PCS MAXIGARD Altra-gap A5000GEC User manual

PCS
PROCESS CONTROL SYSTEMS
TM
TM
A5000GEC ZERO SPEED SWITCH
100-240 VAC
Description
The MAXIGARD™ A5000GEC is a zero speed switch designed to monitor the starting
and stopping of critical rotating shafts. Maxigard™ products are manufactured to monitor
material handling and process equipment in harsh industrial applications.
Principle of Operation
The A5000GEC zero speed switch has a non-contact sensor and is supplied with
a magnetic target. The sensor signal is not impaired by the buildup of dust or any
other foreign material on the magnetic target or sensor. This switch is designed to
detect zero speed (speeds less than 1 RPM) of the monitored shaft.
The A5000GEC has one set of relay contacts. The relay is energized as soon as one
magnet passes in front of the sensor and remains energized until the monitored shaft
speed drops below 1 RPM for more than approximately 3.8 seconds. The relay
re-energizes as soon as the monitored shaft starts to rotate and one magnet passes in
front of the sensor. The switch is designed fail safe and in the event of a power failure
or loss of signal the relay will de-energize.
Components
THE A5000GEC ZERO SPEED SWITCH INCLUDES:
z4” MAGNETIC DISC (OTHER OPTIONAL TARGETS AVAILABLE)
zSENSOR SELF CONTAINED IN CAST ALUMINUM HOUSING WITH CIRCUIT & RELAY
zMOUNTING HARDWARE
327 LAKE HAZELTINE DRIVE, CHASKA, MN 55318 800-328-0738
952-361-3026
PROCESS CONTROL SYSTEMS, INC. (Fax) 952-368-4129
Page 1
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]

1.0 Magnetic Disc
1.1 The end of the shaft to be monitored should be flat to prevent excessive disc
wobble.
1.2 Center drill and tap the shaft end. (Suggested #21 drill and #10-32NF tap). Bolt the
magnetic disc to the end of the shaft. Use “Loc-tite” to keep the bolt and disc tight
on the shaft.
(see figure 1A, page 3).
2.0 Magnetic Collar (optional)
2.1 Separate the two halves of the magnetic collar by loosening the cap screws holding
the two halves together.
2.2 Place both halves of the magnetic collar around the shaft. Re-insert and tighten the
cap screws making sure the collar is square to the shaft.
(see figure 1B, page 3).
3.0 Mounting the Zero Speed Switch
3.1 Place the switch so the sensor is centered directly in front of the magnets in the disc
or optional collar.
(see figure 1A & 1B, page 3).
3.2 The gap setting between the sensor and magnetic disc or magnetic collar should
be approximately 1/8” - 3/4”.
NOTE
There will be a slight gap between the two halves after tightening. This
gap will not affect the generated signal.
Page 2
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
NOTE
There will be a gap between the two halves after tightening. This gap will
not affect the generated signal.

SENSING METHOD
Figure 1A
Optional Magnetic Collar
Figure 1B
3 11/16"
1 7/8"
4 3/4" SENSOR
1" NPT
15/16"
3 13/16"
4 9/16"
2"
Figure 2
DIMENSIONAL DATA
Page 3
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
1/4"
4"
3/16"
1 1/2"
D+3"
D"
2 7/8"
1 15/16"
2 3/4"
1 1/16"
5/16"
1 5/8"
1"
1/8"
Mounting Bracket
A5000GEC
Magnetic Disc
Magnetic Collar
Standard Magnetic Disc
MAGNET
1 5/8"
1/8" TO 3/4" GAP
SHAFT
1/8" TO 3/4" GAP
MAGNET

4.0 A5000GEC Zero Speed Switch Housing
4.1 The A5000GEC zero speed switch housing is certified for Class I,
Div. 1 & 2, Group D. Class II, Div. 1 & 2, Group E, F, & G. Class III.
(see figure 2, page 3)
5.0 Wiring the A5000GEC Zero Speed Switch
 5.1 Power connections and relay connections to the A5000GEC zero speed switch
are shown on figure 3, page 4. Also, figure 4 & 5, page 5 & 6 show typical wiring
diagrams.
5.2 Connect 100-240 VAC power to the RED wire and neutral to the WHITE wire.
Connect the equipment safety ground to the grounding screw inside the
A5000GEC housing.
(see figure 3, page 4)
5.3 Make relay connections to YELLOW, BROWN, and/ or ORANGE wires.
WARNING
To avoid electrical shock disconnect all sources of power before wiring and
observe voltage ratings of the zero speed switch.
YELLOW
BROWN
ORANGE
RED
WHITE
GREEN
COM
N.O.
N.C.
L1, 100-240VAC
L2, NEUTRAL
GROUND
9"
AC WIRING DIAGRAM
Figure 3
Page 4
Bulletin No: A5000GEC
Release Date: April 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
Page 4
Bulletin No: A5000GEC
Release Date: May 2017
(*Connect wire to grounding screw inside housing)
*
To avoid electrical shock disconnect all sources of power before wiring and
observe voltage ratings of the zero speed switch.
WARNING

M
OL’s
120VAC N
COM N.O.
N.C.
M
N.O. AUX
BROWN
ORANGE
STOP START
RED WHITE
GREEN
L1 L2
GND
A5000GEC
YELLOW
TYPICAL MOTOR STARTER WIRING
When 100-240 VAC power is applied to L1 and L2 the zero speed switch is powered
on. When the start pushbutton is pressed the A5000GEC zero speed switch N.O.
(normally open) contact closes and the N.C. (normally closed) contact opens as soon
as one magnet passes in front of the sensor. This completes the circuit around the start
pushbutton sealing the motor starter on. The N.O. contact remains closed and the N.C.
contact remains open until the monitored shaft speed drops below 1 RPM for
approximately 3.8 seconds at which time the relay de-energizes and the motor starter
drops out.
Figure 4
100-240 VAC
Page 5
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
M

N
COM N.O.
N.C.
YELLOW BROWN
ORANGE
RED WHITE
GREEN
L1 L2
GND
I:001/02
I:001/01
I:001/03
I:001/0
AC Power PLC
Input Module
When 100-240 VAC power is applied to L1 and L2 the zero speed switch is powered
on. The A5000GEC zero speed switch N.O. (normally open) contact closes and the
N.C. (normally closed) contact opens as soon as one magnet passes in front of the
sensor. The N.O. contact remains closed and the N.C. contact remains open until
the monitored shaft speed drops below 1 RPM for approximately 3.8 seconds.
Figure 5
Page
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
Page 6
Bulletin No: A5000GEC
Release Date:
100-240 VAC
TYPICAL PLC WIRING
A5000GEC

6.3 Start the monitored machine and run at normal speed with AC power connected to
the switch.
6.4 The RED LED should be flashing or appear "on" (steady) if the shaft is turning fast.
This indicates the speed switch sensor is properly aligned with the magnetic target.
6.5 The GREEN LED should be on indicating the monitored shaft is rotating. The switch
relay is energized when the GREEN LED is on. The GREEN LED shuts off
approximately 3.8 seconds after the monitored shaft stops turning.
6.0 Testing
6.1 Confirm proper mounting and electrical connections as described in sections
3 and 5.
6.2Remove the back cover of the switch housing and locate the RED and GREEN LED's
on the circuit board.
RED LED
GREEN LED
The RED LED flashes every time
a magnet passes in front of the sensor.
When on, the GREEN LED
indicates the relay is energized.
Figure 6
WARNING
Proceed with caution when power is applied to the switch and the back cover
is removed. Stay clear of any moving machinery.
NOTE
The RED LED will remain on if a magnet stops in front of the sensor. The
switch relay will still de-energize as long as the shaft stops for more than 3.8
seconds.
Page 7
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]
A5000GEC LED LOCATION
WARNING
NOTE
Proceed with caution when power is applied to the switch and the back
cover is removed. Stay clear of any moving machinery.
The RED LED will remain on if a magnet stops in front of the sensor. The
switch relay will still de-energize as long as the shaft stops for more than
3.8 seconds.

Spare Parts List
Part No. Description
1213GEC A5000GEC Without Disc and Bracket
1217 Mounting Bracket
1136 Magnetic Disc 4”/ 16 Magnets
1378 Magnetic Disc 8”/ 32 Magnets
1705 Magnetic Disc 8"/ 48 Magnets
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 or implied beyond that set forth
herein.
Page 8
Bulletin No: A5000GEC
Release Date: May 2017
CALL TOLL FREE
800-328-0738
www.maxigard.com
E-mail: [email protected]