Page 1
CONTROLS
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Instruction Manual
Variable Speed Control
125D CONTROL SERIES
LT125D (0408)
P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077
Phone (317) 873-5211
Fax (317) 873-1105
www.dartcontrols.com
A-5-3262D
Page 2
TABLE OF CONTENTS
WARRANTY ............................................................................................................................................................................... 1
INTRODUCTION ........................................................................................................................................................................ 2
CONTROL FEATURES .............................................................................................................................................................. 2
125D SERIES HEATSINK DIMENSIONS .................................................................................................................................. 2
MOUNTING PROCEDURE ........................................................................................................................................................ 3
MODEL SELECTION ................................................................................................................................................................. 3
WIRING PROCEDURE & FUSING ............................................................................................................................................ 3
TERMINAL STRIP WIRING INSTRUCTIONS ........................................................................................................................... 3
123D / 125D HOOK-UP DIAGRAM ........................................................................................................................................... 4
CONTROL START-UP ............................................................................................................................................................... 4
TRIMPOT ADJUSTMENT CHART & PROCEDURE ................................................................................................................. 5
CONTROL MODIFICATIONS .................................................................................................................................................... 6
TWO SPEED OPERATION ..................................................................................................................................................
DYNAMIC BRAKING ............................................................................................................................................................
TACH FEEDBACK/FOLLOWER ..........................................................................................................................................
INHIBIT FUNCTIONS ...........................................................................................................................................................
SPEEDPOT KIT ASSEMBLY ..................................................................................................................................................... 7
OPTION DESCRIPTION ...................................................................................................................................................... 7-10
-1 / -2A OPTIONS ................................................................................................................................................................... 7
-5 / -7 OPTIONS .................................................................................................................................................................. 8-9
-11 / -15B / -K OPTIONS / -29B OPTIONS ............................................................................................................................ 9
-55G / -56G OPTION ........................................................................................................................................................... 10
IN CASE OF DIFFICULTY ....................................................................................................................................................... 11
SPECIFICATIONS .................................................................................................................................................................... 11
TYPICAL MOTOR CURRENTS ............................................................................................................................................... 12
125D SERIES PARTS PLACEMENT & LIST .......................................................................................................................... 12
125D SERIES SCHEMATIC ..................................................................................................................................................... 13
PRODUCT LINE .................................................................................................................................................. BACK COVER
16
16
16
16
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.
1
Page 3
INTRODUCTION
4.250"
MIN
MAX
IR COMP
CUR LIM
P2
ADDER BOARD
CONNECTOR
P3
INHIBIT
PIN
-8
-7
-6
-5
-4
-3
-2
-1
P1
3.625"
3.750"
1.750"
.694"
.380"
1.300"
11/32"
SLOT
DEPTH
.188" DIA.
(6 SLOTS)
.249"
• The 123D variable speed control is available in a range of 150mA through 5.5 ADC (or up to 10 ADC if using a
suitable external heatsink) at 24 through 36 VAC input.
• The 125D variable speed control is available in a range of 150mA through 1/4 H.P. at 120/240 VAC input.
• The 125DV variable speed control is available in a range of 1/8 through 1 H.P. at 120/240 VAC input. With
-HS(125D) or suitable external heatsink (where 125D extrusion temperature does not exceed 70° C.), maximum
U.L./C.S.A. rating can be increased to 2 H.P. and 10 Amps DC.
• The control is designed for DC Permanent Magnet, Shunt Wound, and some Universal (AC/DC) motors in the
above horsepower ranges.
• Incoming AC voltage is converted to adjustable full wave rectifi ed DC voltage to operate the DC motor. Also, a
full wave fi eld voltage is provided for shunt wound motors (see page 11 for voltages).
• The control incorporates transient voltage protection with adjustable current limit which fi ts into a compact
package. It features adjustable minimum and maximum speeds along with adjustable IR compensation and an
inhibit function.
• Options are available to change ACCEL/DECEL time (see page 8, -15 / -K options).
• cULus Recognized under, U.L. File # E78180.
CONTROL FEATURES
MINIMUM SPEED - Allows adjustment of the motor speed when the speedpot is set at minimum (CCW). This permits the user
to eliminate "Deadband" on the main speed control, permitting zero calibration. Clockwise rotation of "MIN" trimpot increases
speed.
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 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.
I.R. COMP (Speed Regulation) - This allows for adjustment of the circuitry that controls the speed regulation of the motor. The
circuitry controls armature speed by changing the armature voltage to compensate for increased or decreased motor loading.
Clockwise rotation of the "IR COMP" trimpot will increase compensation.
CUR. LIM. (Current Limit) - Provides protection from excessive armature current by limiting the maximum armature current
the control can provide. This enables adjustment of the maximum torque the motor can deliver. Torque adjustment (Cur. Lim.) is
preset at 125% of rated motor torque (current) based on horsepower. Clockwise rotation of the "CUR. LIM." trimpot increases the
torque (current) the control will provide.
INHIBIT TERMINAL PIN - 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 6).
TERMINAL STRIP - Allows for connection of AC lines, motor leads, motor fi eld (if needed), and speed potentiometer
125D SERIES HEATSINK DIMENSIONS
AUXILIARY HEATSINK -HS(125D)
.6875
5.625
.6875
1.375
5.625
6.250
STANDARD HEATSINK
.218
2
Page 4
MOUNTING PROCEDURE
1. Six 3/16" wide slots are provided for control mounting.
2. Control chassis can be used as a template.
3. Use standard hardware to mount.
CAUTION:
DO NOT MOUNT WHERE AMBIENT TEMPERATURE IS OUTSIDE THE RANGE OF -10
o
C (15o F) TO 45o C (115
o
F)
MODEL SELECTION
INPUT OUTPUT OUTPUT* MODEL
HORSEPOWER VOLTAGE VOLTAGE AMPS DC NUMBER
150mA thru 5.5 A 24 to 36 VAC 0-20 / 0-30 VDC 5.5A 123D-C*
1/50 thru 1/8 120/240 VAC 0-90 / 0-180 VDC 1.2A 125D-12C
1/8 thru 1 120/240 VAC 0-90 / 0-180 VDC 5.5A 125DV-C*
NOTE: * With -HS(125D) or suitable external heatsink (where 125D extrusion temperature does not exceed 70° C.), maximum U.L.
for Output Amps can be increased to 10 Amps D.C.
WIRING PROCEDURE & FUSING
1. Size all wires which carry armature or line 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 the armature and AC lines when routed in conduit or in wire trays.
3. Fusing - The motor and control are protected against overloads by the current limit circuit and a customer installed fuse in
the AC line. THIS PROTECTION ALREADY MAY BE PROVIDED BY THE CUSTOMER WITH CIRCUIT BREAKERS OR
FUSES IN BOTH MAIN LINES. IF NOT:
FOR 120 VAC INPUT - fuse protection should be added by the customer in AC Line 1 (see following chart)
FOR 240 VAC INPUT - fuse protection should be added by the customer in AC Line 1 and Line 2 (see following chart)
FUSING ADDED BY CUSTOMER (Bussman ABC or Little Fuse 314 Series ceramic fuses)
HORSEPOWER 120 VAC INPUT 240 VAC INPUT
1/50 2 AMP -------- 1/20 2 AMP 1 AMP
1/8 3 AMP 2 AMP
1/4 4 AMP 3 AMP
1/3 6 AMP 3 AMP
1/2 8 AMP 4 AMP
3/4 12 AMP 6 AMP
1.0 15 AMP 8 AMP
1.5 ---------- 12 AMP
2.0 ---------- 15 AMP
NOTE: To determine fusing for the 123D-C Series control (24 to 36 VAC input), use 200% of Full Load Current.
TERMINAL STRIP WIRING INSTRUCTIONS
The 125D Series uses an 8 position terminal strip for ease of connection.
P1-1,2 (AC or L) 120 VAC - Connect incoming hot AC or L (black wire) to P1-1 and neutral AC or N (white wire)
(AC or N) to P1-2. Connect ground (green wire) to CHASSIS of control.
240 VAC - Connect both hot sides (L & N), one to P1-1 and one to P1-2. Connect ground wire
to CHASSIS of control.
P1-3 (+Arm) Connect to PLUS (+) Armature wire on motor. 0-90 VDC for 120 VAC input or 0-180 VDC for 240
VAC input. See “SPECIFICATIONS” for output rating.
P1-4 (-Arm/-Field) Connects to MINUS (-) Armature wire on motor and, if necessary, connect MINUS (-) Field wire
of SHUNT WOUND MOTOR.
3
(continued of following page)
Page 5
(continued)
P1-5 (+Field) DO NOT use for Permanent Magnet Motor. This supplies +Field voltage for a
SHUNT WOUND MOTOR (refer to fi eld voltage table). For motors with dual voltage fi eld
(ie. 50/100V or 100/200V), make sure highest value is connected.
FIELD VOLTAGE TABLE
VAC INPUT 24 36 120 240
VDC FIELD 20 30 100 200
P1-6 (Speedpot Hi) Connects to high side (white wire) of 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. INPUT MUST NOT BE GROUNDED!
P1-7 (Speedpot Wiper) Connects to wiper (red wire) of Speedpot (center lead). For Voltage Follower applications,
this INPUT MUST NOT BE GREATER THAN +12V MAXIMUM AND MUST NOT BE
GROUNDED!
P1-8 (Speedpot Lo) Connects to Low side (orange wire) of 5K Speedpot (CCW end). This input is raised and
lowered by the MIN. trimpot (5K). 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. INPUT MUST NOT BE GROUNDED!
Warning:
1. Be sure the control housing is properly grounded.
2. Armature connections must not be switched or broken while the control is on. Serious control damage may result.
3. For non-speedpot applications, the input connection to the LO, WIPER, and HI terminals must not be grounded!
Serious control damage may result from a grounded input.
123D/125D HOOK-UP DIAGRAM
Warning:
Do not attempt to perform Hi-pot test across AC lines with control in circuit.
This will result in immediate or long term damage to the control.
P1
MIN
MAX
IR COMP
CUR LIM
P3
INHIBIT
PIN
P2
ADDER BOARD
CONNECTOR
-8 SPEEDPOT LO (orange lead)
-7 SPEEDPOT WIPER (red lead)
-6 SPEEDPOT HI (white lead)
-5 + FIELD
-4 -ARMATURE / - FIELD
-3 + ARMATURE
-2 VAC INPUT (N)
-1 VAC INPUT (L)
CONTROL START-UP
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. 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 if maximum speed is higher than desired, see "TRIMPOT ADJUSTMENT CHART " on
page 5.
9. For other problems, consult page 10, “IN CASE OF DIFFICULTY”.
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Page 6
TRIMPOT ADJUSTMENT CHART & PROCEDURE
Settings apply when using a 5K ohm master speedpot. This chart is used
in conjunction with the adjustment procedure and is approximate.
C.L. I.R. MAX MIN
HP
Settings apply when using a 5K ohm master speedpot. This chart is used
in conjunction with the adjustment procedure and is approximate.
C.L. I.R. MAX MIN
HP
1/50
125D-12C
120 VAC input;
0-90 VDC output
1/20
1/8
1/8
1/4
125DV-C
120 VAC input;
0-90 VDC output
1/3
1/2
3/4*
1.0*
Operation of the control beyond ±10% of the normal line voltage could result
in re-adjustment. These adjustments are permanent; periodic re-adjustment
is normally not needed.
*
NOTE: ADDITIONAL CUSTOMER HEATSINK REQUIRED FOR 125DV-C (120 VAC INPUT - GREATER THAN 1/2 H.P. MOTORS) AND (240 VAC INPUT - GREATER THAN 1 H.P.
NOTE: FOR DETERMINING TRIMPOT SETTINGS FOR THE 123D-C SERIES, SEE TRIMPOT SETTINGS PROCEDURE BELOW.
MOTORS). 125 EXTRUSION TEMPERATURES SHOULD NOT EXCEED 70 DEGREES C.
1/20
1/8
1/4
1/4
1/3
1/2
3/4*
1.0*
1.5*
2.0*
125D-12C
240 VAC input;
0-180 VDC output
125DV-C
240 VAC input;
0-180 VDC output
TRIMPOT FUNCTION ADJUSTMENT
MIN. Sets minimum motor speed when speedpot 1. Set Speedpot to zero (fully CCW).
is set at zero. CW rotation will increase min- 2. Rotate MIN trimpot CW until motor starts to rotate.
imum motor speed. 3. Slowly rotate MIN trimpot CCW until motor stops.
NOTE: If motor rotation is desired, rotate MIN trimpot CW
until desired MIN speed is reached.
IR COMP Provides a means of improving motor speed 1. Set Speedpot at 50%.
regulation in the armature feedback mode. If 2. Observe motor speed at no load condition.
a slowdown due to load change is of no con- 3. Apply full load to motor.
cern, rotate this trimpot fully CCW. 4. Turn IR COMP trimpot CW to obtain the same motor
speed as with no load.
MAX. Sets maximum motor speed when speedpot 1. TURN DRIVE POWER OFF!!
is set at maximum (fully CW rotation). CW 2. Connect a DC Voltmeter: + to +ARM, - to -ARM.
rotation of MAX trimpot increases maximum NOTE: Meter must not be grounded!!
motor speed. 3. Set meter voltage range: (90 VDC for 120 VAC, 180 VDC
for 240 VAC).
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 tach-
ometer or strobe.
CUR.LIM. Limits DC motor armature current (torque) to 1. TURN DRIVE POWER OFF!
prevent damage to the motor or control. The 2. Connect a DC Ammeter between A1 on motor and +ARM
current limit is set for the rated motor current. on control. This is in series with the motor.
CW rotation of this trimpot increases the 3. Turn power on.
armature current (or torque produced). 4. Set Speedpot at the 50% position.
5. Apply friction braking to motor shaft until motor stalls.
6. With motor stalled, set current at 125% of rated motor arm-
ature current by adjusting CUR. LIM . trimpot.
5
Page 7
CONTROL MODIFICATIONS
Two pot operation is done using two 10K
ohm speed potentiometers in parallel (both
HI's to P1-6, both LO's to P1-8). The
WIPER is switched using a SPDT switch.
TWO SPEED OPERATION
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 any of the -15 options.
DYNAMIC BRAKING
The customer supplied SPST switch is
connected in series between the speedpot HI
(P1-6) and the Inhibit pin (P3). To inhibit (stop
motor), speedpot HI is closed to the Inhibit pin.
To restart, the switch is returned to open. NOTE:
The control will stop and start fast.
INHIBIT (USED INDEPENDENTLY)
The Common of the SPDT sw
itch is connected to
control pot HI and is switched between Speedpot
Hi and the Inhibit pin (P3). 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.
INHIBIT (USED WITH SPEEDPOT)
-7
-8
-6
P1
SPST
SPEEDPOT
INHIBIT
(P3)
WIPER
LO
HI
-7
-8
-6
P1
SPDT
SPEEDPOT
WIPER
LO
HI
Improves speed regulation to ±1/2% of base speed.
TACHOMETER FEEDBACK
Allows control output to follow tachometer voltage.
TACHOMETER FOLLOWER
-7
-8
W
LO
HI
P1
MOTOR
DYNAMIC
BRAKE
RESISTOR
-7
-8
-6
W
HI
LO
W
HI
LO
P1
HI
SPDT
TWO 10K SPEEDPOTS
TACHOMETER
P3 INHIBIT
P1-4 -ARM
+
-
6 VDC at BASE SPEED (3 VDC at
1000 RPM for 1800 RPM MOTOR)
TACHOMETER
P1-7 POT WIPER
P1-8 POT LO
+
-
12 VDC at FULL SPEED
NOTE: NEED 1% OR LESS - TACH OUTPUT RIPPLE
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.
-5
-6
P3
INHIBIT
INHIBIT
(P3)
-3
-4
Switch or relay must
be rated to 3 times
the Full Load Amps.
DPDT SWITCH (N.C.)
NOTE:
6
Page 8
SPEEDPOT KIT ASSEMBLY
125D SERIES BOARD
-2A OPTION BOARD
CUSTOMER'S
MOUNTING BRACKET
DIALPLATE
2.00" dia.
1.240
SPEEDPOT
KNOB
1.250
.500 .370 .370
.250 Dia.
SPEEDPOT
(5K 2W)
.437
5/32
DIA.
3/8
DIA.
SPEEDPOT LOCATOR HOLE DIMENSIONS
HEX NUT
LOCK
WASHER
OPTION DESCRIPTIONS
-1 option Field or Factory Installed
Electronic Speedpot Interlock Available All Models
The -1 adder board connects to the 125 series board through use of a female connector and plastic standoff support.
When incoming AC power to the control is applied, the Electronic Interlock will prevent the motor from starting until the speedpot
is fi rst rotated to the zero position and then rotated clockwise toward the set speed.
Also, should the incoming AC power be interrupted for any reason, then restored, the Electronic Interlock will prevent an automatic restart of the motor. To restart, the speedpot must fi rst be rotated to the zero position and then rotated clockwise toward
the set speed.
CAUTION: The Electronic Interlock becomes inoperative if SCR failure should occur.
-2A option Field or Factory Installed
Individually Adjustable Linear Accel and Decel Available All Models
This option plugs into the fi ve position expansion connector
on the 125D main board. The -2A option overrides the fi xed
accel ramp built into the 125D control, providing independently
adjustable linear accel and decel from 0.5 to 8.0 seconds. To
install, fl ip over the -2A option board so the pr inted circuit lines
are visible. Align the male connector CN1 (-2A option) with
the female connector P2 (125D board) so terminal CN1-1 fi ts
into P2-6, CN1-2 in P2-5, etc. Align the plastic stand-off on
the -2A option board with the hole shown on the 125D main
board. Once connectors and stand-off are aligned, snap into
place. Adjustment of both trimpots is accomplished via the
labeled access holes on the back side of the -2A option board.
Full CCW rotation equals minimum accel or decel time and
full CW rotation equals maximum accel or decel time. Note:
Each trimpot operates independently of the other.
7
Page 9
-5 option Field or Factory Installed
Isolated 4-20 ma.Signal Follower Available All Models
4 to 20 mA ......... -5
CURRENT
SOURCE
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 P1-6, P1-7, and P1-8 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 specifi c application. If needed then refer to the setup
procedure below.
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.
P1
-1 -2
-3
(125D TERMINAL STRIP)
-4
P16
-5
250/500
-
-1-2
125
+
LINEARITY
ADJUSTMENT
(pre-set & sealed
at factory)
-7 option
Isolated 4-20 ma. Signal Follower Field or Factory Installed
with Auto / Manual Switch Customer Wired
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 P1-6,
P1-7, and P1-8 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
specifi c application. If needed then refer to the setup procedure below.
WHITE
LINEARITY ADJUSTMENT
4 to 20 mA .... -7
Permits the control to follow a 4mA to 20mA
grounded or ungrounded current signal
CURRENT
SOURCE
BALANCE ADJUSTMENT
-1 -2
P1
(125D TERMINAL STRIP)
-3
(pre-set & sealed at factory)
ORANGE
250/500
-1-2
P16
-5
-4
125
from P1-7 of 125D
RED
MANUALAUTO
SPDT
SWITCH
RED
SUPPLIED
SPEEDPOT
8
Page 10
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.
-11 option Field Installed
10 Turn Master SpeedPot Available All Models
Provides fi ner control of speed. Use standard Hook-up directions and Trimpot Chart (page 5).
-15B / -K options
Acceleration Time Ranges Factory Installed
This option provides the Accel times shown below. The standard Accel time is 0.5 seconds.
-15B OPTION -K OPTION
ACCELERATION TIME 4 seconds 6 seconds
USE STANDARD HOOK-UP
-29B option
Manual Forward-Off-Reverse Switch Field Installed Only
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 ARM 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 SWITCH CENTER BLOCK
MAY RESULT IN DAMAGE TO THE CONTROL.
-8
-7
-6
-5
-4
-3
-2
-1
P1
4PDT SWITCH
ARM 2
ARM 1
AC
AC
P1-4 P1-3 P1-2 P1-1
ARM 1 ARM 2 ACAC
9
Page 11
-4 - ARM
-3 + ARM
-5
AC INPUT
AC INPUT
P1
GAIN
TRIMPOT
-55G OPTION BOARD
-2
-1
P2
P3
-3
GROUND
SIGNAL
CUSTOMER WIRING
P4
-3
RANGE
JUMPER
CONNECTOR
-2
-1
-1 -2
-55G option
Isolated Voltage Input Factory or Field Installed
NOTE: This option cannot be used on the 123D-C series control.
This option permits either a grounded or non-grounded remote
DC voltage speed command. This DC input can range from
0-5VDC through 0-25VDC or 0-25VDC through 0-250VDC
(which can be selected via the range jumper clip and adjusted
with the GAIN trimpot). The output of this option board supplies a linear pulse width modulated signal to the control that
is proprotional to the input signal supplied to the option board.
The option replaces the 5K speedpot. Input impedance is 1.2M
ohms on high scale, and 150K ohms on low scale.
NOTE: Range jumper connector is used to select input
voltage range. When installed from P4-1 to P4-2, the range
is 0-25VDC through 0-250VDC; when installed from P4-2
to P4-3, range is 0-5VDC through 0-25VDC.
(FOR SHUNT WOUND MOTOR, SEE PAGE 4 OF MANUAL FOR FIELD CONNECTIONS).
CAUTION: DO NOT use TRIMPOT ADJUSTMENT CHART. Set pots using directions in following SET-UP PROCEDURES.
SETUP PROCEDURE FOR -55G AND -56G OPTIONS
1. With NO power to 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 on option board fully CCW, place range jumper clip in proper position.
3. Preset control as follows: MIN, MAX & IR fully CCW, and Current Limit fully CW.
4. Apply AC power of correct voltage to control and option board.
5. With 0 volts into option board, adjust MIN trimpot of 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. Motor will start to rotate.
7. Adjust GAIN until no further change in control output voltage occurs, back off approximately 1 turn, then set control MAX.
setting to 90 VDC (180VDC for 240V units).
8. Current Limit is set as shown on "TRIMPOT ADJUSTMENT CHART" on page 5.
9. For Closed Looped systems the IR should remain fully CCW. For Open Looped systems, set IR as needed
-56G option
Isolated Voltage Input with Auto / Manual Switch Factory or Field Installed
NOTE: This option cannot be used on the 123D-C series control.
This option permits either a
grounded or non-grounded
remote DC voltage speed
command. This DC input can
range from 0-5VDC through
0-25VDC or 0-25VDC through
0-250VDC (which can be selected via the range jumper
clip and adjusted with the
GAIN trimpot). The output of
this option board supplies a
linear pulse width modulated
signal to the control that is
proprotional to the input signal
supplied to the option board.
The option replaces the 5K
speedpot. Input impedance is
1.2M ohms on high scale, and
150K ohms on low scale.
(FOR SHUNT WOUND MOTOR, SEE PAGE 4 OF MAN-
UAL FOR FIELD CONNECTIONS).
CAUTION: DO NOT use TRIMPOT ADJUSTMENT CHART. Set pots using directions in following SET-UP PROCEDURES.
RANGE
JUMPER
CONNECTOR
-1
-1
-2
-3
P4
GAIN
TRIMPOT
-56G OPTION BOARD
NOTE:
COMMON
-3
-2
P3
-5
-4 - ARM
-3 + ARM
P2
-2
-1
P1
Range jumper connector is used to select
input voltage range. When installed from P4-1
to P4-2, the range is 0-25VDC throug h
0-250VDC; when installed from P4-2 to P4-3,
range is 0-5VDC throug h 0-25VDC.
= CUSTOMER WIRING
= FACTORY WIRING
10
SIGNAL
AUTO
SPEED
SIGNAL
AC INPUT
AC INPUT
1
2
3
DPDT CENTER-OFF SWITCH
TERMINAL DESIGNATION
(BACKSIDE VIEW)
CONNECTS
UNDER WIPER
SCREW P1-7
6 - NO CONNECTION
5 - NO CONNECTION
4 - NO CONNECTION
orange
yellow
white
AUTO
1/2 OF DPDT
SWITCH
2
MANUAL
1
red
3
Page 12
ENGLISH
METRIC
3.625"
92mm
4.250"
108mm
1.300"
33mm
8.00 oz.
228 gms.
WIDTH LENGTH DEPTH WEIGHT
IN CASE OF DIFFICULTY
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION(S)
Motor doesn’t operate - Blown Fuse Replace Fuse
- Incorrect or no power source Install proper service
- Speedpot set at Zero Adjust Speedpot CW to start
- Worn motor brushes Replace brushes
Armature output voltage - No motor or load connected Check that motor or load is connected
cannot be adjusted, output to armature terminals
is a constant DC level - Speedpot low connection open Check that speedpot low wire is connected
Motor stalls, or runs - Low Voltage Check-should be above 100V or 208 V
very slowly with speed - Overload Condition Reduce load
control turned fully CW - Worn motor brushes Replace brushes
- MAX SPEED set incorrectly See ADJUSTMENT PROCEDURE
Motor hunts - Motor current less than 150mA Motor current must be greater than 150mA D.C.
- Too much IR COMP See ADJUSTMENT PROCEDURE
- Motor is in current limit See ADJUSTMENT PROCEDURE
- Motor speed is above rated speed Reduce Speed
- Max set too high See ADJUSTMENT PROCEDURE
Repeated fuse blowing - Low Voltage Check-should be above 100V or 208V
- Overload Condition Reduce load
- Worn motor brushes Replace
- Defective motor bearings Replace
- Defective electrical components Call Dart Distributor or Representative
If control still will not operate, consult your Dart Distributor or Representative.
SPECIFICATIONS
AC input voltage .................................................................................................................................. ±10% of rated line voltage
Acceleration ..................................................................................................................................... 0.5 seconds (standard 125D)
Amps - DC output .......................................................................................................................................... 150 mA to 5.5 ADC*
Controller overload capacity ......................................................................................................................... 200% for one minute
Current limit trimpot range ........................................................................ 0.3 to 2.5 ADC (125D); 1 to 15 ADC (123D & 125DV)
Deceleration .................................................................................................................................... 0.5 seconds (standard 125D)
Dimensions and weights:
Drive service factor ................................................................................................................................................................... 1.0
Effi ciency ..................................................................................................................................................................... 85% typical
Input frequency ....................................................................................................................................................... 50 or 60 Hertz
Max. trimpot speed range ................................................................................................................. 60% to 110% of base speed
Min. trimpot speed range .............................................................................................................. 0% to 30% of maximum speed
Power devices ..................................................................................................................................................... isolated case tab
Shunt fi eld voltage ........................................................................................... 20VDC for 24VAC input; 30VDC for 36VAC input;
Shunt fi eld voltage ........................................................ 100VDC for 120VAC input; 200VDC for 240VAC input; 1 amp maximum
Speed control .................................................................................. via 5Kohms 2W 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**
Trigger ........................................................................................................................................................................ opto-coupler
Type ramp of accel/decel ................................................................................................................................... RC time constant
* With -HS(125D) or suitable external heatsink (where 125D extrusion temperature does not exceed 70° C.), maximum U.L.
rating for output amps can be increased to 10 amps D.C.
** not used on the 123D-C series control
11
Page 13
TYPICAL MOTOR CURRENTS
0.50
0.42
-----
-----
1.00
0.81
0.80
0.40
2.00
1.60
1.20
0.60
3.50
2.70
1.80
1.40
1/50 1/20 1/8 1/4
Horsepower
Typical AC Amps (120VAC)
Typical Arm Amps (120VAC)
Typical AC Amps (240VAC)
Typical Arm Amps (240VAC)
4.40
3.40
2.20
1.70
1/3
6.50
5.00
3.30
2.50
1/2
9.30
8.20
4.80
3.70
3/4
13.20
10.90
6.50
5.00
1.0
-----
-----
9.70
8.20
1.5
-----
-----
12.90
11.60
2.0
125D SERIES PARTS PLACEMENT & LIST
RESISTORS
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
15K 6W
470 7
2.7K
2.7K
82K
5K (MIN TRIM)
300K
180K
1.2M
39K
100K
10K
2.2K
820 7
4.7K
470K
1K
100 7 (I.R. TRIM)
5K (C.L. TRIM)
300K
10K (MAX TRIM)
1K
300K
.01 7 5W
91K
1K
390 7
390 7
5K SPEEDPOT *
ACCEL CHANGES
Replace N.P. cap with
polarized cap (see above)
-15A ... C8 ... 33uf 16V
-15B ... C8 ... 15uf 25V
-15C ... C8 ... 4.7uf 16V
- K ...... C8 ... 22uf 16V
125D-12C (1/50 thru 1/8 H.P.)
CHANGES:
R24 ............... .062 7 5W
D10
Q4
D8
D9
Q3
R16
R28
R23
R26
R25
JU1
R27
Q6
JU2
JU1
JU2
PCB
P1 (-1 THRU -8)
P2 (-2 THRU -6)
P3
R20
P3
D7
U2
R2
C9
D1
D2
R24
R17
C10
R13R10
R22
R12
U5
C1
C5
Q1
D6
D5
MISCELLANEOUS
18GA. SOLID INSULATED WIRE
18GA. SOLID INSULATED WIRE
A-4-2033F PRINTED CIRCUIT
8 POS. TERMINAL STRIP
5 POS. FEMALE CONNECTOR
3/16" MALE SPADE PIN
R11
ACTIVE DEVICES
R6R21R18R19
Q1
U2
Q3
R14
+
C11
R15
Q4
U5
Q6
CAPACITORS
C1
R9
R7
P2
65432
+
C8
+
C2
R5
R4
C3
R1
D4
D3
C4
R8
R3
P1-8-7-6-5-4-3-2-1
C2
C3
C4
C5
C8
C9
C10
C11
DIODES
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
2N6027
3052 MOC
S4015L
S4015L
LM358 IC
275V G-MOV
.01μF 100V
10μF 35V
.01μF 100V
.033μF 400V
.22μF 1KV
1μF 50V N.P.
.0047μF 1KV
.1μF 50V
47μF 16V
1N4005
1N4005
1N914B
1N5242B
1N4005
1N5233B
1N914B
D4015L
D4015L
D4015L
123D-C CHANGES:
D6
Q6
R1
R2
R16
R23
R25
R27
R28
1N914B
(reverse direction)
DELETE
1K 2W
477
220K
47K
15K
477
477
12
Page 14
D6
Q6
R1
R2
R16
.......... 1N914B
.......... DELETE
.......... 1K 2W
.......... 477
.......... 220K
123D-C CHANGES:
R23
R25
R27
R28
.......... 47K
.......... 15K
.......... 477
.......... 477
U5 .................................. LM358 IC
125D-12C (1/50 THRU 1/8 H.P.)
R24 ......... .062 OHM 5W
NOTES:
CHANGES:
2.2K
R13
3052 MOC
U2-1
2
.22uf
1KV
C5
1N5242B
D4
2.7K
1
.033uf
400V
C4
100V
35V
R4
.01uf
10uf
C1
C2
2N6027
Q1
82K
R5
4
-
6
1N914B
D7
7
U5-2
+12V
8
+
5
+12V
100V
.01uf
P1-5
+FIELD
+12.7V
1N4005
D1
P1-1
AC1
1N914B
D3
15K
6W
R1
2.7K
R3
C3
180K
1.2M
REMOTE
P1-6
WIPER
P2-3
HI
P2-4
R8
+12V
R9
R10
39K
P2-5
SPEEDPOT
R29
P1-8
5K
LO
P1-7
300K
R7
MIN
R6
5K
50V N.P.
1uf
C8
1N4005
+12V
1N5233B
1N4005
D2
D5
D6
AC2
P1-2
125D SERIES SCHEMATIC
3052 MOC
U2-2
S4015L
Q3
Q4
46
JU1
OHM
470
R2
A
P1-1
AC1
G-MOV
275V
Q6
AC2
P1-2
B
R12
C10
10K
100K
R11
1
4.7K
P2-6
R15
.01 OHM
R24
5W
MAX
R21
10K
-FIELD
-ARM
P1-4
SENSE RES.
R22
1K
MOTOR
D4015L
D8
U5-1
-
+
3
2
+12V
300K
R20
+ARM
P1-3
INHIBIT
P3
P2-2
300K
R23
P2-1
JU2
91K
R25
.0047uf
1KV
1K
C9
R26
390 OHM
R27
390 OHM
R28
S4015L
OHM
R14
820
50V
.1uf
47uf
16V
C11
R17
1K
A
D4015L
D9
B
D4015L
D10
IR COMP.
100 OHM
R18
470K
R16
5K
CUR. LIM.
R19
13
Page 15
Page 16
REPAIR PROCEDURE
Re-Order from
omegamation.com
Omegamation
TM
1-888-55-OMEGA
1-888-55-66342
1-888-55-66342
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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