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MT400A User Manual 11

1. EZMount Probe 15 59 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 48 49 4 20mA Output Table mA 96 mA 96 mA 400 50 800 100 1200 150 408 51 808 101 1208 151 416 1 52 836 1 a0 52 424 53 824 108 1224 153 432 54 832 104 1232 154 440 55 840 105 1240 155 448 56 848 106 1248 156 456 57 856 107 1966 157 464 58 864 108 1264 158 472 59 872 109 1272 159 480 60 880 110 1280 160 488 61 888 111 1288 161 496 62 896 112 1296 162 504 63 904 113 1304 163 512 64 912 114 1312 164 520 65 920 115 1320 165 528 66 928 116 1328 166 536 67 936 117 1336 167 544 68 944 118 1344 168 25 52 Lir 368 7 1106697 697111 560 70 960 120 1360 170 588 7i 968 121 1368 17i zS I2 15 978 99 9 1 o 728 3 584 73 984 128 1384 173 5 92 74 992 124 1392 174 600 75 1000 125 1400 175 608 76 1008 126 1408 176 1 v7 bliet 4744
2. 251 Reconfirm Field Test RPM under full load capacity 6 MT400 Motion sensor is now ready for normal operation NOTE IF ANY STEP IN THIS TEST PROCEDURE DOES NOT OCCUR AS NOTED PLEASE CONTACT MAXI TRONIC AT 800 659 8250 Date Facility Name Location Leg Name Installer Tested by To register this MT Motion Controller for warranty please fax a copy of this completed checklist to Maxi Tronic Inc at 513 398 2536 Complete one checklist for each MT400 Controller 21
3. 554 78 ies 4045 I 78 4 IF 79 0 32 10 7129 640 80 1040 130 1440 180 648 et 1048 131 1448 181 656 82 1056 132 1456 182 664 83 1064 133 1464 183 672 84 1072 134 1472 184 680 85 1080 135 1480 185 688 86 1088 136 1488 186 696 87 1096 137 1496 187 704 88 11 04 138 1504 188 712 89 1112 139 1512 189 720 90 1120 140 1520 190 728 91 11 28 141 1528 191 736 92 1136 142 1536 192 744 1144 143 1544 193 752 94 1152 144 1552 194 760 95 1160 145 1560 195 1 98 21 3568 lili ser 576 Liner oam n dez 784 98 1184 148 1584 198 792 99 1192 149 1592 199 200 mA 16 00 16 08 16 16 16 24 16 32 16 40 16 48 16 56 16 64 16 72 16 80 16 88 16 96 17 04 17 12 17 20 17 28 17 36 17 44 17 52 17 60 17 68 17 76 17 84 17 92 18 00 18 08 18 16 18 24 18 32 18 40 18 48 18 56 18 64 18 72 18 80 18 88 18 96 19 04 19 12 19 20 19 28 19 36 19 44 19 52 19 60 19 68 19 76 19 84 19 92 20 00 24VAC to 240VAC AC COMMON START oe STOP M MOTOR HOLDING CONTACTS Figure 1 Typical Existi
4. 2 If monitoring higher speeds contact Maxi Tronic to get slower speed MT400 board Note Units can be purchased to detect over speeds and or under speeds 10 If excess wobble should exist after installing the target disc on the rotating shaft perform the following Pull some targets partially out of the disc to even the short side up with the front of the probe These targets are press fit and can be pulled out with pliers If targets can not be pulled out enough then do the following 1 Enlarge the hole in the disc center Note The bolt securing the disc to shaft should have a large diameter washer between bolt head and the disc If not there please install one before performing next step 2 Using original bolt with a large flat washer install disc to shaft Snug the bolt so that step 3 can be performed 3 Using rubber mallet bump disc on the high wobble side until the wobble ceases 4 Tighten bolt 5 Readjust distance between probe and target on disc See drawing on page 11 Warning No metal can be within 1 1 2 inches 40mm of any side of the probe Any metal closer than 1 1 2 inches 40mm can cause probe to malfunction 11 TROUBLESHOOTING 1 PROBLEM Motion sensor shuts equipment down after approximately 3 seconds This indicates that motion was not detected prior to the 3 second startup limit Check to see if target light flashes On and Off when the equipment is started If the Target light does
5. 20 MA current output that is proportional to monitored equipment speed SEE PAGE 14 for mA values MT400A LAYOUT MTA00A ir RIBBON ie CABLE TO DISPLAY b 1 0 3 5 gt RZ aa 4 IH me PM AC S BL mre EXTERNAL 1 nD CA jent a 9 pth R23 Hai 117VAC BOARD ALARM POWER CONTACTS MOTOR TA e STARTUP STARTUP 8 G9 VOLTAGE STARIUP A gy Cas ha LE 9 1 c OFFSET N o iri ispirati N C 1 ff ru gj B BLACK 1 90 COM 2 Vey t Ps ie RIDT jA 1 4 MOTION WHITE VUE i AS me SENSOR UE 1 72 PROBE New Style WHT BRN Or 240VAC for MT 400 model boards marked as being for 240VAC supply BLK BLK GR RD BLU MT 400 WIRING CONNECTIONS 1 Power 117VAC is connected to 117VAC ACCOM and EGND on 2 Motion Sensor Sensor is attached to the Black Red White Green and Shield terminals on TB2 New style Brown White Black Black Red Green Blue Note Minimum 120 Targets per minute 40 RPM with a 3 Target disc 3 STARTUP Motor Startup Voltage 24 240VAC max is applied to the STARTUP A and STARTUP B terminals when the monitored equipment is running The Startup voltage should be 0 zero when the motor Stop button is pres
6. MT400 MOTION CONTROLLER INSTALLATION amp TECHNICAL MANUAL 5 30 2012 PROCESS SENSORS AND CONTROLS 417 Wards Corner Road Loveland OH 45140 800 659 8250 FAX 513 398 2536 www maxitronic com Table of Contents Page 3 Definitions Page 4 MT400 PCB Layout Page 5 MT400 Wiring Page 6 MT400 Operation Page 7 MT400 Relay Interlock Wiring Page 8 Alarm Wiring Page 9 Motion Sensor Probe Page 10 11 400 Calibration Page 12 14 Troubleshooting Page 15 Mounting the Motion Probe Page 16 4 20mA Output Table Page 17 19 Wiring Diagrams Page 20 21 MT400 Installation Checklist Features The MT400 Motion controller is an advanced underspeed detection monitor It provides advanced equipment startup monitoring and dual setpoint underspeed detection for 10 and 20 slowdown detection The target disc is mounted on the end of the rotating shaft with the probe placed to detect the rotating targets The EZMount probe combines target disc and sensor in a single easy to mount unit DEFINITIONS THE FOLLOWING TERMS AND DEFINITIONS ARE PROVIDED TO AID IN UNDERSTANDING THEORY OF OPERATION INSTALLATION PROCEDURES AND TROUBLE SHOOTING 1 START UP CIRCUIT The STARTUP circuit monitors and senses the voltage when the motor is running The function of this circuit is to start the timing circuit in the MT400 Motion Controller when the motor Start button is pressed 2 ARM Once the monitored equipment has succes
7. P A MOTOR STARTER CIRCUIT FROM NEXT MT 400A PCB Ai 6 A 2 DIN RAIL 117VAC ALARM Eus ALARM 117V ALARM r 9 RELAY OUT LAC COMMON UMPERS Ja AC COMMON 2 EARTH GROUND 117 VAC INPUT POWER TERMINAL STRIP LOCATED IN MULTIPLE UNIT HOUSING 117 TRIP N O VAC COM MTDT 24 UNIT OPTIONAL Figure 5 Typical wiring diagram showing multiple MT 400 motion sensors and an option MTDT24 Hazard Temperature Monitor going to one common alarm Each MT400 has its STARTUP circuit wired as specified on the previous figures The Alarm Relay Output of each MT400 board is wired to the coil terminals A1 and A2 of a DIN rail mounted isolation relay The output contacts of the isolation relays are jumpered together so one common alarm will sound if ANY device senses an alarm condition Place a jumper across all 11 and across all 14 terminals the relay jumpers are a piece of metal with blue plastic that slide into place 19 MT400 MOTION CONTROLLER AND SENSOR TEST PROCEDURE CHECKLIST Complete the following procedures after installing or replacing any equipment to ensure the system is fully operational and protecting your equipment Complete one checklist for each Motion Controller IMPORTANT The motion sensor probe is a metal detection device ANY metal within 1 1 2 of the probe will degrad
8. PCB and wiring diagrams indicate the state of the relays in either of the following conditions 1 No power is applied to the circuit board 2 Power is attached to the circuit board Startup circuit is connected and the monitored equipment is running OFFSET 1 10 RELAY CONTACTS e The OFFSET 1 relay activates N C opens when equipment reduces speed 10 below normal operating speed e The 10 LED indicates the status of the OFFSET 1 relay When the LED is illuminated the relay is energized N C is open e The primary function of these contacts is to o start or stop AUXILIARY equipment feeds to the primary equipment o turnonanalarm See drawings ES 400 03 amp 04 OFFSET 2 20 RELAY CONTACTS e The OFFSET 2 relay energizes when equipment reduces speed 20 below normal operating speed The N C contact opens see drawings ES 400 2 and ES 400 4 e The 20 LED indicates the status of the OFFSET 2 relay When the LED is illuminated the relay is energized N C is open See drawing ES400 03 e The primary function of the OFFSET 2 contacts are to o Shut down primary equipment o Energize auxiliary relays or PLC for sequenced shut down of other equipment NOTE If the 20 LED indicator is ON the 20 relay N C contacts will be open and equipment will not operate Pressing the equipment Start Button will start the 3 second Startup timer close the 20 relay and allow the equipment to start ALM ALARM RELAY OUTPUT T
9. ch Ohms test below Note The Green and Red wires are both Ground Don t hold the wires in your fingers when Ohms testing this will affect readings A good ohms reading does not guarantee that the probe is good e BLACK to GREEN 20K Ohms Measure between the Black wire using the positive lead on the Ohm meter and the Green wire using the negative lead on the Ohm meter should be around 20K ohms e WHITE to GREEN 3M Ohms Measure between the White wire using the positive lead on the ohm meter and Green wire using the negative lead will start around 3Meg ohm and may climb off scale to infinity BLACK to WHITE 3M Ohms Measure between the Black wire using positive lead on the ohm meter and White wire negative lead is around 3Meg ohm e WHITE to BLACK 3M Ohms Reverse the leads from the last test Measure between Black wire using negative lead of ohm meter and White wire using positive lead will start around 3Meg ohm and may climb off scale to infinity open circuit 14 INSTALLATION OF TARGET DISC AND 1 PROBE Mounted on end of rotating shaft of monitored equipment d AX Photo 1 Be certain the probe is aligned directly in front of targets on disc see Photo 1 Adjust probe so there is a gap between front of probe and targets of 3 8 to 1 2 10 13mm Note The plastic mounting flange supplied with the probe should be used Please contact Maxi Tronic if other flanges will be used or modifications are made
10. e performance To Test MT400 Motion Controllers and sensors In The Field 1 Start monitored equipment to operating speed with NO load on it running empty Confirm that the monitored shaft RPM is running at the manufacturer specifications Manufacturer specified RPM Field Test RPM 2 Check motion sensor for the following Target indicator should flash steadily for each target that passes by the probe DJ Percent meter should gradually increase then read approximately 100 Fa The Arm Indicator should become lit L 10 Indicator should not be lit 20 Indicator should not be lit 3 Turn the calibration knob fully counter clockwise and check for the following Percent meter reading should start to drop decrease When percent meter drops decreases below 90 10 Indicator will turn ON e If an Alarm is installed the alarm should now be energized and sound Any equipment connected to the 10 relay for shut down will shut down When percent meter drops decreases below 80 20 Indicator will turn ON Equipment connected for shut down 20 reduction of speed will shut down and alarm will shut off 20 4 Recalibrate Motion Controller 5 Turn calibration knob fully clockwise Start monitored equipment to operating speed WITHOUT LOAD I Percent meter should go above 100 Slowly turn calibration knob counter clockwise until percent meter reads 100 5 Verify equipment under load
11. his function allows the user to have a separate alarm output This set of contacts close at 10 speed reduction When the 10 LED is ON then these contacts are closed Please make note of the following e Contacts are dry and rated for 5A e Voltage to power the alarm is applied to the COM terminal The terminal labeled N O is then the voltage output to the alarm e Voltage input on terminal COM comes out on terminal N O when the 10 alarm is activated e For proper alarm sequence perform the following 1 Use the voltage at the STARTUP A terminal voltage to power the alarm Connect this to the ALM COM terminal 2 If the Start Up voltage is 117V then use an 117V AC alarm If Start Up voltage is 240V AC use a 240VAC alarm etc See drawing ES400 03 amp 04 3 When connected in this way the alarm will only sound when monitored equipment slows down 10 from the normal 100 speed There will be a quick beep when monitored equipment starts 4 When monitored equipment is completely Shut Down either by motion sensor or manually this alarm will not sound MOTION SENSOR PROBE The Motion Sensor probe is a metal detection device it is not a proximity type sensor This allows probe to pickup targets of both ferrous and non ferrous metals The motion sensor sends a pulse signal 12 VAC max to the MT400 control as it detect MOVING metal within it s range The closer metal is to the probe the higher the signal level The sensing d
12. istance usually works best between 3 8 to 1 2 The Probe can sense metal from all sides of the tip of the probe The installer must keep metal at least 1 1 2 away from the sides of the front half of the probe to prevent it from shielding proper operation Maxi Tronic motion sensor probes have greater than 2 inch sensing pickup distance This will allow for minor wobble of the target disc The probe could be buried in the ground and still pick up targets passed over it There is no reason to clean built up materials and dirt from the probe Do not run the probe cables in with high voltage 120 440 VAC wires Be sure the probe cables are not wrapped around high voltage lines which turn the cable into a coil and induce noise and voltages into the probe In new plant installations be certain there is no welding on the equipment or structures that the probes are wired to Be sure the probe wires are not connected during construction or maintenance welding etc The probe has components to protect the probe from high voltages If you notice the probes loosing sensitivity then one or more of the fail safe components may be damaged Improper wiring and nearby lightning can damage the probe NOTE Input and output wiring must be acceptable to the authority having jurisdiction and in accordance with local codes Peripheral equipment must be suitable for the location in which used MT400 MOTION CONTROLLER CALIBRATION The Calibra
13. ks and shorts c Clean the connector in plug type Probes d Check continuity of the cable Disconnect wires at motion Probe and from the MT400 circuit board Twist any 2 wires together and verify continuity at the other end Repeat for the other two wires Note If equipment is started and motion sensor allows equipment to operate and tachometer display increases and all other motion sensor functions seem correct then check target indicator This is a LED and will normally last the life of motion sensor control Check for broken leads or a lead shorted to housing Repair or replace as needed 5 Testing MT400 Circuit Board Operation Remove either the Black or the White wire and tap it to it s terminal to simulate a target signal You should be able to bring the meter up to 100 doing this 13 Additional Troubleshooting Check Probe and MT400 voltages NOTE New style sensor Brown White Black Black Red Green Blue 1 Motion Probe VOLTS test Perform this test with the probe wires attached to MT400 circuit board Note The Green and Red wires are both Ground e Black wire to probe Green or Red should read between 4 7 VDC e A broken black wire will cause 12 VDC to be read at the black terminal e White wire to Green or Red should read 12 VDC 2 Motion Probe OHMS test Disconnect the probe wires from the MT400 board before OHMS testing Touch all the probe wires together to drain the internal capacitors before running ea
14. ng Motor Circuit WC LLL AC COMMON HOLDING CONTACTS STARTUP B STARTUP A COM 2 OFFSET RELAY 2 20 SHUTDoww NO2 N C 2 MT 400A CIRCUIT BOARD Figure 2 Connect STARTUP A so it is hot only when the motor is running The 2096 Shutdown relay is interlocked to release the start button holding contacts and stop the motor at a 20 slowdown 17 24VAC to 240VAC AC COMMON 24 240VAC ALARM SAME AS MOTOR STARTER HOLDING CONTACTS ALM RELAY 7 OUTPUT OFFSET RELAY 2 20 SHUTDOWN No 2 MT 400A CIRCUIT BOARD Figure 3 The Alarm Relay ALM will operate at 10 slowdown The Alarm is powered from the STARTUP circuit so it can sound only if the motor is running 250V MAX START STARTER apes VOLTAGE AC COMMON 120VAC ALARM HOLDING CONTACTS com ALM RELAY ZH OUTPUT OFFSET RELAY 2 20 SHUTDOWN N O 2 MT 400A N C 2 CIRCUIT BOARD Figure 4 If the motor starter circuit is not 24 240VAC then an auxiliary relay can be used to connect the STARTUP A B and the Alarm circuit 18 TYPICAL WIRING DIAGRAM FOR MULTIPLE MOTION AND AN MTDT 24 TEMPERATURE UNIT 120VAC Models Shown MT 400A CIRCUIT BOARD 1 AC COMMON EGND m FROM MOTOR 117VAC COM STARTER CIRCUIT gt STARUP B NO J OUTPUT 120VAC FROM STARTU
15. not flash e Remove probe from mounting bracket Move a metal target screw driver etc across front of probe approximately 2 inch away from probe The target light should flash e Goto section Target light stays on or off and perform checks If Target light flashes but is erratic e Check for metal being too close to the probe Make sure the probe is close enough 3 8 5 87 to the target disc 2 PROBLEM You are not able to start the equipment This indicates the STARTUP circuit is not wired correctly Or that the Offset relays are not wired interlocked correctly e Verify the STARTUP voltage across Startup A and B terminals 120VAC when the motor Start button is pressed 0 when Stop is pressed e Verify the OFFSET 2 20 relay is wired correctly interlocked to the Start button holding contacts on the motor starter See wiring diagrams at the end of this manual 3 PROBLEM Motion sensor will not allow auxiliary equipment connected to MT400 motion controller to operate e OFFSET 1 10 relay contacts are not correctly wired interlocked See wiring diagrams at the end of this manual 4 PROBLEM Target light stays on or off at all times when equipment is started Check the following A Motion sensor cable not connected properly e Check at motion sensor terminal for the following a Match wire colors from Probe cable to the MT400 terminal strip label 12 b Check all connections and splices for brea
16. pment during startup without relying on a fixed time limit to reach full operating speed 2 The monitored equipment begins to move e When the motor Start button is pressed the MT400 has a 3 second timer allowing time for equipment to start moving e When motion is detected the TARGET LED on the motion sensor display will start to steadily flash ON and OFF for each target that passes by the motion sensor probe e If motion is not detected within 3 seconds then OFFSET 1 and 2 RELAYS will toggle back to their STOP position and the ARM 10 and 20 LED indicators will illuminate ON 3 As the equipment accelerates to operating speed e With target light flashing you should see the meter percent of operating speed display start to increase e Any deceleration before equipment reaches operating speed will initiate an Alarm and shutdown the equipment e When meter reaches 90 on scale the ARM LED will light This indicates successful equipment startup e The meter display should continue to increase until a reading of 100 NOTE If you notice the equipment is shut down and do not know why look to see if the ARM LED is ON If this LED is OFF then the equipment did not reach 90 of normal operating speed and the system did not Arm OFFSET RELAY OPERATION Equipment Interlock OFFSET RELAY CONTACT RATING Relay contact rating 5 AMP at 110 240VAC Relay contacts are dry NOTE The N O and N C relay contact markings on
17. sed To check the Startup voltage Connect a volt meter across STARTUP A amp B Start the equipment and you should read the same voltage as the motor starter coil 4 External Alarm An external Alarm should be powered the STARTUP A and STARTUP B voltage and wired through the ALM OUTPUT RELAY N O contacts TESTING Connect 120VAC power to the MT400 Motion Sensor board and no power going to STARTUP A B the motor Start button is NOT pressed This will place all relay contacts and LEDs in their Alarm state e The 10 and 20 LEDs illuminate e Both OFFSET relays energize and the N C contacts open up e The ALM RELAY OUTPUT N O terminal closes At this point you can then test the STARTUP circuit by applying 24 240VAC to the STARTUP A B terminals The easiest way to do this is to jumper power from the board by connecting 117VAC to STARTUP A and AC COM to STARTUP B If the MT400 is already wired to the motor Start button you can just press the Start button The board will enter the Startup cycle The 10 and 20 LEDs turn OFF Both of the OFFSET relays will release the N C contacts will close The ALM RELAY OUTPUT terminals open 3 5 seconds later the board will return to its Alarm state provided motion was not detected at the motion probe Or 240VAC on MT 400 boards marked as 240VAC supply models Start Up Circuit The typical way to wire the Startup circuit is to o Run a conduc
18. sfully started and has reached 90 of full operating speed the system is said to be ARMED and the ARM LED will light 2 OFFSET 1 RELAY CONTACTS A relay rated at 5 Amps 117 240V AC This relay is usually used to shut down auxiliary equipment which feeds the primary leg It is also used to turn on an external alarm at a 10 reduction in speed 3 OFFSET 2 RELAY CONTACTS A relay rated at 5 Amps 117 240VAC This relay is usually used to shut down the primary monitored equipment by breaking the Start button holding contacts It can also used to turn on an external alarm at a 20 reduction in speed 4 MOTION PROBE The motion probe is a sensor mounted at the bearing or pulley that detects the speed of the equipment being monitored A signal from the motion probe is fed to the MT400 circuit board over a low voltage cable 5 TARGET DISC A 4 round disc with equally spaced metal TARGETS embedded on its edge and typically mounted to the end of a rotating shaft The motion probe determines the speed of the shaft by detecting the targets passing in front of it 6 MOUNTING FLANGE 15 used to mount and adjust the motion probe in relation to the target disc 8 ALM RELAY OUTPUT ALM Alarm function provides a separate set of relay contacts for an alarm output These 5A rated contacts close at 10 speed reduction When the 10 indicator is lit the contacts are closed 9 4 20 MA CONFIGURATION used to give linear 4 through
19. tion CAL knob is used to adjust the digital display so it reads 100 when the equipment is running empty at it s correct speed To Adjust the MT400 display e Turn calibration control located next to the MT400 digital display fully clockwise e Start equipment operating e After equipment is at full operating speed Start turning calibration control counter clockwise in small increments until tachometer reads 100 Note There is a short delay between what the equipment does and what the meter displays This delay is to take care of normal deviations of equipment operation power fluctuations etc Please allow the meter to stabilize before moving to next increment when calibrating The knob is very sensitive this is normal behavior If calibration potentiometer is fully clockwise and meter does not display above 100 There are not enough targets passing probe The standard MT400 board is designed to detect a range of 200 to 1000 targets per minute 1 Add evenly spaced targets to disc Be sure that targets that are added to disc are not too close With a 1 probe the targets should not be closer than apart 2 If monitoring slower speeds is necessary please contact Maxi Tronic to get a higher speed MT400 board If calibration potentiometer is fully counter clockwise meter will not go below 100 There are too many targets passing the probe 1 Remove targets with the remaining evenly spaced on the target disc
20. tor from the ground common side of the starter coil to the STARTUP B terminal o Runanother conductor from the hot side of the starter coil to STARTUP A terminal See Figure 2 e The STARTUP A and STARTUP B terminals will accept voltages from 120 VAC to 240 VAC only Any other voltage will result in motion controller not working and or damage to motion controller Do not use DC voltages An Auxiliary relay may be used to obtain the proper Startup voltage See Figure 4 e If you are using a Maxi Tronic multi monitor more than one motion controller in one common enclosure the STARTUP voltages must all be 120 VAC 1400 OPERATION 1 When the equipment starter switch is pressed e Voltage is supplied to STARTUP A STARTUP B terminals Note This voltage should be supplied to the STARTUP terminals from the time the start switch closes energized until the stop switch is opened de energized e Input voltage at the Startup terminals activates the MT 400 Startup cycle o 10 and 20 LEDs turn OFF o Output 1 and Output 2 relays toggle to Run position N C is closed o ALM RELAY OUTPUT N O contacts open you may here a brief sound from the external alarm as the relay toggles o The 3 second timer starts allowing time for equipment to start moving o The MT400 is now monitoring for any deceleration in speed before the equipment reaches full operating speed This feature allow the motion sensor to watch the monitored equi

MT400A User Manual 11

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