CONTROLS
Instruction Manual
Variable Speed DC Control
P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077
250G CONTROL SERIES
Phone (317) 873-5211
Fax (317) 873-1105
www.dartcontrols.com
WARRANTY ............................................................................................................................................................................... 1
TABLE OF CONTENTS
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
START-UP PROCEDURE & ADJUSTMENTS .......................................................................................................................... 6
TRIMPOT ADJUSTMENT PROCEDURE .................................................................................................................................. 6
TRIMPOT SETTING CHART ...................................................................................................................................................... 7
CONTROL MODIFICATIONS .................................................................................................................................................. 7-8
TWO SPEED OPERATION ...............................................................................................................................................
DYNAMIC BRAKING ........................................................................................................................................................
TACH FEEDBACK & FOLLOWER ...................................................................................................................................
INHIBIT INSTRUCTIONS ..................................................................................................................................................
OPTION DESCRIPTION ........................................................................................................................................................ 8-12
-5 OPTION ........................................................................................................................................................................... 8
-7 / -9 OPTIONS ................................................................................................................................................................... 9
-11 / -17B / -29 / -29B / -34A OPTIONS ............................................................................................................................ 10
-55G2 / -56G2 CHASSIS OPTIONS & ADJUSTMENT PROCEDURE ............................................................................ 11
-56G2 ENCLOSED OPTION ............................................................................................................................................. 12
IN CASE OF DIFFICULTY ........................................................................................................................................................ 12
SPECIFICATIONS & TYPICAL MOTOR CURRENTS ............................................................................................................. 13
250G SERIES PARTS PLACEMENT & LIST .......................................................................................................................... 13
250G SERIES SCHEMATIC ..................................................................................................................................................... 14
REPAIR PROCEDURE & PRODUCT LINE ........................................................................................................ BACK COVER
17
17
18
18
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 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.
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.
1
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.
• Incoming AC voltage is also converted to adjustable full wave rectified DC voltage (via a packaged bridge) to operate the DC
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.
• cU.L.us Listed.
CONTROL FEATURES
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
seconds. The deceleration time depends on the ACCEL setting. For DECEL time equal to ACCEL time, see -17B option.
I. R. COMP (speed regulation) - adjusts the control output to compensate for speed changes caused by varying motor loads. As
the motor load is increased, I.R. COMP increases the voltage output of the control. Clockwise rotation of the “I.R. 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.
HEATSINK DIMENSIONS
7.000
5.530
5.500
7/32 SLOTS (4)
TYP. .350 DEEP
.750
5.125
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.
2
1.250
SPEEDPOT KIT ASSEMBLY
CUSTOMER'S
MOUNTING BRACKET
DIALPLATE
2.00" dia.
1.240
.500 .370 .370
HEX NUT
SPEEDPOT
KNOB
.250 Dia.
SPEEDPOT
(5K 2W)
.437
3/8
5/32
DIA.
DIA.
SPEEDPOT LOCATOR HOLE DIMENSIONS
LOCK
WASHER
O-RING
MOUNTING PROCEDURE
CAUTION: Do not mount control where ambient temperature is outside the range of -10o C. (15o F.) to 45o C. (115o F.)
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
Note: The minimum current rating for all 250G controls is 150mA.
HORSEPOWER VOLTAGE VOLTAGE AMPS DC MODEL MODEL
1/50
1/20 120 VAC 0-90 VDC 1.2A 251G-12C 251G-12E
1/8
1/8
1/4
1/3
1/2
3/4
1.0
1.5*
2.0*
INPUT OUTPUT OUTPUT CHASSIS ENCLOSED
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
* Not available with 120 VAC input - Input voltage determines maximum allowable H.P.
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.
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 connections to the Lo-Wiper-Hi leads must not be grounded. Serious
control damage may result from a grounded input.
3
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.
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 armature
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.
TERMINAL STRIP WIRING
The 250G Series has an 11 position terminal strip for ease of connection.
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.
FIELD VOLTAGE TABLE
VAC INPUT 120 240
VDC FIELD 100 200
P1-7
P1-8
P1-9
(-FIELD) Connect minus (-) Field wire of SHUNT WOUND MOTOR.
VERY IMPORTANT !!! Refer to “CUSTOMER FUSING”, shown above.
}
CHASSIS VERSION: (SPARE) Make no connection to P1-8 or P1-9
ENCLOSED VERSION: (AC)
120VAC
240VAC
-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.
- Connect both hot sides, one to P1-8 and one to P1-9. Also connect ground
wire to Chassis Ground.
P1-10
P1-11
VERY IMPORTANT !!! Refer to “CUSTOMER FUSING”, shown above.
}
CHASSIS VERSION: (AC)
ENCLOSED VERSION: (SWITCHED AC) No connections to P1-10 and P1-11. This is for switched AC output. Note
120VAC
240VAC
- 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.
- Connect both hot sides, one to P1-10 and one to P1-11. Connect ground
wire to Chassis Ground.
“FACTORY WIRING” (page 5). Pilot lights can be connected between
these terminals. The voltage present at these terminals is AC input voltage.
4
250G SERIES CHASSIS HOOK-UP DIAGRAM
I.R.
Min Max Accel
Inhibit
P2
Pin
orange white
red
P1
-1 -2 -3
Wiper
Pot Lo
Customer Installed
(factory provides 8"
-
-4 -5 -6 -7
-Arm
+Arm
Pot Hi
Speedpot
leads)
-Field
+Field
Comp
-
Spare
Cur.
Lim.
-9-8 -10
Spare
AC
-11
AC
motor
armature
field*
chassis
ground
ac input
* Used for shunt wound motors only! No connection is made to these terminals when using permanent magnet motors.
250G SERIES ENCLOSED HOOK-UP DIAGRAM
HI (white)
WIPER (red)
LO (orange)
DPST SWITCH
SPEEDPOT
(black)
(white)
(black
or brown)
INSIDE OF COVER
Min Max Accel
Inhibit
P2
Pin
I.R.
Comp
Cur.
Lim.
(white
or yellow)
P1
-Arm
Pot Hi
motor
armature
+Arm
+Field
field*
Wiper
Pot Lo
chassis
ground
Endplate with holes for 1/2" NPT conduit
AC
-Field
ac input
-9-8-4 -5 -6 -7-1 -2 -3
AC
-10
-11
Switched AC
Switched AC
* Used for shunt wound motors only! No connection is made to
these terminals when using permanent magnet motors.
In the 250G enclosure kit 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.
5
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.
START-UP PROCEDURE
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”.
ADJUSTMENTS
The trimpot adjustments, MIN, MAX, I.R. 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.
TRIMPOT ADJUSTMENT PROCEDURE
TRIMPOT FUNCTION ADJUSTMENT
MAX
MIN
I.R.
COMP.
CUR.
LIM.
SETS MAXIMUM MOTOR SPEED when
speedpot is set at maximum (100% rotation CW). CW rotation of MAX trimpot
increases maximum motor speed.
SETS MINIMUM MOTOR SPEED when
speedpot is set at zero. CW rotation will
increase minimum motor speed.
CALIBRATES SPEED REGULATION - Provides a means of improving motor speed
regulation in the armature feedback mode.
If a slowdown due to load change is of no
concern, rotate this trimpot fully CCW.
LIMITS DC MOTOR ARMATURE CURRENT
(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. 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.
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.
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.
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 name-
plate motor armature current by adjusting the CUR LIM
trimpot.
ACCEL
TION by user.
1. CW rotation increases time of acceleration.ALLOWS ADJUSTMENT OF ACCELERA-
6
TRIMPOT SETTING CHART
* These settings apply when using a 5000W Master Speedpot.
* Settings will differ when using various options, such as using the -5 or the -7 option.
For the -17B option, Accel/Decel is 20 seconds when pot is turned fully clockwise.
* This trimpot chart is approximate. Use it in conjunction with the Adjustment Procedures.
MIN MAX ACCEL I.R. C.L. H.P.
2
5
1
G
2
5
3
1/50
1/20
1/8
1/8
1/4
1/3
1/2
G
3/4
1.0
TWO SPEED OPERATION
Two pot operation is done using two 10K
ohm speed potentiometers in parallel (both
HI's to P1-3, both LO's to P1-1). The
WIPER is switched using a SPDT switch.
INPUT VOLTAGE OUTPUT VOLTAGE
120VAC
120VAC
0-90VDC
0-90VDC
MIN MAX ACCEL I.R. C.L. H.P. INPUT VOLTAGE OUTPUT VOLTAGE
2
120VAC
0-90VDC
5
3
120VAC
120VAC
120VAC
120VAC
120VAC
120VAC
0-90VDC
0-90VDC
0-90VDC
0-90VDC
0-90VDC
0-90VDC
G
CONTROL MODIFICATIONS
DYNAMIC BRAKING
A DPDT switch is used to inhibit the control and to connect the
DBR. Typical values for the DBR (dynamic brake resistor) are 5
ohms for 120V, 10 ohms for 240V (both 35W to 50W). Note that
motor horsepower, inertia, and cycle time effect sizing of the DBR.
NOTE: This modification cannot be used with the -17B option.
1/4
1/2
3/4
1.0
1.5
2.0
240VAC
240VAC
240VAC
240VAC
240VAC
240VAC
0-180VDC
0-180VDC
0-180VDC
0-180VDC
0-180VDC
0-180VDC
P1
-1
-2
-3
TWO 10K SPEEDPOTS
LO
W
HI
SPDT
W
LO
HI
HI
W
7
LO
HI
P1
-1
-2
-3
-4
-5
P2
INHIBIT
DPDT SWITCH (N.C.)
MOTOR
RESISTOR
DYNAMIC
BRAKE
TACHOMETER FEEDBACK
Improves speed regulation to ±1/2% of base speed. Contol
goes to full output when input goes to zero, above and
beyond MAX trimpot setting
TACHOMETER FOLLOWER
Allows control output to follow tachometer voltage.
+
TACHOMETER
6 VDC at BASE SPEED (3 VDC at
1000 RPM for 1800 RPM MOTOR)
P2 INHIBIT
-
P1-4 -ARM
NOTE: NEED 1% OR LESS - TACH OUTPUT RIPPLE
INHIBIT (USED INDEPENDENTLY) INHIBIT (USED WITH SPEEDPOT)
The customer supplied SPST switch is connected
in series between the speedpot HI (P1-3) and the
Inhibit pin (P2). To inhibit, speedpot HI is closed to
the Inhibit pin. To restart, the switch is returned to
open. NOTE: The control will stop and start fast,
accel is bypassed.
INHIBIT
P1
-1
-2
-3
SPEEDPOT
LO
WIPER
HI
(P2)
SPST
+
TACHOMETER
12 VDC at FULL SPEED
P1-2 POT WIPER
-
P1-1 POT LO
The Common of the SPDT switch is connected to
control pot HI and is switched between Speedpot
Hi and the Inhibit pin (P2). To inhibit (stop motor),
speedpot HI is closed to the Inhibit pin. To restart,
the switch is returned to Speedpot Hi. NOTE: The
control will stop fast and soft start through a fixed
acceleration range.
P1
-1
-2
-3
SPEEDPOT
LO
WIPER
HI
INHIBIT
(P2)
SPDT
NOTE: Permits starting and stopping of motor without breaking AC lines. In the event of SCR failure or false
triggering, the Inhibit circuit will not stop motor.
Always use a shielded wire when connecting to the inhibit terminal. The shield should be connected
to -Armature or Common of the control.
OPTION DESCRIPTION
-5 option
Isolated 4-20 ma.Signal Follower Available on Chassis Only*
LINEARITY ADJUSTMENT
4 to 20mA ........... -5
Input impedance: 500 ohms or less
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.
This option replaces the speedpot with a 4-20 ma. signal to control speed. The current signal input can be either grounded or
ungrounded. The board sets on spacers screwed to terminals P1-1, P1-2, and P1-3 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 controls Max and Min trimpot settings for your specific application. If needed then refer to the setup
procedure below.
CURRENT
SOURCE
P16
125
-1 -2
250/500
8
Field or Factory Installed
Permits the control to
follow a 4mA to 20mA
grounded or
ungrounded current
-7-6-5-4---
(250G TERMINAL STRIP)
-11-9 -10-8
P1
Setting the Min, Max and Linearity Trimpots.
1. Preset the multi-turn Linearity trimpot on the –5 option board full CW, set the Min trimpot full CCW and set the Max trimpot
at about 50% rotation.
2. Input a 4 ma. current signal to the control and turn the Min trimpot CW to your desired minimum output voltage or to deadband
(the point just before you begin to get an output).
3. Input a 20 ma. current signal to the control and set the Max trimpot to the desired maximum speed setting.
4. With 20 ma. still going to the control, turn the Linearity trimpot CCW until your output speed starts to decrease. Then slowly
turn it back CW until you just reach your maximum speed setting.
• For enclosed models use -7 option.
Note: This jumper wire is not used with some options. Consult factory if more than one option is being wired. Using the JU2
jumper wire when not required may cause permanent damage to the control.
-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
Input impedance: 500 ohms or
less
LINEARITY ADJUSTMENT
P16
125
-1 -2
ADJUSTMENT
250/500
BALANCE
CURRENT
SOURCE
Permits the control to
follow a 4mA to 20mA
grounded or
from P1-2 of 250G
ungrounded current
4 to 20mA ........... -7
DO NOT USE TRIMPOT CHART TO ADJUST MIN AND MAX TRIMPOTS ON MAIN BOARD. IF ADJUSTMENT IS NEED THEN
REFER TO THE SETUP PROCEDURE BELOW.
This option 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. The current signal input can be either grounded or ungrounded. The board sets on spacers screwed to terminals P11, P1-2, and P1-3 on the main board using long screws. The current source connects to the + and - two position terminal strip
(P16-1 and -2) on the -7 option board.
This option 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 equals the maximum speed in automatic.
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.
RED
AC AC
-7-6-5-4---
(250G TERMINAL STRIP)
WHITE
SPEEDPOT
-11-9
-10-8
3PDT
SWITCH
P1
HI
LO
AUTO
MANUAL
YELLOW
RED
ORANGE
Setting the Min, Max, Balance and Linearity Trimpots.
1. Preset the multi-turn Linearity trimpot and the Balance trimpot on the –7 option board full CW, set the Min trimpot full CCW
and set the Max trimpot at about 50% rotation.
2. Input a 4 ma. current signal to the control and turn the Min trimpot CW to your desired minimum output voltage or to deadband
(the point just before you begin to get an output).
3. Input a 20 ma. current signal to the control and set the Max trimpot to the desired maximum speed setting.
4. Switch the control to the Manual mode setting and adjust the Balance trimpot CCW as needed to attain your required manual
mode maximum output speed. (Adjustable form 50 to 100% of maximum Auto mode setting)
5. Switch the control back to Auto mode. With 20 ma. still going to the control, turn the Linearity trimpot CCW until your
output speed starts to decrease. Then slowly turn it back CW until you just reach your maximum speed setting.
* Note: This jumper wire is not used with some options. Consult factory if more than one option is being wired. Using the JU2 jumper
wire when not required may cause permanent damage to the control.
-9 option
Factory Installed Only
Special Cover Assembly Enclosed Models Only
NEMA 4/12 enclosure kit without cover mounted on-off switch and speedpot.
9
-11 option
Field Installed Only
10-Turn Speedpot Chassis Models Only
Provides finer control of speed. Use standard hook-up directions and Trimpot Chart (page 7).
-17B option
Factory Installed Only
Acceleration Time Changes Available on all Models
Standard acceleration is variable from 0.5 to 8.0 seconds with the trimpot. The deceleration is between 0.06 and 0.8 seconds. This
option extends the maximum acceleration so the range is between 0.8 and 20.0 seconds. Furthermore, this option has the
deceleration time equal to the acceleration time, so deceleration range is also 0.8 to 20.0 seconds (depends on Accel setting, not
an independent setting).
USE STANDARD HOOK-UP INSTRUCTIONS
-29 and -29B options
Manual Reversing -29B Chassis *
Permits reversing of motor. This is accomplished using a 4PDT blocked center switch. When switched between the forward/
reverse positions, a delay is encountered due to the blocked center position, which protects the control from any voltage that may
be at the armature terminals. The center position is OFF/NEUTRAL.
THE MOTOR MUST COME TO A COMPLETE STOP BEFORE CHANGING DIRECTIONS. IF THE MOTOR DOES NOT COME
TO A COMPLETE STOP, SERIOUS DAMAGE TO THE CONTROL MAY RESULT. BYPASS OF THE CENTER BLOCK OF THE
SWITCH MAY RESULT IN DAMAGE TO THE CONTROL.
-29 (ENCLOSED VERSION) A 4PDT blocked center-off switch is factory installed into the cover assembly. The two position
terminal strip (P3) is factory installed on the main board (below). The output on P3 is the switched (FWD/REV) output and the output
of terminals P1-4 and P1-5 is not switched.
ARM
ARM
AC
AC
P1
-1
-2
-3
-4
-5
P3
-6
-1
-7
-2
-8
black
-9
white
-10
brown
-11
yellow
red
gray or
yellow
purple
or brown
blue
4PDT SWITCH
yellow
brown
purple
or brown
gray or
yellow
-29 Enclosed Factory Installed Only
able on Chassis
AC INPUTARM INPUT
P3-1 P3-2 P1-8 P1-9
P1-4 P1-5 P1-10 P1-11
-29B (CHASSIS VERSION) * 250G control with a 4PDT switch (factory provided). The customer provides interconnecting wiring.
P1
-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-34A option
4PDT
ARM
ARM
AC
AC
AC INPUTARM INPUT
P1-4 P1-5 P1-10 P1-11
ARM 1 ARM 2 AC AC
Factory Installed Only
Torque Control Available Enclosed Only
The TORQUE (CURRENT LIMIT TRIMPOT) is controlled by the faceplate mounted potentiometer. Thus, the internally mounted
MIN trimpot becomes the Speedpot. This speedpot may be moved to a remote location by removing the fixed resistors connected
on P1-1 through P1-3, and installing a standard 5K 2W potentiometer.
1 ohm 3.9K ohm
P1
DO NOT USE TRIMPOT SETTING CHART !
MIN MAX
ACCEL
I.R. COMP
-4-1 -2 -3
10
CURRENT LIMIT
orange
red
white
-55G2 and -56G2 options
Factory or Field Installed
Isolated Voltage Input Chassis Version
-55G2 OPTION (CHASSIS)
This option permits use of either a grounded or non-grounded
remote DC voltage speed command. This DC input range,
which can be selected via the range jumper clip and adjusted
with the GAIN trimpot, can range from 0-5VDC through 025VDC (P4-2 to P4-3) or 0-25VDC through 0-250VDC (P4-1 to
P4-2). The output of this option board supplies a linear signal to
the control. This signal is developed from the input voltage
supplied to the option board. The option is powered by the dual
voltage AC input and replaces the 5K speedpot.
INPUT IMPEDANCE:
1.2M ohm on high scale
150K ohm on low scale
ACCEL IR COMP CUR LIM
-3
-2 -1
P4
red
(P3-1)
(P3-2)
black
(P3-3)
-ARM +ARM
= customer wiring
= factory wiring
P2
-9-8-7-6-5-4
AC
-1 -2
AC1
AC
AC2
CUSTOMER
SIGNAL
CUSTOMER
COMMON
P1
MIN MAX
GAIN
TRIMPOT
RANGE
JUMPER
CONNECTOR
no connection
-56G2 OPTION (CHASSIS)
This is an Auto-Manual version of the -55G2 option. This option
permits use of either a grounded or non-grounded remote DC
voltage speed command. This DC input range, which can be
selected via the range jumper clip and adjusted with the GAIN
trimpot, can range from 0-5VDC through 0-25VDC (P4-2 to P4-
3) or 0-25VDC through 0-250VDC (P4-1 to P4-2). The output of
this option board supplies a linear signal to the control. This
signal is developed from the input voltage supplied to the option
board. The option is powered by the dual voltage AC input and
replaces the 5K speedpot.
MIN MAX ACCEL IR COMP CUR LIM
GAIN
TRIMPOT
RANGE
JUMPER
AUTO
SPEED
SIGNAL
CONNECTOR
SIGNAL
no connection
COMMON
P1
yellow
orange
AUTO
MANUAL
white
-3
-2 -1
P4
(P3-1)
(P3-2)
(P3-3)
-ARM +ARM
CONNECTS
UNDER WIPER
SCREW P1-2
1/2 OF DPDT
SWITCH
red
black
P2
-9-8-7-6-5-4
1
2
DPDT CENTER-OFF SWITCH
TERMINAL DESIGNATION
(BACKSIDE VIEW)
AC
AC
-1 -2
AC1
AC2
6 - NO CONNECTION
5 - NO CONNECTION
4 - NO CONNECTION
ADJUSTMENT PROCEDURE FOR -55G2 & -56G2 OPTIONS
1. With no power at the control, connect a DC voltmeter (meter must not be grounded) to control
outputs as follows: Meter COMMON to the -ARM terminal; Meter POSITIVE to the +ARM
terminal. Select correct meter range (0-90V or 0-180V).
2. Preset GAIN trimpot (option board) fully CCW, place range jumper clip in proper position.
3. Preset control as follows: MIN and I.R. COMP. fully CCW, MAX at 50%.
4. Apply desired AC voltage to control and option board.
5. With 0 volts into option board, adjust MIN trimpot on control to eliminate deadband. To do this,
increase MIN fully CW, then adjust CCW until meter reads 0 volts.
6. Apply maximum input voltage to option board input.
7. Adjust GAIN until no further change in voltage output occurs and turn CCW until a 5V drop
occurs, then set control MAX to 90VDC (180VDC for 240V input).
8. Set CURRENT LIMIT by using “TRIMPOT SETTING CHART” in the instruction manual.
9. For closed loop systems the I.R. COMP. should remain fully CCW. For open loop systems,
set I.R. as per set-up procedure.
10. ACCEL/DECEL adjustments should be set as needed.
11
(continued)
-56G2 option
Factory Installed Only
Isolated Voltage Input Enclosed Version
* Jumper clip is used to select
input voltage range. When installed from P4-1 to P4-2, the
range is 0-25VDC through 0250VDC; when installed from P42 to P4-3, range is 0-5VDC through
0-25VDC.
See the following page for
-55G2 and -56G2 Adjustment Procedures.
Min Max Accel
Inhibit
Pin
P1
Pot Lo
NOTE:
SOME FACTORY
WIRING IS NOT
SHOWN FOR CLARITY
I.R.
Cur.
Comp
Lim.
+Field
(white)
-Field
(brown)
AC
AC
P2
(red)
(white)
(orange)
-4 -5 -6 -7
-Arm
Wiper
+Arm
Pot Hi
motor ac input
CUSTOMER SUPPLIED WIRING
(yellow)
-11-9-8 -10-1 -2 -3
Switched AC
Switched AC
(black)
(blue)
common signal
3PDT Switch
(yellow)
(brown)
(black)
(white)
AC (P3-1)
AC (P3-2)
HI (P3-3)
W (P3-4)
LO (P3-5)
COM (P3-6)
+5V (P3-7)
SIG (P3-8)
P3
P4
-3
-2
-1
-56G2 OPTION BOARD
RANGE
JUMPER
CONNECTOR*
(INSIDE OF COVER)
INPUT IMPEDANCE:
1.2MΩ on high scale
150KΩ on low scale
(red)
Speedpot
(orange)
(white)
BALANCE TRIMPOT
(FACTORY SET - DO NOT
RE-ADJUST)
GAIN
TRIMPOT
IN CASE OF DIFFICULTY
If a newly installed control will not operate, it is possible that a terminal or connection is loose. Check to make sure that all
connections are secure and correct. If control still doesn't operate, refer to the following chart.
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION(S)
Motor doesn't operate
Armature output voltage
cannot be adjusted, output is a constant DC level
Motor stalls, or runs very
slowly with speedpot
turned fully CW
Motor hunts
Repeated fuse blowing
- blown fuse
- incorrect or no power source
- speedpot set at zero
- worn motor brushes
- no motor or load connected
- speedpot low connection open
- low voltage
- overload condition
- worn motor brushes
- max speed set incorrectly
- too much I.R. Comp.
- motor is in current limit
- motor not pulling enough current
- max trimpot set too high
- motor speed is above rated speed
- low voltage
- overload condition
- worn motor brushes
- defective motor bearings
- defective electrical component
replace fuse
install proper service
adjust speedpot CW to start
replace motor brushes
check that motor or load is connected
to armature terminals
check that speedpot low wire is connected
check - should be above 108V
reduce load
replace motor brushes
see ADJUSTMENT PROCEDURE
see ADJUSTMENT PROCEDURE
see ADJUSTMENT PROCEDURE
current must be greater than 150 mA D.C.
see ADJUSTMENT PROCEDURE
reduce speed
check - should be above 108V
reduce load
replace
replace
call Dart Distributor or Representative
Motor runs but will not
stop
If control still will not operate, consult your Dart Distributor or Representative.
- incorrect wiring (enclosed version)
- defective wiring
- defective component
12
check TERMINAL STRIP WIRING for cor-
-rect wiring instructions (note AC line
connection in particular)
check wiring
call Dart Distributor or Representative
SPECIFICATIONS
AC input voltage .................................................................................................................................. ±10% of rated line voltage
Acceleration ....................................................................................................................... 0.5 to 8.0 seconds (note -17B option)
Amps - DC output ............................................................................................................................... 150 mA to 10.8 Amps D.C.
Controller overload capacity ........................................................................................................................ 150% for one minute
Current limit trimpot range ............................................................. 0.3 to 3.0 Amps D.C. (251G); 1.0 to 15.0 Amps D.C. (253G)
Deceleration (dependent on acceleration time setting) .......................................................................... .06 to .80 second range
Dimensions and weight:
WEIGHTHEIGHTLENGTHWIDTH TYPE
ENGLISH
METRIC
5.53"
5.53"
140mm
140mm
7.25"
7.00"
184mm
178mm
3.50"
1.55"
89mm
39mm
25.50 oz.
16.25 oz.
723 grams
413 grams
enclosed
chassis
enclosed
chassis
Drive service factor ................................................................................................................................................................... 1.0
Efficiency..................................................................................................................................................................... 85% typical
Input frequency ....................................................................................................................................................... 50 or 60 Hertz
Max. trimpot speed range ................................................................................................................ 66% to 110% of base speed
Min. trimpot speed range .............................................................................................................. 0% to 30% of maximum speed
Minimum external impedance (pot hi to pot low) ............................................................................................................ 5K ohms
Power devices ...................................................................................................................................... packaged full wave bridge
Shunt field voltage ....................................................... 100VDC for 120VAC input; 200VDC for 240VAC input; 1 amp maximum
Speed control ......................................................................... via 5K ohms 2W linear potentiometer or 0-10VDC isolated signal
Speed range ........................................................................................................................................................................... 50:1
Speed regulation ............................................................................................................................................. ±1% of base speed
Temperature range ............................................................................................................ -10o to 45o C. ambient (15o to 115o F.)
Transient protection ............................................................................................................................................................ G-Mov
Type ramp of accel/decel ...................................................................................................................................................... linear
TYPICAL MOTOR CURRENTS
Horsepower
Typical AC Amps (120VAC)
Typical Arm Amps (120VAC)
Typical AC Amps (240VAC)
Typical Arm Amps (240VAC)
1/50 1/20 1/8 1/4
.70
0.26
.50
0.20
-----
-----
-----
-----
250G SERIES PARTS PLACEMENT & LIST
R12
R28
R31
R21
C10
R32
R
R17
C3
R20
P2
D8
P1-1
P1-2 P1-3 P1-4 P1-5 P1-6 P1-7 P1-8 P1-9 P1-10
NOTE: ALL RESISTORS 1/2W UNLESS SPECIFIED
* CUSTOMER WIRED SPEEDPOT
R22 R9 R23 R15
R29
R30
Q5
R7
R8
R19 R27
D10
D4
C1
C9
C11
R34
R2
D9
R1
R24
R35
R36
R33
C7
R11
C5
R6
R5
Q2
C8
JU1
D3
C2
Q1
R26
R25
D2
R37
Q6
D1
GENTRON PKG.
D5, D6, D7, Q3, Q4
R14
C
R3
2.0
-----
-----
12.90
9.90
1.80
1.40
-----
-----
3.50
2.70
1.80
1.40
1/3
4.40
3.40
2.20
1.70
1/2
6.50
5.00
3.30
2.50
3/4
9.30
7.20
4.80
3.70
1.0
13.20
10.20
6.50
5.00
1.5
-----
-----
9.70
7.50
RESISTORS
R1
15K 8W
R2
2.7K
R3
2.7K
R4
1.2M
R5
180K
R6
R18
R13
R16
C6
H1
JU2
F1
C12
P1-11
82K
R7
470K
R8
15K
R9
250K (ACCEL)
R10
5K SPEEDPOT*
R11
10K
R12
5K (MIN)
R13
470K
R14
300K
R15
5K (C.L.)
R16
4.7K
R17
390K
R18
4.7K
R19
150K
DIODE
D1
1N4005
D2
1N4005
D3
1N914B
D4
1N5242B
D5
L512FY131
D6
L512FY131
D7
L512FY131
D8
1N914B
D9
1N4005
D10
1N5233B
F1
10 AMP FUSE (Bussman ABC or Little Fuse 314
Series ceramic fuses)
H1
S-8201-1X FUSE HOLDER
JU1
1.75" - 16GA. SOLID INS. WIRE
JU2
2.50" - 16GA. SOLID INS. WIRE
P1
11 POS. TERMINAL STRIP
P2
1/4" SPADE PIN TERMINAL
R20
1K
R21
1K
R22
50K (MAX)
R23
100Ω (I.R.)
R24
.01Ω 5W
R25
390Ω
R26
390Ω
R27
1K
R28
20K 1/4W
R29
10K
R30
180K
R31
390K
R32
47K
R33
470K
R34
100K
R35
470Ω
R36
91K
R37
1Ω
ACTIVE DEVICES
Q1
2N6027
Q2
3052 MOC
Q3
L512FY131
Q4
L512FY131
Q5
LM324N IC
Q6
275V G-MOV
MISC. PARTS
-17B CHANGES:
C9 .... 2.2uf 50V N.P.
R28 .. 10K
-34A CHANGES:
R10... Connect to 3 wires
from R15 position
R15 .. Delete trimpot
251G-12C CHANGES:
R24 ... .1& 5W
CAPACITORS
C1
10uf 35V
C2
.01uf 100V
C3
.001uf 1KV
C4
.033uf 400V
C5
.1uf 50V
C6
22uf 16V
C7
.1uf 50V
C8
.0047uf 1KV
C9
.22uf 250V
C10
.01uf 100V
C11
.01uf 100V
C12
.068uf 250V
(across-the-line)
13
B
R30
6
5
180K
+
Q4
L512F
R26
390 OHM
R25
390 OHM
Q3
L512F
Q2-2
3052 MOC
7
Q5-2
D7
P1-5
+ARM
1K
R20
D10
1N5233B
D9
1N4005
L512F
R17
C3
+12V
MOTOR
R21
390K
1KV
.001uf
5W
R24
.01 OHM
SENSE RES.
P1-4
-ARM
1K
50K
R22
MAX
R8
15K
R7
470K
12
R4
1.2M
R5
180K
1K
R27
R33
470K
R28
91K
R36
1/4W
20K 1%
R19
JU1
150K
+TACH
P2
470
R35
OHM
R37
1 OHM
C8
1KV
.0047uf
4
+12V
-
6
R34
100K
R9
250K
ACCEL
10K
R29
F1 *
P1-11
AC2
AC1
P1-10
A
JU2
C12
SPARE
P1-8
250V
.068uf
SPARE
P1-9
C9
.22uf
Q6
250V
275V
G-MOV
P1-7
-FIELD
5K
R15
R14
CUR. LIM.
300K
+12V
R13
470K
2
3
+
-
C7
Q5-1
1
10K
R11
D3
1N914B
13
+
-
Q5-4
14
R6
82K
C4
400V
.033uf
.1uf
50V
R16
4.7K
C5
.1uf
50V
R23
IR COMP.
100 OHM
R18
4.7K
C6
16V
22uf
D6
D5
L512F
L512F
B
A
ALL RESISTORS 1/2W UNLESS NOTED OTHERWISE
NOTES:
1
35V
2
Q2-1
3052 MOC
R3
2.7K
Q2 .................................. 3052 MOC
Q3, Q4, D5, D6, D7 ....... L512FY131 GENTRON
Q5 .................................. LM324N IC
F1 * ................................ BUSS ABC-10 or LITTLEFUSE 314010
250G SERIES SCHEMATIC
+12V
+12V
C2
.01uf
R2
2.7K
D8
1N914B
100V
+12V
D4
1N5242B
Q1
2N6027
C1
10uf
8
C11
.01uf
100V
11
4
Q5-3
-
+
9
10
C10
.01uf
100V
R31
390K
47K
R32
P1-2
WIPER
HI
P1-3
LO
P1-1
5K
MIN
5K
R10
REMOTE
SPEEDPOT
R12
D2
1N4005
B
R1
8W
15K
A
D1
1N4005
+FIELD
P1-6
14
REPAIR PROCEDURE
In the event that a Product manufactured by Dart Controls Incorporated (DCI) is in need of
repair service, it should be shipped, freight paid, to: Dart Controls, Inc., 5000 W. 106th Street,
Zionsville, IN. 46077, ATTN: Repair Department.
Those orders received from anyone without and existing account with DCI will need to specify
if they will be paying COD or Credit Card (Master Card or Visa). This information is required
before work can begin. If you have an account with Dart your order will be processed according
to the terms listed on your account.
Completed repairs are returned with a Repair Report that states the problem with the control
and the possible cause. Repair orders are returned via UPS Ground unless other arrangements
are made. If you have further questions regarding repair procedures, contact your Dart Controls,
Inc. at 317-733-2133 Ext.460.
YOUR MOTOR SPEED CONTROL SOLUTIONS PROVIDER
125D SERIES
AC INPUT - VARIABLE DC OUTPUT
1/50 HP through 1.0 HP
700/COMMUTROL SERIES
DC BRUSHLESS
5 & 20 Amp for
12,24,& 36VDC Inputs
Dart Controls, Inc. is a designer, manufacturer, and
marketer of analog and digital electronic variable speed
drives, controls, and accessories for AC, DC, and DC
brushless motor applica-
tions.
Shown above is just a sampling of the expanded line of
Dart controls that feature the
latest in electronic technology
and engineering. Products are
manufactured in the U.S.A. at
our Zionsville (Indianapolis,
250G SERIES
AC INPUT - VARIABLE DC OUTPUT
1/50 HP through 2.0 HP
MDP SERIES
PROGRAMMABLE
CLOSED LOOP DC
SPEED CONTROL
Indiana) production and headquarters facility - with over
2,000,000 variable speed units
in the field.
In addition to the standard offthe-shelf products, you can select from a wide variety of options to customize controls for
your specific application. For
further information and application assistance, contact your
local Dart sales representative, stocking distributor, or
Dart Controls, Inc.
www.dartcontrols.com
ISO9001:2000 REGISTERED
DC INPUT - VARIABLE DC OUTPUT
CURRENT RATINGS OF 20, 40, AND
60 AMPS
DM SERIES
65 SERIES
FIELD PROGRAMMABLE
DIGITAL TACHOMETER
Dart Controls, Inc.
Manufacturer of high quality DC and AC motor speed
controls and accessories
since 1963.
P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077
Phone: (317) 733-2133
Fax: (317) 873-1105
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