DART Controls 65E Series User manual

65E CONTROL SERIES
LT133 (1120)
Instruction Manual
For DC Input Variable Speed Controls
5000 W. 106th Street
Zionsville, Indiana 46077
Phone [phone]
Fax [phone]
www.dartcontrols.com
CONTROLS
A-5-3921F

1
TABLE OF CONTENTS
WARRANTY ................................................................................................................................................................................. 1
CONTROL DIMENSIONS ............................................................................................................................................................. 1
STANDARD FEATURES............................................................................................................................................................... 2
MOUNTING DIMENSIONS ........................................................................................................................................................2-3
INSTALLATION (DIAGRAM) ........................................................................................................................................................ 3
HOOK-UP DIAGRAMS ..............................................................................................................................................................4-5
65E10/20 HOOK-UP DIAGRAM ............................................................................................................................................ 4
65E10/20 REVERSING HOOK-UP DIAGRAM...................................................................................................................... 5
65E10/20E HOOK-UP DIAGRAM.......................................................................................................................................... 5
FUSING......................................................................................................................................................................................... 6
INHIBITING THE CONTROL......................................................................................................................................................... 6
TRIMPOT AND JUMPER SETUP................................................................................................................................................. 6
OPTIONS ...................................................................................................................................................................................7-8
-UVL....................................................................................................................................................................................... 7
-LED....................................................................................................................................................................................... 8
-FOLLOWER SIGNALS......................................................................................................................................................... 8
CURRENT LIMIT FUNCTIONS..................................................................................................................................................... 8
IN CASE OF DIFFICULTY ............................................................................................................................................................ 9
MODEL SELECTION.................................................................................................................................................................... 9
SPECIFICATIONS......................................................................................................................................................................... 9
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 oper-
ate 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 respon-
sible 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.
CONTROL DIMENSIONS
MODEL WIDTH LENGTH HEIGHT WEIGHT TYPE
inches (centimeters) oz. (gms.)
65E10C 3.620 (9.19) 4.25 (10.76) 1.30 (3.30) 8.0 (227) CHASSIS
65E20C 3.620 (9.19) 4.25 (10.76) 2.026 (5.15) 8.0 (227) CHASSIS
65E10E, 65E20E 5.530 (14.00) 7.30 (18.50) 4.782 (12.1) 40.0 (1134) ENCLOSED

2
P1
P2
-1
-2
-3
-4
-1
-2
-3
-4
-5
TOP VIEW
SIDE VIEW
4.250
.694
1.750
.750
3.620
.250 3.750
4.250
1.295
2.026
.405
11/32"
SLOT
DEPTH
.188" DIA.
(8 SLOTS)
STANDARD FEATURES
●Provides smooth variable speed capability for mobile, solar-powered and other DC powered equipment
●Maintains variable speed control as batteries discharge
●Adjustable maximum speed, minimum speed, current limit, IR compensation, and motor acceleration
●Inhibit terminal permits optional start-stop without breaking battery lines
●Speed potentiometer, knob, and dial plate included
●Increases range or running time of battery operated equipment through high efficiency
●Enclosed model is NEMA 4X rated
● Wide 12-48VDC source power input; up to 20A continuous output current
● High (18KHz) switching frequency for quiet operation
● Improved efficiency (lower voltage drop across control)
● Current Limit Lock Out or High Limit - user selectable
● Solid state Current Limit Output
● Wide temperature range for outdoor applications (-30°C (-22°F) to 60°C (140°F) for Chassis model; -15°C (5°F) to
45°C (113°F) for Enclosed model)
● 0-10VDC Input Follower Signal capability
● Optional source power Under Voltage Lockout (UVL) Option - protects battery source from deep cycle discharge
● Optional remote Power and Current Limit LED driver output for chassis models only
● Power and Current Limit LED's are located in the cover on Enclosed models only
MOUNTING DIMENSIONS
65E10C/20C MOUNTING

3
65E10E/20E MOUNTING
Caution: Do not mount controller where ambient temperature is outside the range of -30°C (-22°F) to 60°C (140°F)
for Chassis model; -15°C (5°F) to 45°C (113°F) for Enclosed model.
INSTALLATION (DIAGRAM)
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.
The suggested female wire connector for the .110" male spade terminal is a Molex Inc. part number 1090030024.
7.300”
5.530”
5.500”
5.125”
.219”
.312”
.900”
4.782”
3.845”
4.264”
2.780”
.875”
TOP VIEW SIDE VIEW
CURRENT LIMIT
TRIP OUTPUT
CURRENT LIMIT
TRIP OUTPUT
LED
VOLTAGE
SELECTOR
12V
24V
36V
48V
MIN
MAX
ACCEL
IR COMP
CUR LIM
JU1
CURRENT LIMIT
SHUTDOWN JUMPER
-1
-2
-3
-4
-1
-2
-3
-4
-5
P1
P2
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
-Arm (P1-4)
+Arm (P1-3)
+Battery (P1-2)
-Battery (P1-1)
POWER LED
P2
-3
-4
-1
-2
-3
-4
-5

4
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.
65E10/20 HOOK-UP DIAGRAM
P1
P2
-1
-2
-3
-4
-1
-2
-3
-4
-5
-Arm (P1-4)
+Arm (P1-3)
+Battery (P1-2)
-Battery (P1-1)
5KΩ
Speedpot
White
Red
Orange
Optional
Inhibit
(see hook-up
below)
+
-
+
-
Battery
Motor
Customer
supplied
SPST switch
or relay
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
Fuse
Accel
Max Speed
Min Speed
Current Limit
IR Comp.
IN4001 thru 4007
12V Relay Coil
Current
Limit Trip
Output
Optional customer
supplied CL output relay

5
65E10/20 REVERSING HOOK-UP DIAGRAM
Caution: When reversing a spinning motor, care must be taken that the resulting current through the armature
of the motor does not exceed the overload ratings of the control, or the demagnetize rating of the motor being
reversed when using a permanent magnet DC motor.
65E10/20E HOOK-UP DIAGRAM
P1
P2
-1
-2
-3
-4
-1
-2
-3
-4
-5
-Arm (P1-4)
+Arm (P1-3)
+Battery (P1-2)
-Battery (P1-1)
5KΩ
Speedpot
Red
Orange
Optional
Inhibit
(see hook-up
below)
+
-
Battery
Customer
supplied
SPST switch
or relay
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
Fuse
Accel
Max Speed
Min Speed
Current Limit
IR Comp.
Current
Limit Trip
Output
Motor
Customer supplied
3PDT Center-off
Center-blocked switch
White
IN4001 thru 4007
12V Relay Coil
Optional customer
supplied CL output relay
+
-
+
-
Battery Motor Optional
Inhibit
(see hook-up
below)
RED
RED
RED
ORANGE
WHITE
Fuse
Gnd
RED
RED

6
FUSING
Externally fuse the +Battery (P1-2) input line with Littlefuse CCMR series or Bussman LP-CC series or equivalent fuses
designed for use with motors and motor control systems; rated for the lesser of:
1) 200% of the continuous current rating of the drive, or 2) 150% of the motor full-load current.
INHIBITING THE CONTROL
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 AND JUMPER SETUP
(See Options Section for UVL Adjustments)
Before the power is applied, the speed potentiometer and trimpots should be preset as follows:
CONTROL PRESET
1. Control Speed pot - Full CCW
2. Min - Full CCW, Max - 50%, Accel - Full CCW, C.L. - Full CW, IR Comp - Full CCW
3. Voltage Selector jumper - Set the jumper to the correct supply voltage being used.
DC power can now be applied to the system and the control adjusted as directed below:
TRIMPOT ADJUSTMENT
MIN - Increase the MIN trimpot in a clockwise direction until just before reaching an output voltage (deadband) or until the
desired minimum speed is reached.
MAX - Turn the Speedpot fully clockwise and adjust the MAX trimpot until the desired maximum speed is reached.
ACCEL - Adjust the ACCEL trimpot to achieve the desired soft start time. CW rotation will increase accel time.
IR COMP - Set the control speedpot to approximately 50% and note the motor RPM unloaded. Load the motor to normal
load condition and adjust IR trimpot CW until motor RPM is equal to unloaded speed.
C.L. - Set the control speedpot to approximately 70% and rotate the CURRENT LIMIT trimpot fully CCW. Apply a full locked
rotor load to the motor. While the motor is stalled, adjust the CURRENT LIMIT trimpot CW until a desired current
setting is obtained. Approximately 125% of rated motor current is recommended.
NOTE 1:
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.
NOTE 2:
CL comes factory set to latch off after 3 seconds. For continuous CL operation without Latch off see section Current
Limit Function below.
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
5KΩ
Speedpot
Orange
Red
White
SPST Switch
open = stop
close = run
P2
Inhibit (P2-5)
Common (P2-4)
Pot Low (P2-3)
Pot Wiper (P2-2)
Pot High (P2-1)
P2
SPST Switch
open = run
close = stop
Inhibit via speedpot - provides starting and
stopping through accel parameters
Using inhibit input - provides fast start-
stop by bypassing accel circuit
VOLTAGE
SELECTOR
12V 24V 36V 48V
MIN
MAX
ACCEL
IR COMP
CUR LIM

7
OPTIONS
-UVL
The UVL Option is a factory installed option intended for applications where a battery is used as the source power for the 65E
control. The Under Voltage Lockout (UVL) protects the battery from potentially damaging (deep) discharge. The UVL includes
two trim pot adjustments: BAT-L and BAT-H. BAT-L is the user-defined voltage level at which the UVL option will shut down the
65E output to the motor when the voltage drops below this setting. BAT-H is the user-defined voltage at which the UVL option
allows the 65E output to resume normal operation. An LED (D1) on the UVL board will illuminate Green when supply voltage
is at or above the BAT-H setting. The same LED will illuminate Red when the supply voltage is below the BAT-L setting.
BAT-L and BAT-H adjustments are set by the following procedure:
1) Set J1 jumper to proper location based upon supply voltage to the control being used
2) Set the Trim pots on the –UVL board to the levels at which you want the drive to shut off and turn back on. Please
reference to chart below for approximation of levels.
For OEM and other volume users, these values may be hard coded into the UVL processor. Please contact your local or fac-
tory Dart Sales representative for more details
The Under Voltage Trip Pin is an open collector NPN transistor. This will pull low when the input Voltage goes below the Under
Voltage Trip Point and stays low until the input Voltage goes above the Auto Reset Voltage Point. This output is rated to 50VDC
at 150mA.
Suggested female wire connector for the .110” male spade terminal is Molex Inc. part number 0190030024.
12.0V* 24.0V* 36.0V* 48.0V*
Under Voltage Trip Point (BAT-L)
110.17 20.34 30.51 40.68
210.40 20.80 31.20 41.60
310.80 21.60 32.40 43.20
411.11 22.22 33.33 44.44
511.47 22.94 34.41 45.88
611.90 23.80 35.70 47.60
712.12 24.24 36.36 48.48
Auto Reset Voltage Point (BAT-H)
112.26 24.52 36.78 49.04
212.47 24.94 37.41 49.88
312.82 25.64 38.46 51.28
413.23 26.46 39.69 52.92
513.58 27.16 40.74 54.32
614.01 28.02 42.03 56.04
714.30 28.60 42.90 57.20
* Battery Voltage
4
1
2
35
6
7
BAT-L
TRIMPOT
UNDER VOLTAGE
TRIP OUTPUT
VOLTAGE
SELECTOR
BAT-H
TRIMPOT
48V
36V
24V
12V
STATUS INDICATOR
LED (D1)

8
-LED
The LED option is a Factory Installed option available on chassis models only. It provides .110” male spade terminal connec-
tions and driver circuits to power customer supplied remote LED’s. This may be needed when the chassis control is mounted
in a cabinet and it is desirable to see the Power and Current Limit status of the drive. LED’s connected to these circuits should
have a Maximum Voltage drop of 2.6V or less and be capable of handling 15mA. The remote Power LED is connected to the
RPL connectors labeled P5 and P11 (just below the ACCEL trimpot); the remote Current Limit LED is connected to the RCL
connectors labeled P9 and P10 (just below the MAX trimpot). This option is standard on all Enclosed models. The Power and
Current Limit LED's are located in the cover of the control.
Suggested female wire connector for the .110” male spade terminal is Molex Inc. part number 0190030024.
REMOTE FOLLOWER SIGNALS
The 65E Series will directly accept 0-10Vdc follower signals, in lieu of the manual speed pot. 0-10V signals are NOT required
to be isolated at the source. The +Signal is connected directly to the 65E Wiper connection, the -V or Common is connected to
the 65E Pot Lo connection.
CURRENT LIMIT FUNCTIONS
When the drive goes into current limit the current limit LED will illuminate and the CL-OUT will be pulled low, if it is used. If the
drive remains in current limit for more than 3 seconds the drive will latch the armature output to the motor OFF until the unit is
Reset. Reset is accomplished by cycling source power or by Inhibiting the drive (connect P2-4 to P2-5). This will clear the cur-
rent limit latch.
As an option, the user may override the current limit shutdown / latch action and instead keep the armature output to the motor
active, with current allowed to flow determined by the CUR LIM trim pot setting. This may be desirable in applications where
the motor load is cyclic and drive shutdowns are not desired. For this action from the drive when in Current Limit, cut the JU1
jumper wire (located below and between the ACCEL and MAX trimpots on the main board).
REMOTE POWER LED +
REMOTE POWER LED -
REMOTE CURRENT LIMIT LED +
REMOTE CURRENT LIMIT LED -
+-
+-
RED CUSTOMER SUPPLIED LED
GREEN CUSTOMER SUPPLIED LED
P5 P9 P10
P11
JU1
CURRENT LIMIT
SHUTDOWN JUMPER
12V
24V
36V
48V

9
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Motor doesn’t run • Incorrect or no power
• Speedpot set at zero
• Worn motor brushes
• Current limit set too low
Install proper service
Rotate speedpot fully CW
Replace motor brushes
Adjust current limit trimpot CW
Motor “hunts” • Max trimpot set too high
•I.R. Comp. trimpot set too high
See “Trimpot Adjustments”
See “Trimpot Adjustments”
Motor runs at “full speed”
uncontrollable
• Loose speedpot connections
• Min. or Max. trimpots not properly adjusted
• Possible control failure
Secure all connections
See “Trimpot Adjustments”
Send to Dart Controls, Inc.
Motor rotates in wrong direction • Motor armature hooked up backwards Reverse armature + and - leads
Motor stalls under a light load • Current limit trimpot improperly adjusted See “Trimpot Adjustments”
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, go to www.dartcontrols.com/support or call [phone].
MODEL SELECTION
SPECIFICATIONS
INPUT VOLTAGE OUTPUT VOLTAGE CONTINUOUS CURRENT CONTROL TYPE MODEL NUMBER
12 - 48 VDC ± 15% 0 to In
p
ut volta
g
e10 Am
p
s D.C. CHASSIS 65E10C
12 - 48 VDC ± 15% 0 to In
p
ut volta
g
e10 Am
p
s D.C ENCLOSED 65E10E
12 - 48 VDC ± 15% 0 to In
p
ut volta
g
e20 Am
p
s D.C. CHASSIS 65E20C
12 - 48 VDC ± 15% 0 to In
p
ut volta
g
e20 Am
p
s D.C. ENCLOSED 65E20E
65E10 / 65E10E
65E20 / 65E20E
Load current (continuous) 10 amps 20 amps
Speed adjustment
5K Ohm potentiometer or 0 to +10VDC input signal
Speed range 30 : 1
Input Voltage 12-48Vdc +/-15%
Power Supply Source Batteries or DC voltage supply
Overload capacity 200% for 10 seconds; 150% for one minute
Current limit adjustable 100% to 200% of full motor load, up to 200% of control current rating
Current limit output Up to 50 VDC at 0.3 A
Acceleration adjustable - 0 to 10 seconds
Deceleration non-adjustable - 0.5 seconds
Maximum speed adjustable - 50 to 100% of base speed
Minimum speed adjustable - 0 to 30% of max speed
Power Connections (P1) Euro-style terminal block (14 Ga. to 28 Ga.) Euro-style terminal block (10 Ga. to 14 Ga.)
Signal Connections (P2) Euro-style terminal block (14 Ga. to 28 Ga.)
Speed regulation
1% of base speed via adjustable IR Compensation trim pot
Operating temperature -300C to +600C (-220F to +1400F) for Chassis.
-150C to +450C (50F to +1130F) for Enclosed.
Package configuration
black anodized aluminum extrusion
Internal operating frequency approximately 18kHz