Aircare VariPhase User manual

AirCare VariPhase™
User Manual
ACV1xxx Family of MODBUSEquipped
Speed Controls for Fans and Blowers
2-14 Amperes
www.aircareautomation.com
Variphase HP
Variphase

Revision 1.1 Variphase User Manual Page 2
Contents
Contents......................................................................................................................... 2
Product Overview........................................................................................................... 3
Part Numbers and Ratin s ............................................................................................. 4
About this User Manual .................................................................................................. 4
Safety............................................................................................................................. 5
Compliance..................................................................................................................... 6
Recognized Component ................................................................................................6
UL Listed evice..........................................................................................................6
Entela Certified evice .................................................................................................6
Installation .................................................................................................................... 7
Additional Information for Networked Systems ...................................................................7
General Operation .......................................................................................................... 8
Variphase Features .........................................................................................................8
Variphase HP Features.....................................................................................................8
Control Mode Overview....................................................................................................9
Option Jumpers ..............................................................................................................9
Address IP Switches ....................................................................................................10
Soft-Start ....................................................................................................................10
Control Confi uration Examples ................................................................................... 10
Analog Speed Control Using Potentiometer.......................................................................10
Overview ..................................................................................................................10
Configuration ............................................................................................................10
Wiring ......................................................................................................................10
Analog Input Closed-Loop Control ...................................................................................11
Overview ..................................................................................................................11
Configuration ............................................................................................................11
Wiring ......................................................................................................................11
Analog Speed Control with Speed Regulation....................................................................12
Overview ..................................................................................................................12
Configuration ............................................................................................................12
LE Indicators..............................................................................................................13
iagnosing Other Faults.................................................................................................13
Electrical Wirin and Specifications ............................................................................. 13
Control Terminal Connections .........................................................................................13
Power Connections........................................................................................................13
Power Wirin for Variphase 2-8 Amp Models ............................................................... 14
3 wire motor connection ................................................................................................14
Power Wirin for Variphase HP Models ........................................................................ 16
3 wire motor connection ................................................................................................16
Network Communications ............................................................................................ 17
Register efinition Summary ..........................................................................................18
Installation...................................................................................................................19
Hall Sensor for Speed Sensing and Regulation ..................................................................19
Frequently Asked Questions......................................................................................... 19
AirCare Console and AirCare Variphase are trademarks of AirCare Automation Inc.
MO BUS is a registered trademark of Schneider Automation

Revision 1.1 Variphase User Manual Page 3
Product Overview
AirCare Variphase™ controls combine intelligent speed control with industry standard MO BUS
networking. The versatile design allows for either analog (0-5V or 20mA loop) or network speed
control.
In network mode, each VariPhase™ unit is assigned a unique address. By linking Variphases
together with networking cables, a Zone of up to 125 units can be built. Each unit can then be
precisely controlled from a single AirCare Console™. Consoles models support up to 4 zones, or
500 Variphases in total.
For optimal efficiency and reduced acoustic noise, Variphase models include intelligent Auxiliary
winding control using a 3rd wire to the motor. Permanent Split Capacitor (PSC) motor loads can
be connected in three-wire mode, or wired conventionally for standard operation.
Variphase’s closed-loop control capability supports a wide range of sensors including air-pressure,
temperature and tachometers. In closed-loop mode, Variphase precisely adjusts motor speed
using a PI loop to maintain a set-point.
Installing a distributed network of AirCare controls is simplified by flexible wiring options and
diagnostic LE s. AirCare can also be controlled from an analog signal source.
Variphases come in three form factors, depending on their current rating. Variphases rated at
less than 2 amps are supplied as a board only and require 4 standoffs for mounting. From 3-6
amps, controls are supplied with a standard aluminum L-bracket that also serves as a heatsink.
16 amp Variphase’s incorporate an extruded aluminum heatsink for robust thermal management.
Optional covers provide NEMA1 level protection for all ratings.
Variphase HP has four sets of power terminals to simplify connection to up to four motors. In this
configuration all four motors will be supplied with the same voltage and run at the same speed.
Variphase is a robust variable-voltage motor speed control. Internal algorithms precisely control
motor voltage resulting in a wide speed range (typically 20-100%).

Revision 1.1 Variphase User Manual Page 4
Part Numbers and Ratings
AirCare’s Variphase line-up consists of 11 base part numbers covering ratings from 115V 1.7A to
277V 14A.
Input / Max Output Volta e
Input/Output
Current at
25°
°°
°C (max)
Ambient
(max) 115Vac
+/- 15%
230Vac
+/- 15%
277Vac
+/- 15%
1.7 Amp 25°C ACV1021 ACV1022
3 Amp 40°C ACV1033
4 Amp 40°C ACV1041 ACV1042
Variphase
8 Amp 40°C ACV1081 ACV1082 ACV1083
Variphase HP 14 Amp 25°C ACV1141 ACV1142 ACV1143
• Refer to individual datasheets for complete information on model ratings.
• Some Variphase models have specific mounting requirements to achieve max current
• All parts operate from both 50Hz and 60Hz AC Line.
• 1.7 Amp models should be de-rated at 0.1 Amps per 3°C up to 40°C
• A ‘U’ suffix indicates UL listed product, other parts are UL recognized components
About this User Manual
This document contains information on installation and use of all Variphase models. For detailed
voltage, current and temperature rating information, refer to individual datasheets. Separate
Application notes provide additional information on Variphase configuration.
For detailed functional and configuration information for AirCare Variphase Controls refer the
Advanced Technical Manual.

Revision 1.1 Variphase User Manual Page 5
Safety
Important Information – please read first
• This product is an open frame design containing dangerous voltages. It should only be
installed by trained personnel. The installer is responsible for ensuring that the control is
safely installed for a particular application. Incorrect installation can result in a serious
shock or fire hazard.
• Wiring should be checked before power is applied. Check that Low Voltage control wiring
is sufficiently insulated from high voltage power wiring.
• The control is designed to operate up to 40ºC ambient temperature. Because factors such
as airflow and orientation affect heat dissipation the installer should ensure that the
heatsink does not exceed 70ºC worst case. Refer to individual datasheets for complete
rating information.
• This control is not recognized for use as a motor protector. The attached motor must have
its own recognized over-load protection device.
• The drive does not have over speed protection
• This product cannot be used in any equipment intended for life support.
• The type of motor control (on/off and speed) provided by this drive is not sufficient for
safety-critical applications without additional mechanical/electrical interlocks.
• Where the control is approved as a recognized component, it is for use only in complete
equipment where the acceptability of the combination is determined by an approved
testing agency.

Revision 1.1 Variphase User Manual Page 6
Compliance
AirCare Variphase products carry the following safety approvals. Model numbers not listed below
are not presently agency approved.
Reco nized Component
UL508c Power Conversion Equipment
CAN/CSA C22.2 No. 14-M91.
UL File number E241590.
ACV1021 ACV1022 ACV1033 ACV1041
ACV1042
UL Listed Device
UL508c Power Conversion Equipment
CAN/CSA C22.2 No. 14-M91.
UL File number E241590.
ACV1033U ACV1041U ACV1042U
Entela Certified Device
UL508c Power Conversion Equipment
ACV1081U ACV1082U ACV1083U

Revision 1.1 Variphase User Manual Page 7
Installation
Because implementations vary, please read the relevant sections of this document thoroughly.
Pay special attention to the safety warnings on Page 5.
The recommended procedure for installing and configuring a Variphase system is:
Networked System Non-networked System
Select appropriate Variphase Model based on
Voltage and Current Requirements
(see Page 4)
Select appropriate Variphase Model ba
sed on
Voltage and Current Requirements
(see Page 4)
Select 2-wire or 3-wire motor control method
(see Page 14-16)
Select Control Console – Available separately
from AirCare Automation Inc.
Select 2-wire or 3-wire motor control method
(see Page 14-16)
Configure Option Jumpers
(see Table 2) Configure Option Jumpers
(see Table 2)
Set each Variphase with a
unique Modbus Address
(see Page 8)
Mount and Enclose Variphase
(see Page 19)
Mount and Enclose Variphase
(see Page 19)
Install Network Wiring
(see Page 17)
Install Control Wiring from Potentiometer or
other analog source
(see Page 10-12)
Install Speed and/or Pressure Sensor if used
(see Page 15 and application notes) Install Speed Sensor (optional) (see Page 12 and application notes)
Install and check Power Wiring
(see Page 14-16) Install and check Power Wiring (see Page 14-16)
Power Up and Test Power Up and Test
Table 1
Additional Information for Networked Systems
For large systems, we recommend testing small sub-systems before completing full-scale
installation.
In some systems additional RS485 devices may be needed to resolve offsets in ground voltage
and ambient noise. For large installations, consult AirCare Automation for advice on RS485
network configuration.

Revision 1.1 Variphase User Manual Page 8
General Operation
Variphase Features
Fi ure 1
Variphase HP Features
Control Terminals
LE Indicators
RS485 Network Ports
Minimum Speed Pot
Power and Motor Connections
Option Jumpers
Address Switches
L-Bracket
Control Terminals
LE Indicators
RS485 Network Ports
Minimum Speed Pot
Power and Motor Connections
Option Jumpers
Address Switches
Heatsink
Fi ure
2

Revision 1.1 Variphase User Manual Page 9
Control Mode Overview
Variphase operates in one of five selectable modes:
1. Networked Speed Control
2. Analog Speed Control
3. Networked Control with Tachometer Speed Regulation
4. Analog Control with Tachometer Speed Regulation
5. Analog Closed Loop Control
Speed regulation modes use an external Hall-effect sensor to provide a speed feedback signal
from the motor. In this mode, Variphase will hold motor speed constant, even under varying load
conditions. In networked mode it also allows the speed to be set in RPM units.
Modes are selected using Jumper Shunts JP1 and JP5, and by network commands from AirCare
Consoles.
In Analog Closed Loop Control Mode, Variphase compares an Analog feedback signal to an Analog
set-point and adjusts speed accordingly.
All Closed Loop control modes (Modes 3-5) use a fully programmable PI loop to allow response
and stability adjustments.
An AirCare networked system requires a compatible Modbus host. In most cases this will be an
AirCare Automation Console, but other Modbus devices can be used if configured correctly. Refer
to the Network Specification section of this document for more information.
Option Jumpers
JP1 JP2 JP3 JP4 JP5 JP6
Analog 20mA Baud 4-20mA Regulate
Speed
4-Wire
Table 2
Analog Install jumper to select analog input speed control from either 0-5V or
4-20mA sources. When jumper position is open, the control responds
to Modbus speed commands.
20mA Install Jumper to enable current loop shunt on Analog Input 1. JP1
should also be closed to enable 4-20mA control. Leave switch open
for 0-5V control.
Baud Install jumper to select 9600 baud. efault is 1200.
4-20 Install jumper to enable 4-20mA loop on Analog Input 1. If jumper
position is open, the 4mA offset will not be factored, resulting in a 0-
20mA control range.
Regulate
Speed
Install jumper to enable closed loop control using an external speed
sensor. The sensor will be used to regulate the set speed in RPM. If
jumper position is open, the sensor input will not be used for motor
speed control but in network control mode, RPM will still be reported if
a sensor is connected.
4-Wire Fit Jumper to select 4-wire (RS422) communications. efault (jumper
open) is 2-wire (RS485) communications.

Revision 1.1 Variphase User Manual Page 10
Address IP Switches
Each Variphase in a network must be set to a unique address between 1 and 127. There are 8
switches on the IP switch block of which switch 1-7 are used for addressing. Switch 8 should be
left in the OFF position (not used for addressing). Refer Figure 10 for switch position examples.
Address 0 is reserved for the Control Console (MO BUS master).
Note: Option jumpers and address settings are only checked by the VariPhase controller at
power-up, so power must be cycled before any changes take effect.
Soft-Start
Normally the motor voltage responds immediately to a change in analog input signal. Some
applications may require a soft-start to reduce start-up currents. To enable soft-start, set the
Soft-Start bit in the Mode Register (Register 23). This register is non-volatile.
When enabled, soft-start will occur when the output changes from a stop to start, either by
increasing the analog input from zero, or by the optional enable/disable signal.
Variphase will ramp to the new set-point at a rate determined by PI Rate Register (Register 20).
Each bit in Register 20 represents 50ms for each percentage speed change. A value of 20, will
give a soft-start of 1% / second (100 seconds to reach full-speed).
Soft-Start has no effect in closed-loop control modes.
Control Configuration Examples
Analog Speed Control Using Potentiometer
Overview
• An external potentiometer controls
output from minimum to 100%.
• Adjust Minimum speed using on-
board MIN speed trim pot and a
screwdriver.
• Turning potentiometer to zero turns
off motor.
Confi uration
• Remove JP2, JP4 and JP5 (if
installed)
• Install JP1 (Enables Analog Input)
• o not make connection to ANA2.
Wirin
7 Way 0.2" Terminal Block Plug
Phoenix 1757064 or sim ilar
Potentiometer
5K - 50K Ohms
+5V
Hall
0V
+12V
ANA2
0V
ANA1
Variphase C ontrol Terminals
Fi ure
3