DC MOTOR SPEED CONTROLLER MODEL: DCI120-12 True Trque TM Thank yu fr chsing Mtrniks t cntrl yur mdel Overview Dimensins: 133x115x57mm Weight: 700g Fr ver 25 years Mtrniks have been at the frefrnt f electrnic speed cntrl design and manufacture fr the hbby industry. Our prducts are designed and manufactured entirely in huse in the UK. The DCI range f cntrllers has been develped ver the last 7 years. The extensive research and design prgram lked at every aspect f the prblems assciated with the speed cntrl f large scale mdels. We hpe yu will find the DCI range f cntrllers is refreshingly different in many ways; it s nt designed dwn t price. We develped a strng cre f electrnics which during rigrus testing, has prven t be well n tp f the jb The use f a large and pwerful cmputer cre has allwed us t incrprate features and prtectin measures nt usually fund n these types f cntrllers. These particular cntrllers are aimed at large lcmtives f 3 ½ gauge and up. This is where we have tested extensively, actually in real applicatins. True Trque TM Mtr trque cntrl system Accurately measuring the current in the mtr can be a difficult prblem t slve in a mdel speed cntrller. Fr this reasn, DC mtr speed cntrllers nrmally cntrl and if necessary limit the battery current. Hwever, at lw mtr speeds and high trque this can lead t severe mtr verlad because the current in the mtr can be much higher than the average battery current. 1 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
Our True Trque cntrl system mnitrs every mtr pulse and if necessary, adjusts the pulse t keep the mtr current (Trque) t the maximum value set n the current cntrl pre-set. The usual prblems f brush burning and mtr verheating which ccur because f magnetic saturatin in verlad are prevented. We very much hpe that using ur cntrllers will help yu t enjy t the full ur great hbby! Using yur cntrller General Yur new cntrller is simple t use and cnfigure fr use in yur mdel, but there are a few imprtant aspects which yu shuld understand BEFORE yu wire it int yur mdel. 1) ALWAYS fit a fuse. A 100Amp fuse in line with the psitive (+ve) 12V supply feed frm yur battery will be suitable fr mst 4 mtr 5 scale mdel lcmtives. Hwever, a smaller fuse can be used with lwer pwer mtrs. 2) Make sure that yu use thick enugh wires, thin wires may heat up and melt, pssibly causing shrt circuits r fires. The currents seen in ride n type lcmtives can easily exceed 100Amps. 3) BE VERY SURE NOT t accidentally reverse cnnect t the battery, even a mmentary tuch n the wrng battery terminal can cause fatal damage t yur cntrller. 4) ENSURE that the dead-man device is fitted arund the drivers wrist, failure t d s is a direct cmprmise n safety. 5) This unit is designed t be used by an adult and nt t be left withut adult supervisin. 6) Always be sure t switch yur handset t standby whenever yu remve the dead man wrist strap r leave yur lc unattended. Installatin ntes Install the cntrller pwer mdule int yur mdel smewhere midway between the battery and the mtr, this helps t keep the battery and mtr wires as shrt as pssible. The pwer mdule gets warm during use, fastening the mdule t a metal chassis is ideal. The pwer mdule has 6 cnnectins, 2 fr the 12V battery supply, 2 fr the mtr/mtrs cnnectins, ne multi-way cnnectr which allws cnnectin t the cntrller handset and ne multi-way cnnectr t allw the cntrl f accessries. NOTE: The small pin cnnectrs are fr factry use nly. These are used fr firmware/sftware updates. Depending n the mdel f the cntrller there may be fibre ptic interface cnnectins fr master/slave peratin. 2 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
Using yur mdel The thrttle cntrl is disabled at switch n, unless it is in the neutral band r is returned t neutral psitin after switch n. The current cntrl pre-set trimmer n yur cntrller is FRAGILE, we strngly recmmend that yu use a jewellers screwdriver t CAREFULLY turn the cntrl up r dwn. If yu knw the manufacturers maximum rated current fr yur mtr then this is the MAXIMUM current yu shuld set n the cntrl. If nt, start lw and wrk up, regularly checking the temperature f the mtr. As a rugh guide there will cme a pint when further upward adjustment des nt imprve the pwer utput. This is the maximum current/trque that the mtr can handle. Adjust the cntrl BACK a little and leave it there. If yu are travelling in ne directin and switch t the ppsite directin using the directin tggle switch, the cntrller will apply maximum brakes and stp. It will nt apply pwer in the ther directin until the thrttle cntrl is first returned t the neutral psitin fr 2 secnds r lnger. If fitted n yur mdel f handset, the emergency stp buttn will, when pressed mmentarily, apply maximum brakes and when clse t stpping, the cntrller will shrt the mtr t apply abslute maximum brakes. The pwer t the unit MUST be switched ff then back n again t reset an emergency stp. The dead man jack plug is lcated n the frnt edge f the cntrller handset, when remved, full brakes are applied as in an emergency stp cnditin. If yur mdel des nt respnd t the handset please check the diagnstic light n the speed cntrller. It may be flashing in a sequence, see belw. 1 Flash = Prblem with the dead man switch check it is secure 2 Flashes = Handset prblem Make sure it is cnnected crrectly and nt damaged 3 Flashes = Master/Slave ptical cupling prblem check cable is nt damaged and fitted k 3 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
Features Fully regenerating, digital, high frequency peratin Anti-lck brakes Peak and Average current limits Master/Slave cnfiguratin Fibre ptic link ptin Intelligent cntrl bus Failsafe & Dead man safety plug Waterprf pwer mdule 12v DC peratin /120Amps maximum Over temperature prtectin Ultra smth pwer cntrl Firmware/Sftware upgradeable 6.0mm studs fr heavy duty pwer cnnectins Optinal Accessries Descriptin Part N. Supply fuse and hlder DC120SF 2m red/black 6.0mm² cable w/cnnectrs DC120W2M 1m red/black 6.0mm² cable w/cnnectrs DC120W1M Spare/Replacement handset DCI Handset Handset cable assembly DCI Cnt Cable Fibre ptic cable (3.0m) DCI Fibre Cable(3m) Fibre ptic cable (10.0m DCI Fibre Cable (10m) Relay bard fr auxiliary utputs DC/AC RL412V Handset extender lead (Varius lengths) Call fr details Master/Slave peratin (Cntrller mdel specific) APPENDIX1 The DCI range f cntrllers cme with the factry specified ptin f being able t link mre than ne cntrller via a fibre ptic cable. This allws 2 r mre cntrllers t be perated tgether frm ne single handset. The maximum length f fibre ptic cable which can be used is 20.0m, this dentes the maximum distance yu can have between 2 cntrllers. Applicatins include tpping and tailing train cnfiguratins and als very high pwer, multi mtr, lcmtives. When the secnd cntrller is set t slave, it is cntrlled, via the ptical link, by the first master cntrller which is cntrlled by the handset. The fibre ptic cable is the ideal way t cnnect the cntrllers, there is n electrical cnnectin between the 2 cntrllers and n wires t damage r shrt ut. 4 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
If the ptical cable is brken, the slave cntrller will revert t neutral and freewheel until yu can stp and repair/replace the cable. Cnnectin details fr ptically cupled systems Speed cntrllers equipped with Master / Slave feature have 2 fibre ptic cable cnnectins and a switch. The switch is used t select which speed cntrller is the master and which is the slave. The 2 fibre ptical cupler cnnectins are clur cded black and white. The white is the OUTPUT cnnectr and the BLACK is the input cnnectr. The utput cnnectr emits a red clured light which cntains all the digitally encded infrmatin fr the 2 nd cntrller. The fibre ptic cable shuld be GENTLY inserted int the white (utput) cnnectr n the MASTER cntrller ( the ne with the handset attached t it) and int the BLACK ( input) cnnectr n the slave cntrller. It is very imprtant that the ends f the fibre ptic cable are clean and cut flat at the ends therwise the transmissin f light can be impeded sufficiently t cause prblems with the peratin f the slave cntrller. The tggle switch is set t slave when it is inbard and master when it is twards the utside edge f the speed cntrller. If there is a cmmunicatin prblem between the speed cntrllers and the slave cntrller lses its signal ( snapped r damaged fibre cable ) then the slave cntrller will fail safe t NEUTRAL and flash its LED cntinuusly t indicate a failure in cmmunicatin. Under these circumstances it is necessary t discnnect the battery supply frm bth speed cntrllers, wait a minute and try again. 5 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
APPENDIX2 Auxiliary switched utputs The DCI cntrller has up t 4 auxiliary switched utputs. These cnnectins are cntrlled by the 4 switches n the handset. The 4 cnnectins n the cntrller are switched t grund utputs. This means that they are designed t switch the cil f a relay. We strngly suggest using the Mtrniks relay bard. Part number: DC/AC RL412V The auxiliary relay bard (DC/AC RL412V) allws yu t wire the 4 auxiliary cnnectins frm the DCI120 t the inputs n the relay bard allwing cntrl f up t 4 auxiliary utputs, such as a hrn r sund mdule. Suggested wiring diagram 6 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
DC/AC RL412V Slid state relay bard instructins fr reference 7 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
Cnnectin f ACi/DCi slid state relay bard The abve diagrams shw the types f slid state relay bard's 4 channels, cntrl cnnectr and psitive battery terminal. Each channel is cntrlled by ne f the auxiliary switches n the ACI/DCI's handset, each has a current carrying capacity f 20A. The relays are slid state, they have n mving parts. When cnnecting the cntact it can either be used t switch the psitive feed r be placed in the negative, but be sure that the negative (-ve) terminal is always mst negative. If switching an inductive lad, a cil mtr r relay etc, then always install a dide acrss the cil. Failure t fit a dide may result in damage t the slid state switch. If in dubt cntact Mtrniks fr details. 8 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016
The cable frm the ACI/DCI unit with the 6-way cnnectr, plugs int the cnnectr n the relay bard Ensure all cabling is capable f carrying the currents cncerned safely. Check cnnectins are sund and crrect. Duble check all cnnectins prir t pwering-up. Apprpriately fuse all feeds frm battery psitive. General user ntes When installing an extensin cable between the speed cntrller and the lcmtive bulkhead it is very imprtant t make sure that the bulkhead cnnectin is electrically insulated frm the lcmtive chassis therwise electrical nise in the chassis can be cupled int the handset cntrl signals causing cut uts and failsafes. The best way t d this is t fit the metal scket at the bulkhead int an insulating munting (this can be fibreglass r plastic) and then fasten the munting t the bulkhead r buffer beam. While yu may be strngly tempted t cnstruct yur wn extensin lead we strngly recmmend the use f ur ptinal accessry as this is a high frequency digital cntrl bus and the signals can easily be crrupted by a pr cnnectin. Brakes The strength f the braking effect f a DC mtr is prprtinal t its speed f rtatin. It fllws that a statinary r very slwly rtating mtr will prvide little r n nticeable braking effect. Fr mst nrmal running, this system wrks well, the faster the mdel is travelling the strnger the available maximum brake will be. The electrnic brake n yur system is NOT a handbrake. Fr this reasn we always strngly recmmend the inclusin f a mechanical brake system t hld the mdel n hills and bring it t a full stp. 9 DCI120-12 True Trque TM Manual Mtrniks Ltd. August 2016