Manual - The M.C. Miller Company
Contents
1. once on one unit only 14 32 10 At 14 32 all units will display LOCh This is a countdown operation to show that the units are performing a calculation When the calculation is complete all the units will immediately commence cycling Since the relays are now in operation try to maintain them in an upright position during transport and installation 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 14 MCM JR 2 Current Interrupter Example 3 Extended Delayed Start Next Day Test Requirements Same as Example I Work Schedule Testing to begin 8 00AM the next morning Present Time 1 30PM Procedure With the following exceptions follow Example 1 Display Reading 1 Press START SET 3 2 0 0 ENTER 32 00 In short add 24 00 to desired start time eg 31 00 would be 7 00 A M plus 24 hours 31 00 Miscellaneous Features If STOP SET is not desired continuous cycling program STOP SET to an illegal time eg 24 01 To create a MASTER unit which never starts cycling program STOP SET to egual START SET Correcting Keypad Entry Errors Press The letter O until display reads 00 00 then enter the correct numeric seguence EXAMPLE 1 3 0 was entered for 1 30PM Press the letter O four times and then press 1 3 3 0 Enter The correct entry reads 13 30 116402. US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com WIGMILLER c Instruments and Equipment for the Corrosion Engineer 15 MCM JR 2 Current Interrupter Synchronizing a Model JR 2 Suppose there are five JR 2 s in the field and one is accidentally turned off and needs to be restarted and resynchronized All the units could be brought back to a single location daisy chained together and started as in example 2 This procedure will work but is rather inefficient Therefore the JR 2 s are constructed so that any one of the operating units may be used as a master to restart the failed slave unit Simply take the slave unit to the working master location and follow the procedure below The JR 2 s automatically output a trigger pulse to the SYNC receptacle once a minute when running Procedure 1 Turn the slave unit to be resynched OFF and then ON Check or set the functions on the slave to the same as those on the master Press the function key on both the master and the slave to display their settings a START SET b ON CYCLE c OFF CYCLE d STOP SET e START RELAY SWITCH CLOSED 3 Press CLOCK SET on the slave and enter a time which is a minute or two ahead of the MASTER 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipme
3. at the far end end furthest away from the 3 pin socket and allowing the door to hinge as shown Step 2 Use pointed pliers to remove the printed circuit board PCB as shown in Figures 4 and 5 In the current example the clear plastic guide attached to the PCB points down to the 120V label on the PCB as shown in Figure 6 Step 3 Rotate the clear plastic guide as shown in Figure 7 until the guide points down to the 240V label as shown in Figure 8 Step 4 Re install the PCB as shown in Figure 9 making sure that the lettering on the PCB faces into the housing and the PCB is firmly seated In this example once the panel door is firmly closed the plastic indicator should now occupy the 240V setting hole as shown in Figure 10 Replacing the fuses Step 1 Gently pry open the panel door using a small flat head screwdriver as indicated in Figure 11 Insert the screwdriver into both slots in turn until the panel door pops open The panel door can then be fully opened by lifting the door at the far end end furthest away from the 3 pin socket and allowing the door to hinge Step 2 Using the same small flat head screwdriver remove 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com WIGMILLER c Instruments and Equipment for the Corrosion Engineer 21 MCM JR 2 Current Interrupter the fuse holder from the power entry module by inserting t
4. for each start up Synchronization Multiple units may be synchronized before or during operation Re synchronization The JR 2 calculates when the relay should be switching based on start time This allows the re synchronization of an existing unit or insertion of additional units during a test in progress Charging System A unique three step system provides faster recharging longer battery life and temperature compensation This allows for indefinite float charging during storage State of Charge Indicator This indicator changes from RED to GREEN when 100 capacity is reached 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 5 MCM JR 2 Current Interrupter Specifications DISPLAY 5 1 2 digit liguid crystal with battery and relay condition annunciators Character height 5 in Operating temperature 20 to 195 degrees F 30 to 90 C degrees TIME BASE 2 MHz Temperature Compensated Crystal Oscillator 0 5 Sec per 24 Hr KEYBOARD Sealed Tactile feedback 16 key Arrangement 5 function keys Time Set Start Set Stop Set 6 On cycle Off cycle 10 digit keys 0 9 1 Enter Key ENTER CYCLE RANGE 1 to 999 9 seconds On Cycle and Off Cycle AUTO START Start Set Programmable delayed Start from 1 minute to 24 hours in one minute increments AUTO STO
5. the mercury relay Warning Always observe the proper safety procedures when working on electrical eguipment Turn off all live wires before inserting the current interrupter TYPICAL INSERTION HIGH CURRENT POINTS FOR AC LOW VOLTAGE AC INTERRUPTION INTERRUPTION cB RECTIFIER A BOA SUPPLY 120 240 VAC CB HIGH CURRENT D C INTERRUPTION STRUCTURE Typical connections for MCM Model JR current interrupters 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com WIGMILLER c Instruments and Equipment for the Corrosion Engineer 10 MCM JR 2 Current Interrupter AC DC Current Carrying Limits JR 2 Current Interrupter JR 2 AC Current Current Amps Normal Operating Range oO Oo O O Q O O x Ny N OV SHOA JR 2 DC Current Normal Operating Range Current Amps 94 SHOA 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 11 MCM JR 2 Current Interrupter Example 1 Delayed Start Interruption Begins Later The units will be put in place befo
6. 6 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com MIGMILLER c Instruments and Equipment for the Corrosion Engineer 24 MCM JR 2 Current Interrupter Figure 9 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com MIGMILLER c Instruments and Equipment for the Corrosion Engineer 25 MCM JR 2 Current Interrupter Figure 10 Replacing the Fuses Figure 11 Figure 12 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 26 MCM JR 2 Current Interrupter Figure 13 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com MIGMILLER c Instruments and Equipment for the Corrosion Engineer 27
7. Model JR 2 Current Interrupter Operating Manual Revised August 19 2011 4 IMIG MILLER co Catalog 12830 MCM JR 2 Current Interrupter Table of Contents Topic Warranty General Capabilities Features Specifications Panel Controls Operations Overview Installation of the Interrupter in the Rectifier AC DC Current Carrying Limits Example 1 Delayed Start Interruption Begins Later Example 2 Intermediate Start Cycle Begins Now Example 3 Extended Delayed Start Next Day Synchronizing a Model JR 2 Maintenance Repairs Low Battery Indication Supply Voltage Selection Charging the Battery Replacement Parts Appendix 1 How to change the voltage setting on the power entry module to match the supply voltage and how to change the fuses JR2 model with 3 pin socket mounted on the back of the unit 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 2 MCM JR 2 Current Interrupter Warranty M C Miller Co Inc warranties each new instrument manufactured and sold to be free from defects in material workmanship and construction except for batteries which may be contained therein When used in accordance with this Operating Manual the unit will perform to applicable specifications for a period of one year after shipment If exami
8. P Stop Set 6 Programmable Stop from 1 minute to 24 hours in one minute increments NOTE Always stops with respect to Start Relay switch Position Open or Closed SYNCHRONIZATION Multiple Unit capability compatible with all JR versions ACCURACY Typically less than 5 sec over 24 hours RELAY Normally Closed Mercury Plunger MAXIMUM RATINGS CURRENT 100 A 48 VDC 100 A 120 VAC 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 6 MCM JR 2 Current Interrupter MAXIMUM RATINGS VOLTAGE 30 A 240 VDC 40 A 600 VAC BATTERY Sealed rechargeable 12 Volt 7 A Hr BATTERY LIFE Is dependent on the interruption duty cycle Examples 4 sec On 1 sec Off Lifetime 50 hours 1 sec On 4 sec Off Lifetime 15 hours Since power is required to hold the relay open in the case of the JR2 battery lifetimes will be shorter for longer Off time duty cycles SIZE Exterior Dim 10 5 8 x 9 11 16 x 6 7 8 Metric Dim 269 875 x 246 050 x 174 625 mm WEIGHT 14bs Net weight 6 4 Kg NOTE The JR 2 needs to be put in an Upright Position in order for the unit to Work The Mercury Relay will not work if it is lying on its side Once the JR 2 is programmed to the proper setting you wish to set at that time you may set the JR in an Upright Position and press star
9. an gualified electronic technicians should attempt servicing the JR 2 Contact the M C Miller Co Inc if a problem arises Low Battery Indication When the battery has discharged to a factory set level a LO BAT indication will display in the upper left portion of the display window Approximately two hours of operating time remains when the indicator displays Supply Voltage Selection for charging and or powering the unit For the JR2 model with the 3 pin socket mounted on the front of the unit case handle side The input voltage supply voltage setting is established via the fuse selector by the customer A small bag with the fuse and the fuse holder is attached on the outside of the case with instructions provided on how to position the fuse in order to establish a particular voltage setting For the JR2 model with the 3 pin socket mounted on the back of the unit Please see Appendix 1 below pages 20 27 How to change the voltage setting on the JR2 s power entry module to match the supply voltage and how to replace the fuses 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 18 MCM JR 2 Current Interrupter Charging the Battery A sealed lead acid gel cell battery furnishes power for the JR 2 The front panel indicator displaying state of charge will be RED
10. during the charging stage When the battery is fully charged the charging indicator will turn GREEN and remain GREEN through the float stage Charging may take place during operation or storage periodically or on a continuous basis If continuous charging during storage is performed the circuit will automatically maintain a full charge regardless of the temperature The battery charging time will depend on the status of the battery prior to beginning the charging process Typical charging times for GREEN light observation are as follows Fully discharged battery approx 11 hours 40 discharged battery approx 5 hours As an example the battery in a unit that has been run for a total of 16 hours in a 0 7sec ON 0 3sec OFF switching mode will be approximately 40 depleted and will require approx 5 hours to re charge to full capacity Replacement Parts Battery 12 Volt 7A Hr Part BATOO8 Sync Cable Assembly Part SUBO26 3 Conductor Line Cord Part CONO14 Power cable Assembly Part SUB577 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 19 MCM JR 2 Current Interrupter Appendix 1 How to change the voltage setting on the JR2 s power entry module to match the supply voltage and how to replace the fuses WARNING Disconnect the external AC power supply before changi
11. he screwdriver into one of the two rectangular holes in the fuse holder as shown in Figure 12 and lifting out the fuse holder with an upward movement of the screwdriver Step 3 Turn the fuse holder upside down to reveal the set of two fuses as shown in Figure 13 and replace the fuses as necessary be careful not to break the retaining posts The fuses are 5nmx20mm 250V 2A fast acting fuses and these fuses protect the unit regardless of the input voltage setting 120V or 230V Note Replacement fuses must have these same specifications Step 4 After replacing the fuses re install the fuse holder Note Make sure that the fuses are downward positioned so that the contact pins located at the bottom of the housing make contact with the fuse terminals the fuses should not be visible after re installation of the fuse holder Step 5 Close the hinged panel door and make sure that the door is firmly seated 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 22 MCM JR 2 Current Interrupter Figure 1 Figure 3 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com MGMILLER c Instruments and Equipment for the Corrosion Engineer 23 MCM JR 2 Current Interrupter e Figure 4 e Figure
12. ir various locations for installation Testing may begin at 8 00 A M Example 2 Immediate Start Cycle Begins Now The JR 2 s will be put in place after interruption cycle begins In other words the units will be synched after the Start cycle time has occurred It is 2 30 in the afternoon and the JR 2 s are in one location ready to be synched They will be installed in the rectifiers later The JR 2 s will start their On Off cycle immediately and remain cycling until 5 00PM in the evening At that time they will shut the relay and wait until 8 00AM the next morning before resuming interruption Test Requirements On Cycle 2 sec Off Cycle 5 sec Work Schedule Start 8 00AM Stop 5 00PM and repeat for XXX days as necessary The present time is 2 30 PM 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 13 MCM JR 2 Current Interrupter Procedure All Units Display Reading Power Switch ON PASS Start Relay Closed PASS Press START SET 8 0 0 ENTER 8AM 8 00 Press STOP SET 6 1 7 0 0 ENTER 5PM 17 00 Press ON CYCLE 2 0 ENTER 2 sec 2 00 Press OFF CYCLE 5 ENTER 0 5 sec 50 Interconnect SYNC jacks on all units daisy chain fashion Press CLOCK SET 1 4 3 2 2 32PM press ENTER 14 32 9 When present time your wrist watch reads 2 32 Press ENTER
13. ity if DC is to be interrupted The JR 2 contains an EEPROM which retains the last entry made under the five function keys Factory testing will leave an existing program which will be overwritten by the next entries The uses for the JR 2 are too numerous to list The following examples will serve as both a set up programming and typical use guide These examples assume instant off testing of multiple rectifier cathodic protection on a structure Note ALWAYS USE THE MILITARY TIME FORMAT WHEN ENTERING TIME DATA FOR EXAMPLE 18 00 INSTEAD OF 6 00 PM Installation of the Interrupter in the Rectifier In general it is physically easier to interrupt across the taps of the rectifier In addition the tap location is best because breaking AC causes less wear on the relay This is due to the AC crossing zero volts and extinguishing the arc whereas DC depends on the distance of the gap to extinguish the arc The next best location to interrupt is the AC power supply The DC side may also be interrupted at the anode or structure leads or output of the rectifier 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com WIGMILLER c Instruments and Equipment for the Corrosion Engineer 9 MCM JR 2 Current Interrupter When using the JR 2 to interrupt on the DC side the indicated polarities should be observed to reduce wear of the plating on the plunger of
14. nation by M C Miller Co Inc discloses that the product is defective then its obligation is limited to the repair or replacement of the defective unit or its components at the option of M C Miller Co Inc M C Miller Co Inc is not responsible for products which have been subject to misuse alteration accident or for repairs not performed by M C Miller Co Inc Instruments must be returned properly packed with the transportation charge prepaid to M C Miller Co Inc 11640 US Hwy 1 Sebastian Florida 32958 Return transportation charges will be F O B factory No parts shall be returned without prior authorization which shall be furnished upon reguest The foregoing warranty constitutes M C Miller Co Inc s sole liability and is in lieu of any other warranty of merchantability or fitness M C Miller Co Inc shall not be responsible for any incidental or consequential damages arising from any breach of warranty 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 3 MCM JR 2 Current Interrupter General The MCM Model JR 2 is a microprocessor controlled high current interrupter featuring a high stability temperature compensated time base The JR 2 was specifically designed for the interruption of multiple rectifier cathodic protection systems in order to conduc
15. ng the input voltage setting or replacing the fuses Changing the voltage setting to match the supply voltage Your JR2 current interrupter will have been shipped to you with an input voltage setting appropriate for your country However since it is extremely important that the input voltage setting match the AC supply voltage applied to the unit for charging and or powering purposes it is critical that you check to make sure that the setting is correct for your application To do so examine the panel directly above the 3 pronged socket The input voltage setting will be indicated by whichever hole is occupied by the plastic indicator 100V 120V 230V or 240V If the input voltage setting is not appropriate for the voltage you will be supplying to the unit please follow the instructions below to change to the correct setting Example Changing from a 120VAC setting to a 240VAC setting The 120VAC setting is indicated in Figure 1 Step 1 Gently pry open the panel door using a small flat 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com WIGMILLER c Instruments and Equipment for the Corrosion Engineer 20 MCM JR 2 Current Interrupter head screwdriver as indicated in Figure 2 Insert the screwdriver into both slots in turn until the panel door pops open The panel door can then be fully opened as indicated in Figure 3 by lifting the door
16. nt for the Corrosion Engineer 16 MCM JR 2 Current Interrupter 4 Press ENTER and then connect the SYNC cable when less than one minute remains between CLOCK SET and the time shown on Master Unit Display the master time by pressing clock set on the master Remove SYNC cable when the display shows some activity such as a flashing colon or LOCh The slave is now resynched and may be returned to service NOTE The above method may be used to synch the JR 2 s one at a time as needed For example there were 6 JR 2 s to be installed over a long distance by one individual One JR 2 could be started and kept in the truck as a master At each location a single JR 2 could be started and installed using the above method Maintenance A few routine maintenance steps will insure the maximum life for your JR 2 A Maintain the battery in as near a fully charged state as possible Never operate the relay in a less than vertical position Observe polarity when interrupting DC D Provide adequate ventilation when interrupting currents in excess of 20 25 AMPS 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 17 MCM JR 2 Current Interrupter Repairs With the exception of the battery and the relay there are no field replaceable parts in the JR 2 No one other th
17. re the interruption cycle begins In other words the units will be synched before the Start cycle time has occurred It is 7 00 in the morning and the JR 2 s are in one location ready to be synched They will be installed in the rectifiers before 8 00 am At 8 00AM the JR 2 s will start their On Off cycle and remain cycling until 5 00PM the same evening At this time the JR 2 s will shut the relay and wait until 8 00AM the next morning before resuming interruption Test Requirements On Cycle 2 seconds Off Cycle 5 seconds Work Schedule Start at 8 00 A M Stop at 5 00 P M and repeat for XXX days as necessary The present time is 7 00AM Procedure All Units Display Reading Power Switch ON PASS Start Relay Closed PASS Press START SET 8 0 0 ENTER 8AM 8 00 Press STOP SET 6 1 7 0 0 ENTER 5PM 17 00 Press ON CYCLE 2 0 ENTER 2 SEC 2 00 Press OFF CYCLE 5 ENTER 0 5 sec 50 Tel 772 794 9448 Fax 772 569 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 12 MCM JR 2 Current Interrupter Interconnect SYNC jacks on all units daisy chain fashion Press CLOCK SET 7 0 2 ENTER 7 02 When present time your wrist watch reads 7 02 Press ENTER once on one unit only 7 02 At 7 02 all units will begin running as evidenced by a flashing colon The sync cables may now be removed and the JR 2 s distributed to the
18. t set so it may operate correctly The level should be at the TOP of the case 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 7 MCM JR 2 Current Interrupter Panel Controls Battery Charging Indicator Light Power Switch Relay Starting Position Switch Synchronizing Receptacle LCD Display Window Low Battery Indicator Rectifier Condition Indicator Display Area for Clock Time Starting Time Countdown Timing and Settings for ON Cycle and OFF Cycle Keyboard for Setting Times ON Cycle OFF Cycle and Activating Clock TONMOODp TA on CHARGER Zu SPO YaLdNYYaLNI LNIHHNID e Bogg Closed ka EN aj EN BOBO T Q eyesed9 0 12p10 ur YBN og isn Keay nosam 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www memiller com WIGMILLER c Instruments and Eguipment for the Corrosion Engineer 8 MCM JR 2 Current Interrupter Operations Overview Turn Power Switch ON Select Start Relay is Closed Also applies to Stop or Night Latch i e Start Closed Stop Closed Enter operating time reguirements under the five function keys Synchronize all units to be used to each other Install units in system to be tested to include Observing polar
19. t synchronized instant off testing for extended periods Capabilities The JR 2 s capabilities include DC interruption in excess of 5 KW loads and AC interruption in excess of 10 KW loads Reactive Also multiple unit synchronous operation is guaranteed for a normal five day workweek The JR 2 is sync and program compatible with all other models of the Model JR family of current interrupters Features Synchronization with any number of Model JR current interrupters Five functions programmable from the front panel keypad Night latch automatically stops relay in closed position when the STOP SET is programmed The operation resumes when the START SET time is reached Relay Condition Displayed as ON or OFF along with a count down of time remaining in that condition Start Condition Switch is Closed now and re defined To include STOP SET or Night Latch Self Diagnostic Automatically performs a system test at start up and displays Pass if the JR 2 is ready to proceed An examination of the programmed parameters may 11640 US Hwy 1 Sebastian FL 32958 Tel 772 794 9448 Fax 772 589 9072 E mail sales memiller com Web Site www mcmiller com IMIGMILLER c Instruments and Equipment for the Corrosion Engineer 4 MCM JR 2 Current Interrupter be done at any time by pressing the appropriate function key Memory The last entry made for each function is Remembered by the JR 2 There is no need to re program
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