KEP MINItrol Operating Manual
MINItrol SERIES
MODELS:MODELS:
MODELS:
MODELS:MODELS:
MRT
MC2
MR2
INSTALLATION & OPERATING INSTRUCTIONS
http://www.kep.com
99306 10/6/98
KESSLER-ELLIS PRODUCTS
10 Industrial Way East
Eatontown, NJ 07724
800-631-2165 • 732-935-1320
Fax 732-935-9344
Proprietary Notice
The information contained in this publication is derived in part from proprietary and patent data of the Kessler - Ellis
Products Company. This information has been prepared for the expressed purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any
rights to use or reproduce it or to use for any purpose other than in connection with the installation, operation and
maintenance of the equipment described herein.
Copyright 1989, Kessler-Ellis Products Co.
Printed in USA. All Rights Reserved.
WARNING
This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling*
procedures must be observed during the removal, installation or handling of internal circuit boards or devices.
*Handling Procedure
1. Power to unit must be removed.
2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other
internal device is installed, removed or adjusted.
3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be
removed from the protective enclosure until the immediate time of installation. Removed boards must be placed immediately in a protective container for transport, storage or return to factory.
Comments:
This instrument is not unique in its content of EDS (electrostatic discharge) sensitive components. Most modern electronic
designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even
small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear
to function properly, exhibit early failure.
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
SPECIFICATIONS ..................................................................................................1
DECODING PART NUMBER..................................................................................2
HOW TO MOUNT THE UNIT..................................................................................3
WIRING MINITROL.................................................................................................4
UP/DOWN CONTROL AND QUADRATURE INPUTS ...........................................4
WHAT CAN YOU VIEW ..........................................................................................6
OUTPUT JUMPER SELECTIONS..........................................................................6
MILLIVOLT INPUT OPTION JUMPER SELECTIONS............................................6
OPERATING FRONT PANEL.................................................................................7
PROGRAMMING FLOW CHART ...........................................................................7
PROGRAM CODES & DESCRIPTIONS ................................................................8
MINITROL TERMINATIONS...................................................................................9
CALCULATING SCALE FACTORS ........................................................................10
MINITROL PROGRAMMING PROCEDURE ..........................................................11
SETTING SCALING FACTORS..............................................................................11
SETTING THE COUNTER......................................................................................12
SETTING THE RATE..............................................................................................13
SETTING THE LOCK CODE & LOCKING THE UNIT............................................14
SETTING THE RELAYS & PRESETS ....................................................................15
OUTPUT WIRING ...................................................................................................16
ANALOG OUTPUT OPTION...................................................................................17
RS232/RS422 SERIAL COMMUNICATIONS.........................................................18
TROUBLESHOOTING GUIDE................................................................................21
WARRANTY
THIS PAGE IS BLANK
DESCRIPTION & SPECIFICATIONS DESCRIPTION & SPECIFICATIONS
DESCRIPTION & SPECIFICATIONS
DESCRIPTION & SPECIFICATIONS DESCRIPTION & SPECIFICATIONS
DESCRIPTION:DESCRIPTION:
DESCRIPTION:
DESCRIPTION:DESCRIPTION:
The Minitrol is a dual input (channel A and B) counter/ratemeter,
each with its own 5 digit dividing scale factor. The two 10AMP
preset relay outputs can be programmed by the user to apply to the
"A" total counter, the "A" ratemeter, or the "B" counter or the net
total of A and B inputs. The user can view the Net Total of "A+B",
the Net Total of "A-B", the rate of A, or A and B counters separately. The "MRT" version shows rate and total (as described
above). The "MC2" is exclusively a counter and the "MR2" is
exclusively a ratemeter.
SPECIFICATIONS:SPECIFICATIONS:
SPECIFICATIONS:
SPECIFICATIONS:SPECIFICATIONS:
DISPLAYDISPLAY
DISPLAY
DISPLAYDISPLAY
6 digit, 0.55" High LED
INPUT POWER:INPUT POWER:
INPUT POWER:
INPUT POWER:INPUT POWER:
110 VAC ± 15% or 12 to 15 VDC
220 VAC ± 15% or 12 to 15 VDC
24 VAC ± 15% or 12 to 15 VDC
CURRENT:CURRENT:
CURRENT:
CURRENT:CURRENT:
250 mA DC max. or 6.5 VA AC
OUTPUT POWER OUTPUT POWER
OUTPUT POWER (AC powered units only)
OUTPUT POWER OUTPUT POWER
+12 VDC @ 50 mA, unregulated -10 + 50%
TEMPERATURE:TEMPERATURE:
TEMPERATURE:
TEMPERATURE:TEMPERATURE:
Operating:
+32°F (0°C) to +130 F (+54°C)
Storage:
-40 F (-40°C) to +200°F (93°C)
MEMORYMEMORY
MEMORY
MEMORYMEMORY
EEPROM stores data for 10 years if power is lost.
INPUTS:INPUTS:
INPUTS:
INPUTS:INPUTS:
3: High Impedance DC pulse input 4-30 VDC (high), Open or 0-
1 VDC (low),10 KΩ imp. 10 kHz max. speed. Accepts simul-
taneous inputs. May be used with KEP 711 series or 715-1
encoders or PD & D series sensors.
3M: Mag. Input, Input A only, accepts 30mV input (50 V max. P/P)
signals 10 KΩ imp. 5 kHz max. (Input B, 4-30V)
3MB: Mag. Input, Inputs A & B, accepts 30mV input (50 V max. P/
P) signals 10 KΩ imp. 5 kHz max.
5: 4-30 V Count pulses on Input A, 4-30 V Direction Control
input (level) on Input B. May be used with KEP 715-2 Encoder.
5M: 30 mV Count pulses on Input A (50 V max. P/P) 4-30 V
Direction Control input (level) on Input B
9: Quadrature, accepts 4-30 V pulses with 90° phase shift for
direction detection. May be used with KEP 716 encoder.
9MB: Quadrature, accepts 30 mV (50 V max. P/P) pulses with 90°
phase shift for direction detection.
NOTE:NOTE:
NOTE: The Mag. inputs have filtering as follows: up to 300hz
NOTE:NOTE:
@30mV, 5KHz @ .25V to 50V max.
RESET:RESET:
RESET:
RESET:RESET:
Front Panel: Resets displayed value and control output
Remote: 4-30 VDC (75-240 V AC/DC, Input 8) negative
edge resets COUNTER "A" and control output
K FACTOR/SCALINGK FACTOR/SCALING
K FACTOR/SCALING
K FACTOR/SCALINGK FACTOR/SCALING
In the standard unit a fixed K-Factor is used to convert the input
pulses to engineering units. The 5 digit K-Factor dividers, with
decimal keyed into any position, allow easy direct entry of any KFactor from 0.0001 to 99999. Separate factors may be entered for
the 2 separate input channels.
CONTROL OUTPUTS:CONTROL OUTPUTS:
CONTROL OUTPUTS:
CONTROL OUTPUTS:CONTROL OUTPUTS:
Relays:
2 each N.O. Relay; 10 Amps120/240 VAC or 28 VDC.
(N.C. relay contacts and NPN transistor output
available with solder jumpers. Transistor output is
internally pulled up to 10 VDC through relay coil, sinks
from 10 VDC to .5 V @ 100 mA)
Analog Output:
An optional 4-20mA (0-20mA) output is available for
the Minitrol series. The output can be programmed
to track rate or total. This feature is available by
adding suffix A to the part number. Connections are
via a 2 terminal pluggable screw connector.
Programming is accomplished by using the front panel
in conjunction with rear dip switches.
Accuracy: 50uA worst case.
Compliance Voltage: 3 to 30 VDC non inductive.
RS232/RS422SERIAL INTERFACERS232/RS422SERIAL INTERFACE
RS232/RS422SERIAL INTERFACE
RS232/RS422SERIAL INTERFACERS232/RS422SERIAL INTERFACE
If the serial interface option is supplied, up to 99 units can be linked
together. (The terminal addressing the unit must be capable of
driving all loads in the loop.) Unit status and new set points can be
communicated by serial communication. Mode changes, however,
must always be made on the front panel. Data is transmitted at
selected baud rates using standard seven bit ASCII characters and
parity with two additional bits of Start and Stop to make up the
standard ten bit character.
Data is received and transmitted over standard EIA RS232 or
RS422 levels. Each 10 bit character is made up of a start bit, 7 bit
ASCII code, parity bit and stop bit. Unit number, baud rate and
parity are entered in the Program Setting set up mode and remain
in memory even if power is off.
Note that the input impedance of RS232 is 3K or 7K Ohm worst
case. The terminal addressing the unit must be capable of driving
all loads in the loop. RS422 input impedance is much higher and
there is usually no problem driving 25 units. Unit serial transmit line
remains in a high impedance OFF state until addressed.
1
SPECIFICATIONSSPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONSSPECIFICATIONS
(continued)
PRESETSPRESETS
PRESETS
PRESETSPRESETS
Two control outputs are provided. To set relay values, press
menu button until Relay appears on the display, the A and B
outputs can be assigned to the ratemeter (high/low), one preset for
rate and one for total, or two presets (2 stage shut off) on the A and
B counters. A 5 digit value can be entered for both presets and the
decimal point location is the same as the counter. The outputs can
be set to energize from 0.1 to 99.9 seconds or latch (0.0). If a
value other than 0.0 is entered, the counters will auto reset at the
preset . In the A-B or A+B versions, the relays will be assigned to
either net total or A rate.
LOCKOUTLOCKOUT
LOCKOUT
LOCKOUTLOCKOUT
Unauthorized front panel changes can be prevented by entering a
user selected 5 digit code, in the LOC , . mode. The front panel
can be completely locked out or the presets can remain accessible.
RATEMETERRATEMETER
RATEMETER
RATEMETERRATEMETER
Accurate to 4 1/2 digits (±1 display digit). The rate meter can be
programmed to accept almost any number of pulses per unit of
measurement, sample from 2 to 24 seconds maximum, and autorange up to 5 digits of significant information. In the RPS mode,
the ratemeter displays in units per second, and in the scale mode,
units per hour or per minute. The unit will display the rate of the A
Input only.
COUNTERCOUNTER
COUNTER
COUNTERCOUNTER
The two 6-digit counters can count at 10Khz speed. Each can
have a 5-digit dividing scale factor. The counter advances on the
positive edge of each pulse. Count up or down modes available,
as are quadrature inputs from encoders for position or length
measurement. The unit can be programmed to view the net value
of "A+B" or "A-B", or A and B as separate counters.
DECODING PART NUMBERDECODING PART NUMBER
DECODING PART NUMBER
DECODING PART NUMBERDECODING PART NUMBER
MINItrol MINItrol
MINItrol (MRT, MC2, MR2)
MINItrol MINItrol
Example:Example:
Example:
Example:Example:
Series:Series:
Series:
Series:Series:
MRTMRT
MRT= 6 digits, counter / ratemeter
MRTMRT
MC2MC2
MC2= 6 digits, counter only with
MC2MC2
MR2MR2
MR2= 5 digits, rate only with
MR2MR2
Operating Voltage:Operating Voltage:
Operating Voltage:
Operating Voltage:Operating Voltage:
AA
A= 110 VAC ± 15% or 12 to 15 VDC
AA
BB
B= 220 VAC ± 15% or 12 to 15 VDC
BB
CC
C= 24 VAC ± 15% or 12 to 15 VDC
CC
Count Inputs:Count Inputs:
Count Inputs:
Count Inputs:Count Inputs:
3 =3 =
3 = Standard, 4-30 VDC simultaneous inputs.
3 =3 =
3M =3M =
3M = Mag. Input, Input A only, 30mV input
3M =3M =
3MB =3MB =
3MB = Mag. Input, Inputs A & B, 30mV input
3MB =3MB =
5 =5 =
5 = 4-30 V pulses on Input A,
5 =5 =
5M =5M =
5M = 30 mV pulses on Input A,
5M =5M =
9 =9 =
9 = Quadrature, accepts 4-30 V pulses
9 =9 =
9MB =9MB =
9MB = Quadrature, accepts 30 mV pulses (A & B)
9MB =9MB =
Options Options
Options (Multiple Options Available)
Options Options
1= 1=
1= RS232 Communications
1= 1=
2=2=
2= RS422 Communications
2=2=
A=A=
A= Analog Output (4-20/0-20 mA)
A=A=
MRTMRT
MRT
MRTMRT
with presets and scaling.
presets and scaling.
presets and scaling.
(Input B, 4-30V)
4-30 V Direction Control input on Input B.
4-30 V Direction Control input on Input B
A A
A
A A
33
3
33
1 A1 A
1 A
1 A1 A
2
HOW TO MOUNT THE UNITHOW TO MOUNT THE UNIT
HOW TO MOUNT THE UNIT
HOW TO MOUNT THE UNITHOW TO MOUNT THE UNIT
The unit is designed to be mounted with a gasket providing a water tight seal. Two mounting brackets are provided to
secure the unit to the panel. A panel less than .1" may distort if the clamps are screwed too tightly.
Slide the body of the unit through the rubber gasket. Insert the unit into the panel. As shown in "FIG. A", slide the brackets
up the groove to press against the back of the panel. Insert screws into rear of brackets and tighten them evenly and
alternately. Do not over tighten! A normal level of torque is required. Maximum torque should be 3" pounds.
This product is designed to be panel mounted and is NEMA 4 rated if proper mounting procedures are followed and the
required and supplied hardware is correctly used.
If the panel in which the unit is mounted is less than .125 of an inch thick, the possibility exists that there will be some
flexing. Should this flexing occur, the resulting deformation of the panel could cause a loss of the water tight seal. In case
this should occur, the use of silicone or other sealant would be recommended.
This product is designed to the NEMA 4 rated. However, the fact that we are unable to control either the location in which
the device is installed or the actual installation itself requires that the company’s liability shall extend only to the repair or
replacement of a defective product.
We are prepared to offer additional assistance in those special situations where normal mounting methods do not seem to
satisfy the customers needs. This assistance may be obtained by calling the factory and asking for Application Engineering.
DIMENSIONSDIMENSIONS
DIMENSIONS
DIMENSIONSDIMENSIONS
3.925
(99.7)
FIG. A
4.437
(112.7)
2.625
(66.68)
0.587
(14.91)
BEZEL
GASKET
4.245
(107.8)
CUSTOMER PANEL
Panel Thickness 0.062" (1.5)
to 0.187" (4.7) max.
3.622
(92)
1.772
(45)
3
WIRING MINITROLWIRING MINITROL
WIRING MINITROL
WIRING MINITROLWIRING MINITROL
The rear terminal contains 12 screw terminals for connecting #14 to #28 gauge wire.
The unit is controlled by a microprocessor and, therefore, an electrically "noisy" environment could cause operating
problems. The input power line should not be common to power lines for motors, pumps, contactors, etc.
The unit is designed to be immune from line or RF voltage interference. In some environments voltage spikes of over 100
volts, even 1000 volts, can occur. When common to a power line driving motors voltage fluctuations can be extreme and
rapid. Lines driving DC or AC solenoids, relays, or actuators can also cause problems.
Four sources of noise can occur:
1) AC power line noise - If the unit cannot be connected to a clean power source, an inductive load suppressing device
(MOV as GE # V130LA1 or Resistor Capacitor as Paktron # .2 uf/220 ohm @ 400V) can be installed. Although locating
the suppressor across the AC supply at the unit should help, best results are obtained by connecting the suppressor
across the leads of the "load" at the device causing the spike.
2) Input line noise -The noise is carried on the input and D.C. ground lines. Make sure the input wires are never run into
the unit in a bundle with power input lines. Also, keep these input lines isolated from inductive lines from devices
drawing heavy loads. If there is a possibility of electrical noise, we recommend using shielded cable, with the shield
being hooked to the D.C. ground terminal on the instrument, and to "earth" at one point in the circuit, preferably at the
D.C. ground terminal of the unit.
3) Output lines - The unit has two relay outputs. When these outputs are used to run external relays or solenoids, spikes
can be generated upon activation. This noise can spread through the instrument causing operating problems. If the
source is a D.C. operated device, a general purpose diode (IN4004) placed across the solenoid prevents electrical
noise spikes. Connect the cathode (banded side) to the more positive side of the coil. If the source is an A.C. operated
device, use a MOV or Resistor Capacitor across the coil.
4) 12 VDC output supply - Noise can be generated on the 12 VDC output supply if it is used to drive inductive loads or if
the current draw exceeds 50 mA. Insure that all inductive loads have a diode (such as IN4004) across the coil and that
the current does not exceed 50 mA.
UP/DOWN CONTROL AND QUADRATURE INPUTSUP/DOWN CONTROL AND QUADRATURE INPUTS
UP/DOWN CONTROL AND QUADRATURE INPUTS
UP/DOWN CONTROL AND QUADRATURE INPUTSUP/DOWN CONTROL AND QUADRATURE INPUTS
QUADRATURE INPUT:
When programming the counter section for quadrature input, you must set the unit for A net B and A sub B (see step 2 in
programming section). This insures proper operation. The rate can only be viewed in one direction. If the unit is a
ratemeter only (MR2), connect only one of the quadrature channels to Input A (pin 5).
UP/DOWN CONTROL:
When using the up/down control option, Input A (pin 5) is the count input and Input B (pin 6) is the up/down control
(direction) input. The counter must be set for A net B and A sub B (see step 2 in programming section).
When the direction input is high (4-30VDC) the count inputs will count up, when the direction input is low (open or less than
1VDC) the count inputs will count down. The direction input must precede the count input by 1 msec when the unit is set for
low CPS and 1 usec when set for high CPS.
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