DART Controls 123D User manual

125D CONTROL SERIES
P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077
Phone [phone]
Fax [phone]
www.dartcontrols.com
Instruction Manual
Variable Speed Control
LT114 (0713)
CONTROLS
A-5-3760B

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 .................................................................................................................................................. 16
DYNAMIC BRAKING ............................................................................................................................................................ 16
TACH FEEDBACK/FOLLOWER .......................................................................................................................................... 16
INHIBIT FUNCTIONS ........................................................................................................................................................... 16
SPEEDPOT KIT ASSEMBLY ..................................................................................................................................................... 7
OPTION DESCRIPTION ...................................................................................................................................................... 7-10
-1 / -2A OPTIONS ................................................................................................................................................................... 7
-5 / -7 OPTIONS .................................................................................................................................................................. 8-9
-15B / -K OPTIONS / -29B OPTIONS .................................................................................................................................... 9
-55H / -56H 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
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 respon-
sibility 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 manu-
facturing 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 dis-
connected position and tag to prevent unexpected application of power. Only a qualified electrician or service person-
nel 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

1.375
.218
5.625
5.625
.6875
6.250
.6875
INTRODUCTION
•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. 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 rectified DC voltage to operate the DC motor. Also, a
full wave field voltage is provided for shunt wound motors (see page 11 for voltages).
• The control incorporates transient voltage protection with adjustable current limit which fits 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 field (if needed), and speed potentiometer
2
AUXILIARY HEATSINK -HS(125D) STANDARD HEATSINK
125D SERIES HEATSINK DIMENSIONS
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"

3
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 -10oC (15oF) TO 45oC (115oF)
MODEL SELECTION
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*
INPUT OUTPUT OUTPUT* MODEL
HORSEPOWER VOLTAGE VOLTAGE AMPS DC NUMBER
NOTE: * With -HS(125D) or suitable external heatsink (where 125D extrusion temperature does not exceed 70° C.), maximum UL
Rating 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 # 18AWG 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)
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
HORSEPOWER 120 VAC INPUT 240 VAC INPUT
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.
(continued of following page)
FUSING ADDED BY CUSTOMER (Bussman ABC or Little Fuse 314 Series ceramic fuses)

4
(continued)
P1-5 (+Field) DO NOT use for Permanent Magnet Motor. This supplies +Field voltage for a SHUNT WOUND
MOTOR (refer to field voltage table). For motors with dual voltage field (ie. 50/100V or 100/200V),
make sure highest value is connected.
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!
VAC INPUT 24 36 120 240
VDC FIELD 20 30 100 200
FIELD VOLTAGE TABLE
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.
WARNING: ALL POWER MUST BE TURNED OFF BEFORE PROCEEDING!
CONTROL START-UP
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 11, “IN CASE OF DIFFICULTY”.
MIN
MAX
IR COMP
CUR LIM
P2
ADDER BOARD
CONNECTOR
P3
INHIBIT
PIN
P1
-8SPEEDPOT 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)

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
TRIMPOT ADJUSTMENT CHART & PROCEDURE
C.L. I.R. MAX MIN
1/4
1/3
1/2
3/4*
1.0*
1/20
1/8
HP
Settings apply when usinga 5K ohm master speedpot. This chart is used
in conjunction with the adjustment procedure and is approximate.
125DV-C
240 VAC input;
0-180 VDC output
1.5*
2.0*
* NOTE: ADDITIONAL CUSTOMER HEATSINK REQUIRED FOR 125DV-C (120 VACINPUT - GREATER THAN 1/2 H.P. MOTORS) AND (240 VAC INPUT - GREATER THAN 1 H.P.
MOTORS). 125 EXTRUSION TEMPERATURES SHOULD NOT EXCEED 70 DEGREES C.
NOTE: FOR DETERMININGTRIMPOT SETTINGS FOR THE 123D-C SERIES, SEE TRIMPOT SETTINGS PROCEDURE BELOW.
1/4
125D-12C
240 VAC input;
0-180 VDC output
C.L. I.R. MAX MIN
1/8
1/4
1/3
1/2
3/4*
1/50
1/20
HP
Settings apply when usinga 5K ohm master speedpot. This chart is used
in conjunction with the adjustment procedure and is approximate.
125DV-C
120 VAC input;
0-90 VDC output
1.0*
1/8
125D-12C
120 VAC input;
0-90 VDC output
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.

CONTROL MODIFICATIONS
Two pot operation is done usingtwo 10K
ohm speed potentiometers in parallel (both
HI's to P1-6, both LO's to P1-8). The
WIPER is switched usinga 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 35Wto 50W). Note that
motor horsepower, inertia, and cycle time effect sizingof 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 switch 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 followtachometer 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
P1-8POT LO
+
-
12 VDC at FULL SPEED
NOTE: NEED 1% OR LESS - TACH OUTPUT RIPPLE
Permits startingand stoppingof motor without breakingAC lines. In the event of SCR failure or false
triggering, the Inhibit circuit will not stop motor.
Always use a shielded wire when connectingto 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

7
SPEEDPOT KIT ASSEMBLY
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 first 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 auto-
matic restart of the motor. To restart, the speedpot must first 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 five position expansion connector
on the 125D main board. The -2A option overrides the fixed
accel ramp built into the 125D control, providing independently
adjustable linear accel and decel from 0.5 to 8.0 seconds.To
install, flip over the -2A option board so the printed circuit lines
are visible. Align the male connector CN1 (-2A option) with
the female connector P2 (125D board) so terminal CN1-1 fits
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.
SPEEDPOT
(5K 1/2W)
CUSTOMER'S
MOUNTING BRACKET
DIALPLATE
2.00" dia.
LOCK
WASHER
HEX NUT
SPEEDPOT
KNOB
SPEEDPOT LO (CCW) (ORANGE)
SPEEDPOT WIPER (RED)
SPEEDPOT HI (CW) (WHITE)
.437
3/8
DIA.
5/32
DIA.
SPEEDPOT LOCATOR HOLE DIMENSIONS
.250 Dia.
.500 .370 .370
1.240
1.250
125D SERIES BOARD
-2A OPTION BOARD

8
-5 option Field or Factory Installed
Isolated 4-20 ma.Signal Follower Available on Chassis Only*
-7-6-5-4-3-2-1
P1
-11-9 -10-8
CURRENT
SOURCE
LINEARITY/GAIN ADJUSTMENT
+-
P16
250/500
125
(250G TERMINAL STRIP)
-7 option Enclosed - Factory Installed only
Isolated 4-20 ma. Signal Follower Chassis - Factory or Field Installed
with Auto/Manual Switch Chassis - switch & wiring are customer provided
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.
The -5 option is a 4-20 mA isolated signal card that replaces the speedpot to control speed. The 4-20 mA signal input can be
either grounded or ungrounded. The board sets on spacers screwed to the pot HI, Wiper, and LO terminals 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 Max and Min trimpot settings on the control for your specific application. If needed then refer to the setup
procedure below.
The -7 option is also a 4-20 mA isolated signal card but it 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. This option also 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 mode equals the maximum speed in Auto mode.
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 specific
application. If needed then refer to the setup procedure below.
The following is the recommended procedure to set up the -5/-7 option on the 125/250/500 Series:
1) With the 125/250/530 oriented so that trimpots are along the top, adjust Min trimpot to minimum (full CCW) and Max trimpot
to 50%. The voltage is set below the typical motor voltage to make certain the drive is NOT in saturation before setting the -5/-7
board saturation point.
2) Set the Linearity/gain pot on the -5/-7 full CW. This is a 20 turn pot and you should hear a clicking with each turn when fully
up or just count 20 turns.
3) Make certain your motor is connected to +/-ARM output of the drive, the AUTO / MAN switch is in AUTO mode for -7
options, and source power for the control is turned on. (Note: For proper tuning this setup is best done on an unloaded motor.)
-7-6-5-4-3-2-1 P1
AUTO
MANUAL
RED
LO
HI
W
from P1-2 of 250G
-11-9
YELLOW
3PDT
SWITCH
-10-8
CURRENT
SOURCE
LINEARITY/GAIN
ADJUSTMENT
+-
P16
WHITE
RED
ORANGE
SPEEDPOT
AC AC
250/500
125
BALANCE
ADJUSTMENT
(250G TERMINAL STRIP)
-8
-8
-8
-5 and -7 option Hookup Procedure

-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.
9
P1
-5
-6
-7
-8
-4
-3
ARM 2
ARM 1
AC
AC
-1
-2
4PDT SWITCH
P1-4 P1-3 P1-2 P1-1
ARM 1 ARM 2 ACAC
-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
4) With power applied and a voltmeter monitoring motor output Vdc, apply 4mA to -5/-7 board. Check voltmeter reading and
adjust the Linearity/gain trimpot, R16, on the -5/-7 board CCW until motor output voltage is less than 0.1Vdc.
5) Now apply 20mA to the -5/-7 board and adjust the Max trimpot to a voltage that is 5 volts (15 volts for the 250G series
controls) above the final desired max motor voltage output. Adjust the Linearity/gain trimpot on the -5/-7 board CCW until the
motor output voltage decreases to the desired max voltage set point.
6) Now, apply 4mA to the -5/-7 board again and adjust the Min trimpot to deadband or the desired minimum motor voltage
output. The deadband point is where you are at 0Vdc and any further increase of the Min trimpot would result in an output to
the motor. Re-apply 20mA to the -5/-7 board and verify max output has not changed. A small adjustment may be needed to the
Max trimpot to reset to desired max output.
7) Adjust 4-20 input to 12mA. If tuned properly the output voltage of an unloaded motor should be within a few volts of ½ output
(based on max output setting above).
-7 option only: With 20mA applied to the -7 in Auto mode, move AUTO/MANUAL switch to MANUAL.
8) In manual mode turn the speedpot full CW, note motor voltage output reading on voltmeter. If not equal to output at 20mA in
Auto Mode, adjust the Balance trimpot on the -7 board (CW or CCW) until the same reading is achieved. The motor output Vdc
should not change more than 1 Vdc when flipping back and forth between AUTO and MANUAL position.

-5
P1
P4 P3
P2
JP2
-4
-3
AC1
AC2
COM
+5V
SIG
4-20
Vin
HI LO
AC INPUT
AC INPUT
ARM
ARM
+
- GROUND
SIGNAL
-55H Option Board
VOLTAGE
RANGE
JUMPER
CONNECTOR
CUSTOMER WIRING
GAIN
POT
INPUT
TYPE
SELECTOR
(Vin OR 4-20in)
10
-55H option
Isolated Signal Input Factory or Field Installed
NOTE:This option cannot be used on the 123D-C series control.
This option card allows for the use of either a grounded or non-
grounded remote DC signal such as 0 to 5 through 0 to 250Vdc,
4-20mA current, or a remote speed pot. The DC input signal type
can be selected for voltage (Vin) or current (4-20mA) via the JP2
jumper clip. There is a Hi/Lo range jumper selection that should
be set to the (Lo) setting when using a 4-20mA signal or voltage
ranges of 0-5 through 0-25Vdc. When using voltage ranges of 0-25
through 0-250 this jumper must be set to (Hi). The GAIN trimpot is
used to set full linear output in reference to the input signal range.
The output of this remote signal isolation board is a linear signal
that is proportional to the remote input signal being supplied.
(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 PROCEDURE.
SETUP PROCEDURE FOR -55H AND -56H OPTIONS
1. With NO power to control, connect a DC Voltmeter 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 pot on the remote signal board fully CCW.
3. Place the JP2 jumper clip in the proper position based on the input signal being used.
4. Place the P4 jumper clip in the Lo position for 4-20mA signals or voltage signals less than 25Vdc. Place the P4 jumper clip
in the Hi position for voltage signals greater than 25Vdc. (NOTE: Never exceed 250Vdc)
5. Make sure all connections are properly made per the hookup connection diagram and then apply AC power to the
controller.
6. Set the remote input signal to its lowest setting. Adjust the MIN trimpot to deadband (the point just before an increase
causes an output).
7. Apply the maximum remote input signal. Motor should start to run. Adjust the GAIN pot CW until no further increase in
control output voltage occurs and then decrease the gain pot slowly until output voltage to the motor drops approximately
5Vdc.
8. Set the MAX trimpot on the control to the correct motor voltage.
9. Some interaction between trimpots may occur. Recheck the Min trimpot setting and repeat steps 6 through 8 as needed.
-56H option
Isolated Signal Input with Auto / Manual Switch Factory or Field Installed
NOTE: This option cannot be used on the 123D-C series control.
The -56H option is identical
to the -55H option with the
added ability to have remote
Auto/Manual switching.
See -55H for more further
detail.
(FOR SHUNT WOUND
MOTOR, SEE PAGE 4
OF MANUAL FOR FIELD
CONNECTIONS).
CAUTION: DO NOT use
TRIMPOT ADJUSTMENT
CHART. Set pots using
directions in the previous
SET-UP PROCEDURE.
2
USE ONLY TERMINALS
1, 2, AND 3
OF DPDT SWITCH
CONNECTS
UNDER WIPER
SCREW P1-7
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.
NOTE:
3
1
= CUSTOMER WIRING
= FACTORY WIRING
red
DPDT CENTER-OFF SWITCH
TERMINAL DESIGNATION
(BACKSIDE VIEW)
1
3
2
6 - NO CONNECTION
4 - NO CONNECTION
5 - NO CONNECTION
-5
P1
P4 P3
P2
JP2
-4
-3
AC1
AC2
COM
+5V
SIG
4-20
Vin
HI LO
AC INPUT
AC INPUT
ARM
ARM
+
- COMMON
SIGNAL
-56H Option Board
VOLTAGE
RANGE
JUMPER
CONNECTOR
CUSTOMER WIRING
GAIN
POT
orange
white
yellow
AUT MANUAL O
INPUT
TYPE
SELECTOR
(V in OR 4-20 mA in)

11
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
Efficiency ..................................................................................................................................................................... 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 field voltage ........................................................................................... 20VDC for 24VAC input; 30VDC for 36VAC input;
Shunt field voltage ........................................................ 100VDC for 120VAC input; 200VDC for 240VAC input; 1 amp maximum
Speed control ......................................................................................... via 5kΩ2W potentiometer or 0-10VDC isolated signal
Speed range ........................................................................................................................................................................... 50:1
Speed regulation ............................................................................................................................................ ±1% of base speed
Temperature range ............................................................................................................. -10oto 45oC. ambient (15oto 115oF. )
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 UL
rating for output amps can be increased to 10 amps D.C.
** not used on the 123D-C series control
ENGLISH
METRIC
3.625"
92mm
4.250"
108mm
1.300"
33mm
8.00 oz.
228gms.
WIDTH LENGTH DEPTH WEIGHT
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

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



IN CASE OF DIFFICULTY

12
TYPICAL MOTOR CURRENTS
125D SERIES PARTS PLACEMENT & LIST
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 1/81/4
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
RESISTORS
CAPACITORS
MISCELLANEOUS
ACTIVE DEVICES
DIODES
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 75W
91K
1K
390 7
390 7
5K SPEEDPOT *
C1
C2
C3
C4
C5
C8
C9
C10
C11
.01μF 100V
10μF 35V
.01μF 100V
.033μF 400V
.22μF 1KV
1μF 50V N.P.
.0047μF 1KV
.1μF 50V
47μF 16V
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
1N4005
1N4005
1N914B
1N5242B
1N4005
1N5233B
1N914B
D4015L
D4015L
D4015L
Q1
U2
Q3
Q4
U5
Q6
2N6027
3052 MOC
S4015L
S4015L
LM358 IC
275V G-MOV
JU1
JU2
PCB
P1 (-1 THRU -8)
P2 (-2 THRU -6)
P3
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
R24
Q1
C4
P1-8-7-6-5-4-3-2-1
C9
U5 R11
R3
U2
P3
D5
Q3
D1
C1
C3
D9
D8
Q4
D10
D3
R4
R5
R25
R2
R27
R26
R23
C8
R7
P2
6
5
432
C11
R12
R13R10
R17
R6R21R18R19
R24 ............... .062 75W
125D-12C (1/50 thru 1/8H.P.)
CHANGES:
D2
R1
R8
D6
D4
C5 C2
R20 R14
R9
R15
R22
R16
R28
D7
Q6
JU2
JU1
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
123D-C CHANGES:
D6
Q6
R1
R2
R16
R23
R25
R27
R28
1N914B
(reverse direction)
DELETE
1K 2W
477
220K
47K
15K
477
477
C10
+
+
+

13
125D SERIES SCHEMATIC
123D-C CHANGES:
D6 ..............1N914B Q6 .............. DELETE R1 .............. 1K2W R2 .............. 477 R16 ............ 220K
R23 ..............47K R25 .............. 15K R27 .............. 477 R28 .............. 477

14
NOTES:

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.
REPAIR PROCEDURE
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: [phone]
Fax: [phone]
Indiana) production and
headquarters facility - with over
2,000,000 variable speed units
in the field.
In addition to the standard
off-the-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.
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.
Shownaboveis justasampling
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,
YOUR MOTOR SPEED CONTROL SOLUTIONS PROVIDER
700/COMMUTROL SERIES
DC BRUSHLESS
5 & 20 Amp for
12,24,& 36VDC Inputs
250G SERIES
AC INPUT - VARIABLE DC OUTPUT
1/50 HP through 2.0 HP
65 SERIES
DC INPUT - VARIABLE DC OUTPUT
CURRENT RATINGS OF 20, 40, AND
60 AMPS
DM SERIES
FIELD PROGRAMMABLE
DIGITAL TACHOMETER
MDP SERIES
PROGRAMMABLE
CLOSED LOOP DC
SPEED CONTROL
125D SERIES
AC INPUT - VARIABLE DC OUTPUT
1/50 HP through 1.0 HP
www.dartcontrols.com
ISO9001:2008 REGISTERED