Omega DPU91-BC User Manual

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User’s Guide

DPU91-BC SERIES

Batch Controller System

TM

The information contained in this document is believed to be correct, but OMEGA accepts no liability for any errors it contains, and reserves
the right to alter specifications without notice.

Servicing North America:

U.S.A. Omega Engineering, Inc.
Headquarters: Toll-Free: 1-800-826-6342 (USA & Canada only)

Customer Service: 1-800-622-2378 (USA & Canada only)
Engineering Service: 1-800-872-9436 (USA & Canada only)
Tel: [phone] Fax: [phone]
e-mail: [e-mail]

For Other Locations Visit omega.com/worldwide

omega.com [e-mail]

TM

3OMEGA DPU91-BC Batch Controller System

• Follow instructions carefully to avoid personal injury.

• This unit is designed to be connected to equipment which can be hazardous to
persons and property if used incorrectly. Read and understand all associated
equipment manuals and safety warnings before using with this product.

• Remove power to unit before wiring input and output connections.

• Wiring connections to this product should only be performed by qualifi ed personnel.

• Do not use unit if display is cracked or broken.

The Omega DPU91-BC Batch Controller is compatible with the Omega

models FP-5300,
FP-8500, FP-5600, FP-5200, FPB, FP-2540, FP-3-1500 paddlewheel fl ow sensors,
models FMG-3000 and FMG-550 insertion magmeters, and models FP-5070 and FP-5060
in-line fl ow sensors.

Your new

DPU91-BC

Batch Controller system includes the following items:

• Omega DPU91P Transmitter (Generation II or later)

• Omega Relay Module DPU90-R

• Omega Batch Module DPU90-BCM

Note:

Verify DPU91 Transmitter Generation under the OPTIONS Menu.

1. Safety

2. Compatibility

3. Description

Contents

1. Safety .........................................................................................................................1

2. Compatibility ..............................................................................................................1

3. Description .................................................................................................................1

4. Dimensions ................................................................................................................4

5. Ordering Information ..................................................................................................5

6. Modules .....................................................................................................................6

7. Terminal Identifi cation ................................................................................................7

8. Wiring .........................................................................................................................8

9. Sensor Wiring ............................................................................................................9

10. Power Wiring............................................................................................................10

11. Batch Module Wiring ................................................................................................10

12. Open Collector Wiring ..............................................................................................11

13. Relay Module Wiring ................................................................................................12

14. Relay Mode Settings ................................................................................................12

15. Operation .................................................................................................................15

16. System Setup...........................................................................................................16

17 Menu System ...........................................................................................................17

18. Error Messages........................................................................................................24

19. Alarm Acknowledgement Messages ........................................................................24

20. Calibration ................................................................................................................25

21. Specifi cations ...........................................................................................................26

22. Ordering Information ................................................................................................28

OMEGA DPU91-BC Batch Controller System4

®

54.10 mm
(2.13 in.)

91.44 mm
(3.60 in.)

29.97 mm
(1.18 in.)

8.13 mm
(0.32 in.)

99.06 mm
(3.90 in.)

99.06 mm
(3.90 in.)

DPU91-BC Batch Controller System

4. Dimensions

5OMEGA DPU91-BC Batch Controller System

Do not mount in direct sunlight.

Field Mount Installation

The DPU91-BC unit can be installed in the optional Wall Mount Accessory DPU90-WM,
for fi eld mount installation.

Recommended clearance on all sides between
instruments is 25 mm (1 in).

1. Place gasket on instrument, and install
through ¼ DIN size opening.

2. Slide mounting bracket over back of
instrument until bracket snaps into latches
on sides of instrument.

To remove:

1. Secure instrument temporarily with tape
from front or grip from rear of instrument.
DO NOT RELEASE.

2. Press bracket clips outward and remove.

Panel Cutout

92 x 92 mm

(+ 0.8, - 0 mm)

3.6 x 3.6 in.

(+0.031, -0 in.)

Panel Cutout

92 x 92 mm

(+ 0.8, - 0 mm)

3.6 x 3.6 in.

(+0.031, -0 in.)

Panel Cutout

92 x 92 mm

(+ 0.8, - 0 mm)

3.6 x 3.6 in.

(+0.031, -0 in.)

Panel Cutout

92 x 92 mm

(+ 0.8, - 0 mm)

3.6 x 3.6 in.

(+0.031, -0 in.)

minimum

clearance

25 mm

(1 in.)

Panel Mount Installation

Tools and Equipment Required

• Fine-tooth fi le

• ¼ DIN punch or jigsaw suitable for cutting panel
opening to within 1 mm (0.04 in) tolerance.

• ¼ DIN punches are available and recommended
for creating clean, precise openings quickly and
easily in most instrument panels.

• If a punch is not available, a jigsaw or other
cutting tool can be used. An adhesive template
is provided to help guide the cutting process.
De-burr and smooth the opening with a fi le.

panel

Quick-clip

gasket on front
side of panel

terminal
blocks

mounting

bracket

DC Power

Loop Voltage

System Start-up: Step 1

Prepare the Controller installation location.
If the back of the Controller is diffi cult to access when installed, wire the
removable terminal plugs fi rst, then attach to DPU91P Transmitter.

Next step: Wiring (Step 2).

• Minimize handling of plug-in modules to reduce the possibility of damage due to ESD.

• Handle modules by the edges. Never touch any exposed circuitry or contacts.

• Wear an anti-static wristband or stand on an anti-static mat, or keep one hand
touching a properly grounded pipe or other properly grounded piece of metal when
handling modules.

CAUTION:

Avoid Electrostatic Discharge (ESD)

5. Installation

OMEGA DPU91-BC Batch Controller System6

Relay Module

In addition to the Open Collector output
in the DPU91P base unit, the DPU91-BC
includes a Relay Module (DPU90-R) which
adds two programmable dry-contact relays.
The Open Collector output in the base unit
uses the Relay 1 setting in the menus.
The Relay Module is assigned to
relays 2 and 3 in the menus.

Dry-contact relays are electromechanical
switches with a moving contact armature.
They are suitable for many general-purpose
applications, AC or DC, including AC loads
up to 250 V.
Install RC Filter Kits, FP90RC, on relays
used to switch motor or inductive loads.

• Two SPDT dry-contact relay inputs

• User programmable

• 250 V, 5 A maximum resistive loading (AC)

• Can switch line voltage
(typically 120 to 240 VAC)

• Can switch DC voltage (< 30 VDC @ 5A)

• Larger voltage and current ratings than
Open Collector outputs
(30 VDC, 50 mA maximum)

Batch Module

Convert a DPU91P Transmitter
(Generation II or later) to a DPU91-BC
Batch Controller System by plugging in
DPU90-BCM Batch Module.

Optional Module Wiring:

• Wire an external button or keypad

(customer supplied) to stop, start or
resume a batch remotely.

• Wire an external input that can inhibit

a batch from starting.

• The Indicator LEDs on the front panel of

the DPU91-BC show the status of
Open Collector (relay 1) and relays 2 and 3.

• Hysteresis and time delay are adjustable
for each relay.

To remove modules:

1) Remove power from the DPU91P

2) Remove the Relay module

3) Loosen bottom screw of Batch module

4) Carefully grip and squeeze the tabs
at the top of the module to release

5) Pull module away from the unit

6) Do not bend the connecting pins

CAUTION:

Switching active loads (usually inductive)
can cause contact arcing suffi cient to
damage the relays. The RC Filter Kit or
“snubber” (part number

FP90RC) is

available as an accessory to reduce or
eliminate these damaging effects.
Recommended for inductive loads
greater than 50 VAC (remote relays,
solenoids, pumps, etc.).

6. Modules

7OMEGA DPU91-BC Batch Controller System

Terminals 1-2: DC Power

• Required by the instrument

• Provides power to sensors, relays and the LCD backlight

Terminals 3-4: 4 to 20 mA

• Passive 4 to 20 mA output

Terminals 5-6: Open Collector

• Software selectable for Normally Open or Normally Closed

Terminals 7-10: Digital (S

3

L)/Frequency Input

• Sensor wiring

• DPU90-COMM wiring

The DPU91-BC requires regulated

10.8 to 35.2 VDC (24 VDC nominal)
from an external power supply.
Maximum current draw is 300 mA.

10978

DATA

GND

SHLD

V+

Digital (S3L) /
Frequency

1
2

3
4

5

6

OC+OC–

PWR +
PWR –
Loop +
Loop –

Power

7. Terminal Identifi cation

Connect power and

open collector wire plug here

as shown on pages 8 and 9.

Connect sensor wire
plug here as shown
on page 7.

DC Power

Loop Voltage

OMEGA DPU91-BC Batch Controller System8

Wiring Tips:

• Do not route the sensor or DC power cables in conduit containing
AC power wiring. Electrical noise may interfere with sensor signal.

• Routing the sensor cable in grounded metal conduit can help
prevent electrical noise and mechanical damage.

• Seal the cable entry points to prevent moisture damage.

• Only one wire should be inserted into a terminal.

• Splice double wires outside the terminal or use appropriate wire
ferrule, not to exceed 2 mm (0.08 in) diameter.

Tools Required

• Phillips
screwdriver

• Flat-head
screwdriver

• Wire strippers

• Minimize handling of plug-in modules to reduce the
possibility of damage due to ESD.

• Handle modules by the edges. Never touch any
exposed circuitry or contacts.

• Wear an anti-static wristband or stand on an anti­static mat, or keep one hand touching a properly
grounded pipe or other properly grounded piece of
metal when handling modules.

CAUTION:

Avoid Electrostatic Discharge (ESD)

All wiring connections to the DPU91-BC are made via removable terminal plugs.

In general:

• Terminals accept 12 to 24 AWG wire.

• Strip 7 mm (0.28 in.) of insulation from wire tips
and tin bare ends to eliminate fraying.

• Insert wire tip or ferrule completely into the terminal
and secure with the screw.

• Do not allow any AC leads that may be connected
to the internal relays to come in contact with low voltage wiring.

CAUTION:

DO NOT bundle Relay Module

wiring with other wiring.

Doing so may cause injury and/or damage to

DPU91P Transmitter, Relay Module, and Batch Module.

8. Wiring

System Start-up: Step 2

Wire the transmitter connections with the power off. Keep any 4 to 20 mA and
relay-actuated output devices that are connected to it offl ine at this time.
Wire the sensor (pg. 7), power (pg. 8) and Open Collector and relay(s) (pg. 9).

Next step: System Setup (Step 3).

9OMEGA DPU91-BC Batch Controller System

FMG-3000
Technical Notes:

• When the blue jumper
illustrated is placed over both
pins, the FMG-3000
(Blind Magmeter) outputs an
open collector frequency signal.
When the jumper is removed
(or placed over one pin for
storage) the FMG-3000 outputs
a Digital (S3L) signal.

DATA

GND

SHLD

V+

Black

Red

Shield

No connection

FP-5300, FP-5600,
FP-8500, FP-5200,
FP-5060, FP-5070

DATA

GND

SHLD

V+

Brown

White

Blue

Black

Shield

S3L

DATA

GND

SHLD

V+

Brown

White

Blue

Black

Shield

X

No
connection

Frequency

FMG-550

Black

Red

Shield

White

V+

DATA

GND

SHLD

3

4

Frequency

S L

3

4

FMG-3000*

*FMG-3000 Blind Magmeter
Output Selection Jumpers

Connect the silver (shield)

wire to earth ground in case

of EMI noise interference.

9. Sensor Wiring

FMG-3000 & FMG-550
Technical Notes:

• Either Frequency or Digital

(S3L) may be used.

• The frequency output will be

displayed as positive fl ow
regardless of the fl ow direction.

• Omega recommends

confi guring the FMG-3000
with the Digital (S3L) output
because it is more accurate.

• Input sensor type is selected by

choosing between “SENSOR
FREQ” and "SENSOR S3L" in
the INPUT menu.

• 5 VDC power is provided to

the FMG-3000 Magmeter by
the DPU91-BC. No additional
power is required.

OMEGA DPU91-BC Batch Controller System10

Stand-alone application

Connection to a 4 to 20 mA device

The DPU91 MUST be powered by 10.8-35.2 VDC ONLY.

CAUTION!

DO NOT connect your DPU91 to AC power.

DPU91P
Terminals

+

–

Power

Supply

12 to 32 VDC

±10%

Black

Red

PWR +

PWR –

Loop +
Loop –

Common

Start

Stop

Resume

Inhibit*

*Wire an external input as override
for preventing batch from starting.

Connect an external button or keypad (not supplied) to remotely
control the DPU91-BC by wiring the Batch Module as shown.

10. Power Wiring

11. Batch Module Wiring

DPU90-BCM

Batch Module

Start

Resume

Common

Stop/Inhibit

+

–

+

–

4 to 20 mA

Device

Blue

Black

Red

PWR +

PWR –

Loop +
Loop –

Power

Supply

12 to 32 VDC

±10%

DPU91P
Terminals