kmk MD21 User manual

96x48
Operating Instructions
for
Measurement Amplifier
TYP MD21
Made in Germany
Measuring Equipment
for plastic extrusion
This instruction manual is only valid for type MD21 Measurement Amplifier.
These are precision measurement amplifier that, with appropriate handling, have a long lifetime
and provide reproducible measurements. The MD21 should be installed and operated by
personnel qualified to install, commission and operate such appliances. The instruction manual
should be at hand at all times. Suitable transport and appropriate storage are prerequisites.
However, if problems occur, please contact our customer service department.

1. Assembly
2
1. Assembly
Sealing
48,0
3,0
139,0
M3
Gap for physical unit
1. After removing the fixing elements, insert the device.
2. Check the seal to make sure it fits securely.
3. Click the fixing elements back into place and tighten the clamping screws by hand.
Then use a screwdriver to tighten them another half a turn.
CAUTION! The torque should not exceed 0.1 Nm!

2. Electrical connection
3
2. Electrical connection
Work at electrical connections should only be carried out by qualified staff, in accordance with
local regulations. The unit has to be connected in accordance with the wiring diagram. Please
pay attention to local regulations on installation and operation of electrical equipment.
CE-sign
For unlimited use of the instrument within the directives for electromagnetic
compatibility 89/336/EC measuring wires have to be used with shielded cable
and cable's shield connected to earth ground at one end only.
+0-10VDC -mAorVDC
20 25
Analog -
output 2
(option)
Digital-
input Limit value
Relais L1
Limit valu e
Relais L2
switching status when
setting parameters
FU-1 and FU2 on High
-+
26
242322
2184 7
Signal+
Signal-
Supply-
Supply+
Cal80%
Screening
17 191815 1614
+-
230 VAC
Option
115 VAC
Option
24 VDC
+0-10VDC
-mAorVDC
11
+0/4-20mA
12
+0/4-20mA
13
Analog -
output 1
Pressure
sensor
65
3
12
N L
9

4
Setting up the measuring range start/offset value OFFS:
The initial value has to be adjusted from the smallest to the highest digit with [▲] [▼]and
needs to be confirmed digit per digit with [P]. A minus sign can only be parametrised on the
highest digit. After the last digit, it can then be chosen between nOCA and CAL.WithnOCA
the display value that has been adjusted bevor can now be taken over, with CAL the matching
is done via the measuring section and the analog input value is taken over. It is always adopted
to 100%. With [P] the selection is confirmed and the device changes back into menu level.
Setting up the measuring range end value End:
The final value has to be adjusted from the smallest to the highest digit with [▲] [▼] and needs
to be confirmed digit per digit with [P]. A minus sign can only be parametrised on the highest
digit. After the last digit, it can then be chosen between nOCA and CAL.WithnOCA the
display value that has been adjusted bevor can now be taken over, with CAL the matching is
done via the measuring section and the analog input value is taken over. It is always adopted to
100%. With [P] the selection is confirmed and the device changes back into menu level.
Selection of the input signal tYPE:
Available as measuring inputs are SEnS.1 for 1 mV/V, SENS.2 for 2 mV/V and SENS.3 for 3.3
mV/V for known sensor sensibilities. Via SEnS.F each sensor is calibrated and measured up to
approx. 4 mV/V. With [P] the selection is confirmed and the device changes back into menu
level.
Parameterisation levelMenu level
4.1. Switching-on
Once the installation is complete, you can start the device by applying the voltage supply.
Before, check once again that all electrical connections are correct.
Starting sequence
For 1 second during the switching-on process, the segment test (8 8 8 8 8) is displayed,
followed by an indication of the software type and, after that, also for 1 second, the software
version. After the starting sequence, the device switches to operation/display mode.
4. Setting up the device
4.2. Standard parameterisation: (flat operation level)
To parameterize the display, press the [P] key in operating mode for 1 second. The display
then changes to the menu level with the first menu item TYPE.
4. Setting up the device

5
4. Setting up the device
flow diagram is shown in chapter 4.4. At AL-1…AL-8 an output can be set and therewith e.g. a
switch of the metering point can be done. If no is selected, the [O]-key has no function in the
operation mode.
Setting of the measuring time, SEC:
The measuring time is adjusted with [▲] [▼]. The display moves up in increments of 0.1 up to
1 second and in increments of 1.0 up to 10.0 seconds. With [P] the selection is confirmed and
the device changes back into menu level.
Setting of the comma / decimal point, dot:
The decimal point of the display can be adjusted with [▲] [▼]. With [P] the selection is
confirmed and the device changes back into menu level.
Parameterisation levelMenu level
then

6
4. Setting up the device
Setting the initial value of the analog output 1, Out.OF:
The initial value is adjusted from the smallest digit to the highest digit with [▲] [▼]and digit by
digit confirmed with [P]. A minus sign can only be parametrised on the highest digit. After the
last digit, the device changes back into menu level.
Selection analog output 1, Out.rA:
Three output signals are available: 0-10 VDC, 0-20 mA and 4-20 mA. With function the desired
signal can be selected.
Setting the final value of the analog output 1, Out.En:
The final value is adjusted from the smallest digit to the highest digit with [▲] [▼]and digit by
digit confirmed with [P]. A minus sign can only be parametrised on the highest digit. After the
last digit, the device changes back into menu level.
Parameterisation levelMenu level

7
4. Setting up the device
Function for threshold value undercut /exceedance, Fu-1:
A limit value undercut is selected with Louu (for LOW = lower limit value), a limit value
exceedance with High (for HIGH = higher limit value). If e.g. limit value 1 is on a threshold level
of 100 and allocated with function High, an alarm is activated by reaching of the threshold
level. If the threshold value was allocated to Low, an alarm will be activated by undercutting
the threshold value, as long as the hysteresis is zero.
Threshold values / Limit values, LI-1:
The limit value defines the threshold, that activates/deactivates an alarm.
Hysteresis for Threshold values, HY-1:
The delayed reaction of the alarm is the difference to the threshold value, which is defined by
the hysteresis.
Parameterisation levelMenu level
Hold function
HLD-1
Indicate delete in sek.
ton-1
The same applies to LI-1 to LI-2 !

8
4. Setting up the device
Activation / deactivation of the programming lock or completion of the standard
parameterization with change into menu group level (complete function range), run:
With the navigation keys [▲] [▼], you can choose between the deactivated key lock Uloc
(works setting) and the activated key lock Loc, or the change into the menu group level ProF.
Confirm the selection with [P]. After this, the display confirms the settings with "-----", and
automatically switches to operating mode. If Loc was selected, the keyboard is locked. To get
back into the menu level, press [P] for 3 seconds in operating mode. Now enter the CODE
(works setting 1 2 3 4) that appears using [▲] [▼] plus [P] to unlock the keyboard. FAIL
appears if the input is wrong. To parameterize further functions ProF needs to be set. The
device confirms this setting with „-----„and changes automatically in operation mode.
User code (4-digit number-combination, free available), U.CodE:
If this code was set (>0000), all parameters are locked for the user, if LOC has been selected
before under menu item run. By pressing [P] for 3 seconds in operation mode, the display
shows COde. The U.Code needs to be entered to get to the reduced number of parameter
sets.
Parameterisation levelMenu level

9
4. Setting up the device
The device has an automatic calibration at mass pressure sensors, where an integrated
switching output operates an often available 80% calibration. Like this offset and final value are
adjusted, and the sensor can be applied directly after this. The calibration can be done via the
4th key or the digital input, depending on the parameterisation.
4.4. Sensor calibration offset / final value
Push Trigger for minimum 3
seconds.
For min. 1 measuring cycle,
min. 1s or max. by trigger.
Current measuring range
value in per cent.
For min. 1 measuring cycle, min. 1s or
max. by trigger.
For min. 1 measuring cycle, min.
1s or max. by trigger.
Current measuring range value in
per cent.
80%-switching output
activated.
For min. 1 measuring cycle,
min. 1s or max. by trigger.
Switch-off 80%-switching ouput
and display for min. 1 measuring
cycle or min. 1s waiting time.
Back to regular operation mode.
Breached at +/- 20% range
monitoring.
Breached at +/-
20% range
monitoring.
Back to regular operation mode
after 1s or 1 measuring cycles.
If a special input range SENS.1, SENS.2, SENS.3 was selected under type, a checking of the
range is done for offset and final value. At an undercut/exceedance of +/- 20% of adjustment
range, an C.FAIl is given out.

10
4. Setting up the device
This device has 4 virtual alarms that can monitor one limit value in regard of an undercut or
exceedance. Each alarm can be allocated to an optional relay output S1-S2; furthermore
alarms can be controlled by events like e.g. Hold or Min-/Max-value.
Function principle of alarms / relays
Operating strom / Quiescent currentWorking principle
Broadness of the window between the switching thresholdsHysteresis
Threshold / limit value of the change-overSwitching threshold
De-activated, instantaneous value, min-/max-value, hold-value,
totaliser value
Alarm / Relay x
4.5. Alarms / Relays
Operating current
By operating current the alarm S1-S2 is
off below the threshold and on reaching
the threshold.
Quiescent current
By quiescent current the alarm S1-S2 is
on below the threshold and switched off
on reaching the threshold.
Switching-on delay
The switching-on delay is activated via
an alarm and e.g. switched 10 seonds
after reaching the switching threshold, a
short-term exceedance of the switching
value does not cause an alarm,
respectively does not cause a switching
operation of the relay. The switching-off
delay operates in the same way, keeps
the alarm / the relay switched longer for
the parametrised time.

6. Technical data
Accuracy
always requiredSensor calibration
0.2% of measuring range in electromagnetic dominated environment,
1% of measuring range in industrial invironment with strong disturbing
source
Measuring error
< 24 V OFF, 10 V ON, max. 30 VDC
RI ~ 5 kΩ
Digital input
approx. 18 Bit at 1s measuring time, 3.3 mV/V measuring rangeResolution
EPDM, 65 Shore, blackSealing material
1mV/V, 2mV/V, 3.3mV/VSensor sensitivity
U/F-conversionMeasuring principle
0.1…10.0 secondsMeasuring time
100 ppm / KTemperature drift
250-500 Ω/ 20-40 mAMeasuring bridge
92.0+0.8 x 45.0+0.6 mmPanel cut-out
96x48x139 mm (BxHxT) including plug-in terminal
Input
0.1 to 10.0 secondsDisplay time
horizontal bars at the bottomUnderflow
horizontal bars at the topOverflow
one LED per setpointSetpoints
-19999 to 99999Range of display
red (optional blue/green/orange)Segment colour
14 mmDigit height
Display
plug-in terminal; wire cross section up to 2.5 mm2
Connection
approx. 300 gWeight
standard IP65 (front), IP00 (back)Protection class
PC Polycarbonate, black, UL94V-0Material
screw elementsFixing
up to 15 mmWall thickness
96x48x120 mm (BxHxT)Dimensions
Housing
11
6. Technical data

12
6. Technical data
Switching output
8 normally open (NO) contacts 30 VDC/AC, 0,4 APhotoMos outputs
230 VAC +/- 10 % max. 10 VA
10-30 VDC galv. insulated, max. 4 VA
Power pack
24 VDC / 50 mA; 10 VDC / 20 mASensor supply
with change-over contacts 250 VAC / 5 AAC; 30 VDC / 5 ADC
30 x 103at 5 AAC, 5 ADC ohm resistive load
10 x 106mechanically
Diversity according to DIN EN50178
/ Characteristics according to DIN EN60255
Output
0/4-20 mA or 0-10 VDC 16 Bit switchableAnalog output
Relay
Switching cycles
EEPROM
Ambient conditions
≥100 yearsData life
EN 61010; EN 60664-1
Safety standard
Conformity according to directive 2004/108/EG
CE-sign
EN 61326
EMV
relative humidity 0-80% on years average without dewClimatic density
-20…80°CStoring temperature
0…50°CWorking temperature
Memory

13
7. Safety advices
Please read the following safety advice and the assembly chapter 1 before installation and
keep it for future reference.
Proper use
The MD21-device is designed for the evaluation and display of sensor signals.
Danger! Careless use or improper operation can result in
personal injury and/or damage to the equipment.
Control of the device
The panel meters are checked before dispatch and sent out in perfect condition. Should
there be any visible damage, we recommend close examination of the packaging. Please
inform the supplier immediately of any damage.
Installation
The MD21-device must be installed by a suitably qualified specialist (e.g. with a
qualification in industrial electronics).
7. Safety advices
Notes on installation
• There must be no magnetic or electric fields in the vicinity of the device, e.g. due to
transformers, mobile phones or electrostatic discharge.
• The fuse rating of the supply voltage should not exceed a value of 6A N.B. fuse.
• Do not install inductive consumers (relays, solenoid valves etc.) near the device and
suppress any interference with the aid of RC spark extinguishing combinations or free-
wheeling diodes.
• Keep input, output and supply lines separate from one another and do not lay them
parallel with each other. Position “go” and “return lines” next to one another. Where
possible use twisted pair. So, you receive best measuring results.
• Screen off and twist sensor lines. Do not lay current-carrying lines in the vicinity. Connect
the screening on one side on a suitable potential equaliser (normally signal ground).
• The device is not suitable for installation in areas where there is a risk of explosion.
• Any electrical connection deviating from the connection diagram can endanger human life
and/or can destroy the equipment.
• The terminal area of the devices is part of the service. Here electrostatic discharge needs
to be avoided. Attention! High voltages can cause dangerous body currents.
• Galvanic insulated potentials within one complex need to be placed on a appropriate
point (normally earth or machines ground). So, a lower disturbance sensibility against
impacted energy can be reached and dangerous potentials, that can occur on long lines
or due to faulty wiring, can be avoided.

14
8. Error elimination
6.
5.
4.
3.
2.
1.
• If you are not sure if the device has been
parameterised before, then follow the steps as
written in chapter 5.2. and set it back to its delivery
status.
The device does not react as
expected.
• Please contact the manufacturer if errors of this
kind occur.
"Err1" lights up in the 7-segment
display
• Programming lock is activated
• Enter correct code
Program numbers for parameterising
of the input are not accessible.
• The unit has found an error in the configuration
memory. Perform a reset on the default values and
re-configure the unit according to your application.
The word "HELP " lights up in the
7-segment display.
• The input has a very low measurement, check the
measuring circuit .
• With a selected input with a low voltage signal, it is
only connected on one side or the input is open.
• Not all of the activated setpoints are
parameterised. Check if the relevant parameters
are adjusted correctly.
The unit permanently shows underflow.
• The input has a very high measurement, check the
measuring circuit.
• With a selected input with a low voltage signal, it is
only connected on one side or the input is open.
• Not all of the activated setpoints are
parameterised. Check if the relevant parameters
are adjusted correctly.
The unit permanently indicates
overflow.
MeasuresError description
8. Error elimination
Sensoren- und
Gerätebau GmbH
Paul-Strähle-Strasse 22
D-73614 Schorndorf
Germany
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
www.kmksensoren.com