Dart Controls MDP Control Series Instruction Manual

CONTROLS

Instruction Manual

Field Programmable Closed Loop DC Speed Control

LT61 (0508)

P.O. Box 10
5000 W. 106th Street

MDP CONTROL SERIES

Zionsville, Indiana 46077

www.dartcontrols.com

Phone [phone]

Fax [phone]

A-5-3241J

Quick Jump

What models and options are available?
See page 3.

Looking for detailed specifi cations?
See page 3 & 4.

Want to get started fast?
See basic electrical hook-up details on page 8.
See mechanical installation details on page 4 & 5.
See some sample applications starting on page 24.

Need Help?
See troubleshooting on page 29.

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 qualifi ed 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.

Table of Contents

Introduction ....................................................................................................................................... 2

General Features .............................................................................................................................. 2

Models & Options ............................................................................................................................. 3

Model Table ................................................................................................................................... 3

Available Options .......................................................................................................................... 3

Recommended Accessories ......................................................................................................... 3

Agency Approvals ......................................................................................................................... 3

Specifi cations ................................................................................................................................... 3

Electrical ....................................................................................................................................... 3

Mechanical ................................................................................................................................... 4

Environmental ............................................................................................................................... 4

Dimension Chart ........................................................................................................................... 4

Installation and Mechanical Dimensions ....................................................................................... 5

Exploded Panel View .................................................................................................................... 5

Cut-out and Mounting Dimensions ............................................................................................... 6

PU-E Series Pickup Installation .................................................................................................... 7

Electrical Installation & Diagrams ................................................................................................... 8

P1 Terminal Block Hook-Up Diagrams .......................................................................................... 8

P1 Terminal Block Descriptions .................................................................................................... 9

-1 Option Wiring .......................................................................................................................... 10

Basic Operating Instructions ........................................................................................................ 10

Control Algorithm Discussion ..................................................................................................... 10

Pulse-Accumulation Loop PI Tuning .......................................................................................... 10

Master (Rate and Time) and Follower (Ratio) Modes Explained ................................................ 11

Visual Reference ........................................................................................................................ 12

How to Change a Parameter's Value (The Short Story) ............................................................. 12

Operating the User Interface (The Long Story) .......................................................................... 12

Detailed Confi guration Instructions ............................................................................................. 13

Default Confi guration .................................................................................................................. 13

Resetting the Unit to Factory Defaults ........................................................................................ 13

JP1 (Program Enable Jumper) .................................................................................................. 13

Software Parameters .................................................................................................................. 14

Parameter Descriptions .............................................................................................................. 16

Application Examples .................................................................................................................... 24

Pump Controller with Audible and Visual Alarm ......................................................................... 24

Conveyor Oven Controller with Two Preset Process Times ........................................................ 25

Synchronized Conveyor Controller with Jog Switch ................................................................... 26

Troubleshooting .............................................................................................................................. 29

Technical Support Options .......................................................................................................... 29

What's Special About www.dartcontrols.com? ........................................................................... 29

1

Introduction

The MDP series motor controls are compact, microprocessor-based units capable of being either fi eld
or factory confi gured for a number of industry's motion control needs. These controls are designed
around a pulse-accumulation PI algorithm. They can be easily confi gured to operate as a digital speed
controller, time-based process controller, or a ratiometric follower controller in master-slave systems.
Utilizing Dart's new modular bus design techniques, the MDP series is ideal for volume OEM applications
requiring specialized inputs and outputs. Contact Dart Controls' Sales Department for details. This
fl exibility makes the MDP series ideal for applications such as:

Water and Waste Treatment Systems

Conveyor Oven Controllers

Synchronized Conveyor Lines

Its durable 1/8 and 1/4 DIN aluminum housings can be easily mounted in a panel or control cabinet.
New optional pluggable terminal block allows the installer to quickly install or replace units without the
hassle of physically removing and reattaching wires. The units can be ordered with either standard
European-style terminal block or optional “pluggable” connector.

General Features

- Microprocessor-based design combines the ultimate in responsiveness and accuracy in one package

- Digital closed-loop algorithm ensures long-term accuracy of +/-1/2 RPM of set speed or equiv.

- Non-volatile memory stores adjustable parameters even when power has been removed

- Factory or fi eld programmable via front-panel keypad

- Adjustable parameters include min, max, accel, decel, display options, alarm options, etc.

- Internal program-enable jumper selectively prevents tampering with unit’s confi guration

- Universal power supply accepts line voltages inputs from 85-265VAC @ 50-60Hz without switches
or jumpers. The unit automatically adjusts as needed.

- Transient voltage protection prolongs unit's life in harsh industrial environments

- Compatible with a variety of signal input types including: Hall-Effect Pickups, Photoelectric, TTL, etc.

Note: Open collector devices must be capable of sinking 3mA.

- Self-contained power supply for external sensor, limited to 5V @ 50mA

- Programmable alarm output with Form C contacts rated to 250VAC @ 5A

- Flexible user inputs support inhibit, emergency stop, and jog functionality.

- 1/8 and 1/4 DIN durable aluminum housing for panel mounting the MD10P and MD3P, respectively.

- Large 4 digit, 1/2” LED display

- G.E. Lexan membrane and gasket (which are included) meet NEMA 4X standards when used with
NEMA 4X enclosures

- European terminal block or pluggable terminal block available

- Recognized, fi le #E78180 (MD10P, MD3P & MD3E)

- Wide operating ambient temperature range of -10C to 45C (14F to 113F)

- Multiple operating modes including:

• Master, Rate Mode – Controls in rate unit such as RPM, Gallons per Second, etc.

• Master, Time Mode – Controls in time unit such as HH:MM, MM:SS, SS:TT, or other unit

• Follower Mode – Controls in percentage of master rate. This mode allows the MDP control to

precisely follow the actions of a master process without any long-term loss of position

2

Model Table

Models & Options

Model

MD10P

MD3P 85-265VAC

MD3E 85-265VAC

Input Voltage

@ 50 - 60Hz

85-265VAC

Output Voltage

@ 120VAC

(@ 240VAC)

90VDC

(180VDC)

90VDC

(180VDC)

90VDC

(180VDC)

Max. Output H.P.

@ 120VAC

(@240VAC)

1/2

1
1

2
1

2

Max Continuous

Armature DC

Amps

5
5

10
10

10
10

Pickup or

Encoder

Required?

Yes

Yes

Yes

Available Options

Option Suffi x Description Example

-1 Expansion board which adds support for remote push button wiring via a
European-style terminal block.

-P Optional pluggable European-style terminal block

-9 Blank Lexan

MD10P-1, MD3P-1

MD10P-P, MD3P-1-P

MD10P-9

Recommended Accessories

Model Description

PU-2E Hall-Effect Pickup, Single Channel 1 1.0 – 50,000 RPM

PU-4E Hall-Effect Pickup, Single Channel 2 0.5 – 25,000 RPM
PU-20E
PU-40E Hall-Effect Pickup, Single Channel 20 0.05 – 2,500 RPM

Hall-Effect Pickup, Single Channel

Pulses per
Revolution

10 0.1 – 5,000 RPM

RPM Range When Used With

MD10P & MD3P

Agency Approvals

Recognized Component MD10P, MD3P ........................................................................................... E78180

MD3E ....................................................................................................................................................34M5

NEMA 4X ....................................................................................................................................MD10P / MD3P / MD3E

Specifi cations

Electrical

Line Input Voltage ........................................................................................................Any Voltage from 85-265 VAC

Line Input Frequency ...................................................................................................... Any Freq. from 48-62 Hertz

Signal Input Voltage Range .................................................................................. 0-5VDC to 0-24VDC square wave

Signal Input Frequency Range .................................................................................... 0 – 50,000 Pulses per Minute

(Higher frequencies are possible when using internal frequency divisor / prescaler)

Display Range ....................................................................................................................................0.001 – 99,990

Units of Operation ..................................................................................................... User Programmable, any Unit

Sensor / Pickup Power Supply ............................................................................................................... 5V @ 50mA

Isolated Alarm Relay Output Ratings ..................................................................................................250VAC @ 5A

Average Armature Output Voltage ................................................. Line Input Voltage Dependent (See model table)

Design Overload Capacity .............................................................................................................200% for 1 minute

3

Mechanical

Display Type ................................................................................................................LED, Red, 4 Digit, ½” Height

Housing Type MD10P & MD3P (with supplied gasket) ..............................................................................NEMA 4X

MD3E NEMA 4

Connector Style (pluggable connector optional) ...................................................12-position 5mm European Style

Terminal Block Torque Setting ............................................................................................... 4.4 in. lb. Max or .5Nm

Faceplate Material .........................................................................................Polycarbonate with GE Lexan Overlay

Housing Material ........................................................................................................................................Aluminum

Length MD10P & MD3P(Required Panel Depth) ..........................................................................4.625”, 117.48mm

Faceplate Width ...........................................................................................................................4.539”, 115.29mm

Weight MD10P .............................................................................................................0.8425 lb, 13.48 oz, 382.14g

MD3P ...................................................................................................................1.52 lb, 24.32 oz, 689.44g

MD3E...................................................................................................................1.64 lb, 26.24 oz, 743.88g

Environmental

Operating Temperature Range ----------------------------------------------------------------------------- -10C to 45C (15F to 115F)

Operating Humidity Range ----------------------------------------------------------------------------------------- 95%, non-condensing

Dimension Chart

Model Width Height Depth

MD10P English (inches)

Housing 3.62 1.66 4.625
Lens 4.539 2.289 0.375

MD10P Metric (millimeters)

Housing 91.94 42.16 117.27
Lens 115.28 58.14 9.53

MD3P English (inches)

Housing 3.60 3.497 4.625
Lens 4.539 4.179 0.375

MD3P Metric (millimeters)

Housing 91.44 88.82 117.27
Lens 115.28 106.15 9.53

MD3E English (inches)

Assembly 5.53 7.40 3.90

MD3E Metric (millimeters)

Assembly 140.46 187.96 99.06

4

Installation and Mechanical Dimensions

Exploded Panel View

CUSTOMER

MOUNTING PANEL

(HOLE CUT-OUT FOR CONTROL

HOUSING APPROXIMATELY

3.622" WIDE BY 1.770" HIGH)

PANEL MOUNTING GASKET

(WITH THE ADHESIVE SIDE OF

GASKET FACING THE CUSTOMER

MOUNTING PANEL)

MD10P

CONTROL

1) GASKET

2) (2) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS

3) (2) #6 NUT WITH LOCKWASHER

CUSTOMER

MOUNTING PANEL

(HOLE CUT-OUT FOR CONTROL

HOUSING APPROXIMATELY

3.622" WIDE BY 3.622" HIGH)

SUPPLIED WITH EACH CONTROL:

PANEL MOUNTING GASKET

(WITH THE ADHESIVE SIDE OF

GASKET FACING THE CUSTOMER

MOUNTING PANEL)

MD3P

CONTROL

1) GASKET

2) (4) 6-32 X 3/4 PANHEAD BLACK OXIDE STAINLESS SCREWS

3) (4) #6 NUT WITH LOCKWASHER

5

SUPPLIED WITH EACH CONTROL:

Cut-out and Mounting Dimensions

5.000"

4.625"

4.179"

1.928"

4.000"

4.000"

3.622"

CONTROLS

Ite

Ite

m

MICRO-DRIVE

MICRO-DRIVE

Tach

ValuPage

Tach

ValPage

ENTER

ENTER

MICRO-DRIVE

CONTROLS

MD10P and MD3P Dimensions

.140" x 2

.140" x 4

MD10P

HOUSING DEPTH

4.625"

PA NEL CUT-OUT

3.622

MD3P

HOUSING DEPTH

4.625"

PA NEL CUT-OUT

0.885"

1.770"

0.811"

3.622"

2.000"

2.289"

5.000"

1.656"

4.625"

6

MD3E Mounting and Dimensions

5.530
7/32" TYP.

(4 SLOTS)
.350 DEEP

7.400

Item

CONTROLS

ValuPage

5.125 TYP.

Tach

ON

OFF

ENTER

5.500

.750

PU-E Series Pickup Installation

The PU-E series pickup is an economical way to monitor motor speed. Its patented design provides for
ease of installation in otherwise diffi cult to reach areas. The PU-E operates from a +5V power supply,
producing a 5 volt square wave whose frequency is proportional to speed. This signal is fed into the
MDP control as a speed or position reference for the microprocessor.

dust

cover

10-32

screw

magnet

disc

flat

washer

PU-E

bearing

3/16"

spacer

tapped

motor

shaft

Model

Number

PU-2E
PU-4E
PU-20E
PU-40E

Pulses per
Revolution

1

2
10
20

Dimensions

1.60 .875

2.40

signal

red wire
+5 volts

black wire

common

white wire

CAUTION:

DO NOT OVER TIGHTEN MOUNTING SCREW !!

No other mounting screws are necessary, as the cord
will keep the unit from rotating.

7

72.00

Caution: The PU-E cord should not be grouped with other wires or cords. For applications with PU-E
wire over 6 feet long, or noisy environments, a shielded cable is recommended. Connect the shield to
the common terminal on the MDP, leaving the shield on the PU-E end fl oating.

Electrical Installation & Diagrams

P1 Terminal Block Hook-Up Diagrams

MDP

MASTER

MDP

FOLLOWER

black

red

white

**

Jog Input

COM (P1-5)

SIGNAL 2

COM (P1-5)

AC INPUT

AC INPUT

Form C
Relay Output
(Programmable)

}

AC INPUT

AC INPUT

Form C
Relay Output
(Programmable)

}

P1-1

P1-2

P1-3

P1-4

P1-5

P1-6

P1-7

P1-8

P1-9

P1-10

P1-11

P1-12

N

L

-A

+A

COM

+5V

S1

S2

NO

C

NC

IN1

* For AC inputs utilizing two hot lines, both inputs should be

protected with appropriately sized fuses or circuit breakers.

** P1-8 & P1-12 user input may be programmed

for a number of functions. Including (jog, inhibit, etc.)

P1-1

P1-2

P1-3

P1-4

P1-5

P1-6

P1-7

P1-8

P1-9

P1-10

P1-11

P1-12

* For AC inputs utilizing two hot lines, both inputs should be

protected with appropriately sized fuses or circuit breakers.

** P1-8 & P1-12 user input may be programmed

for a number of functions. Including (jog, inhibit, etc.)

FUSE

MD10P = 7.5 Amp*
MD3P = 15 Amp*

-ARM

+ARM

COMMON

+5VDC

SIGNAL

Alarm Output - Normally Open

Alarm Output - Common

Alarm Output - Normally Closed

User Input 1

**INHIBIT

N

L

-A

+A

COM

+5V

S1

S2

NO

C

NC

IN1

FUSE

MD10P = 7.5 Amp*
MD3P = 15 Amp*

-ARM
+ARM

COMMON

+5VDC

SIGNAL 1

Alarm Output - Normally Open

Alarm Output - Common

Alarm Output - Normally Closed

User Input 1

**

INHIBIT

85-265VAC

}

MOTOR

}

MOTOR

85-265VAC

black

red

white

black

white

PICK-UP MOUNTED

TO MOTOR SHAFT

(Mounts on rotating

end shaft with 10-32

tapped hole, 1/2" deep)

FOLLOWER PICK-UP

MOUNTED TO

MOTOR SHAFT

(Mounts on rotating

end shaft with 10-32

tapped hole, 1/2" deep)

8