KMC Controls MEP-7 Series User guide

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 1 Applications Guide, AN1113A Rev. D
Applications Guide
MEP-7xxx
Direct-Coupled Actuators (up to 320 in-lb.)
Contents
Important Notices........................................................................................................................... 2
Introduction.................................................................................................................................... 2
Torque Requirements for Dampers ................................................................................................. 2
Models............................................................................................................................................ 3
Accessories ..................................................................................................................................... 4
Auxiliary Switches and End Stops ................................................................................................ 4
Transformers................................................................................................................................ 4
Enclosure, Cord Grip, and Wiring Kits......................................................................................... 4
Thermostat .................................................................................................................................. 4
Mounting Brackets and Crank Arm Kit......................................................................................... 5
Master/Slave Wiring........................................................................................................................ 6
All Master/Slave Combinations.................................................................................................... 6
MEP-7802/7852 Proportional Actuators...................................................................................... 6
MEP-7801/7803 Tri-State Actuators............................................................................................. 7
MEP-7851/7853 Tri-State with Fail-Safe Actuators....................................................................... 7

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 2 Applications Guide, AN1113A Rev. D
Specifications, design, and operation are subject to change without notice.
Configuration.................................................................................................................................. 8
Troubleshooting .............................................................................................................................. 8
Auxiliary Switch Does Not Work ................................................................................................. 8
Fail-Safe Does Not Work.............................................................................................................. 8
Feedback Does Not Work ............................................................................................................ 8
No Rotation................................................................................................................................. 8
Rotation in Wrong Direction ....................................................................................................... 9
Stroke Range Is Wrong ................................................................................................................ 9
Wiring Issues ............................................................................................................................... 9
Index............................................................................................................................................... 9

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 3 Applications Guide, AN1113A Rev. D
Torque Requirements for Dampers
Introduction
This application guide gives torque selection, ac-
cessory, master/slave wiring, troubleshooting, and
other related information.
For help choosing the best model for an application,
see Models on page 4 and also the KMC Actua-
tors Selection Guide.
For specications and other information, see the
MEP-7500/7800 Series Data Sheet.
For general mounting, connections, and congura-
tion, see the MEP-7200/7500/7800 Series Installation
Guide.
For possible proportional heating/cooling applica-
tions 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, Buer-
y Valves (2 to 6")
• VEF-56 Series Three-Way, Rubber-Lined, But-
tery Valves (2 to 6")
The latest support les are always available on the
KMC Controls web site (www.kmccontrols.com).
Important Notices
The KMC logo is a registered trademark of KMC
Controls, Inc. All rights reserved. No part of this
publication may be reproduced, transmied, tran-
scribed, stored in a retrieval system, or translated
into any language in any form by any means with-
out the wrien permission of KMC Controls, Inc.
The material in this document is for information
purposes only. The contents and the product it de-
scribes are subject to change without notice. KMC
Controls, Inc. makes no representations or warran-
ties 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.
Damper manufacturers should provide information
about the required minimum actuator torque. If
that information is not available, use the following
Damper Type
Opposed Blades Without Seals
Parallel Blades Without Seals
Opposed Blades With Seals
Parallel Blades With Seals
Up to 1000 FPM
3 in-lb. per square foot
4 in-lb. per square foot
5 in-lb. per square foot
7 in-lb. per square foot
1000 to 2500 FPM
4.5 in-lb. per square foot
6 in-lb. per square foot
7.5 in-lb. per square foot
10.5 in-lb. per square foot
2500 to 3000 FPM
6 in-lb. per square foot
8 in-lb. per square foot
10 in-lb. per square foot
14 in-lb. per square foot
general guidelines to calculate the required mini-
mum torque.

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 4 Applications Guide, AN1113A Rev. D
Models
Powered Timing (Full Rotation)
MEP-72xx 75–90 seconds,
load dependent
MEP-75xx 90–115 sec., load
dependent
Fail-Safe Timing (Full Rotation)
MEP-725x 65–100 sec., load
dependent
MEP-755x 80–115 sec., load
dependent
*NOTE: The MEP-7200 series (120 in-lb.) has been
discontinued. Use an MEP-75xx (180
in-lb.)—or, if less torque is required, an
MEP-48xx (80 in-lb., non-fail-safe) or MEP-
49xx (90 in-lb., fail-safe) instead. Besides
maximum torque, the dierences between
the MEP-7200 and MEP-7500 series include:
Model #
Torque Control Built-in Options
180 in-lb.
(20 N•m)
min.
320 in-lb.
(36 N•m)
min.
Tri-state
(Floating)
0–10 VDC, 2–10
VDC, or 4–20 mA
Proportional
Feedback:
10K ohm
Potentiometer
Feedback:
0/1–5 or
0/2–10 VDC
Fail Safe
MEP-7x01
7500 series
(x=5)
7800 series
(x=8)
4
MEP-7x02 4 4
MEP-7x03 4 4
MEP-7x51 44
MEP-7x52 4 4 4
MEP-7x53 4 4 4
The MEP-72xx series (120 in-lb.) has been discontinued. Use the MEP-75xx series (180 in-lb.)—or, if less torque is required, an MEP-48xx (80
in-lb., non-fail-safe) or MEP-49xx (90 in-lb., fail-safe) instead.
To replace the MEP-70xx series (150 in-lb.), use MEP-75xx series (180 in-lb.).
To replace the MEP-77xx series (300 in-lb.), use MEP-78xx series (320 in-lb.).
NOTE: See also the KMC Actuators Selection
Guide.
NOTE: Before Jan. 2014, MEP-7xx2 proportional
models had (besides the 4-20 mA input)
a 0–10 VDC input and 0–5 or 0–10 VDC
feedback. From 2014 through July 2015,
they had a 2–10 VDC input and 1–5 or 2–10
VDC feedback instead. Starting in August
2015, all these options were available and
selectable via a jumper and slide switch.
NOTE: When the 0–10 VDC input is selected (with
the jumper), selectable (with a switch)
feedback options are 0–5 or 0–10 VDC.
When the 2–10 VDC input is selected,
feedback options are 1–5 or 2–10 VDC.

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 5 Applications Guide, AN1113A Rev. D
The HMO-4536 adjust-
able end stop kit allows
rotation to be blocked at
a desired angle in one or
both directions.
CME-7001/7002 rotary
switches (SPDT or dual
SPDT) are designed to
start and stop auxiliary
items (such as electric heat
or fans) or to indicate an
actuator’s fully open or
closed position. Switches
are independently adjust-
able for a trip point any-
where within the angular
rotation of the driving
actuator.
Accessories
The HCO-1152 enclosure
kit, consisting of a metal
mounting plate, plastic
cover, non-rotation brack-
et, plug caps, and screws,
is designed to protect
actuators from inclement
conditions. See also the
HMO-4521 cord grip.
For sample proportional
heating/cooling applica-
tions using the CTE-5202
electronic thermostat, see
the CTE-5202 Applica-
tions Guide.
An HMO-4521 liquid-tight
cord grip threads into con-
duit ings on MEP-7xxx
actuators when an ingress
protection rating of IP54 is
required. The HMO-4521
accepts 0.18 to 0.40" diam-
eter cables. See also the
HCO-1152 and HPO-7001.
Thermostat
Auxiliary Switches and End Stops
Transformers
Enclosure, Cord Grip, and Wiring Kits
An HPO-7001 assembled wiring kit has an HMO-
4521 liquid-tight cord grip, a 3-foot plenum-rated
cable, conduit ing, and a pre-wired terminal block
for the MEP-75xx/78xx actuators:
An XEE-6000 series Class-2 transformer provides 24
VAC power to the actuator:
XEE-6111-050 120 to 24 VAC, 50 VA, single-hub
XEE-6112-050 120 to 24 VAC 50 VA, dual-hub

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 6 Applications Guide, AN1113A Rev. D
The HLO-1020 crank arm kit is used when direct
mounting of the actuator is impractical.
One HMO-4535 non-rotation bracket is provided
with each actuator. It can span an open distance, or
be formed (bent) into a shape that increases the dis-
tance between the mounting surface and the actua-
tor.
Mounting Brackets and Crank Arm Kit

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 7 Applications Guide, AN1113A Rev. D
Master/Slave Wiring
All Master/Slave Combinations
1. Follow the instructions in the Wiring (General)
section of the MEP-7200/7500/7800 Series
Installation Guide and also include the following
steps.
2. Connect the actuators according to the relevant
illustration below.
4. Check that the wiring is properly phased (“~”
to “~” and “ ” to “ ”). In tri-state actuators, CW
and CWW are connected to like terminals for
“stacked-mounted” applications and opposite
terminals for “opposite-mounted” applications.
2. On applicable models, set the Master and the
Slave’s CW/CCW switches according to the
relevant illustration and chart.
3. On applicable models, set the Master and the
Slave’s FAIL switches according to the relevant
illustration and chart.
5. If using feedback, connect to one actuator only.
Do NOT interconnect the feedback between the
master and slave.
NOTE: The 4–20 mA input and auto-mapping
options are not available with Master/
Slave actuators.
CAUTION
Miswiring or wrong switch positions could
result in damage to one or more actuators.
Carefully check wiring and switch positions.
MEP-7802/7852 Dual Actuators, 0–10 or 2–10 VDC, OPPOSITE Mount (e.g., on KMC’s flanged globe valves)
CW/CCW Switches Fail Switches (MEP-7852 only) Unavailable Options
Opposite Positions Opposite Positions 4–20 mA input and Auto-Mapping
MEP-7802/7852 Proportional Actuators
MEP-7802/7852 Dual,Triple, or Quad Actuators, 0–10 or 2–10VDC, STACKED Mount (e.g., on KMC’s butterfly valves)
CW/CCW Switches Fail Switches (MEP-7852 only) Unavailable Options
Same Positions Same Positions 4–20 mA input and Auto-Mapping
24 VAC/VDC
Power In
0/2–10 VDC Control Signal
0/1–5 or 0/2–10 VDC
Feedback Signal
Control Signal Common
Input Voltage
Range Set the
Same on Both
Actuators
MASTER SLAVE
(MEP-7802/7852 Opposite Mount, Proportional Input)
MASTER
(MEP-7x52 Only)
CW
CW
CCW
OUT
COM
24 VAC
CCW
OFF
0/1-50/2-10
0/2-10 IN
4-20 mA IN
DIRECTION AND MAPPING
FAIL-SAFE
DIRECTION
~
0-10
2-10
(MEP-7x52 Only)
CW
CW
CCW
OUT
COM
24 VAC
CCW
OFF
0/1-50/2-10
0/2-10 IN
4-20 mA IN
DIRECTION AND MAPPING
FAIL-SAFE
DIRECTION
~
24 VAC/VDC
Power In
0/2–10 VDC Control Signal
0/1–5 or 0/2–10 VDC
Feedback Signal
Control Signal Common
Input Voltage
Range Set the
Same on Both
Actuators
MASTER SLAVE
(MEP-7802/7852 Stacked Mount, Proportional Input)
MASTER
(MEP-7x52 Only)
CW
CW
CCW
OUT
COM
24 VAC
CCW
OFF
0/1-50/2-10
0/2-10 IN
4-20 mA IN
DIRECTION AND MAPPING
FAIL-SAFE
DIRECTION
~
0-10
2-10
(MEP-7x52 Only)
CW
CW
CCW
OUT
COM
24 VAC
CCW
OFF
0/1-50/2-10
0/2-10 IN
4-20 mA IN
DIRECTION AND MAPPING
FAIL-SAFE
DIRECTION
~

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 8 Applications Guide, AN1113A Rev. D
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
MASTER SLAVE
(MEP-7802/7852 Opposite Mount, 0–10 VDC Input)
(MEP-7802/7852 Stacked Mount, 0–10 VDC Input)
(MEP-7851/7853 Opposite Mount)
(MEP-7801/7803 Stacked Mount)
(MEP-7801/7803 Opposite Mount)
(MEP-7851/7853 Stacked Mount)
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
MASTER SLAVE
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
MASTER
7851/7853 Dual Actuators, OPPOSITE Mount (e.g., on KMC’s flanged globe valves)
MEP-7851/7853 Tri-State with Fail-Safe Actuators
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
MASTER SLAVE
(MEP-7802/7852 Opposite Mount, 0–10 VDC Input)
(MEP-7802/7852 Stacked Mount, 0–10 VDC Input)
(MEP-7851/7853 Opposite Mount)
(MEP-7801/7803 Stacked Mount)
(MEP-7801/7803 Opposite Mount)
(MEP-7851/7853 Stacked Mount)
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
MASTER SLAVE
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
MASTER
7851/7853 Dual or Quad Actuators, STACKED Mount (e.g., on KMC’s butterfly valves)
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
MASTER SLAVE
(MEP-7802/7852 Opposite Mount, 0–10 VDC Input)
(MEP-7802/7852 Stacked Mount, 0–10 VDC Input)
(MEP-7851/7853 Opposite Mount)
(MEP-7801/7803 Stacked Mount)
(MEP-7801/7803 Opposite Mount)
(MEP-7851/7853 Stacked Mount)
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
MASTER SLAVE
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
MASTER
MEP-7801/7803 Dual Actuators, OPPOSITE Mount (e.g., on KMC’s flanged globe valves)
MEP-7801/7803 Tri-State Actuators
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
MASTER SLAVE
(MEP-7802/7852 Opposite Mount, 0–10 VDC Input)
(MEP-7802/7852 Stacked Mount, 0–10 VDC Input)
(MEP-7851/7853 Opposite Mount)
(MEP-7801/7803 Stacked Mount)
(MEP-7801/7803 Opposite Mount)
(MEP-7851/7853 Stacked Mount)
24 VAC/VDC
Power In
(MEP-7x52 Only)
0–10 VDC Control Signal
0–5 or 0–10 VDC Feedback Signal
Control Signal Common
(MEP-7x52 Only)
MASTER SLAVE
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
24 VAC/VDC
Power In
CWCCW
SLAVEMASTER
24 VAC/VDC
Power In
CW CCW
SLAVEMASTER
MASTER
MEP-7801/7803 Dual or Quad Actuators, STACKED Mount (e.g., on KMC’s butterfly valves)
RotationTerminals Fail Switches
CW to CCW and
CCW to CW Opposite Positions
RotationTerminals Fail Switches
CW to CW and
CCW to CCW Same Positions

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 9 Applications Guide, AN1113A Rev. D
Troubleshooting
Auxiliary Switch Does Not Work
• Check the auxiliary switch seing. See the
CME-7001/7002 Auxiliary Switches Installation
Guide.
• Check the wiring. See Wiring Issues on page 10.
Fail-Safe Does Not Work
• After initial connection or reconnection to power,
proper fail-safe operation might be delayed up
to 20 seconds for the MEP-725x/755x or up to 40
seconds for the MEP-785x (until the capacitors
are fully charged).
• Check the Fail-Safe Direction switch. See Con-
guration on page 9.
Feedback Does Not Work
• Check the feedback switch seing. See Congu-
ration on page 9.
• Check the wiring. See Wiring Issues on page 10.
No Rotation
• Check that the direction switch (Switch 2) is fully
engaged in the proper position. See Congura-
tion on page 9.
• Check that the shaft moves freely. (Press and
hold the gear disengagement lever and manually
rotate the shaft.)
• Check for a tripped circuit breaker to the trans-
former (or power supply).
• Check polarity and strength of input signal.
• Check for proper supply voltage from the trans-
former (or power supply) and that it has enough
capacity (VA) for all connected devices. See their
respective data sheets and Tips for Connecting
24-Volt Power Application Note (AN0604D).
• Check the wiring. See Wiring Issues on page 10.
For direction, feedback, and auto-mapping setup,
see the MEP-7200/7500/7800 Series Installation
Guide.
NOTE: Before Jan. 2014, MEP-7xx2 proportional
models had (besides the 4-20 mA input)
a 0–10 VDC input and 0–5 or 0–10 VDC
feedback. From 2014 through July 2015,
they had a 2–10 VDC input and 1–5 or 2–10
VDC feedback instead. Starting in August
2015, all these options were available and
selectable via a jumper and slide switch.
NOTE: When the 0–10 VDC input is selected (with
the jumper), selectable (with a switch)
feedback options are 0–5 or 0–10 VDC.
When the 2–10 VDC input is selected,
feedback options are 1–5 or 2–10 VDC.
Configuration

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 10 Applications Guide, AN1113A Rev. D
Rotation in Wrong Direction
• For tri-state models, check the CW/CCW wiring.
• For proportional models, check the position of
the direction switch (Switch 2). See Congura-
tion on page 9.
• For fail-safe operation, check the Fail-Safe Direc-
tion switch. See Conguration on page 9.
Stroke Range Is Wrong
• Use and/or check position of the HMO-4536
adjustable end stop kit.
• On proportional models, check the auto-map-
ping. See Conguration on page 9.
• Check the voltage from the controller or thermo-
stat.
Wiring Issues
• For master/slave wiring, see Master/Slave Wir-
ing on page 7.
• Check for correct wiring for the application.
• Check the wiring at the connected devices.
• Use a voltmeter and ohmmeter to check the
terminals for expected values.
• See Tips for Connecting 24-Volt Power Applica-
tion Note (AN0604D).
NOTE: Wiring must be adequate to avoid exces-
sive voltage drop on long runs! Allow
plenty of “cushion” in measurements. A
meter may be too slow to register tran-
sient dips or peaks during startup.
Index
Symbols
0-5/0-10 vs. 1-5/2-10 VDC Feedback: 4, 9
0-10 vs. 2-10 VDC Inputs: 9
4-20 mA: 7
A
Accessories: 5
Auto-Mapping: 9
Auxiliary Switch: 5, 9
B
Bracket, Non-Rotation: 6
Brackets, Non-Rotation: 6
C
Cable: 5
CME-7001/7002: 5
Conduit Fitting: 5
Configuration: 9
Cord Grip: 5
Crank Arm Kit: 6
CTE-5202: 5
D
Dampers: 3
Direction: 7, 9, 10
E
Enclosure: 5
F
Fail-Safe: 7, 9, 10
Feedback: 4, 9
H
HCO-1152 Weather Shield Kit: 5
HLO-1020 Crank Arm Kit: 6
HMO-4521 Liquid-Tight Cord Grip: 5
HMO-4535 Non-Rotation Bracket: 6
HMO-4536 Adj. End Stop Kit: 5
HPO-7001 Wiring Kit: 5

MEP-7xxx Direct-Coupled Actuators (up to 320 in-lb.) 11 Applications Guide, AN1113A Rev. D
© 2017 KMC Controls, Inc. AN1113A Rev. D
I
Important Notices: 3
Inputs: 4, 9
M
Master/Slave Wiring: 7
MEP-72xx: 4
MEP-7801/7803: 8
MEP-7802/7852: 7
MEP-7851/7853: 8
Models: 4
Mounting: 6
N
Non-Rotation Bracket: 6
O
Opposite Mount, Master/Slave: 7, 8
P
Proportional: 7, 9, 10
R
Range, Stroke: 10
Rotation: 7, 9, 10
S
Selection Guide
Actuator: 3, 4
Torque: 3
Slave Wiring: 7
Stacked Mount, Master/Slave: 7, 8
Stop Kit, End: 5
Stroke Range: 10
Support Files: 3
Switch
Auxiliary: 9
Fail-Safe Direction: 7, 8, 10
Feedback Voltage: 9
Rotation Direction: 7, 8, 10
T
Thermostat: 5
Torque Selection: 3
Tri-State: 8, 10
Troubleshooting: 9
V
Valve Applications: 3
VEB-5x Series Ball Valves: 3
VEF-5x Series Butterfly Valves: 3
W
Weather Shield Enclosure Kit: 5
Web Site: 3
Wiring: 5, 7, 10
X
XEE-6000 Series: 5
KMC Controls
19476 Industrial Drive
New Paris, IN 46553
574.831.5250
Fax [phone]
www.kmccontrols.com
[email protected]