A1000 Installation Instructions
Contents
1. NOTE NEMA 4X STAINLESS STEEL ENCLOSURE DOES NOT INCLUDE SIDE CLAMPS Figure 3A Figure 3B zz CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com 5 0 5 1 5 2 6 0 6 1 6 2 6 3 A102 05 Page 5 SECTION 2 FIELD WIRING Sensor Wiring Connect the sensor cable to terminals black white and shield located on the terminal block TB1 see figure 4 page 6 The sensor comes standard with 10 of cable Additional cable can be added as required Be sure to maintain continuity Wrap the splice with the foil shield and electrical tape SENSING HEAD CABLE Use Belden 8761 or equal Cable should not be run in same conduit as power wires Maximum distance of cable run 10 000 ft Make good splice connections and check continuity Wiring the A1000 Speed Switch WARNING To avoid electrical shock disconnect all sources of power to the motor Starter before wiring and observe voltage ratings of the speed switch Power connections and relay connections to the A1000 speed switch are shown on figure 4 page 6 Also figures 5 6 and 7 show typical wiring diagrams Connect 120 VAC power to L1 and neutral to L2 on terminal block TB2 see figure 4 page 6 See figures 5 6 and 7 for examples of typical wiring diagrams Connect equipment safety ground to GRD on terminal block TB2 Make relay connections2. The power on delay can be disabled by reconfiguring the time delay jumper pins see figure 8 page 10 An additional contact is available to sound an alarm horn turn on another type of warning device or interlock with other equipment ee CALL TOLL FREE 800 328 0738 I mai www maxigard com E mail techsupport maxigard com A102 05 Page 9 TYPICAL WIRING TO PLC OR CONTROL RELAY 120VAC PLC Input Module 120VAC Figure 7 When 120 VAC is applied to L1 and L2 the A1000 speed switch is powered on and a power on delay of approximately 7 seconds begins During the power on delay the relay contacts are held in the switched position allowing the motor to run As long as the monitored shaft is above the set point speed before the power on delay period has expired the relay contacts will remain in the switched position If the monitored shaft speed stops or slows down below the set point speed the N O relay contacts open When the monitored shaft soeed exceeds the set point the N O relay contacts close The power on delay is reset when power is removed from L1 and L2 If the A1000 is continuously powered the power on delay only occurs at initial power up The power on delay can be disabled by reconfiguring the time delay jumper pins see figure 8 page 10 gq CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 10 SECTION 3 C
3. 10 AMP RELAY e NEMA 4 ENCLOSURE zz CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 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 see figure 1A amp 1C 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 1B amp 1D 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 it is centered directly in front of the magnets in the disc or optional wrap see figure 1A 1B 1C amp 1D page 3 The gap setting between the sensor and magnet disc should be approximately 1 8 7 8 qq CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 3 SENSING METHOD STANDARD SENSING HEAD amp MAGNETIC DISC STANDARD SENSING HEAD amp MAGNETIC WRAP 1
4. To calibrate the operating speed place the slide switch in the operating speed position OP With the machine running at normal operating speed adjust potentiometer P3 CCW to increase CW to decrease until the voltmeter reads the recommended DC voltage as shown on table 1 USE P3 TO ADJUST USE P1 TO ADJUST SWI OP SW1 TP RECOMMENDED 100 TACH OUTPUT 120 110 VOLTAGE SETPOINT SETPOINT SETPOINT SETPOINT SETPOINT OPERATING SPEED VOLTAGE VOLTAGE VOLTAGE VOLTAGE VOLTAGE OPERATING SPEED RPM Table 1 To calibrate the set point place the slide switch in the set point position TP Calculate the set point value by taking a percentage of the operating speed tach output voltage from table 1 Adjust potentiometer P1 until you reach the desired set point on the voltmeter CW to increase CCW to decrease The machine does not need to be running to make this adjustment see figure 9 page 12 EXAMPLE If the operating speed of the monitored shaft is 300 RPM set P3 for a voltmeter reading of 1 00 VDC while the machine is running at 100 For an 80 set point 240 RPM setP 1 for a voltmeter reading of 80 VDC 1 00 VDC x 80 80 VDC see table 1 CALL TOLL FREE 800 328 0738 D a as www maxigard com E mail techsupport maxigard com A102 05 Page 12 93 Return the slide switch to the OP position The meter will now display the operating voltage The set point will still function properly if the slide switch SW
5. or implied beyond that set forth herein PAA CALL TOLL FREE 800 328 0738 aiS www maxigard com E mail techsupport maxigard com
6. to terminal block TB2 Normally open contacts are held closed and the normally closed contacts are held open when the shaft speed exceeds the calibrated set point zz CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 6 4 7 8 4 1 4 rte GRD TACH Emea a 7 CALIBRATION CONNECTION 8 L1 SENSING HEAD C 1 SAVIT GE CONNECTION 4 7 8 SET NO 2 POINT OPTIONAL RELAY NC 3 sith C 4 NO 5 SPEED RANGE NC 6 SELECTION DIP SWITCH SW1 PN 1325 CIRCUIT BOARD PN 1315 CIRCUIT BOARD Figure 4 wag CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 7 TYPICAL WIRING TO MOTOR STARTER 120VAC Figure 5 When the start pushbutton is pressed the A1000 speed switch is powered on and a power on delay of approximately 7 seconds begins During the power on delay the relay contacts are held in the switched position allowing the motor to run As long as the monitored shaft is above the set point speed before the power on delay period has expired the relay contacts will remain in the switched position allowing the monitored machine to run normally If the monitored shaft speed slows down or stops below the set point speed the N O relay contact holding in the motor starter contact will open and drop out the motor starter The power on delay is reset when the motor starter drops out and power is interrupt
7. 1 is in the TP position see figure 9 page 12 9 4 A1000 speed switch is now calibrated 10 0 Calibration with Optional Tachometer If the optional tachometer is supplied with the A1000 connect the meter as shown in figure 9 page 12 10 1 To calibrate the operating speed place the slide switch in the operating speed position OP With the machine running at normal operating speed adjust potentiometer P3 until the display meter reads 100 CCW to increase CW to decrease see figure 9 page 12 10 2 To calibrate the set point place the slide switch in the set point position TP Adjust potentiometer P1 until you reach the desired set point on the display meter CW to increase CCW to decrease The machine does not need to be running to make this adjustment see figure 9 page 12 10 3 Return the slide switch to the OP position The meter will now display the operating speed The set point will still function properly if the slide switch SW1 is in the TP position see figure 9 page 12 10 4 The A1000 speed switch is now calibrated TACH CALIBRATION rg Pa OPTIONAL TACHOMETER SLIDE SWITCH a TP Id P1 z OP OPTIONAL SPEED RANGE TACH SELECTION OUTPUT DIP SWITCH POT P1 Swi CW INCREASE CCW DECREASE POT P3 CCW INCREASE CW DECREASE en Figure 9 CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 13 SPARE PARTS LIST Part No Des
8. 8 to 7 8 GAP 1 8 to 7 8 GAP MAGNET WRAP Figure 1A Figure 1B XP SENSING HEAD amp MAGNETIC DISC HO OE I 1 8 to 7 8 GAP 1 8 to 7 8 GAP LB si Figure 1C Figure 1D DIMENSIONAL DATA E 1 1 2 Fe 4 1 1 1 2 p oan 1 Is i 1 2 NPS 3 4 1 2 NPS 3 4 MATERIAL RED ANODIZED 2 2 1 3 8 ALUMINUM 13 8 MATERIAL dey p L PVC STANDARD MAGNET DISC STANDARD SENSING HEAD AND MOUNTING BRACKET NEMA 4X SENSING HEAD AND MOUNTING BRACKET JT 3 had Way 4AN ey 10 OPTIONAL MAGNET WRAP XP SENSING HEAD AND MOUNTING BRACKET mm Figure 2 CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com A102 05 Page 4 4 0 Speed Switch Enclosure 4 1 A1000 enclosures are UL CSA listed rated NEMA 4 dust tight oil tight and water tight painted carbon steel construction suitable for indoor and outdoor use NEMA 4X fiberglass or stainless steel available see figure 3A amp 3B page 4 CAUTION Remove the circuit board from the enclosure before punching or drilling conduit holes Be sure to remove all metal chips and filings NEMA 4 PAINTED CARBON STEEL NEMA 4X FIBERGLASS OR NEMA 4X STAINLESS STEEL 61 2 7 1 8
9. A102 05 Page 1 952 361 3026 PROCESS CONTROL SYSTEMS INC Fax 952 368 4129 PROCESS CONTROL SYSTEMS 327 LAKE HAZELTINE DRIVE CHASKA MN 55318 800 328 0738 MA XIG4RD Altraegap MAXIGARD A1000 SPEED SWITCH Introduction The Maxigard A1000 speed switch is designed to monitor the rotation of critical driven shafts The switch is precision built of quality material and completely factory tested to insure long life and trouble free operation Principle of Operation The Maxigard A1000 speed switch is supplied with a non contacting sensor and magnetic target The sensor signal is not impaired by buildup of dust or any other foreign material on the magnet disc or sensor This switch is designed to detect under speed or over speed of the monitored shaft The A1000 has one adjustable set point and a built in power up time delay of approximately 7 seconds which allows machinery controlled through the motor starter circuit to reach the set point during start up The delay activates on power up only and can be disabled with a field selectable jumper pin configuration When properly installed and calibrated in the event of a power failure or loss of sensor signal the relay will de energize and put the switch into an alarm condition Components THE A1000 SPEED SWITCH INCLUDES e 4 MAGNET DISC OTHER OPTIONAL MAGNETIC TARGETS AVAILABLE e SENSOR WITH 10 OF CABLE AND MOUNTING BRACKET e A1000 SPEED SWITCH CIRCUIT BOARDS WITH
10. ALIBRATION 7 0 A1000 Speed Switch Calibration 7 1 Set the A1000 dip switches for the proper speed range based on the normal operating speed of the monitored shaft see figure 8 page 10 POT P1 POT P3 SETPOINT TACHOMETER ADJUSTMENT CALIBRATION SWITCH OPERATING SPEED TIME DELAY JUMPER SETTINGS JUMPERS ENABLED DISABLED uun 123 800 to 3000 to 3000 9000 RPM RPM Figure 8 8 0 A1000 Start Delay Configuration 8 1 The A1000 can be configured with or without a 7 second start delay With the start delay feature enabled the A1000 relay will automatically energize for 7 seconds upon power up This feature is used to allow the monitored shaft to reach the set point speed during start up without causing an alarm condition If the shaft has not reached the set point speed before the 7 second start delay period has expired then the A1000 switch will go into an alarm condition With the start delay feature disabled the A1000 relay will not energize until the monitored shaft soeed exceeds the calibrated set point see figure 8 page 10 qu CALL TOLL FREE 800 328 0738 www maxigard com E mail techsupport maxigard com 9 0 9 1 9 2 A102 05 Page 11 Calibration with Voltmeter lf the optional tachometer is not supplied with the A1000 a voltmeter can be used to calibrate the speed switch Connect the voltmeter leads to terminal block TB1 optional tach output connections and see figure 9 page 12
11. cription 1315 A1000 Power Supply Circuit Board Without Relay 1325 Low Set Point Circuit Board 1129 Standard Sensor With 10 Cable 1130 Mounting Bracket With Jam Nuts 1132 Explosion Proof Sensor With 10 Cable 1134 Mounting Bracket 1136 4 Magnet Disc 1320 Relay DPDT 10 AMP 120 VAC 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 prepaid 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
12. ed to the A1000 The power on delay can be disabled by reconfiguring the time delay jumper pins see figure 8 page 10 An additional contact is available to sound an alarm horn turn on another type of warning device or interlock with other equipment qa CALL TOLL FREE 800 328 0738 as www maxigard com E mail techsupport maxigard com A102 05 Page 8 TYPICAL WIRING TO MOTOR STARTER 120VAC Figure 6 When 120 VAC is applied to L1 and L2 the A1000 speed switch is powered on and a power on delay of approximately 7 seconds begins During the power on delay the relay contacts are held in the switched position allowing the motor to run As long as the monitored shaft is above the set point speed before the power on delay period has expired the relay contacts will remain in the switched position allowing the monitored machine to run normally If the monitored shaft soeed slows down or stops below the set point speed the N O relay contact holding the motor starter contact will open and drop out the motor starter The power on delay is reset when power is removed from L1 and L2 If the A1000 is powered continuously the power on delay only occurs at initial power up and is not available for later restarts If continuously powered the start pushbutton will need to be held closed until the monitored shaft reaches operating speed allowing the motor starter to seal through the motion switch contact
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