(Power Coil), User`s Manual pdf
Contents
1. 440 LNAHS NO STATOR C x ROTOR C 115 VAC 230 VAC O CAUTION O HIGH LTAGE mO User Calibration Offset Adjustment User Calibration Gain Adjustment Zero Reference Adjustment Scale Adjustment Push DEC switch to decrease torque Push DEC switch to decrease torque output signal offset Push INC switch to Output signal gain Push INC switch to increase torque output signal offset increase torque output signal gain Figure 3 Torque Output Controls and Connections 6 Torque Signal Calibration Controls The Revolution System offers several features for fine tuning the torque output signal to suit the user s application The primary controls are for adjusting the offset zero and gain scale of the system Other operations include activating the remote shunt calibration and changing the default zero output signal from 12 mA to 4 mA All of the controls are described here User Calibration Enable Used to enable the User Calibration Gain and Offset Adjustments Specifically when this switch is in the EN enable position the GAIN and OFFSET INC increment and DEC decrement pushbutton switches are active See description below When swi2. BINSFELD ENGINEERING INC TorqueTrak Revolution Torque and Power Monitoring System Revelution User s Guide 8665009F Table of Contents System Overview System Components Controls and Connections Overview Controls and Connections Power Input Torque Output Signal Torque Signal Calibration Controls Power Output Signal Power Signal Calibration Controls Speed RPM and Direction Output Signals System Status Indicator Lights Transmitter Status Indicator Light Installation Procedure Set Up Procedure Appendix A Revolution Specifications Appendix B Torque Calibration Calculations Appendix C Error Codes amp Troubleshooting Appendix D Strain Gage Application Warranty and Service Information System Overview The TorqueTrak Revolution is a single channel non contact inductively powered system designed to provide continuous torque speed rpm power and direction of rotation data from a rotating shaft The system consists of two primary components the Rotating Shaft Collar with integral Transmitter Module and the Master Control Unit with stationary Power Coil The TorqueTrak Revolution features gt VVVVV VY VW VV WV four simultaneous data signals torque speed power and direction user adjustable scaling for torque and shaft power digital design inherently immune to electrical noise non contact inductive power and data transfer eliminates wear surface for long life without signal degradation
3. TIT B99988890 1 O Oo Ce Oo oe T A YE Q 440 1NNHS NO oo STATOR ROTOR 115 VAC 238 VAC CAUTION ane HIGH VOLTAGE O Power Scaling RPM Factor Switches Use these rotary switches to set the scale factor relating the torque signal to the shaft power signal according to the equation Prs x Constant Trs RPM Factor See details below and in Set Up Procedure Figure 5 Power Output Controls and Connections 10 Power Signal Calibration Controls The Revolution System offers several features for fine tuning the power output signal including adjusting the full scale value and selecting the frequency response The power scaling and configuration controls are described here The only offset zero reference adjustment for the power signal is via switch 3 in the Power Signal Configuration Switch panel See details below If Power Configuration switch 3 is not activated a power output si
4. D T cale N m GF N 16 x 10 1 v Do ii Where E 206 8 x 10 N mm Example Given a solid steel shaft with D shaft diameter measured 2 5 inches GF gage factor from gage package 2 045 Strans transmitter sensitivity 1 mV V Pfui Scale estimated max power level 800 hp 377 60 2 50 in Tull Scale 2 885 ft lb In this example the torque output signal can be interpreted as follows 4mA 2 885 ft lb 12mA 0 ft lb 20mA 2 885 ft lb Note that this is the nominal torque scale that applies before any User Calibration Adjustments are made 28 Appendix Error Codes amp Troubleshooting Indicator Condition Main System Status Red LED On solid No errors Fast flash a Remote Shunt Switch is on b One or more system errors present Stator Green LED On solid Input power to system is in range Fast flash Input power to system is too high Slow flash Input power to system is too low Rotor Green LED On solid Rotating Collar Power is in range and no data errors present Fast flash Rotating Collar Power is too high Slow flash Rotating Collar Power is too low Off Data transmission errors No inductive link Data Green LED On solid Data received without errors Off Data transmission errors No inductive link A flickering Data light indicates intermittent data transmission Range Red LED On solid Sensor input to transmitter is over range Off Sensor input to tra
5. 70 C lt 0 010 FS C 100ppm C 40 to 85 C Non linearity lt 0 05 FS Sensor Connection 4 conductor cable Size Diameter 1 5 inches 38 mm Width 0 75 inches 19 mm Rotating Collar Material Cast nylon Size see appropriate drawing http Awww binsfeld com index php tech_info TT R_dimensioned_drawings Master Control Unit and Power Coil Output Signals Four independent current output signals 1 Torque 4 20 mA nominal scalable usable from 0 24 mA 2 Shaft power 4 20 mA nominal scalable usable from 0 24 mA 3 Speed RPM Pulse Indicator 5 or 19 mA 4 Direction Binary Indicator 5 or 19 mA 25 Input Power 11 16 VDC standard 2A max 0 5A nominal 115VAC or 230VAC option available Output Connections Screw Terminals Size and Weight Master Control Unit 6 x 6 x 4 inches 15 cm x 15 cm x 10 cm 6 Ibs 2 72 kg Size and Weight Collar Outer Diameter see appropriate drawing http Awww binsfeld com index php tech_info TT R_dimensioned_drawings Collar Width 1 25 inch 31 75 mm Weight Dependent on shaft diameter Overall System Resolution 14 bits full scale 16384 points Torque Noise Level lt 0 10 RMS FS Frequency Response Switch selectable Torque and Power 1000 Hz 12 Hz 1 5 Hz or 0 1 Hz 3dB frequency typical Delay 1 msec typical at 1000 Hz setting Slew Rate 33mA msec typical at 1000 Hz setting Sample Rate 4800 Hz Operating Temperature 40
6. STRAIN GAGE VISHAY MEASUREMENTS GROUP RALEIGH NC PHONE 919 365 3800 PART CEA 06 250US 350 Warranty and Service Information LIMITED WARRANTY Please record the date of purchase with the instrument serial numbers Date of Purchase Master Control Unit Rotating Transmitter Binsfeld Engineering Inc warrants that its products will be free from defective material and workmanship for a period of one year from the date of delivery to the original purchaser and that its products will conform to specifications and standards published by Binsfeld Engineering Inc Upon evaluation by Binsfeld Engineering Inc any product found to be defective will be replaced or repaired at the sole discretion of Binsfeld Engineering Inc Our warranty is limited to the foregoing and does not apply to fuses paint or any equipment which in Binsfeld Engineering s sole opinion has been subject to misuse alteration or abnormal conditions of operation or handling This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to any implied warranty of merchantability or fitness fora particular purpose or use Binsfeld Engineering Inc will not be liable for any special indirect incidental or consequential damages or loss whether in contract tort or otherwise NOTE USA only Some states do not allow limitation of implied warranties or the exclusion of incidental or consequential dam
7. does not require shaft modification or machine disassembly to install fully encapsulated rotating electronics with status indicator light on the transmitter switchable low pass filter remote shunt system calibration self diagnosis with error mode indicator lights offset and gain settings stored in non volatile memory high resolution data 14 bit The TorqueTrak Revolution is a rugged precision instrument designed for applications where ongoing measurement of torque and or power on a rotating shaft is required System Components Rotating Shaft Collar with Transmitter Module Clamps to shaft with bolts provided Houses Transmitter Module which converts strain gage signal to digital code Stationary Power Coil Sends power to the Rotating Collar and receives data signal from the Rotating Collar Lead wires from Collar for sensor connection Strain Gage Sensor Glued to shaft not included but ordered as an accessory Converts mechanical Mounting Block with speed sensor Main System torque to electrical Status Indicator signal which is Light transmitted from the Rotating Collar to the Stationary Power Coil Mounting Flange Master Control Unit Provides power signal to Power Coil Processes digital data signal from transmitter to produce four 4 20mA output signals corresponding to torque speed RPM shaft power and direction of rotation Figure 1 Revolution System Components 3
8. to 85 C 0 to 90 relative humidity noncondensing 26 Appendix Torque Calibration Calculations The equations in this Appendix define the full scale torque range of the Revolution system based on shaft parameters e g shaft diameter strain gage parameters e g gage factor and the Revolution transmitter gain setting preset at the factory and documented below For easy calculations use the calculator found at our website http Awww binsfeld com calculators ttrevo_range Calculate Nominal Full Scale Torque Tru scai ft lb To calculate the nominal full scale torque T scale ft lb that corresponds to a nominal system output of 12 8 mA Teull Scale ft lb solid shaft For all other shafts use the more general equation Strans E 4 Do Di Scale ft lb GF N 16 000 1 v D 12 Legend of Terms Shaft Inner Diameter in zero for solid shafts Shaft Outer Diameter in Modulus of Elasticity 30 x 10 PSI for steel F Gage Factor specified on strain gage package Transmitter sensitivity mV V not user configurable Strans Typical is 1 mV V for 500 microstrain range N Number of Active Gages 4 for torque Trullscale Full Scale Torque ft lb v Poisson s Ratio 0 30 for steel 27 For metric applications with D and D in millimeters and Tru scale in Newton meters the general equation is Strans E 4 Do
9. 1 ft lb 1 356 N m 23 Advanced User Calibration Adjustments The torque offset and gain levels can be manually adjusted via the User Calibration Offset and Gain Adjustments described in the Calibration and Controls section of the manual This can be done in one of two ways Deadweight Method The most precise method for determining Sensitivity of the system is a true mechanical calibration sometimes called a Deadweight Test where a known torque a known force weight on a known moment arm is applied to the shaft Example 100 pounds weight on a 1 foot moment arm equals 100 foot pounds known Torque Input Observe the Current Output of the TorqueTrak Revolution system Sensitivity of the entire system is equal to the Torque Input per Current Output Take two or more points of reference using different known Torque Input values as confirmation of the Sensitivity value determined Shunt Calibration Method The easiest and next best way to conduct a calibration is by enabling the Shunt Calibration Switch Alternatively precision resistors can be connected in parallel with one arm of the bridge to simulate a torque load When the Remote Shunt is turned ON a precision resistor internal to the transmitter is activated to simulate a precise strain value equivalent to 50 of Full Scale in the positive direction With the gage installed and wired to the instrument the torque offset value is adjusted until the desired output
10. 1 on page 3 or Figure 10 on page 20 Additional support for the Power Coil may be required depending on the size and application mounting tabs are incorporated into the larger Power Coil designs and brackets are included Remove cover from Master Control Unit Install cable clamps or conduit connectors not provided in holes in bottom of box Insert data signal wires from process control or recording equipment through clamps or connectors then connect to corresponding screw terminals inside unit black connector Note Wiring holes must be sealed accordingly to prevent contamination in the enclosure Connect input power leads through clamps or connectors then connect to corresponding power terminals green connector inside unit NOTE Steps 7 9 outline verification of system operation A star bridge has been pre wired to the Revolution transmitter for this purpose Completing the verification will greatly reduce troubleshooting effort if a system error exists Slide the main power switch to ON After 10 seconds verify that the Main System Status light is on solid indicating successful data transmission Also the transmitter status indicator light should be on at this time and the red led on the supplied star bridge should be on indicating that the excitation voltage is present for the strain gage If Main System Status light is flashing see Appendix C Error Codes amp Troubleshooting Connect an amp meter not provided to the T
11. Controls and Connections Overview Torque Config Switches 2 Neg FS torque 1 amp 2 Zero torque 3 Set zero torque to 4mA 4 Reverse signal polarity 5 Bypass user calibration ie Not used oid Off fon aa Oni A Fier 1000 IEJ 01 2 System Calibration EN to enable Offset Gain switches Signal Output Terminals 1 Torque Output HI 1 2 Torque Output LO 3 Power Output HI 1 4 Power Output LO 1 5 Speed Output HI 1 6 Speed Output LO a 7 Direction Output HI Power Config Switches 1 Pos FS power 2 Neg FS power 1 amp 2 Zero power 3 Set zero power to 4mA 4 Reverse signal polarity 5 Power once revolution 6 ON for lt 10 RPM OJ Off Olay On 8 On Filter MUAY 12 Ee 0 1Hz SAVE to store OSM wr TTT Offset Zero e a p Adjustment Gain Scale Adjustment Main Power Switch Pos HI Chassis STATOR 7 x O RANGE O System Status Indicators Input power level okay ON Collar power okay no errors ON No data transmission errors Range ON Sensor input out of range RPM Flashes 6
12. This will prevent damage to the gages It is not necessary to remove the tape immediately after installation It offers some protection for the gaged surface and may be left until wiring the gage WIRING THE GAGE 13 14 15 Tin each solder pad with a solder dot It is helpful to polish the solder tabs e g with a fiberglass scratch brush or mild abrasive before soldering Trim and tin the ends of the 4 conductor ribbon wire Solder the lead wires to the gage by placing the tinned lead onto the solder dot and pressing it down with the hot soldering iron Note For single stamp torque gages a short jumper is required between solder pads 2 and 4 as shown in the diagram on the next page Use the rosin solvent to clean excess solder rosin from the gage after wiring Brush the gage pads with the solvent and dab with a clean tissue Paint the gage area including the solder pads with M Coat A polyurethane and allow to air dry 15 minutes This protects the gage from moisture and dirt To further protect the gage apply M Coat J protective coating for protection against moisture fluids and mechanical damage 35 For TORQUE Measurement NOMINAL RESISTANCE VALUES EXC TO EXC 350 ohms SEN TO SEN 350 ohms ALL OTHER TESTS 262 5 ohms 36 YIELDS POSITIVE OUTPUT SIGNAL FOR TORQUE DIRECTION SHOWN GAGE CAN BE ROTATED 90 EACH ROTATION OF 90 RESULTS JN CHANGE IN SIGN OF THE OUTPUT SIGNAL gt
13. not shorted to the MCU enclosure by water or other conductive material 2 Remove any surrounding metal other than the shaft within 1 inch 2 5 cm of the Power Coil 3 Clean mating surfaces of the Power Coil and tighten all mounting screws 4 Verify that the Rotating Coil voltage is about 120 mVAC probe the two terminal dots on the outer surface of the coil boards attached to the Rotating Collar 5 Check alignment of the Rotating Collar with the Power Coil the back of the Collar should align with the back edge of the Mounting Block 6 Make certain Rotating Collar connectors are not damaged and are completely engaged Strain gage problem Main System Status flashing fast Range on solid 1 Verify excitation voltage to gage is 2 5 VDC 2 Check solder connections and wiring to gage 3 Balance the gage to reduce offset or apply a new gage 30 Using the BS900 Bridge Simulator for Troubleshooting A BS900 Bridge Simulator is shipped with each Revolution system inside the Master Control Unit The Bridge Simulator is very useful for isolating the cause of a suspect data signal as it simulates a properly installed strain gage By disconnecting the actual strain gage and temporarily connecting the Bridge Simulator to the ribbon cable from the Rotating Collar the user can quickly determine if the suspect output signal is a function of a faulty strain gage installation including solder connections or is due to a malfunctioning Rev
14. power and torque units Power Units Torque Units Constant Horsepower Foot pounds 5252 Kilowatt Newton meter 9550 Step 4 Set the RPM Factor rotary switches in the Master Control Unit to the value calculated in Step 3 Turn system power OFF then ON to register new switch settings System is now set as follows Torque Output Signal 4mA a Scale 12mA 20 mA T Full scale Power Output Signal 4mA Scale 12mA 20 mA PFull Scale Note that these are the nominal torque and power scales that apply before any User Calibration Adjustments are made The TorqueTrak Revolution System is now ready to record data at the nominal gain and offset settings 22 Example Given solid steel shaft with Do shaft diameter measured 2 5 inches GF gage factor from gage package 2 045 Strans Transmitter sensitivity 1 mV V Prull Scale estimated max power level 800 hp 377 60 2 50 in TFull Scale 2 885 ft lb 800 hp x 5252 RPM Factor 1456 switch setting 2 885 ft lb In this example the torque and power output signals can be interpreted as follows Torque Output Signal 4mA 2 885 ft lb 12mA 0 ft lb 20 mA 2 885 ft lb Power Output Signal 4mA 800 hp 12mA 0 hp 20 mA 800 hp Conversion Chart for Common Units Power Torque Kilowatt kW Newton meter N m 1 kW 1 341 hp 1 N m 0 737 ft lb Horsepower hp Foot pound ft lb 1 hp 0 746 kW
15. signal or display value is reached see procedure described on page 7 Next enable the Shunt Calibration Switch and adjust the torque gain value until the desired output signal or display value is reached Repeat the offset and gain adjustments alternating from Shunt Calibration Switch ON and OFF until readings are stable and repeatable NOTE The maximum gain adjustment possible using the Remote Shunt is 3X with dipswitch 3 off IMPORTANT The full scale power range Pfs and power scale RPM Factor must correspond to the actual full scale torque not simply the nominal full scale torque In other words if the full scale torque range is manually adjusted then the full scale power range must be recalculated 24 Appendix A Revolution Specifications Transmitter Module mounted inside Rotating Collar Sensor Input Full 4 arm Wheatstone Bridge strain gage 120 1000 ohms 350 ohms standard Bridge Input Approx 2 5 VDC regulated Sensor Range 500 microstrain Torque or Bending Full Bridge 4 Active Arms 769 microstrain Tension or Compression Full Bridge 2 6 Active Arms Corresponding transmitter sensitivity is 1mV V Microstrain values based on nominal gage factor of 2 0 See data sheet from gage manufacturer for actual gage factor Temp Coefficient Gain lt 0 005 50ppm C 20 to 70 C lt 0 010 FS C 100ppm C 40 to 85 C Zero lt 0 005 FS C 50ppm C 20 to
16. signals 20 Set Up Procedure The power output signal from the Revolution System is generated using the measured torque value from the strain gage and the measured shaft speed RPM System setup requires four basic steps Step 1 Calculate the nominal full scale torque range Step 2 Select an appropriate full scale power level Step 3 Calculate the corresponding RPM Factor Step 4 Set the RPM Factor switches For initial set up it is recommended that all of the Torque and Power Configuration switches be set to the OFF position Step 1 Calculate the nominal full scale torque Tru scale range as described in Appendix B The simplified torque equation is duplicated here for convenience TrullScale ft lb with Do in inches GF Tru Scale N m with D in mm GF 32 02 where Do TFull Scale GF Shaft outer diameter inches or mm Full Scale Torque ft lb or N m Gage Factor from gage package Step 2 Select Power Full Scale Pfui scaie The value you choose to correspond to the full scale power output 20MA 21 Step 3 Calculate the nominal RPM Factor using the following equation Scale X Constant RPM Factor TFull Scale RPM Factor User selectable switch setting at Master Control Unit Pru scae Power Level selected by the user to correspond to 20mA Full Scale Output TrullScale Torque Level that corresponds to 20MA Full Scale Output Constant Dependent on
17. three steps must be completed in sequence within 3 5 seconds Read through instructions before proceeding so there will be no delays Have Ready M Bond Cyanoacrylate Adhesive 2 5 piece of teflon tape Tissues MOUNTING THE GAGE 9 10 Lift the leading edge of the tape and apply a thin bead of adhesive at the gage end where the tape meets the shaft Adhesive should be of thin consistency to allow even spreading Extend the line of glue outside the gage installation area Holding the tape taut slowly and firmly press with a single wiping stroke over the tape using a teflon strip to protect your thumb from the adhesive and a tissue to absorb excess adhesive that squeezes out from under the tape This will bring the gage back down over the alignment marks on the gaging area This forces the glue line to move up and across the gage area A very thin uniform layer of adhesive is desired for optimum bond performance 34 11 12 Immediately using your thumb apply firm pressure to the taped gage by rolling your thumb over the gage area Hold the pressure for at least one minute In low humidity conditions below 30 or if ambient temperature is below 70 F pressure application time may have to be extended to several minutes Leave the mylar tape on an additional five minutes to allow total drying then slowly peel the tape back directly over itself holding it close to the shaft while peeling
18. to the left for 115VAC power One fuse is connected to high Slide to the right for 230VAC power side power one fuse is connected to low side power Figure 2 Power Input Controls and Connections 5 Torque Output Signal The 4 20mA torque output signal is accessed from a removable eight position screw terminal block on the upper most board in the Master Control Unit Torque signal calibration controls including gain and offset adjustments are described below User Calibration Enable Switch ENabled right position Calibration is enabled gain and offset adjustments are active and will affect the torque output signal SAVE left position Calibration is saved gain and offset settings are stored in memory and adjustment switches are disabled Torque Signal Output Terminals Terminal 1 Shaft Torque Output Current Loop l Terminal 2 Shaft Torque Output Current Loop Return Common Torque Signal Configuration Switches Remote Shunt Calibration Switch Used to set data signal options e g Used to place a precision shunt activating low pass filter or reversing resistor across one arm of the full signal polarity See details below bridge strain gage sensor simulating 50 full scale torque Seaseceaa 1
19. T 2M Mylar Tape and place it on the gage and terminal centered Slowly lift the tape at a shallow angle You should now have the gage attached to the tape POSITIONING THE GAGE 6 Using the small triangles located on the four sides of the gage place the taped gage on the shaft perpendicular with the shaft axis aligned with your guide marks If it appears to be misaligned lift one end of tape at a shallow angle until the assembly is free to realign Keep one end of the tape firmly anchored Repositioning can be done as the PCT 2M tape will retain its mastic when removed and therefore not contaminate the gaging area Positioning the Gage on the Shaft 33 7 Gage should now be positioned Once again lift the gage end of the tape at a shallow angle to the surface until the gage is free of the surface Continue pulling the tape until you are approximately 1 8 1 4 beyond gage Turn the leading edge of the tape under and press it down leaving the bonding surface of the gage exposed Apply a very thin uniform coat of M Bond 200 Catalyst to the bonding surface of the gage This will accelerate the bonding when glue is applied Very little catalyst is needed Lift the brush cap out and wipe excess on lip of bottle Use just enough catalyst to wet gage surface Before proceeding allow catalyst to dry at least one minute under normal ambient conditions of 75 F and 30 65 relative humidity NOTE The next
20. ages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may have other rights which vary from state to state For service please contact Binsfeld Engineering Incorporated Phone 1 231 334 4383 Fax 1 231 334 4903 E mail sales binsfeld com 37
21. aper Finish the sanding procedure by wetting the gaging area with M Prep Conditioner A and the wetted surface with 400 grit paper provided Rinse by squirting with M Prep Conditioner A Wipe the area dry with tissue taking care to wipe in only one direction Each time you wipe use a clean area of the tissue to eliminate contamination Rinse shaft this time by squirting with M Prep Neutralizer 5A Wipe the gaging area dry with a clean tissue wiping in only one direction and using clean area of tissue with each wipe Do not allow any solution to dry on the surface as this may leave a contaminating film which can reduce bonding Surface is now prepared for bonding MARKING THE SHAFT FOR GAGE ALIGNMENT 4 The gage needs to be perpendicular to the shaft axis In general this can be accomplished by eye since misalignment of less than 4 degrees will not generate significant errors For higher precision we recommend two methods for marking the shaft a Use a machinist square and permanent marker or scribe for perpendicular and parallel lines or b Cut a strip of graph paper greater than the circumference of the shaft Tape it to the shaft while lining up the edges Mark desired gage position with a scribe or permanent marker 32 5 PREPARING THE GAGE FOR MOUNTING Using tweezers remove one gage from its package Using the plastic gage box as a clean surface place the gage on it bonding side down Take a 6 piece of PC
22. er sensors to shaft being measured See Appendix D Strain Gage Application for simplified instructions Remove large bolts from Rotating Collar if necessary to separate parts Apply anti seize compound provided to the bolt threads Reassemble collar on shaft adjacent to gage with ribbon cable from collar leading towards gage Refer to Figure 1 on page 3 or Figure 10 on page 20 Make certain that connectors are properly aligned Install opposing collar bolts from opposite directions to maintain balance Tighten alternate bolts evenly until gap between collar halves is 100 2 5mm at all junctions See Figure 9 below CAUTION Before proceeding make sure Rotating Collar bolts are tightened adequately to prevent loosening of the collar while rotating but not so tight that the coil boards attached to the Rotating Collar are interfering with each other 0 100 2 5 mm N 0 020 0 5 mm connectors no gap between edge view Figure 9 Correct Collar Gap Spacing 3 Assemble one half of Power Coil to Mounting Block on Master Control Unit using hardware provided Position Master Control Unit with half ring around shaft and assemble second half of Power Coil using hardware provided 18 Securely mount Master Control Unit to machine or mounting bracket not provided so that the back surface of the Collar aligns with the back edge of the Mounting Block Refer to Figure
23. gnal of 12 mA will always indicate zero power and zero power will always correspond to zero torque and or zero RPM Power Scaling RPM Factor Switches Used to set the full scale range for the power output signal as described in the Set Up Procedure There are four rotary switches corresponding to thousands x1000 hundreds x100 tens x10 and units x1 The switches are set by using a small screwdriver to turn the dial indicator to the desired digit and then cycling system power Note System must be turned OFF then ON using Main Power Switch to register new RPM factor switch settings For example if the calculated RPM Factor is 1490 then the switches would be set as follows x1000 position 1 x100 position 4 x10 position 9 1 position 0 IMPORTANT Power supply to the TorqueTrak Revolution must be cycled Off then back On to make effective any changes to the RPM Factor switch setting Note The power signal gain sensitivity is dependent upon and proportional to the torque gain Power Signal Configuration Switches Used to set specific power signal parameters as listed here Note The ON position for each switch is upwards towards the Power Coil 11 Switch Function when switch is ON 1 Generates positive full scale power output signal 20mA 2 Generates negative full scale power output signal 4 mA 1 amp 2 Generates zero power output signal 12 mA 3 Full Scale Torque Output Ra
24. igure 7 Speed and Direction Output Connections The speed RPM output signal is a pulse train that is nominally 5 mA or 19 mA depending on shaft direction which pulses to the alternate current level at the following rate RPM Fpulse 10 Fpu se Frequency of the pulse train in Hertz RPM Shaft revolutions minute 14 When viewed from the front of the Master Control Unit with the black ring on the Rotating Collar in view a clockwise rotation produces a speed signal that is nominally 19 mA with 5 mA pulses Conversely a counterclockwise rotation produces a speed signal that is nominally 5 mA with 19 mA pulses Six magnets in the Rotating Collar trigger the pickup sensor in the Mounting Block on top of the Master Control Unit to generate the speed signal The direction signal is a simple binary indicator 5 mA when the shaft rotates in one direction and 19 mA when it rotates in the other direction Clockwise Shaft Rotation Direction signal 19 mA constant Speed signal 19 mA pulsing to 5 mA at the rate of 6 pulses per revolution Counterclockwise Shaft Rotation Direction signal 5 mA constant Speed signal 5 mA pulsing to 19 mA at the rate of 6 pulses per revolution NOTE The maximum load resistance of any one of the TorqueTrak Revolution output current loops is 500 ohms This means the system can drive the 4 20 mA output signal into resistances of 0 to 500 ohms To calculate the distance the signal ca
25. n travel add the input resistance of the device you plan to drive plus the resistance of the wire length As long as the total resistance is less than 500 ohms the TorqueTrak Revolution output signal will drive the device 15 System Status Indicator Lights There is one Main System Status Indicator light located outside the Master Control Unit at the base of the Power Coil and five secondary system status indicator lights inside the unit See Appendix C Error Codes amp Troubleshooting for indicator details Main System Status Indicator Red light is on solid if no system errors are present ee ee 556666660 EHHHHHHH 1 D 30 LNNHS NO lig 0 STATORO x aa ROTOR O 115 VAC 238 VAC CAUTION HIGH LTAGE ined Secondary System Status Indicators On solid if input power level is in range On solid if collar power is in range and no data errors On solid if no data transmission errors Off if sen
26. nge 4 20mA with dipswitch 3 ON up 12 8mA with dipswitch 3 OFF down Reverses the polarity of the power signal Updates power output signal once per shaft revolution Normally OFF ON for very low speed shafts lt 10 RPM amp 8 Used to set frequency response of power signal i e select cut off frequency for low pass filter as follows NOL Switch 7 Switch 8 Cut off Frequency Off Off 1000 Hz Off On 12 Hz On Off 1 5 Hz On On 0 1 Hz Power Signal Configuration Switches Power Scaling RPM Factor Ss Switches ON KIS 5E qe 44IO0 LNNAHS NO 230 Figure 6 Power Signal Scaling and Configuration Switches 12 When switch 3 is activated the output signal at zero power changes from 12 mA to 4 mA and simultaneously the signal gain is doubled When Switch 5 is OFF the power output signal is calculated and updated 6 times per shaft revolution i e whenever the RPM sensor is triggered When Switch 5 is ON the power output signal is calculated and updated only once per shaft revolution thereby averaging the power data over a complete revolution Switch 6 i
27. nsmitter is within range if stator rotor and data LED s are on solid The Range indicator may flash or flicker with a dynamic over range condition When the Range light is on the torque and therefore power signals are in error RPM Green LED On Speed sensor triggering properly Off Speed sensor not triggering Flashes 6 times per shaft revolution so will appear on solid or flashing depending on shaft speed Transmitter Status Indicator Green LED On solid Sufficient power being received from rotating coil Off Zero or insufficient power from rotating coil or the transmitter has failed 29 In error mode system output 24 Fast flash rate 4 Hz Slow flash rate 2 Hz Indicates normal error free mode Common Error Modes and Suggested Corrective Actions If an error is present the Main System Status Indicator will flash and the system will display an error code briefly another 10 15 seconds before the startup cycle repeats Below are the most common error modes and potential corrective actions Error Mode Symptom Action Error Mode Symptom Action Error Mode Symptom Action Power supply voltage to system is incorrect Main System Status flashing fast Stator flashing 1 Supply correct voltage to the MCU Weak inductive link Main System Status flashing fast Stator on solid Rotor flashing slow Data off or flickering transmitter status indicator off 1 Make certain Power Coil is
28. olution system Connect the BS900 as follows Ribbon Cable from BS900 Bridge Rotating Collar Simulator Pin RED EXC GREEN SENS WHITE SENS BLACK EXC The Bridge Simulator has a three position slide switch to simulate zero load 20 of negative nominal full scale and 20 of positive nominal full scale Shown below are the approximate torque data output signals you should get with the Revolution system at original factory settings Negative Center Positive Torque Output 10 4 mA 12mA_ 13 6 mA IMPORTANT If you get accurate and repeatable output signals using the Bridge Simulator which is normally the case then the Revolution system is operating properly and you should focus your troubleshooting attention on the strain gage installation including possible wiring errors Also you can use the Star Bridge shipped installed on transmitter rotating collar to verify that excitation voltage 2 5VDC is present 31 Appendix Strain Gage Application Also refer to instruction bulletin B 127 12 provided with GAK 2 200 Strain Gage Application Kit from Vishay Measurements Group Inc Raleigh NC 919 365 3800 www measurementsgroup com PREPARING THE SURFACE 1 A 3 inch square area will be used for gaging Scrape off any paint or other coatings and inspect shaft for oil residue If necessary use a degreasing solution or isopropyl alcohol to remove Rough sand the gaging area with 220 grit p
29. orque Signal Output Terminals 1 amp 2 inside MCU Measure the Torque Signal mA Reading should be approximately 12 mA Slide the Remote Shunt switch to ON Main System Status light will flash Measure the Torque Signal current Reading should be approximately 16 mA Slide the Remote Shunt switch to OFF position Main System Status light will return to on solid Slide the Main Power switch to OFF 19 10 Trim ribbon cable from Rotating Collar to length and retain the star bridge The star bridge has a built in led that may be used to troubleshoot future errors Connect solder cable to sensor Refer to Figure 10 below Note Keep ribbon cable as short as practical 6 to 8 inches typical to avoid unwanted electrical noise For long cable runs consider using shielded cable Secure ribbon cable to shaft using adhesive or fiberglass tape or more permanent methods as appropriate CF jumper wire ga 0 Figure 10 Strain Gage Connections 11 Slide main power switch to ON position Confirm that Main System Status light is on solid indicating successful data transmission If Main System Status light is not on solid see Appendix C 12 If possible rotate collar through complete range of motion to verify data transmission in all orientations and to confirm clearance between Rotating Collar and Power Coil 13 Installation is complete Refer to Set Up Procedure to configure torque and power output
30. que output signal may affect the offset zero reference of the torque output signal wT To restore the factory offset and gain settings a Slide SAVE CAL ENable switch to EN position b Activate dipswitch 5 of Torque Signal Configuration panel Bypass User Calibration c Slide SAVE CAL ENable switch to SAVE position d Deactivate dipswitch 5 of Torque Signal Configuration panel See Torque Configuration Switch details below Remote Shunt Calibration Switch Used to verify system operation without directly accessing the strain gage When switched to the ON position a fixed precision resistance inside the Transmitter Module is applied across one arm of the strain gage bridge simulating strain that produces a torque signal output corresponding to 50 of Full Scale in the positive direction at factory default settings In the OFF position the resistance is removed from the sensor Note The System Status Indicator light flashes and the internal Rotor light flashes when the Remote Shunt is applied Torque Signal Configuration Switches Used to set specific torque signal parameters as listed here The ON position for each switch is upwards towards the Power Coil Switch Function when switch is ON 1 Simulates a positive full scale torque input signal from the transmitter nominally generates 20 mA output 2 Simulates a negative full scale torque input signal from the transmitter nominally genera
31. s used when the shaft speed is very low less than 10 RPM When Switch 6 is ON the system adds a delay between the time the RPM sensor is triggered and the time the power output signal is allowed to indicate zero power This feature prevents a slowly rotating shaft from erroneously generating a zero power data signal 13 Speed RPM and Direction Output Signals The 5 or 19mA speed RPM and direction output signals are accessed from a removable eight position screw terminal block on the upper most board in the Master Control Unit as described below Speed RPM Signal Output Terminals Terminal 5 Speed Output Current Loop l Terminal 6 Speed Output Current Loop Return Common Direction Signal Output Terminals Terminal 7 Direction of Rotation Output Current Loop 1 Terminal 8 Direction of Rotation Output Current Loop Return Common HEAHGHHL oe r Om D 440 INNHS ND STATOR C x ROTOR O 115 VAC 230 VAC pata CAUTION _ HIGH LTAGE F
32. sor input signal is within range At slow shaft speeds used to verify operation of RPM sensor LED flashes as magnets trigger pickup sensor Stator Green Rotor Green Data Green Range Red RPM Green Figure 8 System Status Indicators 16 Transmitter Status Indicator Light The green light embedded in the cover of the transmitter module located on the back side of the Rotating Collar is the Transmitter Status Indicator Light Transmitter Status Indicator Light Figure Transmitter Status Indicator Light When the Transmitter Status Indicator Light is on solid the transmitter module is receiving sufficient power from the rotating coil and is sending out viable digital data This indicator is most useful when troubleshooting an error mode refer to Appendix C When the error mode is weak inductive link i e Main System Status light is flashing fast Stator light is on solid Rotor and Data lights are off or blinking and the Transmitter Status Indicator is on it means that the transmitter is still receiving enough power to send data but the data signal being sent to the MCU is not being received If the light is off this may indicate that insufficient power is being supplied to the transmitter or that the transmitter module has failed In either case follow the corrective actions outlined in Appendix C 17 Installation Procedure 1 If not already installed attach strain gage s or oth
33. tched to the SAVE position the current offset and gain adjustments are stored in memory and the GAIN and OFFSET adjustment switches are disabled User Calibration Offset Adjustment Used to manually adjust the offset zero reference point of the torque output signal When User Calibration is enabled see description above pressing the OFFSET INC button will increase the offset thus changing the nominal 12 mA zero reference to a higher value Conversely pressing the DEC button will decrease the offset thus changing the nominal 12 mA zero reference to a lower value The nominal zero reference output of 12 mA can be set to any output level from 0 24 mA Note Changing the offset zero reference of the torque output signal does not affect the gain scale factor of the torque output signal To change the zero reference value from 12 mA to 4 mA i e change the zero to positive full scale output range from 12 20 mA to 4 20 mA activate Torque Signal Configuration Switch 3 as described below User Calibration Gain Adjustment Used to manually adjust the gain scale factor for the torque output signal When User Calibration is enabled see description above pressing the GAIN INC button will increase the torque signal gain Conversely pressing the DEC button will decrease the torque signal gain The torque signal gain can be adjusted to any level from 25 to 400 4x Note Changing the gain scale factor of the tor
34. tes 4 mA output 1 amp 2 Simulates a zero input signal from the transmitter nominally generates a 12 mA output 3 Full Scale Torque Output Range 4 20mA with dipswitch 3 ON up 12 8mA with dipswitch 3 OFF down 4 Reverses the polarity of the torque signal 5 System bypasses the user calibration settings i e manual gain and offset adjustments are ignored 6 Not used 7 amp 8 Used to set frequency response of torque signal i e select cut off frequency for low pass filter as follows Switch 7 Switch 8 Cut off Frequency Off Off 1000 Hz Off On 12 Hz On Off 1 5 Hz On On 0 1 Hz Torque Signal Configuration Switches 1234567 8 QD Power Output Signal The 4 20 mA shaft power output signal is accessed from a removable eight position screw terminal block on the upper most board in the Master Control Unit Power signal scaling and configuration switches are described below Power Signal Output Terminals Terminal 3 Power Output Current Loop l Terminal 4 Power Output Current Loop Return Common Power Signal Configuration Switches Used to set data signal options e g activating low pass filter or reversing signal polarity See table below for details
35. times per revolution C Stator ON Rotor Data Power Scaling RPM Factor Switches Set RPM Factor switches to RPM Factor Prs x C Tes Prs Full Scale Power hp or kW Trs Full Scale Torque in lb or N m 5252 ft lb hp or 9550 N m kW Controls and Connections Power Input The Master Control Unit operates on 11 16 VDC standard or 115VAC or 230VAC optional Power connections are made via a removable three position screw terminal block as shown below WARNING Supply voltage up to 230VAC is live in the Master Control Unit even when the Main Power switch is off Use caution when accessing internal controls Power Input Terminal Block DC Power AC Power Terminal 1 Pos High Terminal 2 Chassis Gnd Chassis Gnd Terminal 3 Neg Low IL I rr 123456728 1 TTT Oj D 440 INNHS ND STATOR x ROTOR OD 115 VAC 230 VAC O RANGE C O Main Power Switch 115VAC 230VAC Switch only available with VAC Option Slide
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