A1100 Installation Instructions
Contents
1. see figure 1B page 3 Magnet Wrap optional Separate the two halves of the magnet wrap by loosening the cap screws holding the two halves together Place both halves of the magnet wrap around the shaft Re insert and tighten the cap screws making sure the wrap is square to the shaft see figure 1A page 3 NOTE There will be a slight gap between the two halves after tightening This gap will not affect the generated signal Mounting the Sensor Place the sensor so that the pole piece is centered directly in front of the magnets in the disc or optional wrap see figure 1A amp 1B page 3 The gap setting between the pole piece and magnet disc should be approximately 1 8 7 8 P CALL TOLL FREE 800 328 0738 ee www maxigard com E mail techsupport maxigard com A211 11 Page 3 SENSING METHOD CTT EI i oa CITE SU 1 8 to 7 8 GAP q Z m UNU MINH DINI F i DU WI FIGURE 1A FIGURE 1B 40 Speed Switch Enclosure 4 1 A1ll00 and A1200 enclosures are rated NEMA 4 dust tight oil tight and water tight steel construction suitable for indoor and outdoor use see figure 2 page 3 CAUTION Remove the circuit board from the enclosure before punching or drilling conduit holes Be sure to remove all metal chips and fillings NEMA 4 ENCLOSURE DIMENSIONAL DATA STANDARD MAGNET DISC lt D 3 gt aa F 4 tees 5 16 OPTIO2. 10 2 10 2 1 10 2 2 10 2 3 10 2 4 Before adjusting the zero and span pots select the speed range as shown in figure 10 page 10 SIGNAL CONDITIONER TRANSMITTER 4 20 Ma or 0 10 Vde Outputs JUMPER PIN ARRANGEMENT SLOW HIGH SPEEDS SPEEDS SPEED RANGE ol SELECTOR PINS PRI 0 250 RPM 250 RPM STANDARD Figure 10 4 20 mA Output Set meter to the milli amp current scale adequate for 4 20 mA calibration Connect voltmeter positive and negative leads to terminal block TB2 term 6 term 7 Turn on power to circuit and with monitored machine at 0 speed turn Zero POT C W to increase and C C W to decrease until voltmeter indicates 4 mA With power on and monitored machine running at full speed turn Span POT C W to increase and C C W to decrease until voltmeter indicates 20 mA 0 10 VDC Output To calibrate the system accurately use a voltmeter as follows Set voltmeter to the DC voltage range adequate for 0 10 VDC calibration Connect voltmeter leads to terminal block TB2 term 6 term 7 Turn on power to Signal Transmitter circuit and with monitored machine at 0 speed turn Zero POT C W to increase and C C W to decrease until voltmeter indicates 0 Volts With power on and monitored machine running at full speed turn Span POT C W to increase and C C W to decrease until voltmeter indicates 10 Volts or to what your system
3. The tachometer output cable e The transmitter output cable Raceways The following are general guidelines for routing cables and wires when you install the A1100 A1200 The guidelines apply to cable and wire routing both inside and outside the enclosure e Wire and raceways must conform to the National Electrical Code and all applicable local codes and practices e Type 1 conductors can be routed with power conductors up to 600 VAC All conductors in the same raceway must be insulated for the highest voltage applied to any one of the conductors in the raceway e Route type 2 conductors in their own separate raceway e Maintain 2 inch minimum spacing between type 1 and type 2 conductors inside the A1100 A1200 enclosure e When conductors carrying unlike signal levels must cross in trays or conduits they should cross at a 90 degree angle with maximum spacing e Type 2 conductors should not be routed near contactors motors generators radio transmitters transformers rectifiers arc welders 480 VAC power lines Three foot separation should be maintained CALL TOLL FREE 800 328 0738 a www maxigard com E mail techsupport maxigard com A211 11 Page 14 Conduit entries to the A1100 A1200 enclosure Figure 11 illustrates conduit entry areas for type 1 and type 2 conductors Figure 12 illustrates recommended conduit and fitting arrangement for wet NEMA 4 locations Grounding Grounding is important for safety in
4. Use copper conductors only in this enclosure More than one disconnect switch may be required to de energize the equipment before servicing See manual for more details 4 Remove printed wiring board chassis from enclosure before punching and drilling hub or conduit holes Be sure to file all sharp edges and remove all metal chips and fillings before installing chassis a CALL TOLL FREE 800 328 0738 ee ae www maxigard com E mail techsupport maxigard com A211 11 Page 15 SPARE PARTS LIST Part No Description 1560UL Circuit Board Power Supply W O Relays 1325UL Circuit Board Set Point Card 1 LO 1350UL Circuit Board Set Point Card 2 HI 1574 4 20 or 0 10 VDC Output 1129 Sensing Head W 10 Cable Std Analog 1130 Mounting Bracket and Jam Nuts Std 1132 Sensing Head W 10 Cable XP Analog 1134 Mounting Bracket XP 1136 Magnet Disc 4 Diameter 1378 Magnet Disc 8 Diameter 1569 Relay DPDT 12 VDC 1139 Cable Sensing Head 2 Wire 1177 Meter Tachometer Analog 1324 Meter Tachometer Digital 3 1 2 LED LIMITED WARRANTY Process Control Systems Inc will repair or replace at their option F O B factory any part or unit which proves to be defective in material or workmanship within five years of purchase date provided that part of the unit was installed and operated as recommended to be established by examination of the part or unit at the factory Goods returned under warranty must be shipped prepa
5. 5 2 3 Do not bundle any low level signal wires with the power wires This will keep any potential noise interference at a minimum 5 2 4 Power for the speed switch can be applied through motor starter auxiliary contacts WARNING To avoid electrical shock disconnect all sources of power to the motor starter before wiring and observe voltage ratings of the speed switch swi LO SET PT POT POLIPI ar e IRCUIT TACH LO S T PT kup Can i SET FT POT P2 CIRCUIT BD Hi SET PT i f PINIS60UL P N1350 osema Miaa CIRCUIT BOARD TRANSMITTER POT PS POT PA bert a PIN129 FOR N SETTINGS adia POINT rm 5 3 TT C NC NO C NC NO C NC NO C NC NO 120Vac or 240Vac NOTE EQUIPMENT POWER CONNECTIONS USE COPPER WIRE ONLY GROUNDING CONNECTOR FOR CONNECTIONS ATTACHED HERE INPUT POWER 120Vac 240Vac JUMPERTEAMINALS 11032704 2703 _APPLYPOWERTO vanoa _ 1anos FIGURE 4 53 Speed Switch Relays NOTE The A1100 and A1200 motion switches low set point relay K1 has a built in time delay of 7 5 seconds Delay activates on start up only 5 3 1 The speed switch can be wired to detect slow downs stopping starting over speed and or under speed 5 3 2 DPDT relay contacts are available for each set point Refer to the specifications for contact ratings see page 11 of these instructions CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A211 11 Page 6 6
6. SWITCH C W RAISE READING POTIPI POTIP3 LO SET PT P N 1325 CIRCUIT BD FIGURE 7 90 HI Trip Point Adjustment K2 A1200 91 Move the slide switch to the TP2 position and adjust POT P2 to desired trip point by watching the meter pointer Turning the POT C W to increase C C W to decrease 9 2 Return the slide switch to the Operate position The motion switch is now calibrated The trip points are set and ready for operation CALL TOLL FREE g CPCS m 800 328 0738 i ae www maxigard com E mail techsupport maxigard com A211 11 Page 9 Hi SET POINT K2 C C W towER READING TP2 C w SLIDE RAISE SWITCH READING POTIP2 HI SET PT PAN 1350 CIRCUIT BD 10 0 Signal Calibration 4 20 mA or 0 10 VDC outputs optional see figure 9 page 9 amp figure 10 page 10 The Signal Transmitter has been calibrated and factory tested as accurately as possible to match your operating speed and output requirements However final calibration will be required during installation and start up This final calibration is made by adjusting the zero and span pots OPTIONAL SIGNAL TRANSMITTER POT P4 POT P6 ZERO SPAN 7 SIGNAL SELECTION SETTINGS TRANSMITTER CIRCUIT BOARD PIN 1574 SEE FIG 4 FOR JUMPER BAR LOCATION za CALL TOLL FREE LECS ax 800 328 0738 ne www maxigard com E mail techsupport maxigard com A211 11 Page 10 10 1 10 1 1 10 1 2 10 1 3 10 1 4
7. requires p CALL TOLL FREE aek CS a 800 328 0738 ae www maxigard com E mail techsupport maxigard com POWER REQUIREMENTS 120 240 VAC 50 60 HZ POWER CONSUMPTION A1100 5 WATTS 34 mA 120 VAC 17 mA 240 VAC A1200 5 WATTS 44 mA 120 VAC 21 mA 240 VAC ENVIRONMENTAL TEMPERATURE INFLUENCE 1 OVER 50 F OPERATING TEMPERATURE 32 F TO 140 F 0 TO 60 C FUNCTIONAL SENSOR OUTPUT ANALOG 0 3 VAC 0 4 5 MILLL AMPS CURRENT LIMITED SENSOR GAP SENSING DISTANCE BETWEEN MAGNET DISC AND SENSOR 1 8 TO 1 ALTRA GAP SIGNAL TRANSMISSION DISTANCE SENSOR TO CIRCUIT UP TO 10 000 FT OPERATING SPEED RANGE 5 RPM TO 10 000 RPM TRIP POINT SETTINGS BY MULTI TURN POTENTIOMETER RELAY DPDT 7 AMP RESISTIVE 120 240 VAC 7 AMP 24 VDC CONTACTS N O AT REST Note 6 6 A Pole 20A Total UL amp CSA Horsepo CALL TOLL FREE 800 328 0738 Ratings sPsT DPDT 240V AG 18 HP 120V AC 1 6 HP ACCURACY 2 FULL SCALE REPEATABILITY 5 FOR CALIBRATION AND SET POINT SETTINGS TIME DELAY LO SET POINT RELAY K1 HAS A BUILT IN TIME DELAY OF 7 5 SECONDS DELAY ACTIVATES ON START UP ONLY CONSTRUCTION MAGNET DISC ANODIZED ALUMINUM CERAMIC MAGNETS MAGNET WRAP OPTIONAL MACHINED ALUMINUM CERAMIC MAGNETS WRAPS ARE BORED TO FIT SHAFT DIAMETER SENSOR ANODIZED ALUMINUM WATER RESISTANT EPOXY ENCAPSULATED COMPLETE WITH 10 CABLE SENSOR CABLE 2
8. 0 Speed Range Selection 6 1 Set dip switch for speed range see figure 5 page 6 POTIP POTIP3 TACH SET PT CALIBRATION CIRCUIT BOARD PIN 1326 DIP SWITCH SETTINGS VERY H SPEED Pl p 0 Arend FIGURE 6 7 0 Switch and Optional Meter Calibration NOTE For best results calibrate meter while machine is running under full load 7 1 Connect power as described in section 5 2 7 2 Run machine that you are monitoring and determine speed of monitored shaft A hand held tachometer is suggested 7 3 Power ON move slide switch to the OP position and turn POT P3 C W to decrease reading C C W to increase Match the readout on the meter with the speed of the monitored shaft see figure 6 page 7 CALL TOLL FREE g 800 328 0738 www maxigard com E mail techsupport maxigard com A211 11 Page 7 NOTE If an optional tachometer is not used or is inoperable a voltmeter set on low range 2 Volt DC can be used to calibrate the speed switch Attach the voltmeter leads to meter output connections on terminal block TB2 terms 4 and 5 The voltmeter scale will display the machine speed in a percentage of the meter scale see figure 4 page 5 EXAMPLE When the full operating speed is reached calibrate POT P3 until the voltmeter reads 1 2 Volt DC full scale range A 1 4 volt reading when calibrating the set point s would equal a 50 drop from 100 operating speed When the slide switch is in th
9. 2 GAUGE 2 WIRE SHIELDED BELDEN 8761 OR EQUAL ENCLOSURE NEMA 4 UL LISTED ELECTRICAL CONNECTIONS SCREW TYPE TERMINALS Relay Chart Contact Ratings V 240 AC 120 AC 36 AC Resistive AJ SPST DPDT 3POT 4PDT sPDT DPDT 3PDT 4POT A211 11 Page 11 OPTIONS DIGITAL OR ANALOG TACHOMETER TRANSMITTER OUTPUTS 4 20 mA INTO A 0 500 OHM LOAD OR VOLTAGE 0 10 VDC INTO A 20K OHM LOAD MINIMUM MAGNET SPLIT COLLAR WRAPS MAGNET PLATES EXPLOSION PROOF SENSOR RELATED BULLETINS INSTALLATION AND OPERATING INSTRUCTIONS A211 PRICING AP145 1 FULL LINE CATALOG A129 NOTE CONSULT FACTORY FOR WRAPS THAT WILL BE TURNING FASTER THAN 3000 RPM Nominal Ratings SPST DPDT 3POT 4PDT SPOT DPDT 3PDT 4POT 5 5 s 7 5 7 5 7 5 7 5 7 5 7 5 Note Inductive load cos 0 3 L R z 7msec www maxigard com E mail techsupport maxigard com A211 11 Page 12 TYPICAL MOTION SWITCH WIRING DIAGRAMS L1 120 240 Vac START STOP MOTION SWITCH THE A1000 A2000 MOTION SWITCH S LO SET POINT RELAY K1 HAS A BUILT IN TIME DELAY OF 7 5 SECONDS DELAY ACTIVATES ON START UP ONLY WIRING DIAGRAM A When the motor is started the motor starter auxiliary contacts close If the monitored shaft is rotating at proper speed the motion switch relay contacts open Should there be an unauthorized slow down or stoppage of the monitored shaft the speed switch relay contacts will then close energiz
10. NAL MAGNET WRAP lt 10 Feet gt XP SENSING HEAD AND MOUNTING BRACKET FIGURE 2 CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A211 11 Page 4 5 0 5 2 5 2 1 5 2 2 SECTION 2 FIELD WIRING Wiring NOTE See wiring Guide supplement part of these instructions pages 13 amp 14 Sensor Wiring Connect the sensor cable to terminal block TB2 terminals 1 2 3 located on the circuit board see figure 4 page 5 The sensor comes standard with 10 of cable if additional cable is required be sure to maintain continuity SENSING HEAD CABLE Use Belden 8761 or equal Cable should not be run in same conduit as power lines Maximum distance of cable run 10 000 Make good splice connections and check continuity Connecting Power WARNING Be sure that line voltage is off before connecting power SEPARATION OF CIRCUITS Field installed conductors in this enclosure connected to TB1 shall maintain a 2 inch minimum spacing between conductors connected to TB2 and shall be segregated from uninsulated live parts Apply 120 or 240 Volts AC power to terminal block TB1 terminals 1 2 3 4 see figure 4 page 5 Connect equipment grounding conductor to the ground terminal provided on the enclosure sub panel see figure 4 page 5 CALL TOLL FREE 800 328 0738 i www maxigard com E mail techsupport maxigard com A211 11 Page 5
11. _ A211 11 Page 1 952 361 3026 PROCESS CONTROL SYSTEMS INC Fax 952 368 4129 327 LAKE HAZELTINE DRIVE CHASKA MN 55318 800 328 0738 _ MAXIGARD Altraegap A1100 AND A1200 use PROCESS CONTROL SYSTEMS Introduction The MAXIGARD A1100 and A1200 are fail safe devices designed to monitor the rotation of critical driven shafts They are precision built of quality material and completely factory tested in insure long life and trouble free operation Principle of Operation While the shaft with magnet disc or wrap attached is rotating a 0 3 Volt AC signal is generated and picked up by the sensing head This signal is not impaired by build up of dust or any other foreign material on the magnet disc or sensing head The signal is processed through an electronic circuit and energizes the relays The relays have DPDT contacts A1100 Single Set Point The A1100 is designed to detect an unauthorized slow down stoppage or over speed of the monitored shaft The A1100 has one adjustable trip point relay and has a built in time delay of 7 5 seconds Delay activates on start up only The relay is DPDT The set point is designed fail safe Should there be a power failure loss of signal component failure etc the relay will de energize and put the switch in alarm condition A1200 Dual Set Point The A1200 is designed to detect over speed under speed slow down or stoppage of the monitored shaft It has two adjustable trip poi
12. e TP1 or TP2 position the voltmeter should read a percentage of the 1 2 volt full scale range see figure 6 page 7 and figure 7 and 8 pages 8 and 9 TACHOMETER METER CALIBRATION C C W SLIDE LOWER SWITCH READING C W RAISE READING POTIP1 POT P3 TACH PIN 1326 CIRCUIT BD FIGURE 6 8 0 Low Trip Point Adjustment K1 A1100 A1200 NOTE Machine does not have to be running to adjust set point However for best results it is suggested these adjustments be made while machine is running under full load w CALL TOLL FREE GRECS o 800 328 0738 S www maxigard com E mail techsupport maxigard com A211 11 Page 8 NOTE The A1100 and A1200 speed switches low set point relay K1 has a time delay of 7 5 seconds Delay activates on power up only 8 1 Move the TP slide switch to TP 1 position and adjust POT P1 to desired trip point by watching indicating meter pointer Turning POT C W to increase C C W to decrease see figure 7 page 8 8 2 Return the TP slide switch to the operate position OP The Motion Switch is now calibrated with trip point set and ready for operation wanting LO SET POINT K1 Do not set the relay t K1 below 5 APM Setting the trip below can result in the CCW relay romalning energized even if the monitored shalt le turning slower then 6 RPM Operate the LOWER TP1 monitored machine and check the set point function before placing system In service L SLIDE
13. electrical installations Proper grounding helps reduce the effects of electrostatic and electromagnetic interference The National Electrical Code gives the requirements for safe grounding Article 250 provides information about the size and types of conductors and methods of grounding electrical equipment The equipment grounding conductor to the A1100 A1200 connects to the terminal marked on the chassis Shielded cables connected to TB2 should have their shields connected to TB2 1 Shields should only be grounded at the A1100 A1200 end of the cable to prevent ground loops SUGGESTED CONDUIT CONNECTIONS TO MAINTAIN NEMA 4 INTEGRITY TYPE 2 CONDUCTOR RACEWAYS SHOULD ENTER THE ENCLOSURE IN THESE AREAS TYPE 1 CONDUCTOR RACEWAYS SHOULD ENTER THE ENCLOSURE IN THESE AREAS CROUSE HINES STL THREAD LUBRICANT l l CROUSE HINES l 3 4 RIGID C one Ronan 7 Wi FORM 7 OR EQUAL SECONDARY LOW POWER AND RELAY CIRCUITS CROUSE HINES OR EQUAL DRAIN ECD11 1 2 USE COPPER WIRE ONLY MAINTAIN 2 INCH SEPARATION BETWEEN TYPE 2 CONDUCTORS Figure 11 Figure 12 1 Separation of Circuits field installed conductors in this enclosure connected to TB1 shall maintain a 2 inch minimum spacing between conductors connected to TB2 and shall be segregated from uninsulated live parts film coated and or printed wire conductors on printed wiring boards See service manual and wiring guide for details
14. id to the factory and accompanied by the serial number description of defect order number and date of purchase This warranty shall not apply to any Maxigard product which shall have been repaired or altered outside of the Process Control Systems factory or has been subject to misuse negligence or accident Process Control Systems Inc warrants its products but not their application and shall not be liable for any incidental or consequential damages incurred through the use or loss of use of a Process Control Systems product No representatives or other person is authorized or permitted to make any warranty or assume for this company any liability not strictly in accordance with this guarantee There is no further warranty either expressed or implied beyond that set forth herein CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com
15. ing the alarm and or interlocking circuits ul q n 120 240 Vac START STOP MOTION SWITCH NOTE THE A1000 A2000 MOTION SWITCH S LO SET POINT RELAY K1 HAS A BUILT IN TIME DELAY OF 7 5 SECONDS DELAY ACTIVATES ON START UP ONLY WIRING DIAGRAM B When the motor is started the motor auxiliary contacts close The motion switch relay K1 is energized initially for approximately 7 5 seconds If the monitored shaft rotates at the proper speed K1 will remain energized holding in the motor circuit and preventing an alarm condition CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A211 11 Page 13 WIRING GUIDE SUPPLEMENT Wiring guidelines These guidelines are a tool to use in avoiding potential electromagnetic interference EMI problems They are not a substitute for the wiring practices called out in the National Electrical Code or applicable local codes Conductor types All conductors connected to TB1 or TB2 on the A1100 A1200 must be copper Two types of conductors are used Type 1 conductors Type 1 conductors are higher power conductors that are more tolerant to electrical noise They are connected to TB1 and include e AC power lines e Set point relay contact connections Type 2 conductors Type 2 conductors are lower powered conductors that are less tolerant to electrical noise They are connected to TB2 and include The speed switch sensor cable e
16. nt relays The low set point relay K1 has a built in time delay of 7 5 seconds Delay activates on start up only the relays are DPDT Each trip point is designed fail safe If there is a power failure loss of signal component failure etc the relay will de energize and put the system into alarm condition The speed switches have automatic resetting when the alarm condition ceases and the speed returns past the preset trip point the relays s will energize and allow the machine or process to restart and operate as normal However in some cases it is desirable that the relay s remain in the alarm condition regardless of the signal being received requiring a manual reset The standard relays can be equipped to perform this latching function Consult factory for latching instructions Components THE A1100 AND A1200 SWITCH PACKAGES INCLUDE 4 MAGNET DISC SENSING HEAD W 10 OF CABLE e MOUNTING BRACKET SPEED SWITCH CIRCUITRY NEMA 4 ENCLOSURE CALL TOLL FREE 800 328 0738 asss www maxigard com E mail techsupport maxigard com A211 11 Page 2 1 0 1 1 1 2 2 0 2 1 2 2 3 0 3 1 3 2 SECTION 1 MECHANICAL Magnet Disc The end of the shaft to be monitored should be square to prevent excessive disc wobble Center drill and tap the shaft end Suggested 21 drill and 10 32NF tap Bolt the magnet disc to the end of the shaft Use Loc tite to keep the bolt and disc tight on the shaft
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