Fantech AVA Series Installation and operating instructions

PRODUCT ADVICE SHEET
Fantech AVA series
 VSD Remote electronic speed control in fan, blower,
pump or applications where the torque varies with
speed. Load independent speed control of universal
& shaded pole motors.
 Energy efficient 3-wire PSC motor configuration. 2
separate outputs for main / auxiliary windings. Can
also be connected as simple 2-wire system.
 Power Control. Remote stepless electronic power
control of resistive loads eg - lamps & heaters.
 Multiple & dissimilar loads accommodated.
 EMI Filters built in. Ctick approved – no external
filters required.
 Selectable input 0–10 VDC or 2 – 20ma control
signal with adjustable min / max levels.
 Factory calibrated for most fans or pumps.
 Easy custom calibration internal test source &
simple range (span & offset) adjustments.
 Auto OFF at low signal levels <0.8V / 1.5ma
 Double isolation of control signal and mains
circuitry via transformer and opto-isolation.
 Range of power ratings 1200 VA - 7200 VA.
 Custom applications. Specific control parameters,
interfaces, environmental probes.
 RoHS compliant and Ctick approved.
 IP65 version available with removable base that
can be separately drilled / mounted
FEATURES
Universal Power / VSD Controllers
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SPECIFICATIONS Fantech Model AVA Universal Power / VSD Controllers
APPLICATIONS
Speed control of most single phase PSC motors with mechanical loads such as fans, centrifugal pumps or
those applications where the torque of the load varies with speed. Can also control shaded pole and
universal motors with any type of mechanical load. Remote stepless power control of all general resistive and
inductive loads such as lamp, heating elements or transformers. Multiple & dissimilar loads can be
accommodated simply by connecting in parallel.
TECHNICAL BASIS
Phase angle control of AC mains. B version – single output for small PSC motors connected as 2-wire,
universal and shaded pole motors, lamps, heaters and transformers. D version – dual outputs for small,
medium and large PSC motors and all other types of loads that require main & auxiliary control outputs.
Standard proportional control via 0–10 V or 2-20ma DC control signal.
RATINGS
RMS continuous
Single phase 240 V AC (+10/-20%) 50 Hz. Also available for 110V 60 Hz.
AVA5.0 – 1200 VA 5A AVA8.0 – 2000 VA 8A AVA10.0 – 2400 VA 10A. (other sizes also available)
Main variable output rated to full rated power and can be varied between ~20 and 100%.
Auxiliary output is zero voltage solid state switched and can be rated up to 100% rated power. Total
controlled plus auxiliary output power should not exceed 100% of maximum controller rated power.
Environmental: up to 50oC in free air for AVA5.0 & AVA8.0 (no de-rating required). For AVA10.0 to
AVA20.0 de-rate (max VA) 1.6% x “max VA rating” per oC above 30oC. Max case temp all models 70 oC.
PROTECTION
Surge protection network incorporated on board for over voltage / noise spikes. Control circuit for remote
control signal operates at 12 volts DC and is totally isolated from the supply mains / load power circuit by a
double insulated fully encapsulated BS415 rated transformer and a 5000V opto coupler between control
input & power output. Generous power design parameters – controller designed for PSC motor starting and
reasonable short term overload conditions. On-board replaceable fuse in ~L line. External DB MCB
overload / isolation protection recommended for motor load is usually adequate to protect controller.
CONTROL INPUTS
0-10 volts terminals B (+ve) & Cwith input resistance 1 Mohm. 2-20ma on terminals B (+ve) & Cwith sink
resistance = 500 ohm. An internal 10V DC source (max 50 ma) is provided between terminals A(+) & C
which can be used for custom remote control applications, a remote or local potentiometer or testing.
AUTO TURN-OFF
At low control levels, the controller is designed to shut down the main control and auxiliary outputs. Normal
operation resumes at higher control levels. Auto turnoff occurs at < 0.8 VDC for voltage input, ~<5% for a
potentiometer, < 1.5 ma for 2 - 20 ma.
COMPLIANCE Fitted with internal Electromagnetic Interference suppression network, and complies with AS/NZS CISPR
14.1:2003 when correctly installed. ACA C-Tick lev 2 N29529. ROHS compliant.

MOUNTING &
CASE
Extruded aluminium. IP30. 174L x 114W x 74D fixing width 111mm wt 0.8 – 1.1Kg. Anodised and wall mountable
extreme environment diecast IP65 options available.
Removable aluminium end plates held in place with cs self tap screws. One end plate cover for terminal access & cable
entry whilst the other is for setting potentiometers.
OPTIONS
Specify at the time
of ordering
Higher Power: AVA15.0 – 3600 VA 15A AVA20.0 – 5000 VA 20A AVA30.0 – 7200VA 30A
B version only 1 auto-off control output Low Power cut-down version (small footprint): AVA3.0 – 600VA 2.5A
Input: * Other current or voltages
Sensors: Proportional or inverse proportional temperature thermistor. Specify ToC range & lead length
Auto off level: * no auto off level * adjustable auto off level (approx. 2 – 35% of max)
Input modules: * PID module for pressure, air velocity , temperature, humidity or other control parameters.
Enclosures: * IP65 powder coated diecast enclosure.
RELIABILITY Fantech controllers are built for long service life and have been proudly designed & manufactured in Australia for
Fantech using pragmatic design criteria and high grade components. Appropriate quality control is ensured throughout
their manufacture. Fantech has a commitment to on-going research and development of its products.
CONNECTION
Internal 300 VAC 30A UL95V0 5-way terminal strip with screw wire protection terminals able to take up to 2 x 2.5mm2
or a 1 x 4mm2conductors. Control input has smaller 300 VAC 5A UL95V0 3-way terminals. Cable entry plate has 2x10
& 1x4mm neoprene grommets or can be specified as blank for customer specific gland / entry requirements.
CONTROL SIGNAL B = +ve signal C= -ve or ground A= +10 volts constant voltage source (max 50ma)
INPUT/OUTPUT: terminal block mounted inside enclosure end plate marked Mm Ma Mc ˜L ˜Lc.
Mm Controlled Output. (Motor main) Up to 100% of total load. NB controlled + aux not to exceed 100% rated VA
Ma Auxiliary Switched Output (Motor aux for 3-wire control). Up to 100% of total load
Mc Common output Note: Mc & Lc are internally connected. Connection of Mc optional if external common used.
˜L – Mains input ˜Lc – Mains common input Scrn – miniature control signal screen earth terminal provided
SETTING &
ADJUSTMENT
A user selectable 2-20ma control input can be selected on the PCB via a miniature link plug. Span and Offset – two
preset potentiometers permit the user to custom calibrate maximum and minimum motor speeds over a range of control
inputs. A switchable internal calibration source with a 3rd preset potentiometer can be used to set up and test the
installation without needing an external control signal. Two test pins are provided to monitor the control signal during set-
up or testing using an external DC voltmeter. Factory calibration is 1VDC for an output of ~120 VAC (RMS) which is ~
32% of power or ~38% of most motors maximum speed and 9.2 VDC for an output ~238 (234 for 2-wire) VAC (RMS)
which is ~ 98% of power / maximum speed. Control input protected for voltages >10 VDC.
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WIRING DIAGRAM
External earth 4mm
Mm Controlled output. Motor main
Ma Auxiliary output. Motor aux
Mc Common output
~Lc Mains input common 240VAC
~L Mains input 240 VAC
+10 VDC test/ aux
-ve signal
Scrn screen for control signal (caution!)
AVA & RC10x series VSD
A
B
C
+ve signal
Heater, Lamp or
Transformer
Mc
Mm m
a
in MOTOR
aux
Earth
com
Motor - 3 wire generic
>200 Watt PSC
Mc
Ma
Mm
Motor - 2 wire option
small PSC, all universal, all shaded pole
m
a
in MOTOR
aux
Earth
com
Mc
Mm
Ma
Optional Switched
Auxilary Circuits
Mc
input
DCV / ma
Prop T
sensor
Inv Prop T
sensor
Pot
240 VAC
Mains L1
Mains L2
L1
L2
remove link
if fitted

GUIDELINES FOR INSTALLING the AVA series of VSD controllers
How does the controller work? Fantech single phase controllers vary available power to the load using phase angle conduction control. As the conduction angle is reduced, the
power to the load is reduced. This reduction is accompanied by a reduction in the AC voltage across the load and can be used as an indicator of the power change or calibration
reference. In resistive, transformer, universal motor and shaded pole motor applications, the main output is used. For PSC motors, either 2 or 3 wire control can be used. 3 wire has
separate outputs for the main and aux windings of the motor from the controller.
How effective and efficient? There is much to be said for keeping things simple! It is in this spirit that Fantech single phase controllers have been designed. There are no micro
controllers or sensitive electronic components – justsimple rugged commercially designed circuitry and industrially rated power components that can be protected using standard
MCB’s and fuses. There are many ways to vary power to AC loads. For resistive and transformer type inductive loads, Fantech Controllers are highly effective and very efficient
(~95%) . For universal brush type motors they are also efficient but for some motors minor “cogging” can occur at very low speed settings due to AC waveform and brush / commutator
being out of sync. For induction type capacitor run PSC motors using a permanent aux/ run capacitor, phase angle control is highly effective for loads where the torque requirements
changes with speed – eg fans and pumps. Efficiency is ~70% for the 2-wire method and can be >90% for 3-wire configurations & comparable to the more complex 3-phase variable
frequency V/F or inverter drives. The graph below shows typical power efficiencies for a single phase fan using std 3-speed windings, 2-wire and 3-wire control.
Motor considerations Phase angle conduction control is suitable for all types loads connected to universal (brush) or shaded pole motors. For PSC capacitor run motors there
are some criteria essential for successful speed control. If a reasonably linear change in speed is required, the motor mustbe suitable for speed control, it must be optimally sized for
the load and the load torque characteristics must change (increase) with speed. Fans and centrifugal pumps are ideal but high starting torque loads such as compressors or loads
whose torque does not change with speed, are not. Split phase and capacitor start capacitor run motors cannot be used with a speed control due to the startcircuit which is usually
motor speed dependant. Inefficient & poorly matched motor / load combinations are more difficult to speed control particularly where the motor is sized much larger than the load
requires.
Output Configurations The AVA can be connected in two different configurations. For transformer, resistive loads, shaded pole motors or universal (brush) motors, the output is
between Mm and Mc. For PSC motors there are two ways in which the motor may be wired. Generally the 2-wire is simplest and can be used for smaller motors <150W output power.
The 3-wire configuration involves connecting the main and auxiliary windings of the motor to different parts of the AVA controller. Three wires are thus involved – input, main output and
auxiliary output. The 3-wire is slightly more complex but for most motors offers better speed control over the range, higher efficiency, lower motor noise and lower motor temperature.
NB: For all Fantech fans, CMG motors and motors >200w, the 3-wire configuration MUST be used. The AVA series of VSD’s can individually control more than one motor (similar or
dissimilar) provided the maximum current of all motors does not exceed the maximum controller current.
Wiring For resistive loads and shaded pole / universal (brush) AC/DC motors use terminals Mm and Mc for the output. This is termed simple 2-wire control. Terminal Ma (ver D) is a
solid state 240 VAC output, uses zero voltage switching & cuts in slightly after the main output. This minimises switching surges and EMI. Terminal Ma in ver D controllers can also be
used for switching auxiliary loads ON/OFF - eg pilot lamps, shutters, contactor, aux motor windings – NB max total power of main and aux outputs must not exceed 100% of total
controller rated power.
For PSC (capacitor run) motors, there are 2 ways in which the motor may be wired to the controller. The 3-wire configuration requires disconnection of one side of the capacitor from
the main motor terminal & route this as the 3rd wire from the motor to the controller aux output – Ma. Fantech fan motors make this easy by removing the link between L1 & L2. L1
goes to Ma and L2 to Mm. On some motors the main, auxiliary and capacitor are wired in the neutral side with the common windings going to active. The mains input to the controller
may be connected either way around in terms of whether the active goes to~L or ~Lc. It is also acceptable to change the motor wiring to a common neutral – there is no difference.
CAUTION: Always isolate the controller / motor OFF via the feed MCB or isolator before working on any wiring. Be careful connecting cables to terminals. Make sure the opposite end
plate (adjusting potentiometers end), is in place and secure as it provides a mechanical end stop for the PCB. Divide individual cable cores evenly across each terminal spade. Tighten
terminals securely. Support back of connector with finger whilst tightening & pushing with a screwdriver. A slot screwdriver may provide better grip than a star or Phillips type.
Electromagnetic Compliance No additional snubbers or external suppressors are required. When properly installed, the AVA series of Fantech controllers meet the
Electromagnetic Compliance (EMC) requirements of Australia & New Zealand. Correct installation requires the Mm conductor between the controller and the load, be screened
(shielded), and that the screen be earthed at one point. Screening may be accomplished by enclosing all the cables between the controller and motor in an earthed screen or metal
conduit. If the motor and controller are installed within a common earthed metal chassis or are close together, then cable screening may not be necessary.
Earthing. The controller must be installed in accordance with AS3000:2000. Thecase of the controller is earthed through the separate external earth lug provided. Caution -
Screened output cable – the cross-sectionalarea of screening on a single screened cable may not be sufficient for it to act as an earth conductor.
Overload Protection. The AVA range is adequately rated for motor starting and a generous short term overload margin is provided for in its design. It is recommended that both
the load and controller are protected by a thermo-magnetic circuit breaker rated according to the motor or appliance manufacturer recommendations and/or local wiring regulations. As
a guide fit circuit breakers: AVA5.0 – 5 or 6 amp AVA8.0 – 8 amp AVA10.0 – 10 amp AVA15.0 – 15 amp AVA120 – 20 amp AVA130 – 30 amp.
Controller Fuse: The controller is fitted with a replaceable fuse just behind terminals A B C. If it blows, something is wrong with your wiring, installation or motor! To check, isolate OFF
then carefully prise out the fuse with a small screwdriver or long nose pliers. Only the following fuses should be used.
AVA5.0 6A slow blow (SB) / 7A fast blow (FB) AVA8.0 10A SB / 12A FB AVA10.0 12A SB / 15A FB AVA15.0 20A SB AVA120 25A SB AVA130 35A SB
When replacing the fuse make sure that the clips are a tight grasp onto the fuse. If not, gently squeeze them together to effect a firm grip on the fuse when it is inserted. Each clip has
an end stop and the fuse should be located centrally between the two opposite end stops. If a fuse blows, there is usually a serious problem that must be investigated & resolved.
Control Signal Screen. A control cable screen earthing point is provided near the terminals. This should be used with caution. Best practice is to earth the screen at one end only
and this ideally should be the source end. Do not earth both ends of a screened control cable as earth loops could result causing erratic control signal problems.
0
10
20
30
40
50
60
70
Relative Power Consumption VA
2400 2000 1600 1200
Fan Speed rpm
COMPARISON OF POWER CONSUMPTION FOR 3
DIFFERENT SPEED CONTROL CONFIGURATIONS
standard 3 speed switched windings 2 wire configuration 3 wire configuration
EBM R2E190.A062-39 fan
3 spd
2W
3W
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GUIDELINES FOR SETTING UP & OPERATING the AVA series of controllers
Operation. When terminal B is at 10 VDC (20ma), the load / motor speed will be at maximum. Reducing the control voltage at terminal Bwill reduce the power / motor speed until
the minimum level is reached when the voltage at terminal Bis 1 volt (2ma). Ensure that at the minimum speed of the control signal, there is sufficient air flow across the motor to
prevent it from overheating. When the voltage at terminal Bis reduced below ~0.8 volts (~1.25 ma), the controller will shut down power electronically to terminals Mm and Ma.
CAUTION – this is an electronic switched STANDBY STATE and should not be used for permanent shutdown or relied upon to switch off / isolate the load for servicing. A separate
mechanical safety isolator switch should be included in the wiring for safe isolation. Dependanton motor type, mechanical load, 2 or 3 wire configuration and efficiency of the motor,
the maximum output of the controller will be achieved from 8.5-9.5 VDC (~15-19 ma) control input.
Manual Control: If manual control is required at any time for testing an installation during commissioning, remove the blank end plate, switch the SEL switch to MAN (left). This
disconnects the control input on terminal B and selects the internal 0 – 10 VDC reference. The MAN pot will now be available for varying the internal control signal between OFF and
100% (0-10 VDC). When finished, remember to switch the SEL switch back to AUTO to reconnectthe signal source. Monitor the control signal on the “SIG” pins (0 – 10 VDC)
Calibration adjustment: The standard factory settings are
optimal for most loads and usually adequate for most fans.Most
BMS controllers can easily take account of different loads. If
custom calibration is necessary, set-up potentiometers (pots) are
provided behind the blank panel opposite the terminal end. These
pots may be horizontal or vertical adjusting. The adjusting end of
the PCB is free of mains potential voltages within the “safe area”
shown 30-60mm. If the installation requires fine tuning for the
particular motor or if the controller is required to operate over a
narrow region of speeds, then two simple adjusting pots are
provided – MAX and MIN. These adjust the span and offset.
Please note that the factory calibration is marked on the pots with
a black line so its easy to get back to this calibration. An internal
variable control signal is provided via the SEL switch and
adjustable via the MAN pot and its operation is described above.
CALIBRATION PROCEDURE
Controller to be connected to motor with normal load. Remove
end faceplate. DC & AC voltmeters required.
1. Connect DC voltmeter (0-10VDC) to SIG test pins. Connect AC
voltmeter (300 VAC) to Mm / Mc terminals.
2. Set SEL switch to MAN. This disconnects the control signal and
connects the internal 0-10 VDC source.
3. What are your control voltages for desired maximum and
minimum motor speeds? You will need to know these!
4. Advance MAN pot until maximum control voltage required is
shown on DC voltmeter – eg say ~9V.
5. Adjust MAX speed pot for desired maximum motor speed eg
AC voltmeter across Mm and Mc – eg say 220 – 235V AC
6. Decrease MAN pot setting to minimum control voltage on DC
voltmeter – eg say ~1V.
7. Adjust MIN speed pot for desired minimum motor speed eg AC
voltmeter across Mm and Mc – eg say 120V.
8. Set SEL switch to AUTO. Remove voltmeters.
9. Replace end plate. The controller is ready for operation.
11. For current control input (2 - 20 ma) fit OPT 2 LINK. Please
note that the voltage on the SIG pins will still be
0-10 VDC which is directly proportional to 0 - 20 ma. The sink
between terminals B & C is 500 ohms. It is an easy calculation to
determine what voltage represents a particular current.

CAUTION: Do not attempt to adjust the other potentiometers
marked SC, SH, SL if fitted. They are used for temp probes and
other interfaces and are factory set.
How does one know if the controller is wired up correctly and the motor is suitable for speed control? Generally for resistive and transformer loads, the current draw should
decrease linearly with decreasing output. For PSC motors, the current should drop with decreasing speed. A simple test of whether a PSC motor is suitable for speed control is to wire
it up in a 3-wire configuration. The current draw at any speed setting (50 – 100%) should never exceed the nameplate maximum current for the motor. If it does, the motor should not
be speed controlled. In general, whether 2 or 3-wire, the current draw should decrease with decreasing speed. What’s better – 2-wire or 3-wire? Generally, for smaller PSC motors
<100 watt, the difference may be small. However, usually for motors >150 watt the 3-wire is optimal. For all Fantech fans > 100W the 3-wire configuration is mandatory. For smaller
fans <100W, the cut-down model VA3.0 (up to 600 VA), which operates in a 2-wire configuration,can be considered.
Problem Oops – the fuse blows. Something is wrong! Check your wiring. Check the motor insulation resistance by meggering. You should be checking everything before switching
ON! The likelihood of an error is very high if you don’t check! The internal wiring of PSC motors can be confusing, particularly with a plethora of wire colours that don’t conform to any
common standard. The common winding can be in the active or neutral lines and for some motors rotation direction can be changed by reversing certain connections. Check the
current draw and don’t ignore or compromise on a slightly abnormal reading – find a reason.
SAFETY Always isolate the controller / motor OFF via the feed MCB or isolator before working on any wiring. NEVER rely on the auto OFF standby for isolation.
Confused / Need Help? Please contact Fantech or your agent for advice & assistance if you are unsure of any aspect of installation, wiring or operation.
Partno.INST‐AVAVSDADVICE      August2012    
MAN AUTO
- MAN + - MAX +
-
MIN +
+SIG -
'Safe Area'
30mm
SEL
MANUAL CONTROL
Set SEL switch to MAN
MAN Pot varies signal / speed
Link=2-20ma
OPT2
SELECT SOURCE
MAN = internal manual control
AUTO = signal terminals control
from terminals B&C
SET MAXIMUM
@ maximum control signal
set speed to maxreqd
SET MINIMUM
@ minimum control signal
set speed to min reqd
'Safe Area'
60mm
SIGNAL TEST
measure signallevel
0 - 10 VDC

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