Omega Products ASP10 Installation Manual

CONTROLS

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Instruction Manual

PROGRAMMABLE DIGITAL CLOSED LOOP MOTOR SPEED

CONTROL SYSTEM FOR AC AND DC DRIVES

LT20 (0208)

ASP10 CONTROL SERIES

P.O. Box 10 5000 W. 106th Street Zionsville, Indiana 46077

Phone (317) 873-5211

Fax (317) 873-1105

www.dartcontrols.com

A-5-3022D

Quick Jump

What models and options are available?

See page 3.

Looking for detailed specifications?

See page 3.

W ant to get started fast?

See basic electrical hook-up details on page 6. See mechanical installation details on page 4. See some sample applications starting on page 21.

Need Help?

See troubleshooting on page 25.

Warranty

Dart Controls, Inc. (DCI) warrants its products to be free from defects in material and workmanship. The exclusive remedy

for this warranty is DCI factory replacement of any part or parts of such product which shall within 12 months after delivery to the purchaser be returned to DCI factory with all transportation charges prepaid and which DCI determines to its satisfaction to be defective. This warranty shall not extend to defects in assembly by other than DCI or to any article which has been repaired or altered by other than DCI or to any article which DCI determines has been subjected to improper use. DCI assumes no responsibility for the design characteristics of any unit or its operation in any circuit or assembly. This warranty is in lieu of all other warranties, express or implied; all other liabilities or obligations on the part of DCI, including consequential damages, are hereby expressly excluded.

NOTE: Carefully check the control for shipping damage. Report any damage to the carrier immediately. Do not attempt to operate the drive if visible damage is evident to either the circuit or to the electronic components.

All information contained in this manual is intended to be correct, however information and data in this manual are subject to change without notice. DCI makes no warranty of any kind with regard to this information or data. Further, DCI is not responsible for any omissions or errors or consequential damage caused by the user of the product. DCI reserves the right to make manufacturing changes which may not be included in this manual.

WARNING

Improper installation or operation of this control may cause injury to personnel or control failure. The control must be installed in accordance with local, state, and national safety codes. Make certain that the power supply is disconnected before attempting to service or remove any components!!! If the power disconnect point is out of sight, lock it in disconnected position and tag to prevent unexpected application of power. Only a qualified electrician or service personnel should perform any electrical troubleshooting or maintenance. At no time should circuit continuity be checked by shorting terminals with a screwdriver or other metal device.

Table of Contents

Introduction .......................................................................................................................................2

General Features ...............................................................................................................................2

Models & Options ............................................................................................................................. 3

Model Options ............................................................................................................................... 3

Available Options ..........................................................................................................................3

Recommended Accessories .........................................................................................................3

Specifications ....................................................................................................................................3

Electrical........................................................................................................................................3

Mechanical ....................................................................................................................................3

Environmental ............................................................................................................................... 4

Mechanical Installation ..................................................................................................................... 4

Exploded Panel View ..................................................................................................................... 4

Cut-out and Mounting Dimensions ................................................................................................ 4

PU-E Series Pickup Installation ....................................................................................................5

Electrical Installation & Diagrams ...................................................................................................6

P1 Terminal Block Hook-Up Diagram ............................................................................................6

P1 Terminal Block Descriptions ..................................................................................................... 7

-1 Option Wiring .............................................................................................................................7

Basic Operating Instructions ........................................................................................................... 8

Control Algorithm Discussion ........................................................................................................8

Pulse-Accumulation Loop PI Tuning ............................................................................................. 8

Master (Rate and Time) and Follower (Ratio) Modes Explained ...................................................9

Visual Reference ........................................................................................................................... 9

How to Change a Parameter's Value (The Short Story) ..............................................................10

Operating the User Interface (The Long Story) ........................................................................... 10

Detailed Configuration Instructions ..............................................................................................11

Default Configuration ...................................................................................................................11

Resetting the Unit to Factory Defaults......................................................................................... 11

JP1 (Program Enable Jumper).................................................................................................... 11

Software Parameters ................................................................................................................... 12

Parameter Descriptions............................................................................................................... 14

Application Examples ..................................................................................................................... 21

Pump Controller with Audible and Visual Alarm .......................................................................... 21

Conveyor Oven Controller with Two Preset Process Times .......................................................22

Synchronized Conveyor Controller with Jog Switch ................................................................... 23

Troubleshooting ..............................................................................................................................25

Technical Support Options ..........................................................................................................25

What's Special About www.dartcontrols.com? ...........................................................................25

Introduction

The ASP10 process controller is a compact, microprocessor-based unit capable of being either field or factory configured for a number of industry's motion control needs. These controls are designed around a pulse-accumulation PI algorithm. They can be easily configured to operate as a digital speed controller, time-based process controller, or a ratiometric follower controller in master-slave systems. Utilizing Dart's new modular bus design techniques, the ASP series is ideal for volume OEM applications requiring specialized inputs and outputs. Contact Dart Controls' Sales Department for details. This flexibility makes the ASP series ideal for applications such as:

Water and Waste Treatment Systems

Conveyor Oven Controllers

Synchronized Conveyor Lines

Its durable 1/8 DIN aluminum housings can be easily mounted in a panel or control cabinet. New optional pluggable terminal block allows the installer to quickly install or replace units without the hassle of physically removing and reattaching wires. The units can be ordered with either standard Europeanstyle terminal block or optional “pluggable” connector.

General Features

- Microprocessor-based design combines the ultimate in responsiveness and accuracy in one package

- Digital closed-loop algorithm ensures long-term accuracy of +/-1/2 RPM of set speed or equiv.

- Non-volatile memory stores adjustable parameters even when power has been removed

- Factory or field programmable via front-panel keypad

- Adjustable parameters include min, max, accel, decel, display options, alarm options, etc.

- Internal program-enable jumper selectively prevents tampering with unit’s configuration

- Universal power supply accepts line voltages inputs from 85-265VAC @ 50-60Hz without switches or jumpers. The unit automatically adjusts as needed.

- Transient voltage protection prolongs unit's life in harsh industrial environments

- Compatible with a variety of signal input types including: Hall-Effect Pickups, Photoelectric, TTL, etc.

Note: Open collector devices must be capable of sinking 3mA.

- Self-contained power supply for external sensor, limited to 5V @ 50mA

- Programmable alarm output with Form C contacts rated to 250VAC @ 5A

- 1/8 DIN durable aluminum housing for panel mounting.

- Large 4 digit, 1/2” LED display

- G.E. Lexan membrane and gasket (which are included) meet NEMA 4X standards when used with NEMA 4X enclosures

- European terminal block or pluggable terminal block available

- Wide operating ambient temperature range of -10C to 45C (14F to 113F)

- Multiple operating modes including:

• Master, Rate Mode – Controls in rate unit such as RPM, Gallons per Second, etc.

• Master, Time Mode – Controls in time unit such as HH:MM, MM:SS, SS:TT, or other unit

• Follower Mode – Controls in percentage of master rate. This mode allows the ASP10 controller

to precisely follow the actions of a master process without any long-term loss of position.

Models & Options

Model Options

Pickup or

Input V o ltage

Model

ASP10 85-265VAC 0-2 VDC

@ 50 - 60Hz

Available Options

Option Suffix Description Example

-1 Expansion board which adds support for remote push button wiring via a European-style terminal block.

-P Optional pluggable European-style terminal block ASP10-P

-9 Blank Lexan ASP10-9

Recommended Accessories

Model Description

PU-2E Hall-Effect Pickup, Single Channel 1 1.0 – 50,000 RPM

PU-4E Hall-Effect Pickup, Single Channel 2 0.5 – 25,000 RPM PU-10E Hall-Effect Pickup, Single Channel 5 0.2 – 10,000 RPM PU-20E Hall-Effect Pickup, Single Channel 10 0.1 – 5,000 RPM

Output Voltage

THROUGH

0-24 VDC

Pulses per

Revolution

Encoder

Required?

Yes

ASP10-1

RPM Range When Used With

MD10P & MD3P

Specifications

Electrical

Line Input Voltage ..................................................................................................... Any Voltage from 85-265 VAC

Line Input Frequency .................................................................................................... Any Freq. from 48-62 Hertz

Pulse Signal Input Voltage Range....................................................................... 0-5VDC to 0-24VDC square wave

Pulse Signal Input Frequency Range......................................................................... 0 – 50,000 Pulses per Minute

(Higher frequencies are possible when using internal frequency divisor / prescaler)

Display Range......................................................................................................................................0.001 – 9999

Units of Operation .................................................................................................... User Programmable, any Unit

Onboard Sensor / Pickup Power Supply............................................................................................... 5V @ 50mA

Isolated Alarm Relay Output Ratings ................................................................................................ 250VAC @ 5A

Pot Lo/Hi supply VDC range .........................................................................................0-2 VDC through 0-24 VDC

Pot wiper VDC range ......................................................................................Pot Lo +50mV through Pot Hi -50mV

Mechanical

Display Type .............................................................................................................. LED, Red, 4 Digit, ½” Height

Housing Type (with supplied gasket in NEMA 4X panel) .............................................................1/8 DIN NEMA 4X

Connector Style (pluggable connector optional)....................................................12-position 5mm European Style

Terminal Block Torque Setting..............................................................................................4.4 in. lb. Max or .5Nm

Faceplate Material........................................................................................ Polycarbonate with GE Lexan Overlay

Housing Material .......................................................................................................................................Aluminum

Length (Required Panel Depth)....................................................................................................4.625", 117.48mm

Faceplate Width ..........................................................................................................................4.539", 115.29mm

Weight ASP10................................................................................................................. 0.900 lb, 14.4 oz, 408.22g

Environmental

Operating Temperature Range....................................................................................... -10C to 45C (14F to 113F)

Operating Humidity Range .................................................................................................... 95%, non-condensing

Mechanical Installation

Exploded Panel View

PANEL MOUNTING GASKET

CUSTOMER

MOUNTING PANEL

(HOLE CUT-OUT FOR CONTROL

HOUSING APPROXIMATELY

3.622" WIDE BY 1.770" HIGH)

(WITH THE ADHESIVE SIDE OF

GASKET FACING THE CUSTOMER

MOUNTING PANEL)

ASP10

CONTROL

1) GASKET

2) (2) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS

3) (2) #6 NUT WITH LOCKWASHER

Cut-out and Mounting Dimensions

4.000"

SUPPLIED WITH EACH CONTROL:

CONTROLS

Ite

MICRO-DRIVE

ACCU-SET

Tac h

ValuPage

Tac h

ValPage

ENTER

.140" x 2

5.000"

2.289"

4.000"

3.622"

ASP10

HOUSING DEPTH

4.625"

PANEL CUT-OUT

1.656"

0.885"

1.770"

4.625"

PU-E Series Pickup Installation

The PU-E series pickup is an economical way to monitor motor speed. Its patented design provides for ease of installation in otherwise difficult to reach areas. The PU-E operates from a +5V power supply, producing a 5 volt square wave whose frequency is proportional to speed. This signal is fed into the ASP10 controller as a speed or position reference for the microprocessor.

PU-E

bearing

flat

dust

cover

10-32

screw

DO NOT OVER TIGHTEN MOUNTING SCREW !!

magnet

disc

black wire

washer

common

CAUTION:

white wire

signal

3/16"

spacer

red wire

+5 volts

No other mounting screws are necessary, as the cord will keep the unit from rotating.

tapped

motor

shaft

Model

Number

PU-2E PU-4E PU-10E PU-20E

Pulses per Revolution

1 2 5

Dimensions

1.60 .875

2.40

72.00

Caution: The PU-E cord should not be grouped with other wires or cords. For applications with PUE wire over 6 feet long, or noisy environments, a shielded cable is recommended. Connect the shield to the common terminal on the ASP10 controller, leaving the shield on the PU-E end floating.

Electrical Installation & Diagrams

P1 Terminal Block Hook-Up Diagram

ASP

MASTER

* P1-9 signal input may be programmed for a number of functions. Incl (jog, inhibit, etc.)

ASP

FOLLOWER

P1-1

P1-2

P1-3

P1-4

P1-5

P1-6

P1-7

P1-8

P1-9

P1-10 P1-11

P1-12

P1-1

P1-2

P1-3

P1-4

P1-5

P1-6

P1-7

P1-8

P1-9

P1-10

P1-11

P1-12

2 AMP

HIGH OUTPUT

WIPER OUTPUT

LOW OUTPUT

COMMON

+5VDC

SIGNAL 1

SIGNAL 2

Alarm Output - Normally Open

Alarm Output - Common

Alarm Output - Normally Closed

2 AMP

HIGH OUTPUT

WIPER OUTPUT

LOW OUTPUT

COMMON

+5VDC

SIGNAL 1

Alarm Output - Normally Open

Alarm Output - Common

Alarm Output - Normally Closed

AC INPUT

black

red

white

SIGNAL 2

85-265VAC

}

Connect to the speedpot of the control being driven. High must be positive

}

voltage with respect to low.

Form C Relay output

}

(Programmable)

AC INPUT

Connect to the speedpot of the control being driven. High must be positive

}

voltage with respect to low.

}

85-265VAC

}

Form C Relay output (Programmable)

black

white

PICK-UP MOUNTED

TO MOTOR SHAFT

(Mounts on rotating

end shaft with 10-32

tapped hole, 1/2" deep)

black

white

FOLLOWER PICK-UP

MOUNTED TO

MOTOR SHAFT

red

(Mounts on rotating

end shaft with 10-32

tapped hole, 1/2" deep)

* Optional Inhibit Switch

P1 Terminal Block Descriptions

P1-1 (AC / N) – For single phase AC lines connect the Neutral side of your AC line to this terminal.

For systems with two hot AC lines, connect either of the Hot AC lines to this terminal.

P1-2 (AC / L) – For single phase AC lines connect the Hot side of your AC line to this terminal. For

systems with two hot AC lines, connect either of the Hot AC lines to this terminal.

P1-3 (HI) - This is the POT HI reference terminal. This terminal must be connected to the most positive

speed pot input terminal of the partner control. This terminal will generally be referred to as Pot HI or +V for positive supplies and Com for negative supplies.

P1-4 (WP) - This is the Wiper output terminal. This terminal will output an analog voltage signal

proportional to the referenced voltage signals connected to P1-3 (HI) and P1-5 (LO). This terminal should be connected to the wiper or signal input of the partner control.

P1-5 (LO) - This is the POT LO reference terminal. This terminal must be connected to the most

negative speed pot input terminal of the partner control. This terminal will generally be referred to as Pot LO or Com for positive supplies and –V for negative supplies.

P1-6 (COM) – This is the common point for the control logic. The speed sensor common lead as well

as any other source needing to reference the control common will be connected to this terminal.

P1-7 (+5V) – This is a self-contained +5VDC power supply capable of up to 50mA. The speed sensor

supply lead can be connected to this terminal for its power source.

P1-8 (S1) – This is the signal input terminal for the motor’s digital pickup or encoder.

P1-9 (S2) – This input can be programmed to perform a number of advanced functions. In Follower

Mode, this input is the signal input terminal for the master’s digital pickup or encoder. In Master modes (Rate and Time), this input can be configured to function as an emergency stop, inhibit, or jog command.

P1-10 (1NO) – This is the normally-open contact of the user assignable relay output.

P1-11 (1C) – This is the common contact of the user assignable relay.

P1-12 (1NC) – This is the normally-closed contact of the user assignable relay output.

-1 Option Wiring

The -1 option board is a module which allows external up and down push buttons to be wired to the unit. These buttons operate exactly like the Up and Down buttons on the user interface. This module is commonly used to allow PLCs or hand-held pendants to operate the front-panel remotely. Wires for the external buttons are attached via a 3mm European terminal block on the -1 option board. The buttons are activated by shorting the terminal labeled Com to either the Up or Down terminal.

REMOTE SWITCHING

MICROPROCESSOR

SERIES PC BOARD

DOWN UP

-1 OPTION BOARD

COMMON

-3

DOWN

-2

-1 UP

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