STANDARD FEATURES ........................................................................................................................................................... 1
CONTROL DIMENSIONS .......................................................................................................................................................... 1
INHIBITING THE CONTROL.......................................................................................................................................................3
IN CASE OF DIFFICULTY ......................................................................................................................................................... 4
MODEL SELECTION ................................................................................................................................................................. 4
65E SERIES PARTS PLACEMENT & LIST .............................................................................................................................. 5
65E SERIES SCHEMATIC ......................................................................................................................................................... 6
REPAIR PROCEDURE & PRODUCT LINE ......................................................................................................... BACK COVER
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.
STANDARD FEATURES
l
Provides smooth variable speed capability for mobile equipment
l
Maintains variable speed control as batteries discharge
l
Adjustable maximum speed, minimum speed, current limit, I.R. compensation, and accel
l
Inhibit terminal permits optional start-stop without breaking battery lines
l
Speed potentiometer, knob, and dialplate included
l
Increases range or running time of battery operated equipment through high efficiency
l
65E40 and 65E60 series only - Automatic current limit foldback decreases current limit to 50% of setpoint when
heatsink temperatures reach 80
6.70”
When mounting the control, allow clearance above
TOP VIEW
NOTE:
components to prevent shorting
TOP VIEW
Caution: Do not mount controller where ambient temperature is outside the range of -10° C (15° F) to 45° (115° F).
INSTALLATION
Before attempting to wire the control, make sure all power is disconnected. Recheck code designation to assure proper voltage
is present for the control. Caution should be used in selecting proper size of hook-up wire for current and voltage drop. Note: the
battery and armature wire size on 65E models must be a minimum of 12 gauge.
HOOK-UP DIAGRAMS
WARNING:
DO NOT REVERSE POSITIVE AND NEGATIVE BATTERY LEADS. THIS WILL DAMAGE THE CONTROL.
TO CHANGE MOTOR DIRECTION, INTERCHANGE THE POSITIVE AND NEGATIVE ARMATURE LEADS.
Refer to the wiring diagrams below for proper connection of DC Voltage, Armature, and Speedpot wiring to the control.
CAUTION !! TURN POWER OFF WHILE MAKING CONNECTIONS .
To properly adjust the CURRENT LIMIT setting, a DC ammeter should be placed in series with the armature line. This meter can
be removed after the control is adjusted.
2
(continued)
Page 4
++
++
(continued)
-
Motor
Motor and battery wire must
be a minimum of 12 ga. and
-
+
+
Customer supplied
SPST switch
Caution:
a maximum of 6 ga.
Battery
65E SERIES HOOK-UP DIAGRAM
Pot High (P2-1)
-Battery (P1-1)
-Arm (P1-2)
No Connect (P1-3)
+Battery (P1-4)
+Arm (P1-5)
P1
Pot Wiper (P2-2)
Pot Low (P2-3)
Common (P2-4)
Inhibit (P2-5)
Current Limit
65E REVERSING HOOK-UP DIAGRAM
P2
Orange
I.R. Comp.
Accel
Max Speed
Min Speed
White
Red
5Ký
Speedpot
Optional
Inhibit
(see hook-up
below)
Customer supplied
3PDT Center-off
Center-blocked switch
Motor
-
Battery
Customer
supplied
SPST switch
Caution:
Motor and battery wire must
be a minimum of 12 ga. and
a maximum of 6 ga.
+
Relays may be used in place of switch, but a neutral position must be provided
to prevent plug reversing. Do not engage opposite direction until motor has
come to a complete stop. Failure to do so may result in damage to the control.
-Battery (P1-1)
-Arm (P1-2)
No Connect (P1-3)
+Battery (P1-4)
+Arm (P1-5)
P1
INHIBITING THE CONTROL
Using inhibit input - provide fast start-
stop by bypassing accel/decel circuit
White
5Ký
Speedpot
Optional
Inhibit
(see hook-up
below)
Pot High (P2-1)
Pot Wiper (P2-2)
Pot Low (P2-3)
Common (P2-4)
Inhibit (P2-5)
Current Limit
P2
Red
Orange
I.R. Comp.
Accel
Max Speed
Min Speed
Inhibit via speedpot - provides starting and
stopping through accel/decel parameters
Pot High (P2-1)
Pot Wiper (P2-2)
Pot Low (P2-3)
Common (P2-4)
Inhibit (P2-5)
P2
SPST Switch
open = run
close = stop
Pot High (P2-1)
Pot Wiper (P2-2)
Pot Low (P2-3)
Common (P2-4)
Inhibit (P2-5)
P2
White
Red
Orange
SPST Switch
open = stop
close = run
5KW
Speedpot
Note: Always use a shielded cable when connecting to the inhibit terminal. The shield of the cable should connect to the Common
terminal of the control.
TRIMPOT ADJUSTMENTS
Before the power is applied, the speed potentiometer and trimpots should be preset as follows:
DC power can now be applied to the system and the control adjusted as directed below:
TRIMPOT ADJUSTMENT
2. Increase the MIN trimpot in a clockwise direction until the desired minimum speed is reached.
3. Turn the Speedpot fully clockwise and adjust the MAX trimpot until the desired maximum speed is reached.
3
(continued on following page)
Page 5
(continued)
4. Adjust the ACCEL trimpot to achieve the desired soft start time. CW rotation will increase accel time.
5. Rotate the CURRENT LIMIT trimpot fully CCW until the motor begins to stall. Apply a full load to the motor. While motor
is stalled adjust the CURRENT LIMIT trimpot CW until a desired current setting is obtained.
6. Adjust I.R. trimpot CW 1/2 way. If motor RPM is inconsistent (jumpy), rotate I.R. trimpot CCW until rotation is stable.
IN CASE OF DIFFICULTY
If a newly installed control will not operate, it is likely that a terminal or connection is loose. Check to make sure connections are
secure and correct. If the control is still inoperative, refer to the following chart for reference:
PROBLEM POSSIBLE CAUSE(S)CORRECTIVE ACTION
Motor doesn’t run• Incorrect or no powerInstall proper service
• Speedpot set at zeroRotate speedpot fully CW
• Worn motor brushesReplace motor brushes
• Current limit set too lowAdjust current limit trimpot CW
Motor “hunts”• Max trimpot set too highSee “Trimpot Adjustments” - page 3-4
• I.R. Comp. trimpot set too highSee “Trimpot Adjustments” - page 3-4
Motor runs at “full speed”• Loose speedpot connectionsSecure all connections
uncontrollable• Min. or Max. trimpots not properly adjustedSee “Trimpot Adjustments” - page 3-4
• Possible control failureSend to Dart Controls, Inc.
Motor rotates in wrong direction• Motor armature hooked up backwardsReverse armature + and - leads
Motor stalls under a light load• Current limit trimpot improperly adjustedSee “Trimpot Adjustments” - page 3-4
MODEL SELECTION
INPUT VOLTAGEOUTPUT VOLTAGECONTINUOUS CURRENTMODEL NUMBER
* 24 volt and 36 volt units with the same current ratings are interchangeable (ie. 24 volt unit will operate with 36 volt input and
a 36 volt unit will operate with 24 volt input, same current rating).
SPECIFICATIONS
65E2065E4065E60
Load current (continuous)20 amps40 amps60 amps
Speed adjustment5K
Speed range30 : 1
Overload capacity200% for 10 seconds; 150% for one minute
Current limitadjustable100% to 200% of full motor load, up to continuous current rating (page 4)
Accelerationadjustable - 0 to 10 seconds
Decelerationnon-adjustable - 0.5 seconds
Maximum speedadjustable - 50 to 100% of base speed
Minimum speedadjustable - 30% of max speed
Connectionsbarrier terminal block (12Ga. to a maximum 6 Ga.)
Speed regulation1% of base speed via adjustable I.R. Compensation trimpot
Operating temperature-10°C to +45°C (14°F to 113°F)
Package configurationblack anodized aluminum extrusion
Internal operating frequencyapproximately 1.6K Hertz
Thermal protectionN/ACurrent foldback at 80
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. Please include Name, Shipping Address (no P.O. Box),
Phone Number and if possible, e-mail address.
Those orders received from anyone without an existing account with DCI must specify if they will
be paying COD or Credit Card (Master Card/Visa/American Express). This information is required
before work will begin. If you have an account with Dart your order will be processed according
to the terms listed on your account. Products with Serial Number date codes over 5 years old
will automatically be deemed Beyond Economical Repair (BER). A new, equivalent device will be
offered at a substantial discount.
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 Dart Controls, Inc.
at 317-873-5211.
YOUR MOTOR SPEED CONTROL SOLUTIONS PROVIDER
125D SERIES
AC INPUT - VARIABLE DC OUTPUT
1/50 HP through 1.0 HP
700/COMMUTROL SERIES
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
applications.
DC BRUSHLESS
5 & 20 Amp for
12,24,& 36VDC Inputs
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 fi eld.
In addition to the standard
off-the-shelf products, you can
select from a wide variety of
options to customize controls
for your specifi c application.
For further information and
application assistance,
contact your local Dart sales
representative, stocking
distributor, or Dart Controls,
Inc.
www.dartcontrols.com
ISO9001:2008 REGISTERED
DC INPUT - VARIABLE DC OUTPUT
CURRENT RATINGS OF 20, 40, AND
65 SERIES
60 AMPS
DM 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) 873-5211
Fax: (317) 873-1105
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