK
OF FIRE , ELECTRIC SHOCK, AND PERSONAL INJUR Y. 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 qualified personnel. Per-
sonnel 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 chem-
icals 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 pr ovided with th e chemicals from the chemical manufacturer. User is
responsible for determining the hazards a ssociated with the chemicals being pumped and u sing 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 ratin g 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), specifications for con-
duit conn ections, wire ga uge a nd type, fastener to rque r atings, a nd operating co nditions must b e
adhered to.
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QUICK START GUIDE
NOTE: Read and understand safety instructions before proceeding
READ
- Read and comply with all safety instructions pr esented in this m anual. In order to comply with th e
requirements of agency approvals (see data plate), specifications 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 (1-5 VDC). Factory set at 4-20 mA.
- Feedback signal output is set to desired operation 4-20 mA 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 set-
ting moves unit to low signal position.
- If reverse action is required (optional, call factory).
WARNING
HAZARDOUS VOLT AGES ARE PRES ENT 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.
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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 a retrofit or a non-standard range is desired, follow the calibration instructions in this man-
ual.
FINISH
- Install cover. Observe torque requirements of 15 ft.-lb. (20 N-m) in hazardous locations.
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TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i
QUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1 - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 PRODUCT MODEL CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 AGENCY APPROVALS (Figures 1, 2 and 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Field Installation of ECC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.2 ECC Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.3 Circuit Board Replacement For ECC(s) Built After January 2000 and/or After A Circuit
Board Retrofit Kit Is Replaced5
2.2 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 STORAGE/IDLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6.1 Installation of Input/Output Command Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6.2 Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6.3 Feedback Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6.3.1 Feedback Output Signal 4-20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6.3.2 Feedback Output Signal 1-5 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6.4 Installation of Primary Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 CIRCUIT BOARD RETROFIT KIT INSTALLATION (Table 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7.1 Remove Old Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7.2 Required Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2.1 ECC Part Number 0152226XXX, 0152195XXX (Figure 6). . . . . . . . . . . . . . . . . . 9
2.7.3 Install New Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 - OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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3.1 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.2 Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 CONTROL RANGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 RETURNING UNITS TO THE FACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 PRINTED CIRCUIT BOARD (PCB) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.1 Removal of PCB (Figure 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4.2 Installation of PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 FEEDBACK POTENTIOMETER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5.1 Removal of Feedback Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5.2 Installation of Feedback Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6 NYLON WORM GEAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6.1 Removal of Nylon Worm Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6.2 Installation of Nylon Worm Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7.1 Removal of Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7.2 Installation of Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.8 ECC CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.8.1 Calibration Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.8.1.1 Calibration A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.8.1.2 Calibration B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.8.1.3 Calibration C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 5 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 - PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3 ELECTRONIC CAPACITY CONTROL PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4 PARTS LIST FOR MROY ECC MOUNTING ADAPTER (MROY “A”) . . . . . . . . . . . . . . . . . . . . 35
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6.5 PARTS LIST FOR MROY ECC MOUNTING ADAPTER (MROY “B”) . . . . . . . . . . . . . . . . . . . . 37
6.6 PARTS LIST FOR MACROY ECC MOUNTING ADAPTER (MACROY “G”, “D” AND MIL-
ROYAL G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.7 PARTS LIST FOR MAXROY ECC MOUNTING ADAPTER (MAXROY “B”) . . . . . . . . . . . . . . . 43
6.8 PARTS LIST FOR MILROYAL ECC MOUNTING ADAPTER AND MOUNTING ADAPTER
GUARD ASSEMBLY (MILROYAL “B”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.9 PARTS LIST FOR MILROYAL ECC MOUNTING ADAPTER AND GEAR DRIVE
(MILROYAL “C”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.10 PARTS LIST FOR MILROYAL ECC MOUNTING (MILROYAL D) . . . . . . . . . . . . . . . . . . . . . . 51
APPENDEX A MAXROY B PUMP ECC INSTALLATION (RETROFIT) . . . . . . . . . . . . . . . . . . . . . . . 53
APPENDEX A MILROYAL B PUMP FIELD INSTALLATION (RETROFIT) . . . . . . . . . . . . . . . . . . . . 55
APPENDEX B MILROYAL C PUMP FIELD INSTALLATION (RETROFIT) . . . . . . . . . . . . . . . . . . . . 57
FIGURE 1. Nema 4 Electronic Capacity Control Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 2. Nema 7 Electronic Capacity Control Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 3. Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 4. Circuit Board Connectors J4 and J5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FIGURE 5. Circuit Board, 30033. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FIGURE 6. Circuit Board, 0152226XXX, 0152195XXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FIGURE 7. Conversion Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
FIGURE 8. Jumper Plugs/Action Mode Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
FIGURE 9. Effect of Zero & Span Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIGURE 10. Split Range Operation w/Two Pumps (Typical pH Control System) . . . . . . . . . . .14
FIGURE 11. Circuit Board, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
FIGURE 12. Circuit Board, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
FIGURE 13. Circuit Board removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FIGURE 14. Potentiometer Connector P2 Pins 1 and 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
FIGURE 15A. Electronic Capacity Control (1022483000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
FIGURE 15B. Electronic Capacity Control (1022483000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
FIGURE 16. mRoy “A” ECC Mounting Adapter (DWG. 1021971000) . . . . . . . . . . . . . . . . . . . . .34
FIGURE 17. mRoy “B” ECC Mounting Adapter (DWG. 10221460003) . . . . . . . . . . . . . . . . . . . .36
FIGURE 18 (Sheet 1 of 2). MacRoy “G” ECC Mounting Adapter (DWG. 1022118000) Design
through “September 2004” and Milroyal “G” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
FIGURE 18 (Sheet 2 of 2). MacRoy “D” ECC Mounting (DWG. 1022728000) . . . . . . . . . . . . . . . . . . .39
FIGURE 19. maxRoy B ECC Mounting Adapter (DWG. 1021572000) . . . . . . . . . . . . . . . . . . . . .42
FIGURE 20 (Sheet 1 of 2). Milroyal B ECC Mounting Adapter (DWG. 1022095000) . . . . . . . . . . . . . .44
FIGURE 20 (Sheet 2 of 2). Milroyal B ECC Mounting Adapter Guard Assy (DWG. 1022095000) . . .45
FIGURE 21. Milroyal C ECC Mounting Adapter (DWG. 10222850002) . . . . . . . . . . . . . . . . . . . .48
FIGURE 22. Milroyal D ECC Mounting Adapter (DWG. 1022906000) . . . . . . . . . . . . . . . . . . . . .50
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1
SECTION 1
DESCRIPTION
1.1 GENERAL INFORMATION
In this age of so phisticated pr ocess control con -
cepts, many people are taking advantage of the lat-
est b reakthroughs in technology to up grade the ir
own equipment and systems. The Milton Roy Elec-
tronic Capacity Control (ECC) easily interfaces with
computerized process and process instruments, as
the ECC will adjust the output of a metering pump
from 0% to 100% in response to a 4 to 20 milliamp
or 1 to 5 VDC sig nal from a co mputer or othe r
source. This outstanding feature can be purchased
as an integral part of the pump, or it can be bought
separately and field installed. The ECC mounts to
the housing of the pump and operates in place of
the manual stroke adjustment.
1.2 PRINCIPLE OF OPERATION
The ECC allo ws remote adjustment of th e volume
of liq uid d elivered b y the metering p ump. Th is is
accomplished by utilizing a 4-20 mA command sig-
nal from a Milton R oy Remote Panel Mount
(ARPM-100/200) or Remo te Wall Mo unt ( ARWM-
100/200) remote controller (manual 3390021000),
or a c ustomer’s cont rol system. I n a closed loop
control system, the ECC a ccepts the com puter o r
controller 4- 20 m A sig nal d irectly an d p rovides
immediate an d accurate control of the pum p flow
under varying process conditions.
When th e ECC re ceives the 4- 20 m A co mmand
signal, the dr ive mo tor responds by mo ving the
ECC to the required position. As the ECC moves, it
changes th e position of the pu mp’s str oke ad just
shaft, thu s altering th e pu mp’s flow rate. Refer to
Table 1 wh ich list s r eference ma nuals containing
information on the stro ke ad just shaf t a nd pump
operation.
If th e pu mp flow r ate n eeds to be m onitored, th e
ECC then communicates its position by outpu tting
a nominal 4-20 mA or (1-5 VDC) signal. This signal
can be inter cepted an d tr anslated b y an ARPM-
100/200 or ARWM-100/200 or other user supplied
equipment to display the current ECC position.
1.3 SPECIFICATIONS
INPUT POWER
115 VAC, 50/60 Hz, 1 phase ±10% (standard)
220 VAC, 50/60 Hz, 1 phase ±10% (optional)
1 amp max
CONTROL SIGNAL INPUT
4-20 mA into 250 ohms impedance (standard)
Direct acting: 4-20 mA (see note below)
Split range: 4-12 mA, 12-20 mA
1-5 VDC 440K load, DIP selectable (optional)
NOTE
As supplied, the ECC is direct ac ting
(pump c apacity increases w ith increasing
input sign al to ECC) alth ough it m ay b e
converted to re verse a cting b y fo llowing
the procedure outlined in Section 3, “Oper-
ation”.
POSITION FEEDBACK OUTPUT
4-20 mA, max 500 ohm load (standard)
1-5 VDC, min. 25 0 o hms imp edance, DIP se lect-
able (optional)
Table 1. Stroke Adjust Shaft & Pump Opera-
tion Reference Manuals
PUMP MANUAL
mRoy 3390047000
maxRoy B 3390005000
Milroyal C 3390009000
Milroyal B 3390066000
Milroyal D 3390010000
MacRoy G 3390049000
MacRoy D 3390076000
Milroyal G 3390064000
Table 1. Stroke Adjust Shaft & Pump Opera-
tion Reference Manuals
PUMP MANUAL
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MOTOR RPM
72
ACCURACY
±0.5%
MANUAL OPERATION
Fluted handwheel with ECC unpowered
ENCLOSURE
NEMA 4, IP55 (standard)
Hazardous location (optional)
Enclosure is alu minum with S tainless S teel (SS)
shaft
TRAVEL TIME (0% TO 100%)
mRoy - 10 seconds
maxRoy B - 3 minutes
Milroyal D - 1 minute
MacRoy D and G - 3 minutes
Milroyal B, C, and G - 3 minutes
DUTY CYCLE
100% Continuous up to 110°F
75% at 120°F
50% at 140°F
ENVIRONMENTAL
-40°F to 120°F (-40°C to 50°C)
Altitude max 6559ft (2000m)
Relative humidity m ax 80 % u p to 87 °F (31°C),
decreasing linearly to 50% at 104°F (40°C)
Installation category 2 (EN61010-1)
Pollution degree 2 (EN61010-1)
1.4 PRODUCT MODEL CODING
MaxRoy B, mRoy , MacRoy an d Milro yal product
family p umps ca n b e ordered with o r wit hout an
ECC already attached. If the ECC is or dered with
the pump, it is indicated in the pump model code by
an “E1”, “E2”, “EA” o r “EB” in the capacity adjust-
ment slot. The pump model code can be found on
the pump data plate, mounted to the pump.
There a re fo ur ECC’ s cu stomarily su pplied with a
pump; th ese models are sh own in th e product
model cod e t ables (Table 2 - T able 8) . Th ere ar e
several very similar ECC dat a plat es; some of
these are shown in Figure 1 and Figure 2. Please
note that the Fig ure 2 d ata plate documents what
safety and/or ha zardous location approvals ap ply
to the unit.
Table 2. mRoy Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
PPRW212RMH Nema 4 115 VAC
PPRW512RMH Nema 4 230 VAC
PPRX212RMH Explosion Proof
(FM Approved)
115 VA C
PPRX512RMH Explosion Proof
(FM Approved)
230 VAC
Table 3. maxRoy B Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
PPGW222RMH Nema 4 115 VAC
PPGW522RMH Nema 4 230 VAC
PPGX222RMH Explosion Proof
(FM Approved)
115 VA C
PPGX522RMH Explosion Proof
(FM Approved)
230 VAC
Table 4. Milroyal B Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
PPGW242LMH Nema 4 115 VAC
PPGW542LMH Nema 4 230 VAC
PPGX242LMH Explosion Proof
(FM Approved)
115 VAC
PPGX542LMH Explosion Proof
(FM Approved)
230 VAC
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1.5 AGENCY APPROVALS (Figures 1, 2 and 3)
WARNING
THE DA TA PLATE DOCUMENT S ALL
SAFETY AND/OR HAZARDOUS LOCA -
TION APPROVALS THAT APPLY.
THESE ARE NOT TO BE EXCEEDED.
The data plate documents all safety and/or hazard-
ous location approvals that app ly to th e un it. Se e
Figures 1 and 2 for data plate configurations.
All of or some of the following approv als may
apply:
MET Labs U.S. Safety and Explosion proof
MET Labs Canadian Sa fety and Explosio n
proof
CSA CSA 25/30
CE
Safety EN61010-1
Installation category 2
Pollution degree 2
EMC directives -
Emissions EN50081-2
Immunity EN50082-2
CENELEC (Flameproof) EN 50014 & 50018
FM Factory Mutual explosion proof
A declaration of conformity (Figure 3) lists the stan-
dards declared by the Milton Roy Company.
Table 5. Milroyal C Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
PPGW482LMH Nema 4 115 VAC
50/60 Hz
PPGW682LMH Nema 4 230 VAC
60 Hz
PPGW782LMH Nema 4 230 VAC
50 Hz
PPGX482LMH Explosion Proof
(FM Approved)
115 VA C
50/60 Hz
PPGX682LMH Explosion Proof
(FM Approved)
230 VAC
60 Hz
PPGX782LMH Explosion Proof
(FM Approved)
230 VAC
50 Hz
Table 6. Milroyal D Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
Low Pressure
PPGW292LMH
Nema 4 115 VAC
Low Pressure
PPGW592LMH
Nema 4 230 VAC
Low Pressure
PPGX292LMH
Explosion Proof
(FM Approved)
115 VA C
Low Pressure
PPGX592LMH
Explosion Proof
(FM Approved)
230 VAC
High Pressure
PPGW212LMH
Nema 4 115 VAC
High Pressure
PPGW512LMH
Nema 4 230 VAC
High Pressure
PPGX212LMH
Explosion Proof
(FM Approved)
115 VA C
High Pressure
PPGX512LMH
Explosion Proof
(FM Approved)
230 VAC
Table 7. Milroyal G Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
PPGW242LMH Nema 4 115 VAC
PPGW542LMH Nema 4 230 VAC
PPGX242LMH Explosion Proof
(FM Approved)
115 VA C
PPGX542LMH Explosion Proof
(FM Approved)
230 VAC
Table 8. MacRoy D and G Model Codes
MODEL
NUMBER
ENCLOSURE VOLTAGE
50/60 HZ
PPGW242LMH Nema 4 115 VAC
PPGW542LMH Nema 4 230 VAC
PPGX242LMH Explosion Proof
(FM Approved)
115 VA C
PPGX542LMH Explosion Proof
(FM Approved)
230 VAC
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Figure 1. Nema 4 Electronic Capacity Control Data Plate.
Figure 2. Nema 7 Electronic Capacity Control Data Plate.
DECLARATION OF CONFORMITY
Application of Council Directive(s): LVD 73/23/EEC as amended by 93/68/EEC;
EMC 89/336/EEC as amended by 91/263/EEC and 92/31/EEC, and CENELEC ATEX 94/9/EG.
Standards to which Conformity is Declared:
LVD: EN61010
EMC: EN50081 and EN50082
CENELEC: EN50014 and EN50018
Declarer's Name/Address: Milton Roy Company - Flow Control Division
201 Ivyland Road
Ivyland, PA 18974 USA
Type of Equipment: Industrial Actuators
Model Number: All "P" series hazardous location.
I the undersigned, hereby declare that the equipment specified above conforms to the above Directive(s)
and Standard(s).
5/8/02
(signature) (date)
Don Weidemann Quality Manager
(printed name) (title)
Figure 3. Declaration of Conformity
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SECTION 2
INSTALLATION
2.1 GENERAL INFORMATION
The ECC is usua lly shipped already mou nted to
the pump. In stallation, therefore, is usuall y only a
matter o f con necting the sign al wir ing ( paragraph
2.6.1) and primary power wires (paragraph 2.6.4).
2.1.1 Field Installation of ECC
Field installation of the ECC to an existing pump is
usually not recommended due to the precise align-
ment required.
MacRoy G and MacRoy D p umps cannot be con-
verted in the field to ECC operation.
MRoy A/B pumps manufactured before 1987 can-
not be converted in the field to ECC operation. The
mRoy A/B pum p ho using must have bee n
machined to mo unt an ECC. Co ntact the M ilton
Roy ser vice dep artment if you wi sh to conver t a
manually adjusted mRoy pump manufactured after
1987 to ECC operation.
If the ECC was supplied as a field m ounting kit,
refer to field installation instructions for the follow-
ing p umps; maxRoy B ( Appendix A) , Milroyal B
(Appendix B) o r Mi lroyal C (Ap pendix C). Upo n
completion of the retrofit, proceed with service con-
nections (paragraph 2.4).
2.1.2 ECC Circuit Board Replacement
As ECC circuit boards fail (ECC(s) built before Jan-
uary 20 00) at f ield ins tallations, th ey ar e replaced
with an ECC circuit board retrofit kit (se e Table 9).
The circuit board retrofit kit replaces the old circuit
board with a new unit. Match your Milton Roy pump
to the correct circuit bo ard re trofit kit part number
using Table 9. Refer to CIRCUIT BOARD RETRO-
FIT KIT INSTALLATION (paragraph 2.7)
2.1.3 Circuit Board Replacement For ECC(s)
Built After January 2000 and/or After A Circuit
Board Retrofit Kit Is Replaced.
After a conversion kit is installed in the field and/or
a new ECC circuit board (ECC(s) built after Janu-
ary 2000) fails order replacement board p/n 30300
for all pu mps e xcept Milroyal C. Order p/ n 39 320
for Milroyal C pumps. When ordering the replace-
ment board (p/n 30300/39320) specify what
pump the unit is being installed on to insure
the replacement board is configured for your
pump. This will eliminate problems during installa-
tion. Refer to Printed Circuit Board Replacement
(paragraph 4.4, Section 4)
2.2 UNPACKING
Units are shipped f.o.b. factory and the title passes
to th e cu stomer wh en the carrier signs for rec eipt
of the unit. In the event that damages occur during
shipment, it is the responsibility of the customer to
notify the carrier immediately and to file a damage
claim.
Carefully examin e the ship ping cr ate/box upon
receipt from carrier to be sure there is no obvious
damage to conten ts. Op en the crate/box car efully
so accessory i tems fastened to the ins ide of the
Table 9. ECC Circuit Board Retrofit Kits
PART
NUMBER
FOR ECC(S) BUILT BEFORE
JANUARY 2000
21226 mRoy A & B with 115 VAC 50/60 Hz
input power
21227 mRoy A & B with 230 VAC 50/60 Hz
input power
21228 Milroyal B, Milroyal G or MacRoy G
with 115 VAC 50/60 Hz input power
21229 Milroyal B, Milroyal G or MacRoy G
230 VAC 50/60 Hz input power
21230 Milroyal C with 115 VAC 50/60 Hz
input power
21231 Milroyal C with 60 Hz 230 VAC input
power
21232 Milroyal C with 50 Hz 230 VAC input
power
21233 Milroyal D or MacRoy D with 115
VAC 50/60 Hz input power
21234 Milroyal D or MacRoy D with 230
VAC 50/60 Hz input power
21235 maxRoy B with 115 VAC 50/60 Hz
input power
21236 maxRoy B with 230 VAC 50/60 Hz
input power
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crate/box will not be damag ed or lost. Examine all
material inside crate/box a nd check against pack-
ing list to be sure that all items are accounted for
and intact.
2.3 STORAGE/IDLE SERVICE
Several ECC components ar e st eel and ar e su b-
ject to corrosive attack during stor age/idle time in
hot, humid environments. The ECC covers are not
air tight. In humid environments, the humidity in the
air can condense during cooler evenings, even to
the exten t that water can accumulate in side the
housing. Milton Roy does not warrant against dam-
age cau sed by co rrosion or atmo spheric co ndi-
tions.
With reasonable care at the site, the products and
packaging methods will effectively protect new ,
uninstalled un its fr om corrosion due to wa ter an d
water vapor for up to one year.
FAILURE TO PROPERLY STORE AND
PROTECT THE EQUIPMENT MAY VOID
ANY W ARRANTY, EXPRE SSED OR
IMPLIED. OUTDOOR STOR AGE IS N OT
RECOMMENDED UNDER ANY CIRCUM-
STANCES UNLE SS SPECIFICALLY
PREPARED FOR STORAGE PR IOR TO
SHIPMENT FROM THE FACTORY.
The amount of time the ECC can remain in storage
or idle se rvice can be exte nded. Depleted, factory
installed desiccant can be removed and re placed
with new desiccant. Call the fa ctory at ( 215) 441-
0800 for instructions to properly extend ECC sto r-
age.
Maximum Estimated Storage
Indoors, dry ambient controlled temperature:
Initial - - - - - - - - - - - - - 12 months
Extend preservation - - 12 additional months
Indoors, dry ambient uncontrolled temperature:
Initial - - - - - - - - - - - - - - - 6 months
Extend preservation- - - - - 6 additional months
Outdoor storage:
Not recommended.
2.4 SAFETY PRECAUTIONS
When ins talling, operating, and maintaining the
ECC, ke ep safety considerations fore most. Use
proper tools, protective clothing, and eye protection
when wor king on the e quipment and inst all th e
equipment with a view toward ensuring safe opera-
tion. Follow the instructions in this manual and take
additional safety measures appropriate to the liquid
being pumped. Be extremely careful in the pres-
ence of hazardous substances (e.g., corro-
sives, toxics, solvents, acids, caustics,
flammables, etc.)
2.5 MOUNTING
The Milton Roy ECC is commonly shipped already
mounted on a pum p. Be cause o f this, installation
usually req uires conn ecting the power an d signa l
wires. If the ECC was shipped without a pump,
mounting to your pu mp a nd m inor calib ration
adjustment is required (Full calibration is per-
formed at the factory and only limited calibration is
required after mounting). ECCs installed on pumps
outdoors sho uld b e pr otected by a shelte r. Car e
should be taken to keep co ndensation and mo is-
ture from entering via the electrical conduit.
2.6 ELECTRICAL CONNECTIONS
The e lectrical con nections for the ECC are inp ut
signal, fee dback output sign al, a nd in put power.
Terminal blo cks, with r emovable conn ectors are
located on the bottom of the circuit board under the
ECC cover. Conduit access to the ECC is via two
threaded 1/2- 14 in ch NP T thre aded o penings i n
the ECC base. All wiring should conform to
National Ele ctrical code s or local codes a s they
apply. Conduit bushings must be chosen to provide
NEMA 4 , and explosion p roof in tegrity. In Nor th
America, use NEMA type 4 and/or explosion proof
conduit fittings. In Eur ope, cable glands with IP66
and/or EExd ratings are readily available with 1/2-
14 inch NPT threads.
WARNING
ALWAYS DISCONNECT PRIMA RY
POWER BEFORE REMOVING THE
COVER FROM THE ECC. FAILURE TO
FOLLOW THESE INSTRUCTIONS
COULD RESULT IN DE ATH OR
SERIOUS INJURY
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TO AVOID DAMAGE TO SENSITIVE
ELECTRONICS, REMOVE THE COV ER
FROM THE ECC CAREFULLY.
2.6.1 Inst allation of Input/Output Comma nd
Signal Wiring
1. Uns crew the ECC cover by turning it counter-
clockwise (as viewed fro m the top ). Lif t th e
cover straight off and away.
IMPROPER CONNECTION OF THE
COMMAND LIN ES CA N CAU SE DA M-
AGE TO THE ECC. USE ONLY 300
VOLT, 105°C RATED WIRE , MINIMUM
22 AWG, MAXIMUM 14 AWG.
2. Maintain integrity of safety approv als us ing
only 300 volt, 105° C (UL 1213 or equiv.) rated
insulation. Maintain CE immunity ratings, using
shielded cable inside of conduit.
3. Feed fo ur (1 4 to 2 2 A WG) shield ed wir es
through appropriately r ated con duit b ushing
inserted into one of the conduit holes in base of
ECC. Ground shields for four wires to a good
chassis ground at control end.
4. Route wires to ECC keeping electrical interfer-
ence to a minimum. Carefully pull four-position
connector J5 from circuit board. Connect com-
mand signa l wir es to co nnector J5 (Figure 4
and 12 ). Re connect con nector J5 to circuit
board.
2.6.2 Input Signal
The input signal, used to control the ECC, can be
either 4- 20 mA or (1-5 VDC). A five-position Dip
switch, SW2 (F igure 11, located on the top of th e
circuit board) selects the control signal used by the
operator. The f actory se ts SW2 fo r the model
ordered and should not need changed. Position
1 (Table 10) of SW2 sets the input signal. Position
2 sets the movement of the ECC after unintentional
loss of the control signal. Position 3 and 4 sets the
ECC for use with a pump o r valve a nd should
always be set to 3- OFF and 4 -ON for the pum p
mode. Position 5 is not used.
Figure 4. Circuit Board Connectors J4 and J5
2.6.3 Feedback Output Signal
A position output, proportional to ECC po sition, is
used for remote position indication. A current of 4-
20 m A or a volt age of 1 -5 VDC is a vailable
between MONIT OR (J5- 4) and COMMON ( J5-3).
Feedback zero an d feed back sp an adju stments
(Figure 1 1) ar e p rovided to fine tu ne th e ou tput
(see calibration instructions). DIP switch SW3 (Fig-
Table 10. SW2 DIP Switch Settings
INPUT SWITCH POSITION
12345
Input Signal of 4-20 mA ON
Input Signal of 1-5 VDC OFF
Hold Position on Loss of
Control Signal
ON
Return to Lower Limit on
Loss of Control Signal
OFF
Pump Mode (limits abso-
lute)
OFF ON
Valve Mode (limits floating) ON OFF
Not Used NC
J4
J5
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ure 11) selects the feedback output signal. Use of
the output signal is optional.
2.6.3.1 Feedback Output Signal 4-20 MA
NOTE
Do not connect the 4-20 mA output to a cir-
cuit with greater than a 500 ohm load
Set SW3 per Table 11 for a 4-20 mA feedback sig-
nal.
2.6.3.2 Feedback Output Signal 1-5 VDC
NOTE
Do no t conn ect the 1- 5 VDC outpu t to a
circuit h aving le ss than 2 50 o hms im ped-
ance.
Set SW3 per Table 11 for a 1-5 VDC feedback sig-
nal.
2.6.4 Installation of Primary Power Wiring
Primary power wirin g to operate th e ECC shou ld
be ro uted via a n on /off switch (th ere are no
switches on the ECC) or a panel breaker switch.
1. Maintain integrity of safety approv als us ing
only 300 volt, 105° C (UL 1213 or equiv.) rated
insulation.
IMPROPER CONNECTION OF THE
POWER LINE OR INCORR ECT SUPPLY
VOLTAGE CAN CAUSE DAMAGE TO
THE ECC. DISCONNEC T ALL POWER
BEFORE CONNECTING WIRES.
2. Feed three (12 to 16 A WG) prim ary powe r
wires through a ppropriately r ated con duit
bushing inserted into th e other conduit hole in
the base of th e ECC. Co nnect ground wire to
screw at ECC end.
3. Carefully pull tw o-position connector J4 from
circuit bo ard ( Figure 4). Con nect HI- blk an d
LO-wht wir es to ter minal blo ck con nector J4
(Figure 12). Reconnect connector J4 to circuit
board.
VOLTAGE SELECTOR SWITCH SW1
LOCATED ON TOP OF THE CIRCUIT
BOARD MUST BE SET TO THE VOLT-
AGE LISTED ON YOUR DATA PLATE
(FIGURE 1 OR 2), OR DAMAGE TO
MOTOR WILL RESULT.
Voltage s elector switch SW1 ( Figure 1 1), locate d
on top of the circuit board, is a two-position switch
used to configure the ECC for an input of 115 VAC
or 230 VAC. Insure SW1 is set to the voltage listed
on your data plate (Figure 1 or 2), attached to th e
enclosure. The fa ctory s ets SW1 fo r the model
ordered and should not be changed. If the oper-
ating voltage must be changed, contact the Milton
Roy factory at [phone] for conversion parts
and instructions.
Table 12. SW1 Voltage Selector Switch Setting
2.7 CIRCUIT B OARD RETROFIT KIT INST AL-
LATION (Table 9)
2.7.1 Remove Old Circuit Board
1. Unscrew ECC cover by turning it counterclock-
wise (as viewed from th e top) . Lift cover
straight off and away.
2. If the bo ard yo u ar e replacing has terminal
blocks fo r pr imary and signal wire s, loose n
screws an d r emove wire s. La bel wir es before
removal to facilitate re-installation.
3. If the old board has plug-in connectors, simply
unplug all connectors from circuit board.
Table 11. SW3 DIP Switch Settings
OTPUT SWITCH POSITION
12345
Output Signal of 4-20 mA ON ON OFF OFF OFF
Output Signal of 1-5 VDC OFF OFF ON ON ON
For Input Power of 115VAC 50/60Hz
Note: The motor and motor run capacitor must be
rated for 115VAC operation, or damage will result.
115
For Input Power of 230VAC 50/60Hz
Note: The motor and motor run capacitor must be
rated for 230VAC operation, or damage will result.
230
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4. Remove cir cuit bo ard from it s three m ounting
standoffs.
2.7.2 Required Modifications
Identify old circuit board type (see Figure 5 and 6)
and fo llow dir ections spe cific to b oard. ECC Part
Number 30033 - (Figure 5)
No adaptation needed. Motor plug is the same, and
the run capacitor will plug di rectly into the new cir-
cuit board. Discard the old cup s tyle safety cover.
Proceed to paragraph 2.7 .3, “ Install New Circuit
Board”.
2.7.2.1 ECC Par t Number 0152226XXX and
0152195XXX (Figure 6)
1. Adapter for the motor plug is required, (Milton
Roy p /n 0 4913009000, a 5 p in m ale to 9 p in
female connector).
2. Appropriate motor ru n ca pacitor is re quired
since the se boards ha d cap acitor sold ered to
circuit board.
3. Motor run resistor if use d, may need to be re-
located on the ba se plate (Fig ure 7) to allow
room to locate the motor run capacitor.
4. The mo tor r un cap acitor sh ould be mo unted
using a new base plate mo unting screw, p/n
0405-0264-031 (6-32 x 7/16”).
VOLTAGE SELECTOR SWITCH SW1
LOCATED ON TOP OF THE CIRCUIT
BOARD MUST BE SET TO THE VOLT-
AGE LISTED ON YOUR DATA PLATE
(FIGURE 1 OR 2), OR DAMAGE TO
MOTOR WILL RESULT.
5. Voltage sele ctor switch SW1 (Figure 11),
located o n top of the ci rcuit bo ard, is a two-
position switch used to co nfigure the ECC for
an input of 115 VAC or 230 VAC. Insure SW1 is
set to the voltage listed on your data plate (Fig-
ure 1 or 2), attached to the enclosure. The fac-
tory set s SW1 for the m odel or dered an d
should not be changed. If the operating voltage
must be changed, contact the Milton Roy fa c-
tory at [phone] for conversion parts and
instructions.
6. Set DIP switch SW2 (Paragraph 2.6.2, Inp ut
Signal).
7. Set DIP switch SW3 for 4-20 mA or (1-5 VDC)
output app ropriately. (Par agraph 2.6 .3, Fe ed-
back Output Signal).
8. Proceed to paragraph 2.7.3 “Install New Circuit
Board”.
2.7.3 Install New Circuit Board
1. Connect:
J1 - - - - - - (9-pin motor connector, use adapter
as required).
J2 - - - - - - (3-pin potentiometer connection.)
J3 - - - - - - (4-pin motor run capacitor connec-
tion.)
J4 - - - - - - (2-pin AC power connector.)
J5 - - - - - - (4-pin control signal connector.)
2. Mount the board on the standoffs utilizing three
captive 8 -32 scr ews. Orie nt circuit bo ard with
voltage selector switch over feedback potenti-
ometer (Figure 7).
3. Calibrate as required Section 4, Maintenance.
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Figure 5. Circuit Board, 30033
Figure 6. Circuit Board, 0152226XXX, 0152195XXX
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Figure 7. Conversion Detail
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THIS PAGE INTRNTIONALLY BLANK
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