TorqueTrak Revolution Torque and Power Monitoring
Contents
1. 440 1NQHS NO CC STATOR x ROTOR _ 115 VAC 238 VAC pata CAUTION roe HIGH VOLTAG eO 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 swit2. Figure 6 Power Signal Scaling and Configuration Switches When switch 3 is activated the output signal at zero power changes from 12 mA to 4 mA and simultaneously the signal g ain is doubled 12 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 is 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 1 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
3. Dh 23 OL z uo Als 23 D BL fo 3 Del gi 440 1NNHS N0 AOFF POWER ON rin Uo c 2 Bo q 8 STATOR x ROTOR C 115 VAC 230 VAC pata c A y RANGE C HIGH V E o Ss Figure 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 Fuse Sesto 10 Feutse 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 C
4. 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 Weight 6 Ibs 2 72 kg 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 Operating Temperature 40 to 85 C 0 to 90 relative humidity noncondensing 26 Appendix B 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 that factory and documented below These equations available as online calculators at www binsfeld com are specific to torque measurements on round shafts full bridge 4 active arms Calculate Nominal Full Scale Torque Teun scale ft lb To calculate the nominal full scale torque T Fut scale ft lb that corresponds to a nominal system output of 12 8 mA on a solid steel shaft with transmitter sensitivity 1mV V use this simplified equation 377 60 D T Ful scale ft lb solid shaft GF For all other shafts use the more general equa
5. 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 other sensors to shaft being measured See Appendix D Strain Gage Installation for simplified instructions 2 Remove large bolts fromRotatingCollarifnecessaryto separate parts Apply antiseize 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
6. 3 or Figure 10 on page 19 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 no gap between 0 020 0 5 mm connectors Z 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 1 on page 3 or Figure 10 on page 19 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 inshotle bottom of box Insert data si
7. 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 for a 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 damages 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 38
8. Output Signal 4mA Pru Scale 12mA 0 20mA P ul scale Note that these are the nominal torque and power scales th at 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 a 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 Pru Scale estimated max power level 800 hp 377 60 2 50 in TFull Scale 2 885 ft lb 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 O ft lb 20mA 2 885 ft lb Power Output Signal 4mA 800 hp 12 mA O hp 20 mA 800 hp Conversion Chart for Common Units Power Torque SI Kilowatt kW Newton meter N m 1 kW 1 341 hp 1 N m 0 737 ft lb English Horsepower hp Foot pound ft lb 1 hp 0 746 kW 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 Withnoload zero torque appliedtothe shaft the torque offset value is adjusted until the desired output signal or disp
9. SHAFT DIA B c D E PA Saar i 0 1 2 75 5 00 5 50 12 88 o N 1 2 3 25 5 50 6 50 13 88 ae 2 4 4 25 6 50 8 50 15 88 FA 4 6 5 00 7 25 10 00 17 38 RADIUS 6 8 6 00 8 25 12 00 19 38 7 90 8 10 7 00 9 25 14 00 21 38 8 90 B 10 12 8 00 10 25 16 00 23 38 9 90 D See 12 14 9 00 11 25 18 00 25 38 10 90 ALL NUMBERS SHOWN IN INCHES o e oO oO on Ol o SPS 400 ik bh 1 o ae MAX BOLT SIZE 0 313 MAX WASHER SIZE 0 750 FRONT Pol VIEW el 1 6 00 gt S i pai r gt ie saa ec L a 00 875 413 2 PLACES eo Nell BOTTOM VIEW 0 88 H CUSTOMER INSTALLED STRAIN GAGE 6 8 INCH SYSTEM LEFT SHOWN IN THIS EXAMPLE VIEW BINSFELD ENGINEERING INC EO TORQUETRAK REVOLUTION MOUNTING DIMENSIONS REVISION 8 37 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
10. 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 positi on Step 1 Calculate the nominal full scale torque Teut scale range asdescribediMppendixB Thesimplifiedtorque equation is duplicated here for convenience 377 60 D T Full Scale ft lb with Do in inches GF Do T Full Scale N m with Do in mm GF 32 02 where Do Tull Scale GF Shaft outer diameter inches or mm Full Scale Torque ft lb or N m Gage Factor from gage package Step 2 Select a full scale power level thatapproximates the maximum shaft power level of interest 21 Step 3 Calculate the nominal RPM Factor using the following equation Peutl Scale X Constant RPM Factor Tutt Scale RPM Factor User selectable switch setting at Master Control Unit Prullscale Power Level selected by the user to correspond to 20mA Full Scale Output Tru Scale Torque Level that corresponds to 20mA Full Scale Output Constant Dependent on 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 intheMaster 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 T Full Scale 12mA 20mA Teulscale Power
11. al 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 6 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 PCT 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 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 endof 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 nec ee Gage should now be positioned Once again lift the gage endof the tape at a shallow angle to the
12. beifn BINSFELD ENGINEERING INC TorqueTrak Revolution Torque and Power Monitoring System User s Guide 8665009D 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 Appendix E Mounting Dimensions 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 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 does
13. ble 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 1 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 cos Cou Cl cow Co DeeceeeeaD o0 AAIO LNNHS NO STATOR J x ROTOR C 115 VAC 230 VAC amO CAU RANGE _ HIGH V ue 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 Tes RPM Factor See details below and in Set Up Procedure Figure 5 Power Output Controls and Connections 10 Power Signal Calibration Controls The Revolutio
14. ched 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 14x to 400 4x Note Changing the gain scale a oo factor of t
15. ections and wiring to gage 3 Balance the gage to reduce offset or apply a new gage 30 Using the BS900 Bridge Simulator for Troubleshooting ABS900 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 Revolution 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 4mA 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 an d you should focus your troubleshooting attention on the strain gage installation
16. em Components se Controls and Connections Overview 1 Pos FS torque 2 Neg FS torque 1 amp 2 Zero torque 3 Set zero torque to 4mA 4 Reverse signal polarity 5 Bypass user calibration oe SNO used oyia Off Cola 1 19 On off on R LLO 12 kE 0 1Hz System Calibration EN to enable Offset Gain switches EIRO 0 a 1 Torque Output HI 1 2 Torque Output LO 1 3 Power Output HI 1 4 Power Output LO I 5 Speed Output HI 1 6 Speed Output LO l 7 Direction Output HI 1 8 Direction Output LO l 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 ee ZON for lt 10 nO ea Off ely e igOn iii aie LLON 12 Gey 0 1Hz s 1 SAVE to store x poe ors fe ome Offset Zero a ps Adjustment ae Main Power Switch Gain Scale Adjustment MmeBoaaBeagadaeD WHYYYHUU Gsaccecaar BIC a nt i i o N 1 Bare Stator ON ON No data transmission errors Range ON Sensor input out of range RPM Flashes 6 times per revolution Input p
17. gnal 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 ammeter not provided to the Torque 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 o
18. he 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 RQUE Measurement NOMINAL RESISTANCE VALUES a EXC TO EXC 350 ohms lege SEN TO SEN 350 ohms f I ALL OTHER TESTS 262 5 ohms J OUN 4 POSITIVE OUTPUT AN BE ROTATED 90 ROTATION OF 90 IN A CHANGE IN SIGN UTPUT SIGNAL STRAIN GAGE VISHAY MEASUREMENTS GR RALEIGH NC PHONE 919 365 3800 PART CEA 06 250US 350 v 36 Appendix E Mounting Dimensions The diagram below shows the basic dimensions for TorqueT rak Revolution systems for up to 14 diameter shafts Ra oe C
19. he torque output signal may affect the offset zero reference of the torque output signal 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 ge
20. 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 D 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 paper 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 gener
21. 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 atta Cr Oe oOo Ou ooe co O 440 LNNHS NO Dy A OF F POWER ON STATOR J x ROTOR _ 11S VAC 238 VAC pata O CAUTION a HIGH VOLTAGE mO J i us AS AS 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 sensor input signal is within range At slow shaft speeds used to verify operation of RPM sensor LED flashes as magnets trigger pickup sensor See Appendix C for more details 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
22. ks 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 ba ck directly over itself holding it close to the shaft while peeling 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 t
23. lay value is reached Then a known torque load moment is applied to the shaft and the torque gain valueis adjusted until the desired output signal or display value is reached 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 torof set value is adjusted until the desired output 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 Pes 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 A
24. mote 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 transmitter 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 In error mode system output 24 mA Fast flash rate 4 Hz Slow flash rate 2 Hz Indicates normal error free mode 29 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 Common E
25. n 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 signal 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 x1 position 0 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 upwa
26. n 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 jumper wire 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 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
27. nerates 4 mA output 1 amp 2 Simulates a zero input signal from the transmitter nominally generates a 12 mA output 3 Effectively changes the zero to positive full scale torque output range from 12 20 mA to 4 20 mA 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 8 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 When switch 3 is activated the output signal at zero torque load changes from 12 mA to 4 mA and simultaneously the signal gain is doubled If switches 1 2 and 3 are all activated the output signal will be 4 mA Torque Signal Configuration Switches 12 34367 8 SAVE CAL EN Z Figure 4 Torque Signal Configuration Switches Power Output Signal The 4 20 mA shaft power output signal is accessed from a remova
28. 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 YVNAAN RN NO ONAN 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 inside Stationary Power Coil Clamps to shaft with bolts provided Sends power to the Rotating Collar Houses Transmitter Module which and receives data signal from the converts strain gage signal to digital Rotating Collar code Lead wires from Collar for sensor ae connection Main System Strain Gage Sensor Status Indicator Glued to shaft not included Light but ordered as an accessory Converts mechanical torque to electrical signal which is 4 transmitted from the Rotating Collar to the stationary Power oe NX Coil Mounting Flange Sase 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 Syst
29. ontrol Unit to generate the speed signal The direction signal is a binary indicator nominally 5 mA or 19 mA depending on direction of shaft rotation 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 19 mA signal and a counterclockwise rotation produces a 5 mA signal To summarize when viewed from the front of the Master Control Unit and with the black ring of the Rotating Collar in view the following output signals are produced 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 the TorqueTrak Revolution output current loop is 500 ohms Thismeansthe system can drive the 4 20mA output signal into resistances of 0 to 500 ohms To calculate the distance the signal can travel add the input resistance of the device you plan to drive plus the resistance ofthe wirelength Aslongas 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
30. ower level okay ON Collar power okay no errors Set RPM Factor switches to RPM Factor Pps x C Tes Prs Full Scale Power hp or kW Trs Full Scale Torque in Ib or N m C 5252 ft lb hp or 9550 N m kW Controls and Connections Power Input The Master Control Unit operates from 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 440 LNAHS NO STATOR x ROTOR C 115 VAC RO CAUTIO ie HIGH VOLTA ee SA J OFF POWER ON N J D VF IAN Al Main Power Switch 115VAC 230VAC Switch only available with VAC Option Fuses Slide
31. ppendix 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 FS C 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 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 and Weight Diameter 1 5 inches 38 mm Width 0 75 inches 19 mm Rotating Collar Material Cast nylon or fiberglass epoxy Size and Weight Outer Diameter 4 to 6 inches greater than shaft diameter Width 1 25 inch 25 mm Weight Dependent on collar diameter Master Control Unit and Power Coil Output Signals Four independent current output signals 1 Torque 4 20 mA nominal scaleable usable from 0 24 mA 2 Shaft power 4 20 mA nominal scaleable usable from 0 24 mA 25 3 Speed RPM Pulse Indicator 5 or 19 mA 4 Direction Binary Indicator 5 or 19 mA Input Power 11 16 VDC standard 2A max
32. rds towards the Power Coil 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 11 3 Effectively changes the zero to positive full scale power output range from 12 20 mA to 4 20 mA 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 amp Used to set frequency response of power signal i e select cut off frequency for low pass filter as follows NOOO 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 Scaling RPM Factor Power Signal Configuration Switches Switches N 1 e345 67 8 oO FF xs ea zA D VO Zoo kOe A D Oe fg hoe fan A gaT X D gorx Ql VS Zoo 7 hk D ATOR C 2 S v Z oa ROTOR C ate 238 VAC om 1 40 LNAHS NO O 1 x Wd
33. rror 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 Power supply voltage to system is incorrect Symptom Main System Status flashing fast Stator flashing Action 1 Supply correct voltage to the MCU Error Mode Weak inductive link Symptom Main System Status flashing fast Stator on solid Rotor flashing slow Data off or flickering transmitter status indicator off Action 1 Make certain Power Coil is 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 Error Mode Strain gage problem Symptom Main System Status flashing fast Range on s olid Action 1 Verify excitation voltage to gage is 2 5 VDC 2 Check solder conn
34. 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 justenoughcatalysttowetgagesurface 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 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 mar
35. tion Strans T E 4 Do D SS ee T Ful Scale ft lb GF N 16 000 1 v D 12 Legend of Terms Di Shaft Inner Diameter in zero for solid shafts Do Shaft Outer Diameter in E Modulus of Elasticity 30 x 10 PSI for steel GF Gage Factor specified on strain gage package S Transmitter sensitivity mV V not user configurable bi Typical is 1 mV V for 500 microstrain range N Number of Active Gages 4 for torque Trutiscatle Full Scale Torque ft lb v Poisson s Ratio 0 30 for steel 27 For metric applications with D and D in millimeters and Tful Scale in Newton meters the general equation is Strans E 4 Do D ee a oe See ea ne T u cale N m GF N 16 x 10 1 v D ve 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 Peull Scale estimated max power level 800 hp 377 60 2 50 in T Full Scale 2 885 ft lb In this example the torque output signal can be interpreted as follows 4mA 2 885 ft lb 12mA O 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 C Error Codes amp Troubleshooting Indicator Condition Main System Status Red LED On solid No errors Fast flash a Re
36. to the left for 115VAC power One fuse is connected to high Slide to the right for 230VAC po wer 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 1 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 a w m EEJ
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