Mounting
INSERT
5"
8"
3"
3/8"
Conduit
fitting
plate
and red
plugs
Direct-Coupled ControlSet® Actuators (120/180/320 in-lb.)
Installation Guide
10 1/8"
HMO-4535 non-rotation
bracket (provided)
8"
Gear disengagement button
2-7/16"
MEP-7200/7500/7800 Series
1. Ensure that the damper can move freely through
its entire range of motion, and x any binding
before installing the actuator. Turn the damper
blade to its fully closed position.
2. Press and hold the gear disengagement buon
(see Illustration 1), rotate the actuator to the fully
closed position, and release the buon.
NOTE: Depending on the damper-seal design,
backing the actuator o its stop
approximately 5° may provide tight
damper shut-o.
3. Depending on the size of the shaft, use the
optional shaft insert as is, reverse it, or remove it.
Slide the actuator onto the shaft.
5"
4. Leaving a gap between the actuator and
mounting surface to prevent any binding, ngertighten the nuts on the V-bolt.
5. Insert the non-rotation bracket (supplied HMO-
4535) into the slot at the base of the actuator.
6. Secure the non-rotation bracket with two (2) #8
self-tapping screws.
NOTE: The two holes at the top of the actuator are
INSERT
Shaft insert
INSERT
Shaft insert
not for use in direct-coupled applications.
They are for remote mounting, such as with
the optional HLO-1020 Crank Arm Kit. (For
accessory information, see the MEP-7xxx
Position insert as
shown for 3/8"
to 9/16" round
shafts or 5/16"
to 3/8" square
shaft (1/2" round
shafts on center)
Illustration 1—Overview (Direct-Coupled Mounting)
Position insert as
shown for 5/8"
to 13/16" round
shafts or 1/2"
to 5/8" square
shafts (3/4"
round shafts on
center)
Remove insert
for 7/8" to
1.05" round
shafts (1.05"
round shafts
on center)
7. Evenly tighten the V-bolt nuts to 110 to 120 in-
8. Verify the operation of the actuator through its
NOTE: Before 2014, MEP-7xx2 proportional
Applications Guide.)
lb. while keeping the shaft insert centered and
square.
full rotational cycle.
models had 0–10 VDC inputs and 0–5 or
NOTE: The MEP-7200 series (120 in-lb.) was
discontinued. Use an MEP-75xx (180
in-lb.)—or, if less torque is required, an
0–10 VDC feedback. Starting in Jan. 2014,
they have 2–10 VDC inputs and 1–5 or
2–10 VDC feedback instead.
MEP-48xx (80 in-lb., non-fail-safe) or MEP49xx (90 in-lb., fail-safe) instead.
MEP-7200/7500/7800 Series 1 Installation Guide
Wiring (General)
24 VAC/VDC
Power In
Feedback
Potentiometer
(MEP-7xx3 only)
24 VAC/VDC
Power In
24 VAC/VDC
Power In
2–10 VDC Control Signal
4–20 mA Control Signal
1–5 or 2–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
Feedback
Potentiometer
(MEP-7xx3 only)
CW
CCW
CW
CCW
1. Loosen the screws on the tethered access cover
and remove the cover.
2. Slide the conduit ing plate out.
3. Using a utility knife or drill, cut the red plug
to accept wiring or replace the plug with an
application-specic ing.
NOTE: The red plugs (or similar ings) protect
the internal components from debris,
helping to ensure long actuator life.
4. Thread wires through the plugged opening and
connect to the terminal block according to the
appropriate model and options desired. (See
Illustrations 2 through 5.)
NOTE: For your convenience, the wiring terminal
block is removable.
NOTE: For two-position wiring on a fail-safe tri-
state actuator (see Illustration 5), choose
one of these (jumpered) rotation options:
1. For clockwise rotation when the 24 volt
circuit switch/contact is closed, jumper
the 24 VAC terminal to the CW terminal
and select CCW on the Fail switch. When
the circuit opens, the actuator rotates
fully counterclockwise.
2. For counterclockwise rotation when
the 24 volt circuit switch/contact is
closed, jumper the 24 VAC terminal to
the CCW terminal and select CW on the
Fail switch. When the switch opens, the
actuator rotates fully clockwise.
24 VAC/VDC
Power In
Control Signal Common
2–10 VDC Control Signal
4–20 mA Control Signal
1–5 or 2–10 VDC Feedback Signal
(MEP-7x52 Only)
Illustration 2—MEP-7xx2 Wiring (Proportional)
24 VAC/VDC
Power In
CW
CCW
Feedback
Potentiometer
(MEP-7xx3 only)
Illustration 3—MEP-7x01/7x03 Wiring (Tri-State, Non-Fail-Safe)
Feedback
Potentiometer
(MEP-7xx3 only)
24 VAC/VDC
Power In
CW
CCW
5. Reinstall the terminal block on the pins (if
removed) and the conduit ing plate.
6. For MEP-7xx2 (proportional) models, adjust the
Illustration 4—MEP-7x51/7x53 (Normal) Wiring
(Tri-State, Fail-Safe)
auto-mapping range reset, rotation direction,
and feedback voltage as needed. See Direction,
Feedback, & Auto-Mapping (Proportional MEP7xx2 Models) on page 3.
7. For MEP-7x5x models, adjust the fail-safe
(clockwise, counter-clockwise, or o) selector
24 VAC/VDC
Power In
Switch/Contact
Jumper
1
Feedback
Potentiometer
(MEP-7xx3 only)
2
2
1
switch, beside the terminal block, as needed.
NOTE: After initial connection or reconnection
to power (until the capacitors are fully
charged), fail-safe operation might be
delayed up to 20 seconds for the MEP725x/755x or up to 40 seconds for the MEP785x.
8. Reinstall the tethered cover and tighten the
screws.
MEP-7200/7500/7800 Series 2 Installation Guide
Illustration 5—MEP-7x51/7x53 Two-Position Wiring
(Tri-State, Fail-Safe)
Wiring (Master/Slave)
See the MEP-7xxx Applications Guide.
Direction, Feedback, & Auto-Mapping (Proportional MEP-7xx2 Models)
2–10 VDC Control Signal
4–20 mA Control Signal
1–5 or 2–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
NOTE: Before Jan. 2014, MEP-7xx2 proportional
models had 0–10 VDC inputs and 0–5 or
0–10 VDC feedback. Starting in 2014, they
have 2–10 VDC inputs and 1–5 or 2–10
VDC feedback instead.
Proportional models oer selectable actuator rota-
tion direction and selectable proportional feedback
of 1–5 VDC or 2–10 VDC (in either direction).
To access the selector switches (see Illustration 6.),
loosen the screws on the conduit ing and lift up to
remove the ing. The selector switches are shipped
from the factory in the 1–5 VDC (#1) and CW movement with increasing voltage (#2) positions.
Switch (#1) Feedback (#2)* Direction
Up 1–5 VDC CCW
Down 2–10 VDC CW
NOTE: The auto-mapping feature works best for
ranges that are more than about 45°.
To set the auto-mapping:
1. If desired, use the HMO-4536 adjustable end stop
kit to limit the stroke of the actuator.
2. With power applied to the actuator, ip selector
switch #2 (from its required CW or CCW
increasing voltage direction) to start the reset
mode. The actuator will rst move to the CCW
limit. The complete reset process will take
approximately four minutes.
NOTE: On fail-safe models, wait for at least one
minute after power has been applied to
the actuator (allowing the capacitors to
fully charge) before initiating the automap
feature.
3. Return selector switch #2 to the required
increasing voltage direction before the reset
nishes. The reset process is complete after the
actuator has moved to the CW limit and has
begun to position normally.
Illustration 6—Feedback Selector Detail MEP-7xx2
*NOTE: Selector Switch #2 has two functions:
1. Switch #2 determines the direction to rotate
(CW or CCW) with increasing voltage and is
factory set in the CW position (down). To
change, remove power before ipping the
switch up to the CCW position. Removing
power prevents initiation of the auto-mapping
feature.
2. Switch #2 initiates the auto-mapping
feature. (See description below.) This feature
is initiated only by cycling the switch with
power applied to the unit. The auto-mapping
feature will NOT begin if the switch position
is changed with power removed or in the
event of a power failure.
MEP-7xx2 models also oer a actuator/signal range
reset program (auto-mapping) feature that reassigns
the full 2–10 VDC input signal scale over a reduced
stroke range for more precise control.
4. Verify that the actuator travels completely across
the new range.
For example, after completing the auto-mapping
program, the new actuator stroke is 0–80°:
• Before Jan. 2014, a 5 VDC input signal (halfway
between 0–10 VDC) will drive the actuator to the
40° position (50% of its adjusted range) and the
feedback voltage will be 2.5 VDC if switch #1 is set
at the 0–5 VDC position or 5 VDC if switch #1 is
set at 0–10 VDC.
• Starting in Jan. 2014, a 6 VDC input signal
(halfway between 2–10 VDC) will drive the
actuator to the 40° position (50% of its adjusted
range) and the feedback voltage will be 3 VDC if
switch #1 is set at the 1–5 VDC position or 6 VDC
if switch #1 is set at 2–10 VDC.
NOTE: The auto-mapping option is not available
with Master/Slave applications.
MEP-7200/7500/7800 Series 3 Installation Guide
Fail-Safe Direction (MEP-7x5x)
Feedback
Potentiometer
(MEP-7xx3 only)
(MEP-7x52 Only)
Feedback
Potentiometer
(MEP-7xx3 only)
Important Notices
All fail-safe models oer selectable CW/CCW fail
direction and the option to turn o the fail-safe using
a slide switch to the right of the terminals.
Illustration 7—Fail-Safe Direction Switch
NOTE: After initial connection or reconnection to
power, proper fail-safe operation might
be delayed up to 40 seconds (until the
capacitors are fully charged).
Maintenance
No routine maintenance is required. The motors are
permanently lubricated. Careful installation will also
ensure long term reliability and performance.
Accessories
See the MEP-7xxx Applications Guide.
The KMC logo is a registered trademark of KMC
Controls, Inc. All rights reserved. No part of this
publication may be reproduced, transmied, transcribed, stored in a retrieval system, or translated
into any language in any form by any means without
the wrien permission of KMC Controls, Inc.
The material in this document is for information
purposes only. The contents and the product it
describes are subject to change without notice.
KMC Controls, Inc. makes no representations or
warranties with respect to this document. In no event
shall KMC Controls, Inc. be liable for any damages,
direct or incidental, arising out of or related to the
use of this document.
More Information
For models, specications, and additional
information, see the
MEP-7500/7800 Series
Data Sheet on the KMC
web site.
Specifications
See the MEP-7500/7800 Series Data Sheet.
Applications
For possible proportional heating/cooling applications using the CTE-5202 electronic thermostat, see
the CTE-5202 Applications Guide.
For valve applications, see information on:
• VEB-53 Series Two-Way, Flanged Ball Valves (4
to 6")
• VEB-56 Series Three-Way, Flanged Ball Valves
(4 to 6")
• VEF-53 Series Two-Way, Rubber-Lined, Buer-
y Valves (2 to 6")
• VEF-56 Series Three-Way, Rubber-Lined, But-
tery Valves (2 to 6")
The latest support les are always available on the
KMC Controls web site (www.kmccontrols.com).
For accessories, troubleshooting, master/slave
wiring, torque selection,
links to sample applications, and other information, see the MEP-7xxx
Applications Guide on
the KMC web site.
KMC Controls, Inc.
19476 Industrial Drive
New Paris, IN 46553
574.831.5250
www.kmccontrols.com
info@kmccontrols.com
MEP-7200/7500/7800 Series 4 Installation Guide
© 2013 KMC Controls, Inc. 031-019-01H
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