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BTR Controls, Inc.

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DG-Mini V7 Rev. C Standard HW manual V 1.0.2

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Summary of Contents for DG-Mini

Page 1: ...DG Mini Rev C Standard HW manual V 1 0 0 1 DG Mini Universal Door Control ...

Page 2: ...Safety warnings 6 Controller overview 8 Basic wiring 9 Wiring Specification 9 Mains connection 10 Motor connection 11 Motor brake 12 Encoder 13 Reference limit 14 Limit switches 15 Safety edges 16 Photoeye 18 Programmable Inputs 21 Front Panel Button Connections 21 Power up sequence 22 Screen Shots 22 Menu Navigation 23 Layout 23 Button functionality 23 Menus 24 ...

Page 3: ... Limit Setup 33 Limit setup 34 System Config 35 Timers 36 Outputs 37 Relay Output functions 38 Input functions 39 Menu Item 39 Position sensor 42 Safety Edges 44 Compatible Safety Edges 44 Monitored Photoeyes 47 Motor config 48 Frequencies 51 Ramps 52 SeyWave 54 System 57 QUICK SETUP 58 Screen Shots 58 Troubleshooting 60 Overview 60 Error Messages 60 Table of Error Codes 60 Specifications 64 Produ...

Page 4: ...BTR Controls Inc TABLE OF CONTENTS DG Mini V7 Rev C Standard HW manual V 1 0 2 4 Technical specifications 67 Appendix 68 Repair and maintenance 70 ...

Page 5: ...a product Disclaimer Every effort has been made to ensure that the information in this manual is accurate and correct BTR Controls Inc cannot be held liable for damage and or injury due to any omission or error The DG Mini Controller and associated products must be installed by a qualified person familiar with the products and the door or gate using this product BTR Controls Inc assumes no liabili...

Page 6: ...ay WHO IS THIS MANUAL INTENDED FOR This manual is intended for installers and door and gate manufacturers It is not intended for the end user It is the responsibility of the door and gate manufacturer to supply the end user documentation SAFETY WARNINGS This unit must only be installed by qualified personnel with experience in automatic doors gates Knowledge of the relevant regulations is required...

Page 7: ...d and connected as shown in this manual WARNING Do not mount the controller in direct sunlight or other sources of heat as this may cause the controller to overheat WARNING There are no user serviceable parts inside the DG Mini Repairs can only be done by BTR Controls Inc WARNING Disconnect mains supply and follow all appropriate lock out tag procedures when installing or servicing the controller ...

Page 8: ...INS CONNECTIONS POWER RELAY MOTOR CONNECTIONS INCREMENTAL ENCODER CONNECTIONS SAFETY EDGE CONNECTIONS PROGRAMABLE INPUTS PHOTOEYE CONNECTIONS FRONT PANEL PUSH BUTTON CONNECTIONS ABSOLUTE ENCODER CONNECTIONS OPTO EDGE CONNECTIONS NOTE Photoeyes may be connected to different terminals based on the type of photoeye ...

Page 9: ...4 5 3 lb in Wiring Specifications Item Specification Power Unshielded 12 AWG 600V 75C or 90C THHN THWN or equivalent Motor Shielded 14 AWG 600V 75C or 90C RHH RHW 2 VFD rated cable required Control Unshielded 16 AWG 600V 75C or 90C THHN THWN or equivalent Communication 22AWG 0 8mm2 twisted pair 100 shield with drain WARNING ELECTRICAL HAZARD Always disconnect mains supply before servicing the high...

Page 10: ...personnel as well as the operation of the DG Mini controller A floating or ungrounded mains supply can create a hazardarous condition or permantely damage the controller If the service transformer cannot be grounded an isolation transformer with a grounded secondary is required CAUTION To comply with EN61000 please use mains filter part number B 1309105 made by BLOCK For further information please...

Page 11: ...speed dual winding delta wye motor example 230V 3PH DELTA 460V 3PH STAR WARNING A shielded cable must be used to connect the motor to the controller Connect both the ground and shield wires to the chassis on the motor side Also connect both the ground and shield wires to PE terminals on the controller ...

Page 12: ...e motor is mounted with an electromechanical brake that restrains the motor while not running The example shown uses the power relay to control an AC motor brake NOTE Set the power relay to Door Moving by using the menu System Config Outputs Power Relay This setting will activate the power relay activate when the door is moving ...

Page 13: ...encoder using the menu System Config Position Sensor Type Encoders Compatible with the DG Mini BTR MIG Incremental Kostal GFA MFZ Connection table for encoders Encoder type DG Mini terminals Name Type 5 24V 6 A 7 B 10 0V 28 12V 30 A 31 B 32 0V MIG Incremental Brown Yellow Green White BTR Absolute Black Brown Gray White Blue Kostal MFZ GFA Absolute 12V RS485A RS485B 0V Pin 6 Pin 4 Pin 2 Pin 3 A ref...

Page 14: ... change state only once during the complete travel of the door A reference switch mounted at the open position must be a normally open switch A reference switch mounted at the closed position must be a normally closed switch The controller uses the state of the switch to determine the direction the door is to travel during the reference run The illustration below shows the possible locations and s...

Page 15: ...nt is two switches four are preferable NOTE Limit switches are not a standard feature consult BTR Controls Inc for details Switch No DG Mini terminal Description 1 9 Pre Open limit switch 2 7 Open limit switch 3 Open safety limit switch 4 Close safety limit switch 5 6 Close limit switch 6 8 Pre close limit switch Reference NOTE Use the 24V output at terminal 5 for common supply ...

Page 16: ...e value of the required termination resistor and contact type must match the setting in the DG Mini If no safety edge is connected the door will only operate in jog mode Note Set the type of connected safety edge using the menu System Config Safety Edges Refer to the Safety Edge menu description for additional information WARNING It is essential that a UL 325 compliant entrapment protection device...

Page 17: ...rd HW manual V 1 0 2 17 O S E OPTO TYPE 3 WIRE SYSTEM Connect the receiver and transmitter wires with the same color into the same terminal Parallel Type Terminal No X29 0V X27 Signal X28 12V Fraba System White Green Brown Telco SG15 OSE Blue Black Brown ...

Page 18: ...e input is compatible with a standard NPN N C type photoeye output This must be connected as illustrated below to 0V REC input and 24V Refer to the photoeye manufacturor s datasheet for specific wiring and mounting information Wire colors shown on right are for example only Note When using a PNP type photoeye connections are made to the programmable inputs See the Programmable Input section of thi...

Page 19: ... DG Mini V7 Rev C Standard HW manual V 1 0 2 19 NC Switch type The photoeye input is compatible with a standard N C switch type output such as a relay contact This must be connected between 0V and the REC input as illustrated below ...

Page 20: ...side of the door The exact position can be adjusted for the best alignment using the control panel as described below Alignment When the D O T system is the selected photoeye type an additional menu is available in the System Status menu Test the photoeyes while the door is closing to ensure correct operation of the system NOTE To aid in alignment use the menu System Status Photocells This menu is...

Page 21: ... Programmable input default assignments Terminal Default function 8 Photoeye 1 9 Photoeye 2 11 Open 12 Close 13 Partial 14 Auto 15 Stop 17 Hand Crank FRONT PANEL BUTTON CONNECTIONS The front panel buttons can be programmed to function as Open Close Stop Open with Auto close or Jog mode Note To program control signals parameters please use the menu System Config Inputs See Input configuration secti...

Page 22: ...0 2 22 POWER UP SEQUENCE When power is switched on the display will show the model information i e power voltage rating serial number software version and active profile Screen Shots Product Serial Number Firmware Version Wireless Status Active Door Profile Final Splash Screen ...

Page 23: ...T The door controller has a graphic display and 3 buttons for configuring the controller BUTTON FUNCTIONALITY Button Short press Function Long Press Function 2 seconds Enter selected menu Exit menu Navigate one step UP Scroll UP Navigate one step DOWN Scroll DOWN System display Menu navigation buttons ...

Page 24: ... The sub menus below the main menu are text listed menus Menus are navigated using the UP DOWN and MENU ENTER buttons A menu or submenu is entered by a short press of the MENU ENTER button A short press of the MENU ENTER Button while inside of a submenu will confirm a selection A long press of the MENU ENTER Button will exit the submenu or menu ...

Page 25: ...BTR Controls Inc MENU NAVIGATION DG Mini V7 Rev C Standard HW manual V 1 0 2 25 MENU TREE ...

Page 26: ... gain access Use the UP and DOWN Buttons to enter the access code and then press the ENTER button Holding either the UP or DOWN button will increase the rate at which the value changes Code Description 104 Installer 123 Tech Support 236 OEM NOTE The DG Mini will automatically exit the menu after a short period of inactivity The Access Level code will need to be entered again to gain access to the ...

Page 27: ...ess and hold MENU ENTER button An example for setting the open frequency is shown below Selecting an item When selecting an item from a list based menu the currently enabled item is indicated by a filled box The UP or DOWN buttons are used to navigate the list The current position is highlighted A short press of the MENU ENTER button will enable the highlighted item and is indicated by the box bei...

Page 28: ...The message is displayed briefly for a momentary event or for the duration of a maintained event Controller States Display Description OFF Door controller is disabled IDLE Door is stopped but not at a defined position Such as Partial 1 Partial 2 or Fully Open FIND REF Door must perform a reference run LOCKED Door is locked and cannot operate until the lock signal removed JOG Door is in operating i...

Page 29: ...DC Link voltage Position Displays the current position in Encoder Counts Measured Frequency Displays the measured frequency calculated from a compatible encoder Output Frequency Displays the frequency output to the motor Auto 1 Timer Shortcut to adjust the Auto 1 Timer Man 1 Timer Shortcut to adjust the Manual 1 Timer DTO Timer Shortcut to adjust the Delay To Open Timer DTC Timer Shortcut to adjus...

Page 30: ...ause all related parameters to be overwritten with the defaults of the loaded profile Limit Setup A menu to setup or adjust the door positions System Config A menu to configure the controller s settings SYSTEM STATUS Description Overview Displays the controller s serial number ratings and software revision Photoeyes Displays the status of the photoeyes Change between photoeye 2 by pressing the UP ...

Page 31: ...AMMING DG Mini V7 Rev C Standard HW manual V 1 0 2 31 Safety Edge Displays the current status of the wired safety edge Inputs Displays the state of the controller s digital inputs Active inputs are indicated by a filled box ...

Page 32: ...splays the current internal DC Link voltage and the range it should be within Internal Levels Displays the controller s internal supply voltages The Internal 12V supply should be within 1V and the internal 24V supply should be in the rage of 20 24V PROFILE SELECTION Description To simplify installation the DG Mini contains preset defaults called profiles Each profile contains the manufacturer s re...

Page 33: ...ition Description Breakaway This is a position used on some door types to reset a breakaway condition Fully Open Highest position the door will travel to under normal operation Pre Open The position at which the controller starts to slow down an opening door Part 1 A position below Fully Open usually used for man or low height vehicle traffic Part 2 A position lower than Part 1 also usually used f...

Page 34: ... be performed before manual adjustment using the menus below Please see the section Quick Setup for further details Closed Each submenu allows the manual adjustment of a specific door position if required The door can be jogged by using the UP DOWN buttons on the controller or front panel buttons The MENU ENTER key is used to save the position and to exit the submenu Pre Closed Pre Open Open Open ...

Page 35: ...the position sensor Safety Edges A submenu for configuring the wired safety edge Mon Photo Eyes A submenu for configuring monitored photoeyes Motor Config A submenu for configuring motor related settings Frequencies A submenu for configuring motor frequencies Ramps A submenu for configuring motor frequency ramps DG Xnet A submenu for configuring the DG Xnet wireless options Options A submenu for c...

Page 36: ...the door initiates an opening cycle Set to zero to disable Delay to Close A time period imposed prior to any door closing event Set to zero to disable Open Alarm The maximum time period the door can remain in the Open position before an Open Alarm error occurs Set to zero to disable Run Timer A safety feature that stops door movement if the DG Mini detects that the door is still in motion after th...

Page 37: ...ay 1 See Relay Output Function table below CAUTION Do not exceed the relay s maximum electrical ratings of 1A 24V DC 0 5A 120V AC Resistive loads only Power Relay Configuration of the Power Relay See Relay Output Function table below CAUTION Do not exceed the relay s maximum electrical ratings 5A 240V AC Resistive loads only ...

Page 38: ...zero and the door is commanded to open The input must remain activated until the Delay To Open Timer has expired the output will be active during this time Upon expiration of the timer the door opens and the output is deactivated Auto 1 Active Output is active whenever the Auto Close Timer is greater than zero System Error Output is active whenever an error is present Pre Warn Output is active whe...

Page 39: ...used in the configuration menu Logic Submenu to select the logic for the input either NO NC INPUT FUNCTIONS MENU ITEM Description when the input is active No Function Input is disabled Manual 1 An activation of this input will open the door unless the door is already at an open position In this case the door will close If the Man 1 Timer is set greater than zero the controller will delay closing o...

Page 40: ...ooting section for details Open Part 1 Activation of this input will open the door to the Open Part 1 position Open part 2 Activation of this input will open the door to the Open Part 2 position Auto 1 Part 1 Activation of this input will open the door to the Open Part 1 position The controller will then delay the door for the duration of the Auto 1 Timer Upon expiration of the timer the door will...

Page 41: ...ormally Closed 9 Aux 3 Photoeye2 Photoeye2 Normally Closed 11 Open Open Open Normally Open 12 Close Close Close Normally Open 13 Partial Open Part 1 Open Part 1 Normally Open 14 Auto Auto 1 Auto 1 Normally Open 15 Stop Stop Stop Normally Closed 17 Off Hand Crank Hand Crank Normally Closed For reference only may change based on profile Front Panel Input Configuration Option Description Normal Open ...

Page 42: ...oller then uses this value to operate the motor and to determine door position The controller is optimized when full door travel open position closed position is greater than 1000 counts but less than 10000 counts The number of counts for full door travel as described above is dependent on the resolution of the position sensor used and its mounting location The controller uses an internal position...

Page 43: ...nge of 32767 An optimal Pulse Count setting of 32 is desired Since the controller is optimized for a Pulse Count setting of 32 Divide the encoder s native resolution by Pulse Output A BTR encoder specific menu to set the number of pulses per revolution which is used in closed loop feedback It is unlikely that a user will need to change this parameter as it is automatically computed when the Gear R...

Page 44: ...f compatible Safety Edges below Retry Count Sets the number of consecutive retries attempts when the edge has been activated during a closing cycle Choose between No Retries 1 5 or unlimited retries Operational Mode Normal When Normal mode is selected the door will stop reverse direction and open to the Fully Open position when the safety edge is activated The DG Mini will attempt to retry closing...

Page 45: ...ETY EDGES Type Description NO with 8K2 Safety Edge is a Normally Open contact in parallel with an 8 2k ohm resistor NC with 8K2 Safety Edge is a Normally Closed contact in series with a 8 2k ohm resistor NO with 1K2 Safety Edge is a Normally Open contact in parallel with a 1 2k ohm resistor ...

Page 46: ...h 1K2 Safety Edge is a Normally Closed contact in series with a 1 2k ohm resistor Diode Cap Safety Edge is a Normally Open contact in parallel with a 9 1V Zener diode and a capacitor FRABA Radioband SeyWave Ext Lightcurtain Opto 1 Opto 2 Not supported in standard software consult factory when using any of these safety edges ...

Page 47: ...RAMMING DG Mini V7 Rev C Standard HW manual V 1 0 2 47 Monitored Photoeyes Description NOTE The Monitored Photoeyes feature is not currently supported OFF Monitored Photoeyes are disabled ON Monitored Photoeyes are enabled ...

Page 48: ... listed for 50Hz then enter that value otherwise convert the nameplate speed to 50Hz based on the equation below To convert a 60Hz speed rating to 50Hz divide by 1 2 Example 1750 RPM at 60Hz 1 2 1458 RPM at 50Hz Gear Ratio This is the number of motor revolutions per one full revolution of the encoder NOTE ONLY USED WITH BTR ABSOLUTE ENCODER Direction Motor Encoder direction NOTE The controller wil...

Page 49: ...ue 2 5 kHz Note Increasing this setting will increase the power losses and raise the temperature of the motor and controller Position Tol This sets the tolerance the controller uses when positioning the door Example If the Fully Open position is set at 700 and Position tolerance is set to 5 the DG Mini will stop driving the motor when the position reaches 695 Continued on next page ...

Page 50: ...tion reaches 670 DC Brake Cur DC braking is used to inject DC current into the motor windings which help stop the door within the position tolerance at the end of travel DC Brake Time This is the duration of time DC current is injected into the motor after it has stopped Note In applications where the ambient temperature is below 0 C 32 F the controller can be configured to provide a constant DC c...

Page 51: ...ets the maximum speed between the pre open and the Fully Open positions Close This frequency sets the maximum speed between the open and pre closed positions Pre Close This frequency sets the maximum speed between the between the pre closed and the Fully Closed positions Dead man This frequency sets the maximum speed when operating under a constant pressure mode or during a reference run Minimum T...

Page 52: ...p is the rate at which the motor will accelerate while the door is closing Dec Open This ramp is the rate at which the motor deaccelerates to the Fully Open position Dec Close This ramp is the rate at which the motor deaccelerates to the Fully Closed position Dec Stop Open This ramp is the rate at which the motor will decelerate if the Stop Button is activated This parameter should be set so that ...

Page 53: ... DG XNET MENU Submenu Description Enable Enable Submenu to enable or disable DG Xnet operation Disable Discover Used to find other DG Xnet devices in range Connect Submenu to enable communication between other DG Xnet devices X Lock Submenu to enable a wireless airlock between and up to five other DG Xnet devices Clear all Used to disconnect all previously connected DG Xnet devices from the DG Min...

Page 54: ... Seywave Wireless System supports a Sensor module that meets UL 325 Standards for Entrapment Protection The Illumadoor is an LED strip light that can be used to provide visible indication of status for industrial doors Each strip has 30 individual Red Amber and Green LED s that can be wirelessly controlled from the DG Mini when using the BTR Illumadoor combination power supply and junction box The...

Page 55: ...yWave devices from the DG Mini Performing this step will require all SeyWave devices to be Paired again Performing this step will also cause the Internal SeyWave to automatically change the communication settings which include the channel and address used by the system These settings are not user configurable Perform a Clear All if performance issues are encountered Information This submenu displa...

Page 56: ... individual outputs of a paired Illumadoor power supply There are two submenus for each output FUNCTION and FLASH The FUNCTION submenu includes the same functions as described in the Relay Output function table Refer to this table for descriptions The FLASH submenu enables or disables flashing for that particular output when it is active Flash Rate This menu sets the flash rate of the output if th...

Page 57: ...Clear Cycle Cnt Factory use only Sound This submenu is used to enable or disable the internal sounder Backlight This submenu is used to enable or disable the display s backlight Contrast This submenu is used to set the display s contrast SW Update This submenu is used for updating the DG Mini firmware System Info This submenu is used to identify the DG Mini and includes Type Power Size and Voltage...

Page 58: ...erform a Quick Setup Screen Shots Step Display screens Action 1 Use the UP and DOWN Buttons to move the door to near the center of travel Note The door may travel in the opposite direction of the button pressed This is okay and is corrected in a later step Press ENTER when finished 2 Press and hold the UP Button until the door stops automatically 3 When the door has stopped follow the on screen pr...

Page 59: ...to the desired Fully Closed position Press ENTER to store 7 If everything was set correctly and no errors encountered Quick Setup Done will be displayed The menu will automatically exit and return to the Idle screen The DG Mini is now ready for operation If an issue was encountered Quick Setup Aborted will be displayed followed by a corresponding error message ...

Page 60: ... Depending on the type of error user interaction may be required to clear the error The error window closes when the error has been cleared corrected For example error E17 Reset Limits in the example above is because the door limits cannot be verified In this case the only corrective action is to perform a Quick Setup to re establish the door s positions Table of Error Codes Error Code Description...

Page 61: ...verheating inside the panel the inverter is too hot Check ventilation Check that current limits have not been exceeded HE 12V Supply Shorted Fault Specific HE 24V Supply Shorted Fault Specific Low internal 12V or 24V supply Check I O wiring for short or overload E01 Mechanical Overload Low Priority Mechanical overload slip monitoring or missing signal from the encoder Check the encoder wiring Chec...

Page 62: ...s a mechanical obstruction in the door opening closing E13 No Encoder Movement Medium Priority No Encoder Movement E14 Encoder Comm Loss Fault Specific Communication error with the absolute encoder Check the wiring of the absolute encoder E15 Encoder Fault Low Priority Encoder Fault Redo the quick setup E16 Encoder Fault High Priority E17 Reset Limits Fault Specific Reset Limits Rerun the quick se...

Page 63: ...Photoeye 1 Activated Low Priority Photoeye 1 Activated Normal message if the photoeye is active Otherwise check alignment and wiring E29 Photoeye 2 Activated Low Priority Photoeye 2 Activated Normal message if the photoeye is active Otherwise check alignment and wiring E30 Input Timer Exceeded Medium Priority Input Timer Exceeded Check for stuck input such as a pushbutton that has been activated f...

Page 64: ...l This label informs you of the model type of the enclosed controller This label informs you of the controller type number serial number test at factory date and relevant electrical environmental specifications MODEL IDENTIFICATION I out Mains input Mains filter Brake chopper 3 x 4A 3 x 10A 120VAC 1 Phase 230VAC 1 phase DG Mini 750G 120 DG Mini 750G ...

Page 65: ...BTR Controls Inc SPECIFICATIONS DG Mini V7 Rev C Standard HW manual V 1 0 2 65 DG Mini 1500G ...

Page 66: ...BTR Controls Inc SPECIFICATIONS DG Mini V7 Rev C Standard HW manual V 1 0 2 66 MECHANICAL DIMENSIONS ...

Page 67: ... output for O S E safety edge 19 Exclusively used for signals to photo transmitter 24 25 26 Relay Max 1A 24V DC 0 5A 120V AC Power relay on bottom PCB Max 5A 240V AC Digital Inputs 11 to 15 12 24V DC compatible 6 7 Quadrature inputs for encoder or standard digital inputs Analog Inputs 21 Exclusively used for analog signals from photoeye receiver Safety Inputs 1 2 Safety Edge input for monitored ed...

Page 68: ...BTR Controls Inc APPENDIX DG Mini V7 Rev C Standard HW manual V 1 0 2 68 APPENDIX ...

Page 69: ...BTR Controls Inc APPENDIX DG Mini V7 Rev C Standard HW manual V 1 0 2 69 ...

Page 70: ...mpt to repair it dangerous voltages exist inside Do not take the controller apart or attempt to repair it this is related to serious danger and is a task for a qualified technician only Please contact the manufacturer if you require technical support or if the product is damaged This product should be disposed and treated as WEEE Waste Electrical and Electronic Equipment For additional technical a...

Page 71: ...BTR Controls Inc APPENDIX DG Mini V7 Rev C Standard HW manual V 1 0 2 71 ...

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