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Milton Roy
339-0083-000 5-2005 Electronic Capacity Control

339-0083-000 5-2005 Electronic Capacity Control

Product catalog summary

Important Safety Instructions: The manual stresses the necessity of adhering to safety precautions to prevent fire, electric shock, and personal injury during the installation, calibration, or operation of the actuator. It is essential to read all instructions beforehand and ensure that only trained personnel handle installation and maintenance, especially when dealing with hazardous voltages and chemicals.

Quick Start Guide: This section offers a step-by-step guide for setting up the actuator, including connecting AC power, grounding the unit, and configuring command and feedback signals. It emphasizes verifying voltage settings and DIP switch configurations before powering the unit.

Table of Contents: The manual is organized into sections such as Description, Installation, Operation, Maintenance, Troubleshooting, Parts List, and Warranty, each providing detailed information on specific aspects of the actuator's use and maintenance.

Installation: Detailed instructions are provided for field installation, circuit board replacement, and electrical connections, with an emphasis on safety precautions and proper mounting techniques to ensure safe and effective installation.

Operation: This section covers controls and initial start-up procedures, including operating modes and input signal configurations, and provides guidance on adjusting the control range for optimal performance.

Maintenance: The manual outlines maintenance procedures, including spare parts management, returning units to the factory, and replacing components such as printed circuit boards, feedback potentiometers, and motors. Calibration routines are detailed to ensure accurate operation.

Troubleshooting: A troubleshooting section is included to help diagnose and resolve common issues that may arise during operation.

Parts List: Comprehensive parts lists are provided for various components and mounting adapters, ensuring users can identify and order necessary parts for maintenance and repairs.

Warranty: The manual concludes with a limited warranty section, outlining the terms and conditions of the product warranty.

General Information: The document discusses the Milton Roy Electronic Capacity Control (ECC), which integrates with computerized process instruments to adjust the output of a metering pump based on a 4-20 mA or 1-5 VDC signal. This feature can be purchased with the pump or separately for field installation.

Principle of Operation: The ECC allows remote adjustment of the pump's liquid delivery volume using a 4-20 mA command signal, providing immediate and accurate control of pump flow under varying conditions, with feedback output for monitoring.

Specifications: The ECC operates on 115 VAC or 220 VAC power, with control signal input options of 4-20 mA or 1-5 VDC. It features a NEMA 4, IP55 enclosure, and supports continuous duty cycles up to 110°F.

Product Model Coding: ECCs can be ordered with various Milton Roy pump models, indicated by specific codes on the pump data plate. Model codes are provided for different pump types, including mRoy, maxRoy B, Milroyal B, C, D, G, and MacRoy D and G.

Agency Approvals: The ECC complies with various safety and hazardous location standards, including MET Labs, CSA, CE, and FM approvals. A declaration of conformity is included, listing applicable standards.

Installation: ECCs are typically pre-mounted on pumps, requiring only signal and power connections. Field installation is not recommended for certain pump models due to alignment requirements. Circuit board replacement procedures are outlined for ECCs built before and after January 2000.

Unpacking and Storage: Instructions for unpacking and storing ECCs are provided, emphasizing protection against corrosion and atmospheric conditions. Indoor storage is recommended, with specific guidelines for extending storage time.

Safety Precautions: Safety measures are highlighted for installation and operation, including the use of proper tools and protective gear, especially when handling hazardous substances.

Mounting and Electrical Connections: Details on mounting ECCs and making electrical connections are provided, with warnings about disconnecting power before removing covers to prevent injury or damage.

Specifications and Safety: Use 300 volt, 105° C (UL 1213 or equivalent) rated insulation to maintain safety approvals. Ensure CE immunity ratings by using shielded cable inside conduit. Feed four shielded wires (14 to 22 AWG) through a rated conduit bushing into the ECC base. Ground shields to a good chassis ground. Route wires to ECC minimizing electrical interference. Connect command signal wires to connector J5 on the circuit board.

Input Signal: The ECC can be controlled by a 4-20 mA or 1-5 VDC input signal. A five-position DIP switch (SW2) selects the control signal. The factory sets SW2 for the ordered model, and it should not be changed. Positions on SW2 configure input signal type, ECC movement after signal loss, and mode (pump or valve).

Feedback Output Signal: Feedback output is proportional to ECC position, available as 4-20 mA or 1-5 VDC. Adjustments for feedback zero and span are provided. DIP switch SW3 selects the feedback output signal.

Primary Power Wiring Installation: Use 300 volt, 105° C rated insulation for safety. Feed three primary power wires (12 to 16 AWG) through a conduit bushing into the ECC base. Connect the ground wire. Connect HI-blk and LO-wht wires to terminal block connector J4. Ensure the voltage selector switch SW1 is set to the correct voltage (115 VAC or 230 VAC) as per the data plate.

Circuit Board Retrofit Kit Installation: Remove the old circuit board by unscrewing the ECC cover and disconnecting wires. Identify the old circuit board type and follow specific instructions for modifications if needed. Install the new circuit board by connecting various connectors (J1 to J5) and mounting the board on standoffs.

Operation: The ECC is equipped with a hand wheel for repositioning the shaft when power is off. During initial start-up, check signal connections and apply a command signal. Ensure the voltage selector switch is set correctly. The ECC can operate in direct-acting or reverse-acting modes, determined by the model number.

Control Range Adjustment: Remove the ECC cover and locate the zero and span adjust controls on the circuit board. Adjust the zero and span controls to set the desired control range.

Maintenance: The ECC is reliable and requires minimal maintenance. Typical procedures include replacing the printed circuit board, feedback potentiometer, nylon worm gear, or motor. For PCB replacement, ensure power is disconnected and follow the removal and installation instructions.

Installation and Maintenance Procedures:
1. PCB Installation: Connect connectors J1 to J5 to the bottom of the PCB. Place the PCB on standoffs and tighten screws with nylon washers. Perform calibration B or C based on factory calibration status.
2. Feedback Potentiometer Replacement: Removal: Set pump stroke to 0%, disconnect power, remove PCB, and unscrew potentiometer assembly. Installation: Align and install the new potentiometer, apply lithium grease if needed, compare wire colors, and install jumper cable if necessary. Reinstall PCB and perform calibration A.
3. Nylon Worm Gear Replacement: Removal: Set pump stroke to 0%, disconnect power, remove PCB and potentiometer, and remove the nylon gear. Installation: Align and install the new gear, reinstall capacitor, potentiometer, and PCB, and perform calibration A.
4. Motor Replacement: Removal: Set pump stroke to 0%, disconnect power, remove ECC, gearbox, and motor components. Installation: Mount the new motor, connect wires, install worm gear, attach adapter plate, apply grease, and perform calibration A.
5. ECC Calibration: Calibration A: Synchronize ECC with pump after component replacement. Use a digital volt meter and adjust potentiometers for zero and span settings. Calibration B: Synchronize ECC with pump after replacing a factory-calibrated circuit board. Calibration C: Complete calibration for a new, non-factory-calibrated circuit board. Used for diagnostics and setup for different pump series.
Warnings: Always disconnect electrical power before maintenance to prevent injury. Calibration involves working with high voltages and should be performed by qualified personnel.

Specifications and Procedures: Ensure the voltage selector switch is set to the correct voltage (115 VAC or 230 VAC) as indicated on the data plate. Adjust DIP switches SW2 and SW3 for proper operation. Initial adjustments involve setting resistances and offsets on the circuit board using a digital voltmeter (DVM) and adjusting various potentiometers (VR2, VR7, VR9, VR5) for specific voltage readings. Adjustments for span and feedback span require disconnecting the motor lead and applying specific input signals to achieve desired voltage outputs. Reconnect components and verify operation by varying input signals and observing motor response. Final adjustments involve setting the pump stroke to specific positions and ensuring proper engagement with the ECC drive pin.

Troubleshooting: If the ECC moves to the same position regardless of the signal, check the command signal, mode setup, and feedback potentiometer. Flickering limit lights may indicate a bad feedback potentiometer or connection issues. If the ECC does not respond to a 4-20 mA command signal, check for power, signal polarity, and motor condition. ECC traveling in one direction or chattering may require circuit board or potentiometer replacement.

Parts List: The parts list provides detailed information on replaceable components, including item numbers, descriptions, part numbers, and quantities. Specific parts are listed for different models such as MacRoy, mRoy, and Milroyal, with variations in components like motors, bushings, and circuit boards. Illustrated parts lists and exploded view illustrations help identify unknown part numbers.

Figures and Illustrations: Figures provide visual references for electronic capacity control and mounting adapters for various models. Each figure is associated with a detailed parts list, indicating the components used in specific models and configurations.

Introduction: This document provides a detailed procedure for retrofitting a Milroyal C pump with an electronic capacity control (ECC) system. The retrofit kit includes essential components such as the ECC and worm gear speed reducer assembly, lead screw with splined shaft, adapter, and necessary hardware.

Safety Precautions: Before beginning the procedure, ensure that the power to the pump motor is disconnected and the switch is locked and tagged to prevent accidental power restoration.

Installation Procedure: Clamp the ECC in a vise, remove the cover, and apply power to run the unit to its lower limit. Disconnect power and replace the cover. Drain oil from the pump gear chamber. Adjust the pump capacity to 0% using the micrometer knob. Rotate the pump motor shaft to access the gear housing and loosen the set screws to remove the lead screw shaft. Remove the handknob and the 0-100% plate from the rear hub, as these parts will not be reused. Install the new lead screw shaft and align it with the keys, then secure it with set screws. Attach the aluminum mounting adapter and slide the ECC gearbox onto the splined shaft, securing it with lockwashers and screws. Apply the 0-100% label to the indicator tube and align it with the indicator ring. Refill the pump drive gearbox with oil. Perform the ECC initial start-up procedure and re-calibrate if necessary.

Conclusion: This procedure outlines the steps for successfully retrofitting a Milroyal C pump with an ECC system, ensuring improved control over pump capacity. Adherence to safety precautions and detailed instructions is crucial for effective installation.

Catalog excerpts

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339-0083-000 5-2005 Electronic Capacity Control-3

WHEN INSTALLING, CALIBRATING, OR OPERATING THIS ACTUATOR, BASICSAFETY 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 operationGENERAL 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 existinside the actuator....

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NOTE: Read and understand safety instructions before proceeding READ - Read and comply with all safety instructions presented in this manual. In order to comply with therequirements of agency approvals (see data plate), specifications for conduit connections, wire gaugeand type, fastener torque ratings, and operating conditions must be adhered to. CONNECT VERIFY - Connect AC power. Use conduit connections or cable glands. - Ground unit. - Connect command signal.- Connect feedback signal. - Voltage selector switch is set to the required voltage (115 or 230 VAC).- DIP switches are set for desired...

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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 fulltravel 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. iii >

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IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iQUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiSECTION 1 - DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 PRINCIPLE OF OPERATION . . . . . ....

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3.1 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2 INITIAL START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2.1 Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.2.2 Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3 CONTROL RANGE ADJUSTMENT . . . . . . . ....

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6.5 PARTS LIST FOR MROY ECC MOUNTING ADAPTER (MROY BӔ). . . . . . . . . . . . . . . . . . . . 376.6 PARTS LIST FOR MACROY ECC MOUNTING ADAPTER (MACROY GӔ, DӔ AND MIL-ROYAL G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406.7 PARTS LIST FOR MAXROY ECC MOUNTING ADAPTER (MAXROY BӔ). . . . . . . . . . . . . . . 436.8 PARTS LIST FOR MILROYAL ECC MOUNTING ADAPTER AND MOUNTING ADAPTER GUARD ASSEMBLY (MILROYAL BӔ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476.9 PARTS LIST...

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Table 1. Stroke Adjust Shaft & Pump Opera-tion Reference ManualsPUMPMANUAL 1.1 GENERAL INFORMATION In this age of sophisticated process control con-cepts, many people are taking advantage of the lat-est breakthroughs in technology to upgrade theirown equipment and systems. The Milton Roy Elec-tronic Capacity Control (ECC) easily interfaces with computerized process and process instruments, asthe 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 signal from a computer or other source. This outstanding feature can be purchasedas an integral...

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Table 5. Milroyal C Model CodesMODELNUMBERENCLOSUREVOLTAGE PPGW482LMHNema 4115 VAC50/60 HzPPGW682LMHNema 4230 VAC60 HzPPGW782LMHNema 4230 VAC50 HzPPGX482LMHExplosion Proof(FM Approved)115 VAC50/60 HzPPGX682LMHExplosion Proof (FM Approved)230 VAC60 HzPPGX782LMHExplosion Proof (FM Approved)230 VAC50 Hz Table 8. MacRoy D and G Model CodesMODELNUMBERENCLOSUREVOLTAGE50/60 HZ PPGW242LMHNema 4115 VACPPGW542LMHNema 4230 VAC PPGX242LMHExplosion Proof (FM Approved)115 VACPPGX542LMHExplosion Proof (FM Approved)230 VAC 1.5 AGENCY APPROVALS (Figures 1, 2 and 3) Table 6. Milroyal D Model CodesMODELNUMBERENCLOSUREVOLTAGE50/60...

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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....

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Table 9. ECC C board (p/n 30300/39320) specify whatpump the unit is being installed on to insure the replacement board is configured for yourpump. This will eliminate problems during installa-tion. Refer to Printed Circuit Board Replacement (paragraph 4.4, Section 4 ) > 2.1 GENERAL INFORMATION The ECC is usually shipped already mounted tothe pump. Installation, therefore, is usually only a matter of connecting the signal wiring (paragraph2.6.1) and primary power wires (paragraph 2.6.4). 2.1.1 Field Installation of ECC Field installation of the ECC to an existing pump isusually not recommended...

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