DART Controls 250G Series Manuel utilisateur

250G CONTROL SERIES

LT67 (0220)

5000 W. 106th Street

Zionsville, Indiana 46077

Phone (317) 873-5211

Fax (317) 873-1105

www.dartcontrols.com

Instruction Manual

Variable Speed DC Control

CONTROLS

A-5-3263N

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 respon-

sibility 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 manu-

facturing 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.

WARRANTY ............................................................................................................................................................................... 1

INTRODUCTION ........................................................................................................................................................................ 2

CONTROL FEATURES .............................................................................................................................................................. 2

HEATSINK DIMENSIONS .......................................................................................................................................................... 2

SPEEDPOT KIT ASSEMBLY ..................................................................................................................................................... 3

MOUNTING PROCEDURE ........................................................................................................................................................ 3

MODEL SELECTION ................................................................................................................................................................. 3

WIRING PROCEDURE & FUSING ............................................................................................................................................ 4

TERMINAL STRIP WIRING ....................................................................................................................................................... 4

CHASSIS & ENCLOSED MODEL HOOK-UP DIAGRAMS .................................................................................................... 5-6

START-UP PROCEDURE & ADJUSTMENTS ........................................................................................................................... 6

TRIMPOT ADJUSTMENT PROCEDURE .................................................................................................................................. 7

TRIMPOT SETTING CHART ..................................................................................................................................................... 7

CONTROL MODIFICATIONS .................................................................................................................................................... 8

TWO SPEED OPERATION ............................................................................................................................................... 18

DYNAMIC BRAKING ........................................................................................................................................................ 18

TACH FEEDBACK & FOLLOWER ................................................................................................................................... 18

INHIBIT INSTRUCTIONS ................................................................................................................................................. 18

OPTION DESCRIPTION ........................................................................................................................................................9-13

-5 OPTION ..................................................................................................................................................................... 9-10

-7 OPTIONS ................................................................................................................................................................... 9-10

-11 / -17B / -29 / -29B / -34A OPTIONS ...................................................................................................................... 10-11

-55H2 / -56H2 CHASSIS OPTIONS & ADJUSTMENT PROCEDURE ............................................................................ 12

-56H2 ENCLOSED OPTION ............................................................................................................................................. 13

IN CASE OF DIFFICULTY ....................................................................................................................................................... 13

SPECIFICATIONS & TYPICAL MOTOR CURRENTS ............................................................................................................. 14

250G SERIES PARTS PLACEMENT & LIST .......................................................................................................................... 14

250G SERIES SCHEMATIC .................................................................................................................................................... 15

REPAIR PROCEDURE & PRODUCT LINE ........................................................................................................ BACK COVER

TABLE OF CONTENTS

INTRODUCTION

• The Dart 250G Series variable speed DC motor control is a versatile, general purpose control rated to 2 HP, available in

chassis mount or enclosed conﬁgurations; with options for speciﬁc applications.

• The 251G model is available with an adjustable HP range of 1/50 thru 1/8 at 120 VAC input.

• The 253G model has a dual voltage input (may accommodate either 120 or 240 VAC). It is available with an adjustable HP

range of 1/8 thru 1 HP for 120 VAC, and 1/4 thru 2 HP for 240 VAC input.

• Designed for DC Permanent Magnet, Shunt Wound, and some Universal (AC/DC) motors in the above horsepower ranges.

• IncomingACvoltageis also converted to adjustablefullwaverectiﬁedDCvoltage(viaapackagedbridge)tooperatetheDC

motor. Also, a full wave ﬁeld voltage is provided for shunt wound motors (see page 4 for voltages).

• The control incorporates transient voltage protection with adjustable current limit and an AC fuse for protection. It

features adjustable minimum and maximum speeds along with adjustable acceleration and IR Compensation. Tach feedback

is accomplished thru a connection to a pin (P2) on the printed circuit board.

• The 250G Series has a linear acceleration/deceleration ramp.

• The control also has a barrier type terminal strip for all power and control wiring.

• The enclosed model uses a gasketed cover assembly that is rated NEMA 4/12.

• cULus Listed.

HEATSINK DIMENSIONS

FOR CHASSIS VERSION: Allow 1.55" for height clearance, 7.00" for overall length.

FOR ENCLOSED VERSION: Allow 3.50" for height clearance, 7.40" for overall length.

MIN. SPEED (minimum speed) - Allows adjustment of the motor speed when the speedpot is set at minimum (CCW). This

permits the user to eliminate the “deadband” on the main speed control permitting zero calibration. Clockwise rotation of “MIN”

trimpot increases minimum motor speed.

MAX. SPEED (maximum speed) - provides for adjustment of the motor speed when the speedpot is set at maximum (CW).This

permits the user to eliminate the top end “deadband”, which will provide full speed at maximum rotation. Rotation of the “MAX”

trimpot in the clockwise direction increases the maximum motor speed.

ACCEL (acceleration) - allows adjustment of the motor acceleration from a minimum of 0.5 seconds to approximately 8.0 sec-

onds. The deceleration time depends on the ACCEL setting. For DECEL time equal to ACCEL time, see -17B option.

IR COMP (speed regulation) - adjusts the control output to compensate for speed changes caused by varying motor loads. As

the motor load is increased, IR COMP increases the voltage output of the control. Clockwise rotation of the “IR COMP” trimpot

will increase compensation.

CUR. LIM. (current limit) - provides protection from excessive armature current by limiting the maximum armature current the

control can provide. This enables adjustment of the maximum torque the motor can deliver. Current limit adjustment (CUR LIM)

is set at 125% of the rated motor current (torque) based on horsepower. Clockwise rotation of the “CUR LIM” trimpot increases

the current (torque) the control will provide.

INHIBIT TERMINAL PIN (P2) - allows the user a choice of stopping and starting hard (fast) or stopping hard with a soft start

through an adjustable acceleration ramp, without breaking the AC lines (see page 8).

TERMINAL STRIP - allows for connection of AC lines, motor leads, motor ﬁeld (if needed), and speed potentiometer.

CONTROL FEATURES

5.500

7.000

.750

5.125

7/32 SLOTS (4)

TYP. .350 DEEP

5.530

WARNING

1. Be sure the control housing is properly grounded.

2. Arm connections must not be switched or broken while the control is on. Serious damage may result.

3. For non-speedpot applications,the input connectionsto the Lo-Wiper-Hileads mustnotbegrounded.Serious

control damage may result from a grounded input.

SPEEDPOT KIT ASSEMBLY

MOUNTING PROCEDURE

CAUTION: Do not mount control where ambient temperature is outside the range of -10oC. (15oF.) to 45oC. (115oF.)

1. Four 7/32" diameter slots are provided for control mounting.

2. The chassis of the control can be used as a template.

3. Use standard hardware to mount.

4. The enclosed version has two threaded holes (1/2" NPT) provided on the bottom side endplate near the terminal strip to

facilitate wiring.

MODEL SELECTION

The 251G will operate a 90 VDC motor in the H.P. range of 1/50 through 1/8 H.P., using different trimpot settings. The 253G will

operate a 90 VDC motor in the H.P. range of 1/8 through 1 H.P., and a 180 VDC motor in the range of 1/4 through 2 H.P., using

different trimpot settings.

* Not available with 120 VAC input - Input voltage determines maximum allowable H.P.

INPUT OUTPUT OUTPUT CHASSIS ENCLOSED

HORSEPOWER VOLTAGE VOLTAGE AMPS DC MODEL MODEL

1/50

1/20 120 VAC 0-90 VDC 1.2A 251G-12C 251G-12E

1/8

1/4

1/3

1/2

3/4

1.0

1.5*

2.0*

120/240 VAC 0-90/0-180 VDC 10.8A 253G-200C 253G-200E

Note: The minimum current rating for all 250G controls is 150mA.

240 VAC 0-180 VDC 10.8A 253G-200C 253G-200E

SPEEDPOT

(5K 1/2W)

CUSTOMER'S

MOUNTING BRACKET

DIALPLATE

2.00" dia.

LOCK

WASHER

HEX NUT

SPEEDPOT

KNOB

SPEEDPOT LO (CCW) (ORANGE)

SPEEDPOT WIPER (RED)

SPEEDPOT HI (CW) (WHITE)

.437

3/8

DIA.

5/32

DIA.

SPEEDPOT LOCATOR HOLE DIMENSIONS

.250 Dia.

.500 .370 .370

1.240

1.250

P1-7 (-FIELD) DO NOT USE for permanent magnet motor. Connect minus (-) Field wire of SHUNT WOUND MOTOR.

P1-8 VERY IMPORTANT !!! Refer to “FUSING”, shown above.

P1-9 CHASSIS VERSION: (SPARE) Make no connection to P1-8 or P1-9

ENCLOSED VERSION: (AC) 120VAC - Connect incoming hot AC (black wire) to P1-9 and Neutral (white wire) to

P1-8. Connect ground (green wire) to Chassis Ground, as shown in

diagram - page 5.

240VAC - Connect both hot sides, one to P1-8 and one to P1-9. Also connect

ground wire to Chassis Ground.

P1-10 VERY IMPORTANT !!! Refer to “FUSING”, shown above.

P1-11 CHASSIS VERSION: (AC) 120VAC - Connect incoming hot AC (brown or black wire) to P1-11 and Neutral (white

or yellow wire) to P1-10. Connect ground (green wire) to Chassis Ground.

240VAC - Connect both hot sides, one to P1-10 and one to P1-11. Connect ground

wire to Chassis Ground.

ENCLOSED VERSION: (SWITCHEDAC) No connectionstoP1-10andP1-11.Thisisfor switchedACoutput.Note

“FACTORY WIRING” (page 5). Pilot lights can be connected between these

terminals. The voltage present at these terminals is AC input voltage.

FIELD VOLTAGE TABLE

VAC INPUT 120 240

VDC FIELD 100 200

}

P1-1 (SPEEDPOT LO) Connects to low side (orange wire) of the 5K speedpot (normally the CCW end). This input is raised

and lowered by the MIN. trimpot. Electronic speed input (voltage follower) may be referenced to speedpot LO if the MIN

trimpot adjustments are to be active. Otherwise, inputs may be referenced to -ARM, which will bypass the MIN trimpot.

NOTE: INPUT MUST NOT BE GROUNDED!!

P1-2 (SPEEDPOT WIPER) Connects to wiper (red wire) of the 5K speedpot (center lead). For voltage follower applications,

this INPUT MUST NOT BE GREATER THAN +12 VOLTS MAXIMUM AND MUST NOT BE GROUNDED!

P1-3 (SPEEDPOT HI) Connects to high side (white wire) of the 5K speedpot (CW end). This is internal +12 volts. For start-

stop applications, the connection between this terminal and speedpot HI can be opened and closed by a SPST switch.

NOTE: INPUT MUST NOT BE GROUNDED!!

P1-4 (-ARM) Connects to minus (-) Armature wire (A2) on motor. For voltage follower applications where the MIN trimpot is

bypassed, connect minus (-) of the follower to this terminal.

P1-5 (+ARM) Connects to plus (+) Armature wire (A1) on motor. 0-90 VDC for 120 VAC input OR 0-180 VDC for 240 VAC

input. See “SPECIFICATIONS” for output rating.

P1-6 (+FIELD) DO NOT USE for permanent magnet motor. This supplies +Field voltage for a SHUNT WOUND MOTOR.Refer

to Field Voltage table. For motors with dual voltage ﬁeld (i.e. 50/100V or 100/200V), make sure highest value is connected.

WIRING PROCEDURE

1. Size all wires which carry armature or line current to handle currents as speciﬁed by national, state, and/or local codes. All

other wires may be #18 AWG or smaller as permitted by local code.

2. Separate control wires from all the Armature and AC line wires when routed in conduits or in wire trays. The enclosed

version has two threaded holes (1/2" NPT) in one endplate, located near the terminal strip, for this purpose.

The 250G Series has an 11 position terminal strip for ease of connection.

TERMINAL STRIP WIRING

FUSING

The 250G is provided with a fuse in AC line 1 (P1-11).This fuse is sized to open in the event of a shorted armature or if an arma-

ture line is shorted to earth ground. As long as 120 VAC input is connected properly, there is no additional fusing needed.

For 240 VAC applications, an external fuse may be used in AC line 2 (P1-10).This fuse should be a Bussman ABC10 or LittleFuse

314-010. This added fuse will provide protection on both AC legs to the 250G. If you desire not to fuse both legs, the fuse in the

control will open in the event of excessive armature currents.

Note: AC current is determined by motor characteristics. In some applications it may be necessary to increase fuse value.

120/240 VAC 0-90/0-180 VDC 10.8A 253G-200C 253G-200E

240 VAC 0-180 VDC 10.8A 253G-200C 253G-200E

INSIDE OF COVER

SPEEDPOT

DPST SWITCH

(black)

(black

or brown)

Endplate with holes for 1/2" NPT conduit

-11

-9-8-4 -5 -6 -7-1 -2 -3

Inhibit

Pot Lo

Wiper

Pot Hi

-Arm

+Arm

P1_6

P1_7

motor

armature ac input

field*

chassis

ground

Switched AC

Min Max Accel

Comp

Cur.

Lim. LO (orange)

HI (white)

WIPER (red)

(white)

(white

or yellow)

-10

250G SERIES ENCLOSED HOOK-UP DIAGRAM

250G SERIES CHASSIS HOOK-UP DIAGRAM

In the 250G enclosure kit (250GCK) you will ﬁnd 2 endplates,

a cover assembly (containing speedpot, DPST switch, gasket

and wiring), and 8 screws.Install both endplates using (4) #5

screws, and the cover assembly, using (4) #6 screws.Before

screwing down cover assembly, route wiring through conduit

holes in endplate by terminal strip.

* Used for shunt wound motors only! No connection is made to

these terminals when using permanent magnet motors.

* Used for shunt wound motors only! No connection is made to these terminals when using permanent magnet motors.

-11

-5

motor

armature

ac input

-8

-9-8 -10

field*

chassis

ground

-4 -5 -6 -7

orange white

red

-1 -2 -3

Customer Installed

Speedpot

(factory provides 8"

leads)

Inhibit

Min Max Accel

Comp

Cur.

Lim.

Pot Lo

Wiper

Pot Hi

-Arm

+Arm

P1_6

P1_7

Spare

The trimpot adjustments, MIN, MAX, IR COMP, and CUR LIM are checked at the factory using a typical motor at 240 VAC input.

Use the TRIMPOT SETTING CHART on page 7 to preset the trimpots for the proper setting for your application. The remaining

trimpot - ACCEL, is a variable acceleration and should be set for your particular application.

The trimpot chart is approximate. The chart is valid when using the speedpot or a 0-10/12 VDC input signal to set speed.

These adjustments are permanent; periodic readjustment is normally not needed. Operation of the control beyond ±10% of normal

line voltage could result in readjustments.

ADJUSTMENTS

WARNING: ALL POWER MUST BE TURNED OFF BEFORE PROCEEDING !!!

1. Recheck all wiring. Accidental grounds, loose or pinched wires on armature or speedpot wires may damage the control

when power is applied.

2. Check to see that incoming service is of correct voltage.

3. Turn speedpot to zero (fully CCW).

4. Turn power on and advance speedpot while observing motor.

WARNING: POWER MUST BE OFF BEFORE STEP 5 CAN BE ACCOMPLISHED!

5. If motor rotation is incorrect, turn power off at external disconnect and reverse +ARM and -ARM connections.

6. Check for satisfactory operation throughout the speed range.

7. If operation is satisfactory, no readjustments are needed.

8. If instability or surging is observed, or maximum speed is higher than desired, see section “TRIMPOT ADJUSTMENT”.

9. For other problems, consult section “IN CASE OF DIFFICULTY”.

START-UP PROCEDURE

Warning: Do not attempt to perform a Hi-Pot test across AC lines with control in circuit.

This will result in immediate or long term damage to the control.

INSIDE OF COVER

SPEEDPOT

DPST SWITCH

(black)

Endplate with holes for 1/2" NPT conduit

-11

-9-8-4 -5 -6 -7-1 -2 -3

Inhibit

Pot Lo

Wiper

Pot Hi

P1_6

P1_7

motor

armature ac input

field*

chassis

ground

Switched AC

Min Max Accel IR

Comp Cur.

Lim. LO (orange)

HI (white)

WIPER (red)

(white)

-10

-Arm

+Arm

(brown)

(yellow)

(purple)

(gray)

(blue)

(red)

-1 -2

250G SERIES -29 HOOK-UP DIAGRAM

Inthe250Genclosure kit(250GCK29)youwillﬁnd2endplates,

a cover assembly (containing speedpot, DPST switch, gasket

and wiring), and 8 screws.Install both endplates using (4) #5

screws, and the cover assembly, using (4) #6 screws.Before

screwing down cover assembly, route wiring through conduit

holes in endplate by terminal strip.

* Used for shunt wound motors only! No connection is made to

these terminals when using permanent magnet motors.

IR IR

1. CW rotation increases time of acceleration.

ALLOWS ADJUSTMENT OF ACCELERA-

TION by user.

1. TURN DRIVE POWER OFF !!

2. Connect a DC ammeter between A1 on the motor and

+ARM on the control. This is in series with the motor.

3. Turn power on.

4. Set speedpot at the 50% position.

5. Set CUR LIM trimpot fully CCW.

6. Apply friction braking to the motor shaft until motor is

stalled (zero RPM).

7. While motor is stalled, set current at 125% of rated

nameplate motor armature current by adjusting the

CUR LIM trimpot.

LIMITSDCMOTOR ARMATURECURRENT

(Torque) to prevent damage to the motor

or control.The current limit is set for the

rated motor current. CW rotation of this

trimpot increases the armature current

(or torque produced).

1. Set speedpot at 50%,

2. Observe motor speed at no load condition.

3. Apply a full load to the motor.

4. Adjust IR COMP trimpot CW to obtain the same motor

speed as with no load.

CALIBRATES SPEED REGULATION - Pro-

vides a means of improving motor speed

regulationinthearmaturefeedbackmode.

If a slowdown due to load change is of no

concern, rotate this trimpot fully CCW.

1. Set speedpot to zero (fully CCW).

2. Rotate MIN trimpot CW until motor rotates.

3. Slowly rotate MIN trimpot CCW until motor stops. NOTE:

If motor rotation at zero is desired, rotate MIN trimpot

CW until desired minimum speed is reached.

SETS MINIMUM MOTOR SPEED when

speedpot is set at zero. CW rotation will

increase minimum motor speed.

1. TURN DRIVE POWER OFF!!

2. Connect DC Voltmeter: + to +ARM, - to -ARM.

3. Set meter voltage range: (90VDC or 180VDC).

4. Turn power on. Set speedpot at 100%.

5. Adjust MAX trimpot to rated motor armature voltage as

shown on meter.

NOTE: A tachometer or strobe may be used in lieu of a meter.

Follow above steps, except adjust MAX trimpot to rated

motor base speed indicated by tachometer or strobe.

SETS MAXIMUM MOTOR SPEED when

speedpotisset atmaximum(100%rotation

CW).CWrotationof MAXtrimpotincreases

maximum motor speed.

TRIMPOT FUNCTION ADJUSTMENT

MAX

MIN

COMP.

CUR.

LIM.

ACCEL

TRIMPOT ADJUSTMENT PROCEDURE

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



 











 

 





 























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

















          





















 





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

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





OPTION DESCRIPTION

-5 option Field or Factory Installed

Isolated 4-20 ma.Signal Follower Available on Chassis Only*

-7-6-5-4-3-2-1

-11-9 -10-8

CURRENT

SOURCE

LINEARITY/GAIN ADJUSTMENT

P16

250/500

125

(250G TERMINAL STRIP)

-7 option Enclosed - Factory Installed only

Isolated 4-20 ma. Signal Follower Chassis - Factory or Field Installed

with Auto/Manual Switch Chassis - switch & wiring are customer provided

DO NOT USE TRIMPOT CHART TO ADJUST MIN AND MAX TRIMPOTS ON MAIN BOARD. IF

ADJUSTMENT IS NEEDED THEN REFER TO THE SETUP PROCEDURE BELOW.

The -5 option is a 4-20 mA isolated signal card that replaces the speedpot to control speed. The 4-20 mA signal input can be

either grounded or ungrounded. The board sets on spacers screwed to the pot HI, Wiper, and LO terminals on the main board

using long screws. The current source connects to the + and - two position terminal strip (P16-1 and -2) on the -5 option board.

The Linearity trimpot on the -5 option board is set at the factory for proper linearity, however this trimpot may need to be re-

set after tuning the Max and Min trimpot settings on the control for your speciﬁc application. If needed then refer to the setup

procedure below.

The -7 option is also a 4-20 mA isolated signal card but it allows the control to be run in either the Manual mode via a speed

pot or the Auto mode via the 4-20 mA signal. This option also includes a Balance trimpot which is used to scale the maximum

speed in the Manual mode. It is factory set so the maximum speed in Manual mode equals the maximum speed in Auto mode.

The Linearity trimpot on the -7 option board is set at the factory for proper linearity, however this trimpot may need to be re-set

after tuning the Max and Min trimpot settings on the control or if the Balance trimpot on the –7 must be reset for your speciﬁc

application. If needed then refer to the setup procedure below.

-7-6-5-4-3-2-1 P1

AUTO

MANUAL

RED

from P1-2 of 250G

-11-9

YELLOW

3PDT

SWITCH

-10-8

CURRENT

SOURCE

LINEARITY/GAIN

ADJUSTMENT

P16

WHITE

RED

ORANGE

SPEEDPOT

AC AC

250/500

125

BALANCE

ADJUSTMENT

(250G TERMINAL STRIP)

JU1

JU3

JU2

-5 and -7 option Hookup Procedure

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