Graham Vari Speed S1000 User manual

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Installation, Operation and
Maintenance Manual
Vari Speed S1000
Instruction Manual
TRANSMISSIONS, Inc.
Graham
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TABLE OF CONTENTS
Introduction 4
Unit Features 5
Operating Conditions 6
Specifications 7
Ratings Chart 8
Dimensions 9
Mounting & Installation 10
Unit Functions 13
Schematic Block Diagram 14
Wiring 18
Verification Test 19
Component Location 21
Set-Up Procedures 22
Two-Speed Application 27
Troubleshooting Guide 28
Plug-On Terminal Option 30
Available Options 31
Warranty 32
Details and specifications presented in this manual are
subject to change without notice.
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4
INTRODUCTION
The new Vari Speed S1000 is setting new standards in the field
of inexpensive DC motor controllers. The smallest member of the
Graham Transmissions, Inc. family includes features and
performance only before thought possible in larger, more
expensive units. By utilizing the latest in surface mount
component technology and manufacturing processes, this
controller is unsurpassed in performance and reliability.
Graham Transmissions, Inc. Vari Speed S1000 is a solid state
controller that converts single phase AC line power into an
adjustable DC power source. The unit has been designed to
control permanent magnet (PM), or shunt wound DC motors from
1/20 to 2HP. This NEMA Code K (2 SCR’s, 2 diodes, and a
freewheeling diode) converter ensures good form factor and
smooth, efficient motor operation. Because of the unit’s small
physical size and convenient mounting arrangement, it can be
located in panels with very limited space.
If you have any questions regarding the Vari Speed S1000,
please contact your local distributor, or consult the factory by
calling toll free 1-888-363-1313.
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5
UNIT FEATURES
The following features are standard on all Vari Speed S1000 DC
controls:
•Surface mount technology - reduces size, improves
performance and reliability.
•Power supply uses control transformer and voltage regulators
for optimum performance.
•Full wave bridge rectifier with free-wheeling diode for
optimum performance.
•Full or half wave field supply for wound field DC motors.
•Speed controlled by 5k ohm potentiometer, 0-5V or 0-l0V
input signal.
•AC line switching for ON/OFF with automatic ramp reset.
•RUN/STOP and INHIBIT control via external switches (user
supplied).
•Status LED’s for CURRENT LIMIT and RUN.
•Plug-In Current Sense Resistor easily changed to provide
Armature Feedback for wide horsepower range (optional
heatsink required for larger horsepower).
•Independently Adjustable MIN/MAX Speed.
•Adjustable Current (Torque) Limit.
•Adjustable IR Compensation.
•Independently Adjustable linear ACCEL/DECEL.
•100% factory tested for assured reliability.
•Full two (2) year warranty.
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6
OPERATING CONDITIONS
AC Line Voltage Variation Rated Voltage
(+/- 10%)
AC Line Frequency 48 to 62 HZ
Ambient Temperature 32° F to 131° F
(0°C to 55° C)
Elevation Up to 3000 Feet
(1000 meters) without
aerating
NOTE: The Ambient Temperature specification is referring to the
environment surrounding the S1000 printed circuit board, not
necessarily the room temperature.
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7
CONTROL SPECIFICATIONS
Service Factor 1.0
Form Factor 1.3 5
Duty Continuous
Overload Capability 150% for 1 minute
Speed Regulation 2% of Base Speed (for
95% Load Change)
Speed Range 50:1 @ Full Torque
Speed Potentiometer 5k ohm, 1W available accessory
Process Signal Input 0-5VDC or O-10VDC
(See Wiring and Warning on pg. 16)
Adjustments Minimum Speed (0-50%)
of motor base speed)
Maximum Speed (50
110% of motor base speed )
IR Compensation
(Adjustable from O to 25%
of rated output.)
Current Limit (10-150% of
Control Rating)
Acceleration (1/2 to 15
Seconds)
Deceleration (1/2 to 15
Seconds)
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8
RATINGS CHART
Note: If motor horsepower to be used falls between two of the standard Current Sense Resistors, use the higher values of the two (Example: 1/3 HP uses 1/2 HP Current Sense Resistor)
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9
DIMENSIONS
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10
MOUNTING AND INSTALLATION
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 all warnings and notes before proceeding to install or
operate this control.
The Vari Speed S1000 should be mounted in an enclosure
appropriate for the application’s environment. Failure to do so
could cause equipment malfunction or serious personal injury.
When using the higher horsepower units, the optional 176B1122
heatsink is recommended to ensure the proper heat dissipation.
The 176B1122 provides 160 square inches. This figure is based
on anodized aluminum; the type of metal and its finish will affect
the thermal resistance. The area will have to increase accordingly
to ensure proper cooling.
NOTE: Recommended minimum mounting clearance on the top
and bottom perimeter of 2 inches should be maintained to
ensure proper cooling. NOTE: Fast-on (1/4” and 3/16”)
connectors are required for wiring when optional terminal board
is not used.
1. WARNING: IMPROPER INSTALLATION OF MOTOR AND
CONTROLLER MAY CAUSE EQUIPMENT FAILURE, OR SERIOUS
PERSONAL INJURY.
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11
FOLLOW INSTRUCTION MANUAL, LOCAL, STATE, AND
NATIONAL SAFETY CODES FOR PROPER INSTALLATION.
ALWAYS DISCONNECT POWER TO THE CONTROL BEFORE
MAKING ANY WIRING CHANGES, OR BEFORE INSPECTING
EQUIPMENT.
2. It is strongly recommended that the “L” bracket or heatsink
of the unit is mounted to a grounded surface.
3. The National Electrical Code requires a separate fused
disconnect or circuit breaker be installed in the incoming AC
power line. See Ratings Chart (page 8) for proper sizing.
4. All components on printed circuit board are at line potential.
Extreme caution should be exercised when working on unit.
Except where required for set-up, power should always be
disconnected from the unit before any work is attempted.
5. Do not apply AC line voltage to any terminals except L1 and
L2. Failure to comply will cause permanent damage to the
control.
6. All remote connections to the controller should use shielded
wire; Speed adjust potentiometers -3 conductor shielded; Run
Circuit, Tach Feedback, Tach Follower, and voltmeters
connected to Tach Generators -2 conductor shielded. Shields
should be grounded at the control only. The other end should
be isolated to avoid accidental grounding. Route these
conductors separately from motor and power wiring.
Automatic restart of control may occur if line power has been
temporarily lost. Caution should be exercised under such
circumstances.
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12
Motor overload protection must be provided by the equipment
manufacturer or person installing controls per National Electrical
Code.
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13
UNIT FUNCTIONS
RUN/STOP:
A closed contact between the RUN and V+ will start the control
as long as the INHIBIT is not activated. At the time of the START
command, the unit will follow the adjustable ACCEL ramp to the
Speed Input setting. Opening the contact between RUN and V+
will initiate a STOP command to the unit. The control will follow
the setting the adjustable DECEL ramp to zero speed.
INHIBIT (INH):
The INHIBIT input is the priority logic command, overriding all
others. When activated, the INHIBIT will turn the control’s
armature output off, regardless of a RUN or Speed Command
input. As the INHIBIT circuit is activated, any DECEL ramp the
control is set for will be cancelled. This allows the control’s
output and internal logic to reach their OFF-state as fast as
possible. The time it takes for the motor to reach a zero speed
condition, however, will be dependent on the inertia present on
the motor’s shaft.
To provide the optimum flexibility for various logic schemes, the
INHIBIT may be set for use with Normally Open (NO) or Normally
Closed (NC) types of contacts. This allows the S1000 INHIBIT
circuit to be activated during either an Open or a Closed contact
condition.
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14
NOTES:
1. Factory set at 0 Vdc.
2. Factory set for 90 Vdc for 120V controllers, 180 V dc for 240 V controllers.
3. Factory set for 100% of controller rating.
4. Factory set for zero compensation.
5. Factory set for 1/2 second.
6. Factory set for 1/2 second.
7. If half wave field is required, motor field windings are to be connected
between F1 and L1.
8. Factory set to accept 0 - 5 Vdc; cut J2 for 0 - 10 Vdc operation.
*Verify that INHIBIT Is properly
wired for application. See
pages 14 & 15 for details.
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15
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16
UNIT FUNCTIONS CONTINUED
To program the S1000 for either a NO or NC type INHIBIT
conditions, the unit’s logic should be set with Jumper J1. Jumper
J1 is a 10K ohm; 1/4 watt resistor which is located between the
inhibit and SP2 terminals on the S1000 circuit board. See
Component Location page 21 for further information. The two
methods for using the INHIBIT are described further on the
following page.
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17
Note: In the CLOSED method, the RUN (green) LED will remain lit
if a RUN command is present, even if unit is INHIBITED.
If the INHIBIT function is not desired, CUT jumper J1 and wire the
RUN/STOP circuit as shown in the CLOSED method. No wiring to
A1 or INHIBIT will be required.
CAUTION: INHIBIT is a logic convenience and should not be used
as an Emergency Stop. INHIBIT cannot override a catastrophic
drive failure. A system Emergency Stop function, necessary to
protect personnel or equipment, will always remove AC power
from the S1000.
Jumper J1: IN Place*
INH-Activated during OPEN
condition, must be CLOSED
for unit to RUN
RUN-Close to RUN; Open to
Stop
Jumper 1: Cut
INH-Activated during a CLOSED
condition, must OPEN for
unit to RUN
RUN-Close to RUN; Open to
STOP
*Factor installed
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18
WIRING
1. Refer to Ratings Chart (pg 8) for incoming line current and
fuse rating. It is the responsibility of the user or person
installing the controller to provide branch circuit protection
according to NEC and local codes. On controllers using 120
VAC input, be sure 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 120 VAC line is 100 VDC. If
the motor requires a 50VDC (half wave) field voltage,
connect field windings from F1 to L1. Field voltage on 240
VAC line is 200 VDC. If the motor requires a 100 VDC filed,
follow the procedure outline above.
3. Refer to Ratings Chart (pg 8) for appropriate Current Sense
Resistor size that is needed, depending upon the horsepower
of motor to be used.
4. A speed potentiometer is available for use with each
controller and is rated at 5k ohm, 1W.
5. An isolated process signal may be used instead of a
potentiometer by connecting signal leads between terminals
SP2 and A1, with positive to SP2. The S1000 is factory set
to follow a 0-5VDC signal. By removing Jumper J2, a O-
10VDC signal may be used. Jumper J2 is a 22ohm: i/4 watt
resistor located next to SP2 and SP3 terminals on the S1000
circuit board. BE SURE THAT SIGNAL IS ISOLATED FROM
GROUND, OR CONTROL WILL BE DAMAGED.
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19
6. WARNING: ALL TERMINALS OF THE UNIT ARE AT LINE
POTENTIAL AND CAN BE EXTREMELY: HAZARDOUS. POWER
MUST BE REMOVED FROM UNIT BEFORE ANY WIRES ARE
CONNECTED. FAILURE TO COMPLY MAY RESULT IN PERSONAL
INJURY, EQUIPMENT FAILURE, OR BOTH.
7. Switching devices to be used for RUN/STOP or INHIBIT must
meet the following specifications: 15VDC, 15 mA, with
leakage current less than 1 mA.
VERIFICATION TEST
Use caution during these procedures because the line voltage will
be present on the power and motor terminals, as well as on the
printed circuit board, when power is on. See the Component
Location (pg 8) to identify parts referenced during these
instructions.
CAUTION: Do not earth ground the switch and Speed Pot
terminals.
NOTE: If, at any stage of this procedure, the control does not
act as indicated, refer to the Troubleshooting Guide page .
1. With AC power off, recheck to be sure that all power and
control connections are properly secured and connected
according to the WIRING section.
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