Gi VARI SPEED A2000 User manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
REVISION B 01/04176R0210
©2004 GRAHAM MOTOR AND CONTROLS™. ALL RIGHTS RESERVED.
A2000
VARI SPEED
RELIABILITY + COMPATIBILITY SINCE 1935
>
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21
GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
Graham Motors and Controls is a manufacturer of electronic controls for DC
motors. The warranty policy is as follows.
A) Controls: We warrant that the AGAO and AGBO controls are free of
defective materials and workmanship and are tested and inspected before
leaving the factory to insure that the controls comply with the specifications as
stated by Graham Motors and Controls. The term of this warranty is for a
period of two (2) years from the date of the invoice. Any control failing to meet
those specifications will be repaired or replaced free of charge if the following
conditions are met:
1) Buyer notifies Graham Motors and Controls in writing of the nature of
defect or failure, and the serial number of the control, within two (2) years of
the date of the invoice.
2) Graham Motors and Controls gives Buyer shipping instructions for the
return of the defective control, and Buyer returns it, with shipping charges
prepaid, to Graham Motors and Controls.
3) Repair or replacement by Graham Motors and Controls of defective
controls shall constitute the fulfillment of our obligation to the Buyer. We will
not be liable for consequential damages, direct or indirect, resulting from any
defects or delays. Damaged Graham Motors and Controls controls resulting
from improper installation, handling, storage or operation by the Buyer may
be specifically excluded from the warranty. Under no circumstances will
Graham Motors and Controls honor any invoices, or be held responsible for
any attempted repair of controls still under the warranty.
B) General: Replacement or repair of our controls, no longer covered by the
warranty, will be performed at a nominal cost at our plant, when request is
accompanied by the purchase order and shipped prepaid to Graham Motors
and Controls. return shipment of any such controls will be made F.O.B
Milwaukee, (no freight allowed).
C) Service: Qualified Graham Motors and Controls technical personnel are
available to perform field service. Charges for these services are made on a
“per diem” rate, plus transportation and living expenses. Any request for field
service must be accompanied by a purchase order.
WARRANTY
for purchasing a Graham Motor and Controls product. Graham
Motors and Controls™ is the foremost designer and manufacturer
of DC Drives, Mechanical Variable Speed Drives and integrated
Motor packages. For more than 50 years, Graham has made
quality products with an exceptional reputation for durability.
We are taking new steps to evolve into the reliable and innovative
resource providing the drive and control solutions you can depend
on. Whether it’s a simple speed control solution or a custom built
application, Graham will deliver the durable components you
expect.
Innovation. Evolution. Durability.
To check out the rest of the Graham product line log on to
grahammotorsandcontrols.com
THANK YOU
>>
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120 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
Control Features
Options
Application Data
Operating Conditions
Control Ratings Chart
Mounting
Dimensions
Installation and Wiring
Typical Wiring Diagram
Schematic (Block Diagram)
Installation and Wiring continued
Component Location
Start-Up Procedure
Set-Up Procedure
Recommended Fuse Chart
Trouble Shooting Guide
2
2
3
3
4
4
5
8
9
10
12
14
15
16
19
20
TABLE OF CONTENTS
Motor will not run:
1. Make sure power LED is lit. If not, make sure disconnect fuses
or circuit breaker in line are okay.
2. Check line fuse. If open, replace. (See Fuse Chart)
3. Make sure “RUN” switch is on. (RUN LED should be lit.)
4. Be sure speed pot is not set to zero.
5. Unit is in current (torque limit). Check I-LIM LED (if lit, this
indicates that I-LIM pot is set too low or motor is overloaded).
6. With power removed from unit and motor leads disconnected,
check for worn or improperly seated brushes.
7. Defective control.
Fuse blowing:
1. Improper wiring.
2. Motor brushes worn or improperly seated.
3. Motor load is too heavy. Check for machine “jam-up” or
excessive load.
4. Defective control. If the control has failed, always check the
motor and wiring for short circuits and grounding before replacing
the control.
No speed control:
1. Speed pot or wiring defective.
2. Control not set up properly. (See Set-up Procedures)
3. Defective Control.
Motor will not run at 1725 RPM:
1. Improper setting of MAX speed trim pot. (Range trim pot
TROUBLE SHOOTING GUIDE
>>
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192 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
RECOMMENDED AC LINE PROTECTION
FUSE CHART
These features are standard on all VariSpeed A2000 DC controls:
• Run/Stop control from switch
• Speed controlled by potentiometer or 0-10V process signal.
• May be turned on and off via line switching.
• Signal terminal strip requires no wire lugs.
• Power terminal strips with saddle clamps.
• Operates on either 50 or 60 Hertz line without adjustments.
• Transient protected by metal oxide varistor and R-C snubbers.
• Status LED’s for power on, run, current limit.
• Armature or tachometer feedback.
• Wide operational speed range.
• Adjustable min/max speed, current limit, IR comp, accel/decel
• Packaging flexibility - Chassis, NEMA 12 (can be field installed).
• 100% factory tested for assured reliability.
• Full two (2) year replacement warranty.
• Chassis units are UL cUL listed for U.S. and Canada.
• Available in 120V, 1/8 to 1HP units and 240V, 1/8 to 3HP units.
Isolation:
Two Isolation Options, AGAO and AGBO, are available both
featuring easy plug-on assembly to the A2000. Both options allow
the use of non-isolated input command signals and 7V or
20.8V/1000 RPM tachometer feedbacks. The AGBO Isolation
Option also provides a speed follower and current limit output
indication.
Enclosure:
Three Enclosure Options, NEMA 4 and NEMA 12 with operators
and NEMA 4 without operators are available.
If Isolation and/or Enclosure options are used the A2000 is no
longer listed by UL, cUL.
CONTROL FEATURES
>>
AVAILABLE OPTIONS
>
AC Line Voltage
120
240
Motor Horsepower
1/8
1/4
1/3
1/2
3/4
1
1/8
1/4
1/3
1/2
3/4
1
1-1/2
2
3
Dual Element Fuse Amps
2.5
4
5
10
15
20
1.5
2
2.5
4
5
10
15
20
25
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318 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
APPLICATION DATA
(Clockwise increases compensation)
If tachometer feedback is used, be sure that this adjustment is set
fully counter-clockwise. IR Compensation should not be used with
tachometer feedback.
This adjustment is provided to overcome the motor’s natural
tendency to slow down with increasing load. If improved
load/speed performance is required, this adjustment may be used.
NOTE: In order to optimize performance with this adjustment,
some means of determining motor shaft speed is required. (i.e.,
hand held tachometer).
1. Set motor speed to 1/2 of base speed rating or to the speed
where the greatest accuracy is required and motor load to
minimum.
2. Load motor to 100% nameplate rating.
3. Turn IR COMP clockwise until motor returns to original
unloaded RPM.
4. Turn off load and notice if RPM increases beyond original
setting. If so, adjust trimpot while changing from no load to full
load to give minimum RPM change for each.
NOTE: Setting IR COMP too high can cause motor speed
instability, Turn IR COMP pot counter-clockwise until motor speed
stability is achieved.
Acceleration (ACCEL)/Deceleration DECEL Adjustments
Set these two trim pots for desired times. Both ACCEL and DECEL
trim pots adjust from 1/2 to 5 seconds. Acceleration time may be
extended with I-LIM if reflected inertia is high. DECEL may also be
longer if reflected inertia is high.
Service Factor
Duty
Overload Capability
Speed Regulation
Speed Range
Potentiometers
Process Signal Input
Adjustments
Elevation
Ambient Temperature
AC Line Voltage Variation
AC Line Frequency
IR COMPENSATION ADJUST
>>
OPERATING CONDITIONS
>
- 1.0
- Continuous
- 150% for 1 minute
- Armature Feedback
±2% Base Speed (for 95% Load Change)
- Tachometer Feedback
±1/2% Set Speed (for 95% Load Change)
- Armature Feedback
50:1 @ Full Torque
- Tachometer Feedback
200:1 @ Full Torque
- 5K Ohm, 1W potentiometer supplied with
ease control
- 0-10V
- Min. Speed (0-50% of motor base speed)
- Max. Speed. (50-100% of motor base
speed)
- IR Comp. (0-25% of rate output)
- Current LIM. (10-15-% of Cntrl. Rating)
- Acceleration ( 1/2-5 Seconds)
- Deceleration ( 1/2-5 Seconds)
- Up to 3300 feet (1000 meters)
without derating
- Chassis: 32 - 131˚F (0-55˚C)
- NEMA 12: 32-104˚F ( 0-40˚C)
- Rated Voltage ±10%
- 48 to 62 Hz
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174 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
(Clockwise increases maximum speed)
MAX SPEED may be adjusted from 50% of motor base speed to
approximately 115% of base speed.
1. With motor operating at full load, and the speed control knob
turned all the way to maximum, adjust the MAX SPEED trimpot
until desired speed is set. (NOTE: Extended motor speed can be
achieved with the trimpot. Caution should be taken not to
exceed maximum motor nameplate speed rating.)
2. Recheck MIN SPEED adjustment, as there may be ome
interaction.
(Clockwise increases current)
I-LIM may be adjusted from 0 to 150% of control rating.
There are two methods for adjusting I-LIM.
Method One:
1. Start the machine and apply maximum load to the motor, and
turn I-LIM trimpot fully clockwise.
2. Turn the I-LIM trimpot counter-clockwise until the I-LIM LED (red)
lights, and the machine starts to slow down.
3. Turn the I-LIM trimpot clockwise until the I-LIM LED just turns off.
Method Two:
1. Turn off AC power
2. Lock up the motor shaft, taking care not to cause damage.
3. Connect a DC ammeter in series with the motor armature.
4. Turn I-LIM trimpot fully counter-clockwise.
5. Turn speed pot fully counter-clockwise.
6. Turn on AC power and start control (red LED should be on).
7. Turn speed pot clockwise to about 1/3 speed setting.
8. Adjust I-LIM trimpot clockwise for desired motor current.
(Do not set for current greater than either the motor or control
nameplate rating.)
9. Turn off AC power, disconnect ammeter, and unlock motor shaft.
MAX SPEED ADJUSTMENT (MAX)
*Does not include motor field current where used.
**15% extended voltage capability standard.
The VariSpeed A2000 should be mounted horizontally in order to
insure maximum heatsink efficiency. With plate units, the plate
should be mounted directly against a 12 gauge metal panel
measuring at least 13 in. (330 mm) by 15 in. (380 mm).
CONTROL RATINGS CHART
>>
CURRENT (TORQUE) LIMIT ADJUST (I-LIM)
>
MOUNTING
>
On enclosed versions, over tightening cover
screws can damage mountings and cover gasket.
(Torque specs. 8-12 in. lbs.)
Control
Rating
HP
0.5
0.75
1.0
1.0
1.5
2.0
3.0
Control
Rating
Input
Voltage
120
120
120
240
240
240
240
Rated
AC Line
Amps*
10
15
20
10
15
20
23
Rated
DC
Armature
Voltage**
0-90
0-90
0-90
0-180
0-180
0-180
0-180
Armature
Current
Amps
6.8
9.6
12.2
6.1
8.3
10.8
16.0
Field
Current
Amps
1
1
1
1
1
1
1
Field
Voltage
50/100
50/100
50/100
100/200
100/200
100/200
100/200
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516 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
STAND ALONE VERSION
The VariSpeed A2000 has been set up at the factory to satisfy most
application needs. You may, however, wish to tailor your control
specifically to your application requirements. If so, use the following
instruction for proper set-up.
NOTE: Before making any adjustments, start control and run
motor fully loaded for at least 30 minutes so that motor
temperature will stabilize. (Motor speed will increase as
temperature increases unless tachometer feedback is used.)
Factory Settings
Min. Speed - Zero Volts
Max. Speed - 90VDC Output for 120VAC line
- 180VDC Output for 240VAC line
IR Compensation - Zero
Accel - 1/2 Second
Decel - 1/2 Second
(Clockwise increases minimum speed)
MIN SPEED may be adjusted from 0 to 50% of motor base speed.
1. Turn speed pot fully counter-clockwise (CCW).
2. Turn MAX SPEED trimpot fully CCW.
3. Adjust MIN SPEED trimpot until desired minimum speed is set. If
desired minimum speed is zero, adjust trimpot so that motor
barely stops turning. (This will give the best motor speed linearity.)
NOTE: If unit will not obtain 0V output with MIN SPEED trimpot
fully CCW, turn THRESHOLD trimpot CCW.
4. Reset MAX SPEED ADJUSTMENT.
Drive shown without protective barrier.
Drive shown without protective barrier.
SET-UP PROCEDURES
>>
CHASSIS PLATE VERSION
>
MINIMUM SPEED ADJUST (MIN)
>
6.50 (165)
6.12 (156) (5)
0.19
3.87
(98)
0.72
(18)
Optional isolation board
2.0
(51)
2.75
(70)
5.31
(135)
8.00 (203)
7.38 (187) (8)
0.31
4.31
(109)
0.31
(8)
Optional isolation board
2.25
(57)
3.15
(80)
4.94
(125)
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156 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
Use caution during these procedures because line voltage will
be present on the power and motor terminals as well as on the
printed circuit board when the power is on.
NOTE: If, at any stage of this procedure, the control does not act
as indicated, refer to Troubleshooting section.
1. With AC power off, recheck to be sure that all power and
control connections are properly secured and connected
according to the installation instructions.
2. With enclosed units, be sure that the ribbon cable front the
cover is plugged into S1 on the A2000 PC board (or, if used,
S3 on the Isolation Option PC board).
3. Set the speed pot to minimum speed (CCW) and place the
ON/OFF switch in the OFF position.
4. Apply power to the control and confirm that the POWER ON
(green) LED glows. If the LED does not glow refer to the
Troubleshooting section.
NOTE: On enclosed versions the indicators in the cover glow.
The indicators on the printed circuit assembly are disabled by
having the cover connected.
5. Place ON/OFF switch in the ON position. The RUN (yellow)
LED should glow, but the motor should not turn.
6. Slowly rotate speed pot in a clockwise direction. Motor
should begin turning. Continue to rotate speed pot until
desired motor speed is achieved.
SET-UP PROCEDUREHEAT SINK VERSION
>>
Drive shown without protective barrier.
8.00 (203)
7.38 (187) (8)
0.31
4.31
(109)
0.31
(8)
Optional isolation board
3.15
(80)
4.05
(103)
4.94
(125)
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Input (Line) Terminals
714 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
ENCLOSED PLATE AND ENCLOSED
HEAT SINK VERSIONS
COMPONENT LOCATION
>>
Drive shown without protective barrier.
1
Chassis Ground (GND)
2
Output (Motor) Terminals
3
RA Resistor
4
Factory Adjust
5
Current Limit (I-LIM) Adjust
6
IR Compensation Adjust
7
Acceleration Adjust
8
Minimum Speed Adjust
9
Deceleration Adjust
10
Maximum Speed Adjust
11
Control Terminal Strip
12
Indicator LEDs
13
Ribbon Cable Socket
14
Input Line Fuse
15
5.44
(138)
4.94
(125)
3.69 (99)
3.69 (99)
8.50 (216)
8.88 (226)
9.38 (238)
2.00(51)
6.12
(156)
3.47
(88)
3.69
(94)
1
10 9 8 7 6 5 4 23
1514
13
12
11
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138 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
WIRING (CONTINUED)INSTALLATION AND WIRING
>>
Branch circuit protection and Motor overload protection must be
provided by the equipment manufacturer or person installing the
controls per the National Electrical Code (NEC) and local codes.
This equipment should be installed, adjusted and serviced by
qualified electrical maintenance personnel familiar with the
construction and operation of this type of equipment and the
hazards involved. It is the responsibility of the equipment
manufacturer or person installing the controller to take diligent
care. Read this instruction manual and all warnings and notes
before proceeding to install or operate this control.
Improper installation of motor and
controller may cause equipment failure or
serious personal injury. Follow instruction
manual, local, state and national safety codes for proper
installation. Always disconnect power from the controller before
making any wiring changes or before inspecting equipment.
1. Shielded cable recommended but not required.
2. Be certain that a ground wire form the incoming AC power line
is properly connected to the chassis ground terminal provided.
Failure to properly ground the control and
motor may result in injury or death.
6. A 5K Ohm, 1 Watt rated speed potentiometer is provided with
each controller. On chassis versions, a knob and dial plate are
also provided.
7. An isolated process signal (0-10V) may be used instead of a
potentiometer by connecting signal leads between terminals 4
and 5 on TB3 with positive to terminal 4.
Be sure that the signal generated is isolated from ground, or the
A2000 and the process signal source will be damaged. For signals
that are ground referenced, the optional input signal isolator board
must be read.
8. For those applications requiring tachometer feedback the
tachometer should be rated for 21VDC per 1000 RPM (with a
1800 RPM motor).
9. When tach feedback is used, the RA resistor (see Component
Location drawing) must be removed.
10. S1 socket is provided for use with optional enclosures with
operators. Be sure that the ribbon cable is oriented as shown,
or equipment failure may result.
11. The TB3 terminal strip will accept wire sizes between #16 and
#24 AWG.
All terminals of TB3 are at line potential
and can be extremely hazardous. Power
must be removed from unit before any
wires are connected or disconnected. Wires connected to TB3 must
be isolated from ground. Failure to comply may result in injury,
equipment failure, or both. Contact with wiring or terminals while
power is applied may result in shock, injury, or death.
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912 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
INSTALLATION AND WIRING (CONTINUED)
WIRING (STANDARD AND ENCLOSED UNITS)
>>
TYPICAL WIRING DIAGRAM
>
3. The National Electrical code requires a separate fused disconnect
be installed in the incoming AC poser line. See Ratings Chart and
Fuse Chart for proper sizing.
4. All components on the printed circuit board are at line potential.
Extreme caution should be exercised when working on unit.
Power should always be disconnected from the unit, before any
work is attempted, except where required for set-up.
5. DO NOT apply AC line voltage to any terminal except L1 and L2.
Failure to comply will cause permanent damage to the control.
6. Automatic restart of the control may occur if line power has been
temporarily lost. Caution should be exercised under such
circumstances.
Motor overload protection must be provided by the equipment
manufacturer or person installing controls per the National Electrical
Code.
1. Refer to Rating Chart for incoming line current and voltage. It is the
responsibility of the user or person installing the controller to provide
branch circuit protection according to the NEC and local codes. On
controllers using 120VAC input, be sure that the incoming hot lead is
connected to L1 and common is connected to L2.
2. A full wave field is provided for use with shunt wound motors when
required. Field voltage on 120VAC line is 100VDC. If the motor
requires a 50VDC (half wave) field voltage, connect field windings from
F1 to L2. Field voltage on 240VAC line is 200VDC. If the motor
requires a 100VDC field, follow the procedure outlined above.
3. Be sure that rated motor current and voltage do not exceed the ratings
label on the control. If using a motor with a lower rating than the
control, see Recommended Fuse chart for fuse size.
4. A chassis ground terminal has been provided to facilitate grounding of
the controller.
Be certain that a ground wire form the incoming
AC power line is properly connected to the
provide terminal. Failure to do this could result
in serious injury, equipment failure, or both. Conduit to enclosed units
cannot be used for grounding purposes since the enclosure is not metal.
5. The switch provided on enclosed models is RUN/STOP/JOG. Jog
speed is determined by speed pot setting.
RUN/STOP/JOG switch is for signal switching
only. Be certain, before working on either the
controller or machine, that AC power is
disconnected from L1 and L2 terminals. Failure to do so could result in
serious injury or death.
1Switch
S1 (13) TB1 L1
F1
A2,F2TB3
Run/Stop Switch (5,6)
Speed Potentiometer (7,8)
Tachometer (9,10) (3)
Ground Terminal (4)
Motor Field (2)
A1
AC Input (1)
Enclosure with Operator (when used)
TB2 (11,12)
2
3
4
5
6
T+– +
–
Switch
Pot Hi
Wiper
Pot Lo
L2
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1. Refer to Installation Instructions, and Wiring Instruction for
further information
2. Must be removed for tachometer feedback.
3. When optional isolation is used the RUN LED will light on the
isolation board.
4. Factory set at OVDC.
5. Factory set for 90VDC for 120V controllers, and 180VDC for
240V controllers.
6. Factory set for 100% of controller rating.
7. Factory set for zero compensation.
8. Factory set for 1/2 second.
9. Factory set for 1/2 second.
10. If half wave field is required, connect between F1 and L2.
11. Shielded cable recommended but not required.
1110 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
NOTES
>
1
TB2
Run/Stop
Switch
(Close to run)
Max. Speed (5)
Min. Speed (4)
Accel
(9)
Decel
(8)
Run
Indicator
(Yellow)
(3)
5K
Speed
Pot
DC
Tach
(If used)
+
–
+
–
+12V
+12V
(1) RA (2)
T
2
3
4
5
6
+12V
Speed
Error
Inte-
grator
Zero
Crossing
Detector
Regulated
Power
Supply
Diode
Bridge
Option
Board
16
PIN
DIP
Socket
Gate 1
Gate 2
120/240V
SCR1 D1 Fuse TB1
AC
Line
Earth
Ground
DC
Motor
Field
(If Used)
(10)
L1
SCR2
Field Diodes
Current
Shunt
4.5AMP-16AMP
OV
D2
AC
AC
Comparator
Current
Limit (I-LIM)
Indicator
(Red)
Current
F.B.
IR Comp
(7)
I-LIM
(6)
Power
Indicator
(Green)
Pulse
Generator
Driver
TB3
F1
F2
A2
A1
DC
Motor
L2
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1. Refer to Installation Instructions, and Wiring Instruction for
further information
2. Must be removed for tachometer feedback.
3. When optional isolation is used the RUN LED will light on the
isolation board.
4. Factory set at OVDC.
5. Factory set for 90VDC for 120V controllers, and 180VDC for
240V controllers.
6. Factory set for 100% of controller rating.
7. Factory set for zero compensation.
8. Factory set for 1/2 second.
9. Factory set for 1/2 second.
10. If half wave field is required, connect between F1 and L2.
11. Shielded cable recommended but not required.
1110 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
NOTES
>
1
TB2
Run/Stop
Switch
(Close to run)
Max. Speed (5)
Min. Speed (4)
Accel
(9)
Decel
(8)
Run
Indicator
(Yellow)
(3)
5K
Speed
Pot
DC
Tach
(If used)
+
–
+
–
+12V
+12V
(1) RA (2)
T
2
3
4
5
6
+12V
Speed
Error
Inte-
grator
Zero
Crossing
Detector
Regulated
Power
Supply
Diode
Bridge
Option
Board
16
PIN
DIP
Socket
Gate 1
Gate 2
120/240V
SCR1 D1 Fuse TB1
AC
Line
Earth
Ground
DC
Motor
Field
(If Used)
(10)
L1
SCR2
Field Diodes
Current
Shunt
4.5AMP-16AMP
OV
D2
AC
AC
Comparator
Current
Limit (I-LIM)
Indicator
(Red)
Current
F.B.
IR Comp
(7)
I-LIM
(6)
Power
Indicator
(Green)
Pulse
Generator
Driver
TB3
F1
F2
A2
A1
DC
Motor
L2
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912 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
INSTALLATION AND WIRING (CONTINUED)
WIRING (STANDARD AND ENCLOSED UNITS)
>>
TYPICAL WIRING DIAGRAM
>
3. The National Electrical code requires a separate fused disconnect
be installed in the incoming AC poser line. See Ratings Chart and
Fuse Chart for proper sizing.
4. All components on the printed circuit board are at line potential.
Extreme caution should be exercised when working on unit.
Power should always be disconnected from the unit, before any
work is attempted, except where required for set-up.
5. DO NOT apply AC line voltage to any terminal except L1 and L2.
Failure to comply will cause permanent damage to the control.
6. Automatic restart of the control may occur if line power has been
temporarily lost. Caution should be exercised under such
circumstances.
Motor overload protection must be provided by the equipment
manufacturer or person installing controls per the National Electrical
Code.
1. Refer to Rating Chart for incoming line current and voltage. It is the
responsibility of the user or person installing the controller to provide
branch circuit protection according to the NEC and local codes. On
controllers using 120VAC input, be sure that the incoming hot lead is
connected to L1 and common is connected to L2.
2. A full wave field is provided for use with shunt wound motors when
required. Field voltage on 120VAC line is 100VDC. If the motor
requires a 50VDC (half wave) field voltage, connect field windings from
F1 to L2. Field voltage on 240VAC line is 200VDC. If the motor
requires a 100VDC field, follow the procedure outlined above.
3. Be sure that rated motor current and voltage do not exceed the ratings
label on the control. If using a motor with a lower rating than the
control, see Recommended Fuse chart for fuse size.
4. A chassis ground terminal has been provided to facilitate grounding of
the controller.
Be certain that a ground wire form the incoming
AC power line is properly connected to the
provide terminal. Failure to do this could result
in serious injury, equipment failure, or both. Conduit to enclosed units
cannot be used for grounding purposes since the enclosure is not metal.
5. The switch provided on enclosed models is RUN/STOP/JOG. Jog
speed is determined by speed pot setting.
RUN/STOP/JOG switch is for signal switching
only. Be certain, before working on either the
controller or machine, that AC power is
disconnected from L1 and L2 terminals. Failure to do so could result in
serious injury or death.
1Switch
S1 (13) TB1 L1
F1
A2,F2TB3
Run/Stop Switch (5,6)
Speed Potentiometer (7,8)
Tachometer (9,10) (3)
Ground Terminal (4)
Motor Field (2)
A1
AC Input (1)
Enclosure with Operator (when used)
TB2 (11,12)
2
3
4
5
6
T+– +
–
Switch
Pot Hi
Wiper
Pot Lo
L2
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138 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
WIRING (CONTINUED)INSTALLATION AND WIRING
>>
Branch circuit protection and Motor overload protection must be
provided by the equipment manufacturer or person installing the
controls per the National Electrical Code (NEC) and local codes.
This equipment should be installed, adjusted and serviced by
qualified electrical maintenance personnel familiar with the
construction and operation of this type of equipment and the
hazards involved. It is the responsibility of the equipment
manufacturer or person installing the controller to take diligent
care. Read this instruction manual and all warnings and notes
before proceeding to install or operate this control.
Improper installation of motor and
controller may cause equipment failure or
serious personal injury. Follow instruction
manual, local, state and national safety codes for proper
installation. Always disconnect power from the controller before
making any wiring changes or before inspecting equipment.
1. Shielded cable recommended but not required.
2. Be certain that a ground wire form the incoming AC power line
is properly connected to the chassis ground terminal provided.
Failure to properly ground the control and
motor may result in injury or death.
6. A 5K Ohm, 1 Watt rated speed potentiometer is provided with
each controller. On chassis versions, a knob and dial plate are
also provided.
7. An isolated process signal (0-10V) may be used instead of a
potentiometer by connecting signal leads between terminals 4
and 5 on TB3 with positive to terminal 4.
Be sure that the signal generated is isolated from ground, or the
A2000 and the process signal source will be damaged. For signals
that are ground referenced, the optional input signal isolator board
must be read.
8. For those applications requiring tachometer feedback the
tachometer should be rated for 21VDC per 1000 RPM (with a
1800 RPM motor).
9. When tach feedback is used, the RA resistor (see Component
Location drawing) must be removed.
10. S1 socket is provided for use with optional enclosures with
operators. Be sure that the ribbon cable is oriented as shown,
or equipment failure may result.
11. The TB3 terminal strip will accept wire sizes between #16 and
#24 AWG.
All terminals of TB3 are at line potential
and can be extremely hazardous. Power
must be removed from unit before any
wires are connected or disconnected. Wires connected to TB3 must
be isolated from ground. Failure to comply may result in injury,
equipment failure, or both. Contact with wiring or terminals while
power is applied may result in shock, injury, or death.
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Input (Line) Terminals
714 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
ENCLOSED PLATE AND ENCLOSED
HEAT SINK VERSIONS
COMPONENT LOCATION
>>
Drive shown without protective barrier.
1
Chassis Ground (GND)
2
Output (Motor) Terminals
3
RA Resistor
4
Factory Adjust
5
Current Limit (I-LIM) Adjust
6
IR Compensation Adjust
7
Acceleration Adjust
8
Minimum Speed Adjust
9
Deceleration Adjust
10
Maximum Speed Adjust
11
Control Terminal Strip
12
Indicator LEDs
13
Ribbon Cable Socket
14
Input Line Fuse
15
5.44
(138)
4.94
(125)
3.69 (99)
3.69 (99)
8.50 (216)
8.88 (226)
9.38 (238)
2.00(51)
6.12
(156)
3.47
(88)
3.69
(94)
1
10 9 8 7 6 5 4 23
1514
13
12
11
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156 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
Use caution during these procedures because line voltage will
be present on the power and motor terminals as well as on the
printed circuit board when the power is on.
NOTE: If, at any stage of this procedure, the control does not act
as indicated, refer to Troubleshooting section.
1. With AC power off, recheck to be sure that all power and
control connections are properly secured and connected
according to the installation instructions.
2. With enclosed units, be sure that the ribbon cable front the
cover is plugged into S1 on the A2000 PC board (or, if used,
S3 on the Isolation Option PC board).
3. Set the speed pot to minimum speed (CCW) and place the
ON/OFF switch in the OFF position.
4. Apply power to the control and confirm that the POWER ON
(green) LED glows. If the LED does not glow refer to the
Troubleshooting section.
NOTE: On enclosed versions the indicators in the cover glow.
The indicators on the printed circuit assembly are disabled by
having the cover connected.
5. Place ON/OFF switch in the ON position. The RUN (yellow)
LED should glow, but the motor should not turn.
6. Slowly rotate speed pot in a clockwise direction. Motor
should begin turning. Continue to rotate speed pot until
desired motor speed is achieved.
SET-UP PROCEDUREHEAT SINK VERSION
>>
Drive shown without protective barrier.
8.00 (203)
7.38 (187) (8)
0.31
4.31
(109)
0.31
(8)
Optional isolation board
3.15
(80)
4.05
(103)
4.94
(125)
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516 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
STAND ALONE VERSION
The VariSpeed A2000 has been set up at the factory to satisfy most
application needs. You may, however, wish to tailor your control
specifically to your application requirements. If so, use the following
instruction for proper set-up.
NOTE: Before making any adjustments, start control and run
motor fully loaded for at least 30 minutes so that motor
temperature will stabilize. (Motor speed will increase as
temperature increases unless tachometer feedback is used.)
Factory Settings
Min. Speed - Zero Volts
Max. Speed - 90VDC Output for 120VAC line
- 180VDC Output for 240VAC line
IR Compensation - Zero
Accel - 1/2 Second
Decel - 1/2 Second
(Clockwise increases minimum speed)
MIN SPEED may be adjusted from 0 to 50% of motor base speed.
1. Turn speed pot fully counter-clockwise (CCW).
2. Turn MAX SPEED trimpot fully CCW.
3. Adjust MIN SPEED trimpot until desired minimum speed is set. If
desired minimum speed is zero, adjust trimpot so that motor
barely stops turning. (This will give the best motor speed linearity.)
NOTE: If unit will not obtain 0V output with MIN SPEED trimpot
fully CCW, turn THRESHOLD trimpot CCW.
4. Reset MAX SPEED ADJUSTMENT.
Drive shown without protective barrier.
Drive shown without protective barrier.
SET-UP PROCEDURES
>>
CHASSIS PLATE VERSION
>
MINIMUM SPEED ADJUST (MIN)
>
6.50 (165)
6.12 (156) (5)
0.19
3.87
(98)
0.72
(18)
Optional isolation board
2.0
(51)
2.75
(70)
5.31
(135)
8.00 (203)
7.38 (187) (8)
0.31
4.31
(109)
0.31
(8)
Optional isolation board
2.25
(57)
3.15
(80)
4.94
(125)
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174 GRAHAM MOTORS AND CONTROLS VARI SPEED® A2000RELIABILITY + COMPATIBILITY SINCE 1935
(Clockwise increases maximum speed)
MAX SPEED may be adjusted from 50% of motor base speed to
approximately 115% of base speed.
1. With motor operating at full load, and the speed control knob
turned all the way to maximum, adjust the MAX SPEED trimpot
until desired speed is set. (NOTE: Extended motor speed can be
achieved with the trimpot. Caution should be taken not to
exceed maximum motor nameplate speed rating.)
2. Recheck MIN SPEED adjustment, as there may be ome
interaction.
(Clockwise increases current)
I-LIM may be adjusted from 0 to 150% of control rating.
There are two methods for adjusting I-LIM.
Method One:
1. Start the machine and apply maximum load to the motor, and
turn I-LIM trimpot fully clockwise.
2. Turn the I-LIM trimpot counter-clockwise until the I-LIM LED (red)
lights, and the machine starts to slow down.
3. Turn the I-LIM trimpot clockwise until the I-LIM LED just turns off.
Method Two:
1. Turn off AC power
2. Lock up the motor shaft, taking care not to cause damage.
3. Connect a DC ammeter in series with the motor armature.
4. Turn I-LIM trimpot fully counter-clockwise.
5. Turn speed pot fully counter-clockwise.
6. Turn on AC power and start control (red LED should be on).
7. Turn speed pot clockwise to about 1/3 speed setting.
8. Adjust I-LIM trimpot clockwise for desired motor current.
(Do not set for current greater than either the motor or control
nameplate rating.)
9. Turn off AC power, disconnect ammeter, and unlock motor shaft.
MAX SPEED ADJUSTMENT (MAX)
*Does not include motor field current where used.
**15% extended voltage capability standard.
The VariSpeed A2000 should be mounted horizontally in order to
insure maximum heatsink efficiency. With plate units, the plate
should be mounted directly against a 12 gauge metal panel
measuring at least 13 in. (330 mm) by 15 in. (380 mm).
CONTROL RATINGS CHART
>>
CURRENT (TORQUE) LIMIT ADJUST (I-LIM)
>
MOUNTING
>
On enclosed versions, over tightening cover
screws can damage mountings and cover gasket.
(Torque specs. 8-12 in. lbs.)
Control
Rating
HP
0.5
0.75
1.0
1.0
1.5
2.0
3.0
Control
Rating
Input
Voltage
120
120
120
240
240
240
240
Rated
AC Line
Amps*
10
15
20
10
15
20
23
Rated
DC
Armature
Voltage**
0-90
0-90
0-90
0-180
0-180
0-180
0-180
Armature
Current
Amps
6.8
9.6
12.2
6.1
8.3
10.8
16.0
Field
Current
Amps
1
1
1
1
1
1
1
Field
Voltage
50/100
50/100
50/100
100/200
100/200
100/200
100/200
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