Dart Controls MDP Control Series Instruction Manual

	<![if ! IE]> <![endif]>SERIES	CONTROLS
		Instruction Manual
	<![if ! IE]> <![endif]>CONTROL
		Field Programmable Closed Loop DC Speed Control
	<![if ! IE]> <![endif]>MDP	P.O. Box 10	Phone [phone]
		5000 W. 106th Street	Fax [phone]
		Zionsville, Indiana 46077	www.dartcontrols.com
	LT61 (0508)		A-5-3241J

Quick Jump

What models and options are available?

See page 3.

Looking for detailed specifications?

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 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.

Table of Contents
Introduction.......................................................................................................................................	2
General Features ..............................................................................................................................	2
Models & Options .............................................................................................................................	3
Model Table...................................................................................................................................	3
Available Options ..........................................................................................................................	3
Recommended Accessories.........................................................................................................	3
Agency Approvals.........................................................................................................................	3
Specifications ...................................................................................................................................	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 Configuration Instructions .............................................................................................	13
Default Configuration ..................................................................................................................	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 field or factory configured for a number of industry's motion control needs. These controls are designed around a pulse-accumulation PI algorithm. They can be easily configured 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 flexibility 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 field 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 configuration

-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, file #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

•FollowerMode–Controlsinpercentageofmasterrate.ThismodeallowstheMDPcontrolto precisely follow the actions of a master process without any long-term loss of position

2

Models & Options

Model Table

		Input Voltage	Output Voltage	Max. Output H.P.	Max Continuous	Pickup or
	Model		@ 120VAC	@ 120VAC	Armature DC	Encoder
		@ 50 - 60Hz
			(@ 240VAC)	(@240VAC)	Amps	Required?
	MD10P	85-265VAC	90VDC	1/2	5	Yes
			(180VDC)	1	5
	MD3P	85-265VAC	90VDC	1	10	Yes
			(180VDC)	2	10
	MD3E	85-265VAC	90VDC	1	10	Yes
			(180VDC)	2	10

Available Options

Option Suffix	Description	Example
-1	Expansion board which adds support for remote push button wiring via a	MD10P-1, MD3P-1
	European-style terminal block.
-P	Optional pluggable European-style terminal block	MD10P-P, MD3P-1-P
-9	Blank Lexan	MD10P-9

Recommended Accessories

	Model	Description	Pulses per	RPM Range When Used With
			Revolution	MD10P & MD3P
	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	Hall-Effect Pickup, Single Channel	10	0.1 – 5,000 RPM
	PU-40E	Hall-Effect Pickup, Single Channel	20	0.05 – 2,500 RPM

Agency Approvals

Recognized Component MD10P, MD3P	........................................................................................... E78180
MD3E ....................................................................................................................................................	34M5
NEMA 4X ....................................................................................................................................	MD10P / MD3P / MD3E
Specifications
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)

SUPPLIED WITH EACH 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)

PANEL MOUNTING GASKET

(WITH THE ADHESIVE SIDE OF GASKET FACING THE CUSTOMER MOUNTING PANEL)

MD10P

CONTROL

PANEL MOUNTING GASKET

(WITH THE ADHESIVE SIDE OF GASKET FACING THE CUSTOMER MOUNTING PANEL)

MD3P

CONTROL

SUPPLIED WITH EACH CONTROL:

1)GASKET

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

3)(4) #6 NUT WITH LOCKWASHER

5

Cut-out and Mounting Dimensions

4.000"	4.000"
	3.622"

	m	Valu TaTachch		MD10P
CONTROLS	Paggee IteIte
			ENTER	HOUSING DEPTH
				4.625"
	MICRO-DRIVE		.140" x 2	PANEL CUT-OUT

3.622

ENTER

MD3P

.140" x 4

MICRO-DRIVE	HOUSING DEPTH
	4.625"

CONTROLS	PANEL CUT-OUT

MD10P and MD3P Dimensions

5.000"

5.000"

			4.179"
2.289"

1.656"

0.885"

1.770"

0.811"

3.622"

2.000"

1.928"

4.625"

4.625"

6

MD3E Mounting and Dimensions

		5.530	7/32" TYP.
			(4 SLOTS)
			.350 DEEP
Page	Item	Valu	Tach
			ENTER
	CONTROLS
7.400			5.500
			ON
			OFF
			.750
		5.125 TYP.

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 difficult 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.

			PU-E
		flat	bearing	tapped
				motor
10-32		washer
				shaft
screw
dust	magnet			3/16"
				spacer
cover	disc

black wire				red wire
common				+5 volts

white wire signal

CAUTION:

DO NOT OVER TIGHTEN MOUNTING SCREW !!

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

Model	Pulses per
Number	Revolution
PU-2E	1
PU-4E	2
PU-20E	10
PU-40E	20

Dimensions

1.60	.875
	2.40

72.00

7

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 floating.

Electrical Installation & Diagrams
P1 Terminal Block Hook-Up Diagrams
			FUSE	AC INPUT
		N		AC INPUT }
	P1-1		MD10P = 7.5 Amp*				85-265VAC
			MD3P = 15 Amp*
		L
	P1-2
	P1-3	-A	-ARM
		+A
	P1-4		+ARM			MOTOR
MDP									PICK-UP MOUNTED
	P1-5	COM
			COMMON	black					TO MOTOR SHAFT
MASTER	P1-6	+5V	+5VDC	red
	P1-7	S1	SIGNAL	white
		S2
	P1-8		**Jog Input
									(Mounts on rotating
		NO	Alarm Output - Normally Open
	P1-9				}				end shaft with 10-32
		C	Alarm Output - Common			Form C			tapped hole, 1/2" deep)
	P1-10
						Relay Output
	P1-11	NC	Alarm Output - Normally Closed			(Programmable)
		IN1	User Input 1
	P1-12
			**INHIBIT
			COM (P1-5)					black
	* For AC inputs utilizing two hot lines, both inputs should be								white
	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	AC INPUT
		N
	P1-1		MD10P = 7.5 Amp*					85-265VAC
		L	MD3P = 15 Amp*	AC INPUT }
	P1-2
	P1-3	-A	-ARM
		+A
	P1-4		+ARM			MOTOR			FOLLOWER PICK-UP
MDP		COM							MOUNTED TO
	P1-5								MOTOR SHAFT
			COMMON					black
FOLLOWER	P1-6	+5V	+5VDC					red
	P1-7	S1	SIGNAL 1					white
		S2
	P1-8			SIGNAL 2
									(Mounts on rotating
	P1-9	NO	Alarm Output - Normally Open		}				end shaft with 10-32
		C	Alarm Output - Common			Form C			tapped hole, 1/2" deep)
	P1-10					Relay Output
	P1-11	NC	Alarm Output - Normally Closed			(Programmable)
	P1-12	IN1	User Input 1
			**INHIBIT
			COM (P1-5)

*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.)

8