Omega Products MD10P Installation Manual

CONTROLS
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Omegamation
TM
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1-888-55-66342
Field Programmable Closed Loop DC Speed Control
MDP CONTROL SERIES
LT61 (0709)
P.O. Box 10 5000 W. 106th Street Zionsville, Indiana 46077
Phone (317) 873-5211
Fax (317) 873-1105
www.dartcontrols.com
A-5-3241L
Quick Jump
What models and options are available? See page 3.
Looking for detailed specifi cations? See page 3 & 4.
Want to get started fast? See basic electrical hook-up details on page 8. See mechanical installation details on page 4 & 5. See some sample applications starting on page 24.
Need Help? See troubleshooting on page 29.
Dart Controls, Inc. (DCI) warrants its products to be free from defects in material and workmanship. The exclusive remedy
Warranty
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.
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 qualifi ed 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.
WARNING
Table of Contents
Introduction ....................................................................................................................................... 2
General Features .............................................................................................................................. 2
Models & Options ............................................................................................................................. 3
Model Table ................................................................................................................................... 3
Available Options .......................................................................................................................... 3
Recommended Accessories ......................................................................................................... 3
Agency Approvals ......................................................................................................................... 3
Specifi cations ................................................................................................................................... 3
Electrical ....................................................................................................................................... 3
Mechanical ................................................................................................................................... 4
Environmental ............................................................................................................................... 4
Dimension Chart ........................................................................................................................... 4
Installation and Mechanical Dimensions ....................................................................................... 5
Exploded Panel View .................................................................................................................... 5
Cut-out and Mounting Dimensions ............................................................................................... 6
PU-E Series Pickup Installation .................................................................................................... 7
Electrical Installation & Diagrams ................................................................................................... 8
P1 Terminal Block Hook-Up Diagrams .......................................................................................... 8
P1 Terminal Block Descriptions .................................................................................................... 9
-1 Option Wiring .......................................................................................................................... 10
Basic Operating Instructions ........................................................................................................ 10
Control Algorithm Discussion ..................................................................................................... 10
Pulse-Accumulation Loop PI Tuning .......................................................................................... 10
Master (Rate and Time) and Follower (Ratio) Modes Explained ................................................ 11
Visual Reference ........................................................................................................................ 12
How to Change a Parameter's Value (The Short Story) ............................................................. 12
Operating the User Interface (The Long Story) .......................................................................... 12
Detailed Confi guration Instructions ............................................................................................. 13
Default Confi guration .................................................................................................................. 13
Resetting the Unit to Factory Defaults ........................................................................................ 13
JP1 (Program Enable Jumper) .................................................................................................. 13
Software Parameters .................................................................................................................. 14
Parameter Descriptions .............................................................................................................. 16
Application Examples .................................................................................................................... 24
Pump Controller with Audible and Visual Alarm ......................................................................... 24
Conveyor Oven Controller with Two Preset Process Times ........................................................ 25
Synchronized Conveyor Controller with Jog Switch ................................................................... 26
Troubleshooting .............................................................................................................................. 29
Technical Support Options .......................................................................................................... 29
What's Special About www.dartcontrols.com? ........................................................................... 29
1
Introduction
The MDP series motor controls are compact, microprocessor-based units capable of being either fi eld or factory confi gured for a number of industry's motion control needs. These controls are designed around a pulse-accumulation PI algorithm. They can be easily confi gured 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 MDP series is ideal for volume OEM applications requiring specialized inputs and outputs. Contact Dart Controls' Sales Department for details. This fl exibility makes the MDP series ideal for applications such as:
Water and Waste Treatment Systems
Conveyor Oven Controllers
Synchronized Conveyor Lines
Its durable 1/8 and 1/4 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 European-style 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 fi eld 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 confi guration
- Universal power supply accepts line voltages inputs from 85-265VAC (85-250 VAC for MD3E models) @ 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
- Flexible user inputs support inhibit, emergency stop, and jog functionality.
- 1/8 and 1/4 DIN durable aluminum housing for panel mounting the MD10P and MD3P, respectively.
- 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
- Recognized, fi le #E78180 (MD10P, MD3P & MD3E)
- 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 MDP control to
precisely follow the actions of a master process without any long-term loss of position
2
Models & Options
Model Table
Model
MD10P
MD3P 85-265VAC
MD3E 85-250VAC
Input Voltage
@ 50 - 60Hz
85-265VAC
Output Voltage
@ 120VAC
(@ 240VAC)
90VDC
(180VDC)
90VDC
(180VDC)
90VDC
(180VDC)
Max. Output H.P.
@ 120VAC
(@240VAC)
1/2
1
1 2
1 2
Max Continuous
Armature DC
Amps
5 5
10 10
10 10
Available Options
Option Suffi x Description Example
-1
-P Optional pluggable European-style terminal block MD10P-P, MD3P-1-P
-9 Blank Lexan MD10P-9
OPT3 Sine wave to square wave converter for magnetic pickup Ordered Separately
Expansion board which adds support for remote push button wiring via a European-style terminal block.
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-20E PU-40E Hall-Effect Pickup, Single Channel 20 0.05 – 2,500 RPM
Hall-Effect Pickup, Single Channel
Pulses per Revolution
10 0.1 – 5,000 RPM
RPM Range When Used With
Pickup or
Encoder
Required?
Yes
Yes
Yes
MD10P-1, MD3P-1
MD10P & MD3P
Agency Approvals
Recognized Component MD10P, MD3P ........................................................................................... E78180
MD3E ....................................................................................................................................................34M5
NEMA 4X ....................................................................................................................................MD10P / MD3P / MD3E
Specifi cations
Electrical
Line Input Voltage .................................................... Any Voltage from 85-265 VAC (85-250 VAC for MD3E models)
Line Input Frequency ...................................................................................................... Any Freq. from 48-62 Hertz
Signal Input Voltage Range .................................................................................. 0-5VDC to 0-24VDC square wave
Signal Input Frequency Range ....................................................................................0 – 50,000 Pulses per Minute
Display Range ....................................................................................................................................0.001 – 99,990
Units of Operation ..................................................................................................... User Programmable, any Unit
Sensor / Pickup Power Supply ............................................................................................................... 5V @ 50mA
Isolated Alarm Relay Output Ratings ..................................................................................................250VAC @ 5A
Average Armature Output Voltage ................................................. Line Input Voltage Dependent (See model table)
Design Overload Capacity .............................................................................................................200% for 1 minute
(Higher frequencies are possible when using internal frequency divisor / prescaler)
3
Mechanical
Display Type .................................................................................................................LED, Red, 4 Digit, ½” Height
Housing Type MD10P & MD3P (with supplied gasket) ...............................................................................NEMA 4X
MD3E .......................................................................................................................................................... NEMA 4
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 MD10P & MD3P(Required Panel Depth) ......................................................................... 4.625”, 117.48mm
Faceplate Width ........................................................................................................................... 4.539”, 115.29mm
Weight MD10P ............................................................................................................. 0.8425 lb, 13.48 oz, 382.14g
MD3P ................................................................................................................... 1.52 lb, 24.32 oz, 689.44g
MD3E ................................................................................................................... 1.64 lb, 26.24 oz, 743.88g
Environmental
Operating Temperature Range ----------------------------------------------------------------------------- -10C to 45C (15F to 115F)
Operating Humidity Range ----------------------------------------------------------------------------------------- 95%, non-condensing
Dimension Chart
Model Width Height Depth
MD10P English (inches)
Housing 3.62 1.66 4.625 Lens 4.539 2.289 0.375
MD10P Metric (millimeters)
Housing 91.94 42.16 117.27 Lens 115.28 58.14 9.53
MD3P English (inches)
Housing 3.60 3.497 4.625 Lens 4.539 4.179 0.375
MD3P Metric (millimeters)
Housing 91.44 88.82 117.27 Lens 115.28 106.15 9.53
MD3E English (inches)
Assembly 5.53 7.40 3.90
MD3E Metric (millimeters)
Assembly 140.46 187.96 99.06
4
Installation and Mechanical Dimensions
Exploded Panel View
CUSTOMER
MOUNTING PANEL
(HOLE CUT-OUT FOR CONTROL
HOUSING APPROXIMATELY
3.622" WIDE BY 1.770" HIGH)
MD10P
CONTROL
SUPPLIED WITH EACH CONTROL:
1) GASKET
2) (2) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS
3) (2) #6 NUT WITH LOCKWASHER
PANEL MOUNTING GASKET
(WITH THE ADHESIVE SIDE OF
GASKET FACING THE CUSTOMER
MOUNTING PANEL)
CUSTOMER
MOUNTING PANEL
(HOLE CUT-OUT FOR CONTROL
HOUSING APPROXIMATELY
3.622" WIDE BY 3.622" HIGH)
SUPPLIED WITH EACH CONTROL:
1) GASKET
2) (4) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS
3) (4) #6 NUT WITH LOCKWASHER
5
PANEL MOUNTING GASKET
(WITH THE ADHESIVE SIDE OF
GASKET FACING THE CUSTOMER
MOUNTING PANEL)
MD3P
CONTROL
Cut-out and Mounting Dimensions
4.000"
CONTROLS
MICRO-DRIVE
MICRO-DRIVE
Tach
ValuPage
Ite
Tach
Ite
ValPage
m
ENTER
.140" x 2
4.000"
3.622"
MD10P
HOUSING DEPTH
4.625"
PANEL CUT-OUT
3.622
0.885"
1.770"
ENTER
MICRO-DRIVE
CONTROLS
MD10P and MD3P Dimensions
5.000"
2.289"
4.625"
.140" x 4
1.656"
4.179"
MD3P
HOUSING DEPTH
4.625"
PANEL CUT-OUT
5.000"
4.625"
0.811"
3.622"
2.000"
1.928"
6
MD3E Mounting and Dimensions
5.530 7/32" TYP.
(4 SLOTS)
.350 DEEP
CONTROLS
ValuPage
5.125 TYP.
Tach
ENTER
5.500
ON
OFF
.750
Item
7.400
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 diffi cult 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 MDP control as a speed or position reference for the microprocessor.
dust
cover
10-32 screw
magnet
disc
flat
washer
PU-E
bearing
3/16"
spacer
tapped
motor
shaft
Model
Number
PU-2E PU-4E PU-20E PU-40E
Pulses per
Revolution
1
2 10 20
white wire
signal
red wire +5 volts
black wire
common
DO NOT OVER TIGHTEN MOUNTING SCREW !!
CAUTION:
No other mounting screws are necessary, as the cord will keep the unit from rotating.
7
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 PU-E wire over 6 feet long, or noisy environments, a shielded cable is recommended. Connect the shield to the common terminal on the MDP, leaving the shield on the PU-E end fl oating.
Electrical Installation & Diagrams
P1 Terminal Block Hook-Up Diagrams
**
Jog Input
User Input 1
COM (P1-5)
black
white
red
AC INPUT
AC INPUT
}
85-265VAC
}
MOTOR
Form C Relay Output (Programmable)
PICK-UP MOUNTED
TO MOTOR SHAFT
(Mounts on rotating
end shaft with 10-32
tapped hole, 1/2" deep)
black
white
MDP
MASTER
FUSE
N
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-10
P1-11
P1-12
* For AC inputs utilizing two hot lines, both inputs should be
protected with appropriately sized fuses or circuit breakers.
** P1-8 & P1-12 user input may be programmed for a number of functions. Including (jog, inhibit, etc.)
MD10P = 7.5 Amp* MD3P = 15 Amp*
L
-A
-ARM
+A
+ARM
COM
COMMON
+5V
+5VDC
S1
SIGNAL
S2
Alarm Output - Normally Open
NO
Alarm Output - Common
C
Alarm Output - Normally Closed
NC
IN1
**INHIBIT
MDP
FOLLOWER
User Input 1
COM (P1-5)
AC INPUT
AC INPUT
SIGNAL 2
Form C Relay Output (Programmable)
}
FUSE
N
P1-1
P1-2
P1-3
P1-4
P1-5
P1-6
P1-7
P1-8
P1-9
P1-10
P1-11
P1-12
* For AC inputs utilizing two hot lines, both inputs should be
protected with appropriately sized fuses or circuit breakers.
** P1-8 & P1-12 user input may be programmed for a number of functions. Including (jog, inhibit, etc.)
MD10P = 7.5 Amp* MD3P = 15 Amp*
L
-A
-ARM
+A
+ARM
COM
COMMON
+5V
+5VDC
S1
SIGNAL 1
S2
Alarm Output - Normally Open
NO
Alarm Output - Common
C
Alarm Output - Normally Closed
NC
IN1
**
INHIBIT
}
MOTOR
85-265VAC
black
red
white
FOLLOWER PICK-UP
MOUNTED TO MOTOR SHAFT
(Mounts on rotating
end shaft with 10-32
tapped hole, 1/2" deep)
8
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