DART Controls DM4000 Series User manual

DM4000 CONTROL SERIES
LTDM4 (IM-DM4-0501)
P.O. Box 10
5000 W. 106th Street
Zionsville, Indiana 46077
Phone [phone]
Fax [phone]
www.dartcontrols.com
Instruction Manual
Low Voltage DC Brushless Control
CONTROLS

WARRANTY
DartControls,Inc.(DCI)warrantsitsproductstobefreefromdefectsinmaterialandworkmanship.Theexclusiveremedyforthis
warrantyisDCIfactoryreplacementofanypartorpartsofsuchproductwhichshallwithin12monthsafterdeliverytothepurchaser
bereturnedtoDCI factory with alltransportationchargesprepaid and which DCIdeterminestoits satisfaction to bedefective.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
thanDCIor to any articlewhichDCI determines has beensubjectedto improper use. DCIassumesno responsibility for thedesign
characteristicsofanyunitoritsoperationinanycircuitorassembly.Thiswarrantyisinlieuofallotherwarranties,expressorimplied;
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.
Allinformationcontainedinthismanualisintendedtobecorrect,howeverinformationanddatainthismanualaresubjecttochange
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
personnelshouldperformanyelectricaltroubleshootingormaintenance.Atnotimeshouldcircuitcontinuitybechecked
by shorting terminals with a screwdriver or other metal device.
INTRODUCTION
The Dart DM4000 Series is available in two basic field programmable models:
DM4004 - RATE BASED DISPLAY - Displays the rate of shaft rotation in RPM, GPM, FPM, etc.
DM4005 - PROCESS TIME DISPLAY - Displays the time of the process, based upon shaft rotation.
STANDARD FEATURES
TheDM4000Seriesfeaturesasturdy1/8DINaluminumhousingwithgasketedfaceplatekitforpanelmount.Itwillacceptavariety
of signal inputs, and is field programmable via dip switches. The compact series provides a five position barrier terminal strip for
ease of connection and a large 1/2" four digit LED display, including customer selectable decimal points. Self-contained power
supply for transducer of +5VDC and 75mA output.
Works in conjunction with a transducer
The Dart PU-E pick-up is recommended for use with the DM series, however the DM4000 will accept inputs from a variety of
transducertypes.Includedarehall-effect,photo-electric,magnetic,TTL,orany+5to24VDCdevice.See“Pick-upSelectionChart”
on page 3. Operates on either a 50 or 60 Hertz signal
TheDM4000 Series comesstandard fora 60 Hertzsignal, but can be easilychanged to 50Hertz byusing the “FieldProgramming
Formula” on page 4. This program simply changes the time base settings, substituting 3000 for 3600 in the Field Programming
Formula. This compensates for the change in the clock frequency from 60 Hertz to 50 Hertz.
TABLE OF CONTENTS
WARRANTY ............................................................................................................................................................................... 1
INTRODUCTION & STANDARD FEATURES ........................................................................................................................... 1
THEORY OF OPERATION......................................................................................................................................................... 2
OPTION DESCRIPTION............................................................................................................................................................. 2
CUT-OUT & MOUNTING DIMENSIONS .................................................................................................................................... 2
MOUNTING INSTRUCTIONS .................................................................................................................................................... 2
PU-E SERIES PICK-UP INSTALLATION .................................................................................................................................. 3
DM4000 SERIES HOOK-UP & WIRING .................................................................................................................................... 3
FIELD PROGRAMMING THE DM4000 SERIES .................................................................................................................... 4-5
DECIMAL POINT SELECTION .................................................................................................................................................. 5
COMMONLY ASKED QUESTIONS ........................................................................................................................................ 5-6
SPECIFICATIONS ...................................................................................................................................................................... 6
PRODUCT LINE ................................................................................................................................................... BACK COVER
1

TRANSDUCER PULSES
50 or 60 HERTZ
x M
÷ S
COUNT and
DISPLAY
input
display and reset
command
THEORY OF OPERATION
The input pulses from the transducer are counted and then multiplied by “M” (input count multiplier). In order to have a steady
display,the displayis updated every.0167 secondsx “S” (divide by counttime) forthe DM4004. The multiplier “M” isa phaselock
loop,whilethedivideby,“S”,isasimpletimersetviabinaryswitches. Thus,wehavefieldprogrammablescaling. Theunitprovides
+5 VDC for the transducer.
OPTION DESCRIPTION
240VAC input (50 or 60 Hertz) ............................................................................................................ -5 OPTION
CUSTOMER
SUPPLIED
MOUNTING SCREWS
PANEL MOUNTING GASKET
(NARROWER SIDE OF GASKET GOES
ON TOP, WITH THE ADHESIVE SIDE OF
GASKET FACING THE CUSTOMER
MOUNTING PANEL)
CUSTOMER
MOUNTING PANEL
(HOLE CUT-OUT FOR CONTROL
HOUSING APPROXIMATELY
3.675" WIDE BY 1.770" HIGH)
DM4000 SERIES
CONTROL
DM4000 SERIES
FACEPLATE
ASSEMBLY
2
CUT-OUT & MOUNTING DIMENSIONS
STEP 1: Remove two screws securing red lens.
STEP 2: Mount the DM4000 series meter into the panel cut-out. Note diagram for cut-out dimensions shown below. Allowance
for easy insertion of meter into panel must be made.
STEP 3: Secure meter into panel. The two mounting holes have a diameter of .141 inch. Use #6 hardware to fasten to panel.
4.000"
.885" 1.770" x 3.675" cut-out
weight: 12.5 oz.
C
L
LENS & HOUSING DIMENSIONS PANEL CUT-OUT DIMENSIONS
4.420"
2.250"
0.25" lens
depth
Programmable Tachometer
3.620"
1.655"
4.125"
housing
depth
MOUNTING INSTRUCTIONS
Note:
Use caution to prevent
pinching the ribbon cable
between red lens and heatsink
metal during reassembly.

P1
-5
-4
-3
-2
-1
AC - connect either side of incoming AC line
AC - connect either side of incoming AC line
COUNT SIGNAL INPUT from pick-up (for PU-E, connect white wire)
+5 VDC to pick-up (for PU-E, connect red wire)
COMMON from pick-up (for PU-E, connect black wire)
PICK-UP
INPUTS
DM4000
SERIES AC
AC
SIG
+5V
COM
TOP VIEW
3
PU-E SERIES PICK-UP INSTALLATION
model pulses per minimum maximum
number revolution RPM RPM
PU-2E 1 125.0 5000
PU-4E 2 62.5 5000
PU-10E 5 25.0 5000
PU-20E 10 12.5 5000
ThePU-Eseriespick-upisaneconomicalwaytomonitormotorspeed.Itspatenteddesignprovideseaseofinstallationinotherwise
difficultto reach areas. The PU-E pick-up operates at a +5 volt level, producing a 5volt squarewave output,which may be fed into
Dart’s DM4000 series field programmable tachometer, closed loop controls, or any other digital device.
CAUTION: DO NOT OVER TIGHTEN MOUNTING SCREW !!
DIMENSIONS
72.00
2.40
1.60 .875
In order to obtain a stable reading on the display, the DM4000 series requires a
minimum input of 125 pulses per minute, and a maximum output no greater than
600,000 pulses per minute.
Caution: The PU-E cord should not be grouped with any other wires or cords. For applications with PU-E wire over 6 feet
long,ornoisyenvironments,ashieldedcableisrecommended.ConnecttheshieldtothecommonterminalontheASP10,
leaving the shield on the PU-E end floating.
No other mounting screws are necessary, as the cord will keep the unit from rotating.
ThePU-Egivesahighsignalwhenthenorthpoleofthemagneticdiskcrossesthehall-
effect. The signal is switched low when the south pole crosses the same resistor.
EXAMPLE:
If the motor shaft is rotating at 14 RPM, a PU-20E pick-up, which has 10 pulses per
revolution (PPR) out, is recommended. Thus 10 PPR multiplied by 14 RPM equal 140
PPM(pulsesperminute),whichsatisfies the minimum requirement of 125PPM(ie.10
pulses/revolution x 14 revolutions/minute = 140 pulses per minute).
DM4000 SERIES HOOK-UP & WIRING
CAUTION: Do not connect any other power source to the +5 volt supply!!
LIFT UP TOP COVER OVER
ENDPLATE AND SLIDE BACKWARDS
TO EXPOSE TERMINAL STRIP.
REMOVE 2 SCREWS FROM BACK
ENDPLATE AND REMOVE. WIRE
TERMINAL STRIP AS NECESSARY.
TheDM4000seriesisfactorypreset to measure an inputofone
(1)pulseperrevolution(PU-Epick-upnotincluded).Ifadifferent
pulserateisdesired,thenfieldprogrammingisrequired.Thread-
ing wires through back of endplate should be done before
connecting wires to the terminal strip of the meter.
dust
cover
10-32
screw
magnet
disc
flat
washer
PU-E
bearing
3/16"
spacer
black wire
common
white wire
signal
red wire
+5 volts
tapped
motor shaft
(.250" deep)

M = INPUT COUNT MULTIPLIER (TRIMPOT SETTING OF EITHER 1, 10, OR 100)
R = RATIO OF:
S = COUNT TIME IN 1 CYCLE PER SECOND INCREMENTS (SWITCH SETTING)
I p = INPUT PULSES PER REVOLUTION (SEE PICK-UP SELECTION GUIDE - page 3)
DESIRED DISPLAY READING AT KNOWN RPM
KNOWN RPM
(This is specified by the user. It is necessary to know the desired display readout at a particular RPM).
MS = R x 3600
(use 3000 for 50 Hertz application)
I p
4
FIELD PROGRAMMING THE DM4000 SERIES
The DM is supplied from the factory preset to measure an input of 1 pulse per revolution - read in RPM (Pick-up not
included). If operating with different pulse inputs, field programming is required.
STEP 1 Remove the 2 black screws from the lens face and remove the lens assembly.
STEP 2 Locate the Timer Switches and the Multiplier Trimpot by observing the diagram below.
DM4005 FIELD PROGRAMMING FORMULA:
MULTIPLIER
TRIMPOT
DISPLAY
PANEL
TIMER
SWITCHES
DM4000 - FRONT VIEW WITHOUT LENS
Example: Find R - We want the meter to display 15 feet per minute at a shaft speed of 1000 RPM.
Therefore R = 15 / 1000 = 0.015.
Example: Use Programming Formula for the DM4004 - A motor drives an auger which moves material and we want displayed
lbs/hr. of material moved. We know that at 990 RPM we move 435 lbs. of material per hour. We selected the PU-2E
as the appropriate pick-up from the SELECTION CHART on page 3. The PU-2E has an Ip of 1.
Therefore MS = 435/990 x 3600 = 1581.8
1
STEP 3 DM4004 FIELD PROGRAMMING FORMULA:
M = INPUT COUNT MULTIPLIER (TRIMPOT SETTING OF EITHER 1, 10, OR 100)
A = KNOWN RPM
S = COUNT TIME IN 1 CYCLE PER SECOND INCREMENTS (SWITCH SETTING)
Ip = INPUT PULSES PER REVOLUTION (SEE PICK-UP SELECTION GUIDE - page 3)
(Maximum reading of 59 minutes and 59 seconds).
MS = [A x (B x 60 + C)] x Ip
3600 (use 3000 for 50 Hertz application)
B = DESIRED DISPLAY (READING IN MINUTES)
C = DESIRED DISPLAY (READING IN SECONDS)
(continued on following page)

(continued)
Example: Use Programming Formula for the DM4005 - A conveyor oven needs to cook a pizza in 8 minutes and 31 seconds,
and we have determined the motor speed is 1000 RPM. A PU-2E with an Ip of 1 is being used.
Therefore MS = [1000 x ( 8 x 60 +31 ) ] = 1000 x 511 = 142.
3600 3600
STEP 4 Establish the “M” (multiplier trimpot setting) and “S” (switch setting) values. Keep “S” as large as possible, but
less that 255.
Example: If MS = 1581, then our best choice for “S” would be 158 (it is as large as it can be without being equal to or greater
than 255). This makes the Multiplier (M) = 10.
Examples: MS = 12, 235. Therefore S = 122. M = 100.
MS = 123.85. Therefore S = 124. M = 1.
STEP 5 Set the Timer Switches. The value of the switches that are to be activated must add up to the value of “S” (see
value chart).
Examples: If S (total) = 15, then S4 (8) + S3 (4) + S2 (2) + S1 (1) = 15.
If S (total) = 226 then S8 (128) + S7 (64) + S6 (32) + S2 (2) = 226.
STEP 6 Set the Multiplier trimpot using the “M” value determined in STEPS 3, 4 and 5.
DECIMAL POINT SELECTION
All decimal points are illuminated and are covered with black adhesive backed dots. If a decimal point is needed, remove dot to
illuminate the desired decimal point.
COMMONLY ASKED QUESTIONS
Q. Can the DM4000 Series be used above 9,999 RPM?
A. Yes, there will be only a 4 digit display. Note: The bearings of the Dart PU-E Pick-up are not rated above 5,000 RPM.
Q. I want a stable reading, but the last digit fluctuates. What should be done?
A. The reading can be multiplied by ten using the “M” adjustment with the last digit covered. (continued on following page)
x 10
M = 100
x 100x 1
M = 10M = 1
5
FRONT VIEW
ACTIVATE SWITCH BY TURNING OFF
SWITCHES ARE ACTIVE WHEN OFF !!!
SWITCHES ARE ACTIVE WHEN OFF !!!
EXAMPLE: SWITCHES 3, 4, AND 7 HAVE BEEN ACTIVATED
SINCE S3 = 4, S4 = 8, S7 = 64
THEREFORE: 4 + 8 + 64 = 76 = S
S1 = 1
S5 = 16
" S " VALUE CHART
S2 = 2
S6 = 32 S3 = 4 S7 = 64 S4 = 8 S8 = 128
ON
S8 S7 S6 S5 S4 S3 S2 S1
ACTIVATE

6
(continued)
Q. Can I use the Dart PU-E pick-up located more than 6 feet from the display?
A. The PU-E pick-up operates at a 5 Volt level, producing a 5 volt Square Wave. If noise is present on the line to or from the
pick-up, some information may be lost and the DM4000 Series may not be able to distinguish between the noise and the
relatively small 5 Volt square wave. For this reason, we would recommend that in a “normal” environment the PU-E pick-
up not be located more than six (6) feet from the display. In a particularly noisy environment, six feet may exceed the cord
length necessary for an error free signal from the PU-E pick-up. If it is absolutely necessary to exceed six feet, or in a par-
ticularly noisy application, shielded cable should be used, connecting the shield to the COMMON terminal on the wire end
of the PU-E housing. In such cases, the PU-E pick-up cord should not be grouped with any other wires or cords in the
shielded cable.
Q. Can the decimal point be easily changed?
A. Yes,alldecimalpointsareilluminatedandhavebeenmaskedwithablackstickertomaketheminvisible.Removethefront
lens and remove the appropriate sticker.
Q. How many displays can one PU-E pick-up operate at once?
A. We recommend no more than nine.
Q. Can the DM4000 Series be switched between inputs?
A. Yes. On the PU-E pick-up, switch the “SIG” wire and leave the “COM” and “+V” connected to each pick-up (do not exceed
nine PU-E pick-ups per DM unit).
Q. Can I tie the DM4000 Series to a computer?
A. No, there are no computer outputs available from the DM4000 Series.
Q. What is the update time?
A. This varies with the programming of the “S” value setting, which ranges from .0167 through 4.25 seconds. The DM4004
update time = .0167 x “S” (in seconds). See SPECIFICATIONS section shown below.
Q. How can I program “MS” in order to display RPM using a DM4004 and a PU-2E?
A. Activate switches 3 and 6 in the DM4004 [M(100) x S(36) = 3600].
SPECIFICATIONS
INPUT VOLTAGE .............................................................. 120VAC ±10% (optional 240VAC input); 50/60 Hertz
AC CURRENT - MAXIMUM ........................................................................................................................ 225 mA
DECIMAL POINT .................................................... Illuminated, covered with adhesive dots (field removable)
DISPLAY.............................................................................................................................. 1/2" red L.E.D. 4 digit
DISPLAY ACCURACY ............................................................................................................................. ± 1 count
DISPLAY RANGE................................................................................................................................. 125 to 9999
INPUT PULSE RATE......................................................................... Minimum required: 125 pulses per minute
..................................................................................................... Maximum allowed: 600,000 pulses per minute
MINIMUM SINE WAVE ....................................................................................................................... 175 mV RMS
(that can be recognized as a signal when used with Proximity Pick-ups)
MOUNTING.............................................................................................. Panel mounted (screws not provided)
TEMPERATURE ...................................................................................................... -10oto +45oC. (15oto 115oF.)
TIME BASE.............................................................................................................................. A.C. line frequency
TRANSDUCER POWER SUPPLY VOLTAGE .......................................................... +5 VDC, 75 mA. maximum
TRANSDUCER TYPES (capable of sinking 3mA) .............. Hall-Effect, Photo-Electric, Magnetic (Proximity),
......................................................................................... TTL, or any +5 to +24VDC NPN open collector device
UPDATE TIME ..................................................................................................... Range .0167 thru 4.25 seconds
Varies with programming of “S” value setting (DM update time = .0167 x S (in seconds))