Dart Controls 530B Control Series Instruction Manual

CONTROLS

Instruction Manual

Variable Speed DC Control

LT530B (0505)

P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077

Phone [phone]

Fax [phone]

www.dartcontrols.com

530B CONTROL SERIES

A-5-3271B

TABLE OF CONTENTS

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

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

COMMONLY ASKED QUESTIONS ................................................................................................................................................................... 2

BASIC MODEL SELECTION .............................................................................................................................................................................. 2

CONTROL FEATURES ....................................................................................................................................................................................... 3

OVERALL CONTROL DIMENSIONS ............................................................................................................................................................. 3-4

SPEEDPOT MOUNTING DIMENSIONS ............................................................................................................................................................. 4

MOUNTING INSTRUCTIONS ............................................................................................................................................................................. 4

WIRING PROCEDURE ......................................................................................................................................................................................... 4

TERMINAL STRIP WIRING - P1 ......................................................................................................................................................................... 5

TERMINAL STRIP WIRING - P2 ...................................................................................................................................................................... 5-6

SETTING INPUT VAC .......................................................................................................................................................................................... 6

SWITCH LADDER CIRCUIT DIAGRAMS .......................................................................................................................................................... 6

“RE” CONTROL PANEL IDENTIFICATION ..................................................................................................................................................... 6

INITIAL START-UP .............................................................................................................................................................................................. 7

TRIMPOT ADJUSTMENT PROCEDURE ........................................................................................................................................................ 7-8

TRIMPOT SETTING CHART .............................................................................................................................................................................. 8

1.5 AND 3.0 HORSEPOWER - MODEL 533BC ................................................................................................................................................. 8

BASIC HOOK-UP DIAGRAM WITHOUT OPTIONS ................................................................................................................................... 9-10

530BC, 533BC & 530BRC HOOK-UP DIAGRAMS .................................................................................................................................... 9

PILOT RELAY SWITCHING .......................................................................................................................................................................... 9

530BRE HOOK-UP DIAGRAM ................................................................................................................................................................... 10

JU2 JUMPER WIRE SELECTION CHART ...................................................................................................................................................... 10

CONTROL MODIFICATIONS ...................................................................................................................................................................... 10-11

TWO SPEED OPERATION ......................................................................................................................................................................... 10

DYNAMIC BRAKING ................................................................................................................................................................................... 10

TACHOMETER FEEDBACK & FOLLOWER ............................................................................................................................................ 11

INHIBIT INSTRUCTIONS ............................................................................................................................................................................ 11

OPTIONS ....................................................................................................................................................................................................... 11-15

-4 OPTION .................................................................................................................................................................................................... 11

-5 OPTION ......................................................................................................................

-7 / -11 / -15A OPTIONS .............................................................................................................................................................................. 13

-36M / -38M OPTIONS ............................................................................................................................................................................ 14-15

IN CASE OF DIFFICULTY ................................................................................................................................................................................ 15

FUSING ............................................................................................................................................................................................................... 15

SPECIFICATIONS .............................................................................................................................................................................................. 16

530B SERIES PARTS PLACEMENT & LIST ................................................................................................................................................... 17

530B SERIES SCHEMATIC ............................................................................................................................................................................... 18

PRODUCT LINE ............................................................................................................................................................................ BACK COVER

.............................................................................. 12

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 530B Series is a high performance, dual voltage versatile DC motor control which provides a wide range of standard features,
with many options that extend its capabilities. The 530B Series will operate 1/8 through 1.0 horsepower at 115VAC input, and 1/
4 through 2.0 horsepower at 230VAC input. A chassis only model is available to operate a 1.5 horsepower motor at 115VAC input,
or 3.0 horsepower at 230VAC input. Reference “Basic Model Selection” guide.

The 530B Series consists of three basic types:

C = Chassis mounted, no enclosure, no power relay's.
RC = Chassis mounted, no enclosure, with power relay's.
RE = Plastic enclosure with power relay's - Nema 4/12 standard.

The 530B Series is designed for Permanent Magnet, Shunt Wound, and some Universal Series (AC/DC) motors in the above
horsepower ranges. The 530B Series incorporates transient voltage protection with adjustable Current Limit and AC fuses for
protection. Minimum and Maximum speeds are easily adjusted by trimpots, as is the I.R. Compensation. Acceleration and
Deceleration are fully adjustable via individual trimpots.

COMMONLY ASKED QUESTIONS

Q. Can I run two or more motors from the same drive?

A. Not recommended. The I.R. Compensation (regulation) and Current Limit circuits would have difficulty sensing the different

load on each motor.

Q. Can I change the horsepower of my motor and still use the same control?

A. Yes, provided you do not deviate outside the horsepower range for the voltage you are using. The trimpots would need

readjustment; see “Trimpot Chart” for approximate settings.

Q. Can I use the 530B Series as a Current Follower?

A. Yes, there is a field installable -5 or -7 option shown in "Options" section.

Q. Can I use the 530B Series on Tachometer feedback?

A. Yes, see +Tach (P2-9) under “Terminal Strip Wiring - P2”.

Q. Can I use the Stop (P2-11), Start (P2-13), and Common (P2-12) to stop-start the control on the “C” chassis version?

A. No. Terminals P2-11, P2-12, and P2-13 are only active on the relay versions; “RE” and “RC”. These terminals are

non-operative on the “C” version.

Q. Can the 530B Series be used as a Voltage or Tachometer Follower?

A. Yes. The voltage must be ungrounded and no more than +12 VDC (See “Terminal Strip Wiring” for proper hook-up).

Q. How would I proceed to stop/start the 530B Series with my own relay?

A. You can use the contact of your relay in place of the AMP REF to REV 1 (P2-2 to P2-7) jumper wire. Since this is a low

level signal (12 volts at 2mA), you must use a logic type relay (preferably gold contacts). This cannot be done on controls
using some options. Consult your Dart Representative if options are involved.

Q. Why is a jumper wire between AMP REF (P2-2) and REV 1 (P2-7) needed on drives with no options?

A. REV 1 (P2-7) and REV 2 (P2-8) are two identical stop inputs. One of these must be held low (to Amp Ref P2-2) for the control

to run. If the drive has no options, this must be jumpered to satisfy the “OR” gate. This requirement is satisfied by some
options. For these options, a connection must be made to these terminals. Instead of a jumper wire, the option is wired
to these terminals. (See “Jumper Wire Selection”).

BASIC MODEL SELECTION

115/230 VAC INPUT 0-90/0-180 VDC OUTPUT 100/200 VDC FIELD

HP RANGE

1/8 - 2.0 530BC 530BRC 530BRE

1

CHASSIS CHASSIS ENCLOSED

RELAY RELAY

115/230 VAC INPUT 0-90/0-180 VDC OUTPUT 100/200 VDC FIELD

HP RANGE

1.5 and 3.0 533BC Not Available Not Available

Notes:

1) 1/8 - 1.0 h.p. uses 115VAC input, 0-90VDC output and 100VDC field; 1/4 - 2.0 h.p. uses 230VAC input, 0-180VDC output and 200VDC field

2) 1.5 h.p. uses 115VAC input, 0-90VDC output and 100VDC field; 3.0 h.p. uses 230VAC input, 0-180VDC output and 200VDC field

2

CHASSIS CHASSIS ENCLOSED

RELAY RELAY

2

CONTROL FEATURES

INPUT VOLTAGE SELECTION SWITCH

MIN SPEED

- (Minimum speed) Allows adjustment of the motor speed when the speedpot is set at minimum. This permits the user

- Switch selectable between 115 VAC and 230 VAC input.

to eliminate the “Deadband” on the main speed control, permitting zero calibration. Clockwise rotation of the “MIN” trimpot
increases output VDC.

ACCEL

- (Acceleration) Allows adjustment of the motor acceleration from a minimum of 0.3 seconds to a maximum of 12 seconds.

The -15A option extends the maximum acceleration time to 30 seconds.

DECEL

- (Deceleration) Allows adjustment of the motor deceleration from a minimum of 0.6 seconds to a maximum of 12 seconds.

The -15A option extends the maximum deceleration time to 30 seconds.

MAX SPEED

- (Maximum speed) Allows adjustment of the motor speed when the speedpot is set at maximum (CW). This permits
the user to eliminate the “DEADBAND” of the speedpot, providing full speed at maximum rotation. Rotation of the “MAX” trimpot
in the clockwise direction increases maximum output VDC.

I.R. COMP

controls the speed regulation of the motor. This feature controls

- (Speed Regulation) Allows adjustment of the circuitry that

CUR LIMMIN ACCEL DECEL MAX IR COMP

armature speed by changing the armature voltage to compensate
for increased or decreased motor loading. Clockwise rotation of the
“I.R. COMP” trimpot will increase gain 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. Set Current Limit (CUR. LIM.) at 125% of the rated
motor current. Clockwise rotation of the “CUR. LIM.” trimpot increas­es the torque (current) the control will provide.

TACH INPUT SELECTION

- Factory set at 3V per 1000 RPM, jumper
selectable (JU3) to 7V per 1000 RPM. Refer to “Tach Feedback”
section in “Control Modifications” for more information.

TERMINAL STRIP P1

- Barrier type terminal strip provides for connec­tion of AC lines, motor leads, motor field (if necessary), and earth
ground.

TERMINAL STRIP P2

- Barrier type terminal strip provides for connec-

OVER CUR OUT

AMP REF

POT LO

POT WIPER

POT HI

SPARE

REV 1

REV 2

+TACH

PILOT LAMP

STOP

COMMON

START

-10

-11

-12

-13

P2

-1

-2

RELAY

RELAY

TACH INPUT
SELECTION

+3V+7

JU3

PROVIDES SUPPORT

AND TRIGGERING FOR

OPTIONS

RELAY

-3

-4

-5

-6

-7

-8

-9

tion of speed potentiometer and any accessories and/or jumper
wires which control the drive.

RELAY

- (Power Interrupt Relay's) Available only on the “RC” and the
“RE” versions, the relay's permits the switching of AC power with a
low current signal. For the “RE” version, the relay's will not allow start
up after power failure without manually restarting.

INPUT VOLTAGE

SELECTION SWITCH

115

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

GND AC AC +A -A -F +F

AC FUSES

P3

P1

OVERALL CONTROL DIMENSIONS

9.00

7.50

“C” and “RC”

SERIES HOUSING

DIMENSIONS

7/32 DIA.
(4 SLOTS)

TOP VIEW

3

0.20

6.30

6.70

2.00

END VIEW

(Control dimensions continued)

BOTTOM VIEW

7.50

0.20

3.88

SPEEDPOT

9.00

10.00

SIDE VIEW

7/32 DIA.
(4 SLOTS)

0.87

CUSTOMER'S

MOUNTING BRACKET

CUSTOMER'S MOUNTING BRACKET

1.240

.500 .370 .370

6.30

2.63

0.50

6.70

1.13

“RE” SERIES

HOUSING

DIMENSIONS

END VIEW

6.02

4.64

2.502.13

DIALPLATE

2.00" dia.

SPEEDPOT

HEX NUT

KNOB

.875 DIA.
(2 HOLES)

MOUNTING

DIMENSIONS

(For “C” and “RC” versions)

1.250

.250 Dia.

SPEEDPOT

(5K 2W)

.437

3/8

5/32

DIA.

DIA.

SPEEDPOT LOCATOR HOLE DIMENSIONS

LOCK

WASHER

O-RING

EXPLODED VIEW

DO NOT MOUNT CONTROL WHERE AMBIENT TEMPERATURE IS OUTSIDE RANGE OF -10° to 45° C. (15° to 115° F.)

MOUNTING INSTRUCTIONS

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

2. The 530B Series chassis can be used as a template.

3. Use standard hardware to mount.

4. For the “RE” version ONLY: Two 7/8" diameter holes are provided in one endplate to facilitate wiring. This allows for easy
connection of 1/2" conduit.

NOTE: For enclosed models using 1 h.p. 90V or 2 h.p. 180V motors, the control MUST be mounted vertically.

CAUTION:

DO NOT ATTEMPT TO PERFORM HI-POT TEST ACROSS AC LINES WITH THE CONTROL IN CIRCUIT.

THIS WILL RESULT IN IMMEDIATE OR LONG TERM DAMAGE TO THE CONTROL.

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 # 20AWG or smaller as permitted by local code.

2. Control wire (Pot, Tach, etc.) should be separated from all the Armature, Field (if Shunt Wound), and the AC wires when routed

in conduits or in wire trays. The enclosed version has two holes on one endplate for this purpose.

4

TERMINAL STRIP WIRING - P1

CAUTION: BE SURE CONTROL HOUSING IS PROPERLY GROUNDED.

The 530B Series uses a 7 position barrier type terminal strip to handle the power connections.

P1-1

P1-2

P1-3

P1-4

P1-5

P1-6

P1-7

(EARTH GROUND) - Ground the control by connecting the ground wire to this terminal. NOTE: Terminals P1-5 (-ARM)

and P2-2 (AMP REF) are electrically the same, which is the common reference point (low voltage common) for the control
logic. The EARTH GROUND terminal (P1-1) is electrically different from common. If connected together, either at the
amplifier or in any other fashion, fatal or hazardous operation may occur and permanent damage to the control WILL result!

(AC1) 115VAC - Connect incoming hot AC (black wire) to this terminal. NOTE: This is fused (F1) on the control.
(AC1) 230VAC - Connect either hot side.

(AC2) 115VAC - Connect the neutral AC (white wire) to this terminal. NOTE: This is fused (F2) on the control.
(AC2) 230VAC - Connect either hot side.

(+ ARMATURE) - Connects to the plus (+) Armature wire on the motor. 0-90VDC for 115VAC input or 0-180VDC for 230

VAC input. See “SPECIFICATIONS” for output rating.

CAUTION: ARMATURE CONNECTION MUST NOT BE SWITCHED OR BROKEN WHILE CONTROL IS ON
OR SERIOUS DAMAGE TO THE CONTROL MAY RESULT.

(- ARMATURE) - Connects to minus (-) Armature wire (also considered circuit common) on the motor.

(- FIELD) - Connect minus (-) Field wire of the Shunt Wound motor (not used on PM motors).

FIELD VOLTAGE TABLE

Model # VAC Input VDC Field

530B Series

(+ FIELD) - DO NOT use for Permanent Magnet motor. This supplies + Field voltage for a Shunt Wound motor. See chart
above for dual voltage Field Wound motors. This output is rated at 1 Amp for 530B series controls and 1.5 Amps for the
533B control. For motors with dual voltage field (ie. 50/100V or 100/200V), make sure the highest value is connected.

115 100

230 200

TERMINAL STRIP WIRING - P2

The 530B Series uses a 13 position barrier type terminal strip for control connections.

CAUTION: NONE OF THE P2 TERMINALS SHOULD BE EARTH GROUNDED!

P2-1

P2-2

P2-3

the MIN trimpot adjustments are to be active. Otherwise, inputs may be referenced to AMP REF (P2-2), which will bypass
the MIN trimpot.

P2-4

P2-5

(OVER CURRENT OUT) - Can be used to signal that the control is in current limit. It can also signal other devices or alarms.

This is a low level logic signal which goes “high” when the current limit amplifier is in current limit. The logic of this control
is +12 volts, while the output at this terminal is approximately 1.5 volts through a 1000Ω resistor when in Current Limit.

(AMP REF) - This is the common point of the logic. It is used as common with OVER CURRENT OUT (P2-1), +TACH (P2-

9), REV 1 (P2-7), REV 2 (P2-8), and WIPER (P2-4). NOTE: Never connect this terminal to earth ground !! Serious damage
and injury may result !! This terminal is electrically the same point as -ARM (P1-5).

(SPEEDPOT LO) - Connects to the 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 (voltage follower) may be referenced to Speedpot LO if

INPUT MUST NOT BE GROUNDED !

CAUTION FOR VOLTAGE FOLLOWER APPLICATIONS:

THE INPUT CONNECTION TO THE SPEEDPOT MUST NOT BE GROUNDED !!

SERIOUS DAMAGE TO THE CONTROL MAY RESULT FROM A GROUNDED INPUT.

(SPEEDPOT WIPER) - Connects to the wiper (red wire) of the Speedpot (center lead). Use this input for the plus (+) side

of voltage follower operation or tach follower. The minus (-) side connects to AMP REF (P2-2).
GREATER THAN +12V MAXIMUM AND MUST NOT BE GROUNDED !

(SPEEDPOT HI) - Connects to high side (white wire) of the Speedpot (CW end). This is internal +12 volts. INPUT MUST
NOT BE GROUNDED !

INPUT MUST NOT BE

P2-6

(SPARE) - This terminal is not connected to the control circuit. It can be used as a terminal for field modifications.

5

(P2 wiring continued)