MOTION MASTER SENSOCONTROLLER - PRODUCT SPECIFICATION S MMS WA-5, SU-5, EXP-5 WA-5 SU-5 EXP-5

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1 MOTION MASTER SENSOCONTROLLER - PRODUCT SPECIFICATION S MMS WA-5, SU-5, EXP-5 VER5.2 WA-5 SU-5 EXP-5 GENERAL DESCRIPTION Belcatec Design Inc. designs and manufactures Motion Master Sensocontroller safety systems otherwise referred to as motion failure alarms or zero-speed switches intended to provide safety protection for rotating and reciprocating devices and specifically for shaft less screw conveyors installations. Our systems have been successfully applied in a variety of shaft less screw conveyor functions providing much needed safety in such applications as live bottoms in storage and out loading silo, submersible grit extracting screws in grit aerated chambers, grit classifiers and multiple conveyors connected in series transporting and dosing wet sludge s, dry pellets, municipal screenings, fly ash and chemical powders and slurries. Motion Master Sensocontroller detects movement of ferromagnetic objects when magnetic field of its sensor is disrupted generating voltage that is further amplified and digitally processed with pre-set tolerances. Motion Master Sensocontrollers are intended to continuously monitor operation of rotating ferrous conveyor spirals, detect disruption from nominal rotational speed and provide alarm that stops moving conveyor thus guarding conveyor system from costly damage or process failures. Belcatec Design Inc. has been engaged in a rigorous research and development program that has led to integration of most advanced digital technology currently available to provide reliable and dependable MOTION SENSOR products. 1

2 MOTION MASTER SENSOCONTROLLER - FEATURES AND ADVANTAGES 1. INTEGRATED SPACE SAVING SENSOCONTROLLER ENCLOSURE. No need for external boxes, your wiring is simplifies and less costly 2. EXCEPTIONAL MOTION DETECTION SENSITIVITY. Your detector can work even if distance between screw and sensor is 100mm, 4 inches. Our sensor can work even if your trough is in steel (limited to 2.5 range, 50mm) so you do not have to cut trough to install it. In case you use stainless steel screw; we can supply you with small magnet to imbed in screw. 3. LATEST CMOS LOGIC CONTROL. Your sensors are constructed using programmable micro-controller which allows us to build not just sensor but intelligent controller that will protect your operation better than any others on market. 4. NO REQUIREMENT FOR MANUAL CALIBRATION OR FIELD MAINTENANCE. Sensocontroller is self adjusting to it environment. No local adjustment required. Just place the sensor and start your system. 5. BUILT-IN INTELLIGENCE, SELF LEARN AUTO RE-CALIBRATION AND SELF STABILIZATION CAPABILITY. Your sensors are self calibrating. It will sense rotation and adjust itself to speed. It allows increasing rotation speed. Calibration is revalidated every 20 turns. It allows reducing speed but will limit to ½ of calibrated speed (Every 20 turns) 6. SIMPLE IN-FIELD INSTALLATION AND WIRING CONNECTION. Only 4 wires cable is use for field installation. WA-5 have connection box. SU-5 have water protected SO cable with 15 meters (45 feet) long. EXP-5 have hazardous location connecting box with removable connector. They may be connected directly to PLC or use one relay in your control panel BASIC ENCLOSURES AVAILABLE FROM STOCK. A) WASHDOWN ENCLOSURE, NEMA 4X MODEL MMS WA-5 B) SUBMERSIBLE PVC ENCLOSURE (15 M DEPTH MAX.) MODEL MMS SU-5 C) EXPLOSION PROOF ENCLOSURE - NEMA 7 CLASS 1 DIVISION 1 GROUP B, C, D, MODEL MMS EXP-5 8. MMS UNITS ARE NORMALLY SUPPLIED WITH SEPARATE POWER SUPPLY UNIT (PSU-010) 120VAC or 220 VAC TO 24 VDC, MOUNTED ON A COMMON BOARD CONTAINING 10 amperes 120v or 220 VAC RELAY, STATUS LED and TERMINAL BLOCK. If you like to build it yourself, we will give connection diagram free! 2

3 9. BUILT TO CSA APPROVED STANDARD (CSA not required UNIT is low voltage low current device) Belcatec Design Inc. is CSA certified (Canada & US) as control panel builder and uses it expertise to build safe devices The EXP-5 is certified for Hazardous location Class I Division 1 Group B 9. TWO TYPES OF SENSOCONTROLLER DESIGNS AVAILABLE THAT COMPLY WITH MAJORITY OF USES. FROM 3 RPM TO 60 RPM MODEL 5 (EQUIVALENT LINEAR SPEED AS LOW AS 500 mm/ MINUTE) FROM 0.3RPM TO 10 RPM MODEL 5S (EQUIVALENT LINEAR SPEED AS LOW AS 20 mm/ MINUTE) If you need higher speed contact us we can build special unit just for your application MODEL MMS WA-5 MODEL MMS SU-5 MODEL MMS EXP-5 3

4 MMS-WA-5 5S SU-5 5S EXP-5 5S MOTION MASTER SENSOCONTROLLER SPECIFICATIONS SEE FIGURES FOR INSTALLATION DETAILS (at end of document) 1. GENERAL DESCRIPTION SENSOCONTROLLER is designed to be used in hash environment. SENSOCONTROLLER contains motion sensing probe and electronic signal amplifier and controller all potted in case. Unit is capable of detection of ferromagnetic object movement such as shaftless spirals by placing it in line with screw (inline with movement of material) Mounting bracket (supplied by others) normally welded to outside of stainless steel conveyor trough is used for field installation of unit. Unit is simply slid inside U-bracket and locked in place using a rubber wedge gasket or tight up with bolt. Installation must be stable. SENSOCONTROLLER must not move in reference with trough. Unit is fitted with ½ FPT coupling for field connection of rigid or flexible reinforced (supplied by others) to protect external connections wiring in accordance with local safety regulations. SENSOCONTROLLER -5 is capable of detection of rotational movement of ferromagnetic objects as slow as 3 rotations per minute and as high as 60 rotations per minute. SENSOCONTROLLER -5S is capable of detection of rotational movement of ferromagnetic objects as slow as 0.3 rotations per minute and as high as 10 rotations per minute. SENSOCONTROLLER is normally wired to MOTION MASTER PSU-010 POWER SUPPLY UNIT (See specification of PSU-010) DIMENSION OF SENSOCONTROLLER WA-5 and 5S: common 304 stainless steel enclosure measuring only 2 x2 x7 (60x60x180mm). SU-5 and 5S: PVC tube 2 (60mm) diameter schedule 40 white 5 long with 15 meters (45 feet) cable. EXP-5 and 5S: Tube 2 (60mm) diameter stainless steel tubing 6 long with connecting box. 4

5 2- OPERATIONAL RANGE SENSOCONTROLLER is capable of detecting ferromagnetic object movement from distance of 4 inches (100mm) when rotational speed of the object is as low as 3 pulses per minute. SENSOCONTROLLER is capable of detecting ferromagnetic object movement from distance of 8 inches (200mm) when rotational speed is in range of 20 to 40 pulses per minute. The detection range is reduced to 4 inches (100mm) when pulses or rotational frequency period is in range of 50 to 60 per minute. NOTE: Maximum detection perimeter may be up to 24 inches (600 mm) range of sensing area. Movement of objects in that range may be detected. Detection capability of probe increases with reduction of rotational speed. 3- INSTALLATION MMS WA-5 probe is normally inserted into U-shaped stainless steel square bracket which is tack welded to outside of conveyor trough or its cover. Simply slide probe in place and lock with rubber wedge-spacer or bolt. Side shown. MMS SU-5 probe is normally inserted into U-bolt stainless steel bracket which is screw to support over rotating screw, cable shall be protected by stainless steel or PVC tube. MMS EXP-5 probe is normally inserted into round shape stainless steel bracket or U-bolt and secured in place. 5

6 4- OPERATION Power on to energize electronic circuitry of probe. 4.2 Output relay goes on when power supply is energized. 4.3 A delay of 0.5 sec. is initiated to allow sensitive electronic circuitry to stabilize. 4.4 A delay of 1 sec. is initiated to allow conveyor to attain nominal rotational speed. 4.5 Each times ferromagnetic object passes in probes sensing area LED of PSU illuminates. 4.6 Following (6) six pulses or spiral revolutions LED dims for 1/2 second period indicating end of calibration sequence. 4.7 Following first successful calibration other subsequent re-calibrations will be generated automatically every 20 pulses. This feature allows to increase or decrease conveyor spiral rotational speeds to comply with process variations if required. 4- OPERATION 5S 4.1 Power on to energize electronic circuitry of probe. 4.2 Output relay goes on when power supply is energized. 4.3 A delay of 5 sec. is initiated to allow sensitive electronic circuitry to stabilize. 4.4 A delay of 1 sec. is initiated to allow conveyor to attain nominal rotational speed. 4.8 Each times ferromagnetic object passes in probes sensing area LED of PSU illuminates. 4.9 Following (2) two pulses or spiral revolutions LED dims for 1/2 second period indicating end of calibration sequence Following first successful calibration other subsequent re-calibrations will be generated automatically every 6 pulses. This feature allows to increase or decrease conveyor spiral rotational speeds to comply with process variations if required. 5- CALIBRATION Before achieving first calibration, system have cut-off delay of 1.5 minutes for model -5 and 5 minutes for model -5S. Following first calibration, system have cut-off delay of 1.5 pulses, meaning that when conveyor spiral will stop rotating due to disconnection of a coupling disk or other breakage, system will RELEASE signal to relay within time equivalent to 1.5 revolutions. System automatically re-learns conveyors rotational speed every 20 revolutions for model -5 and 6 revolutions for the -5S therefore intentional changes in speed variations are possible. Increasing rotational speed has no limitation; however reduction to lower speed shall be limited within 1/2 of previously calibrated speed. 6- OPERATING TEMPERATURE Probe operates from 50C up to 55C Electronic circuitry of probe accepts 2 degrees C variation per minute of operation. 7-ELECTRICAL SPECIFICATION Voltage supply VDC non-regulated or regulated When connected to MMS PSU-010 Current draw from power supply. Power-ON (Relay ON & LED ON) 0.140amp draw Power-OFF (Relay OFF & LED OFF) 0.050amp draw Note: Up to nine probes may be connected to same PSU. If -5 is connected to foreign PSU limit the current from Relay output and LED output to 0.9 amps. The probe is built with delay reset able fuse limiting maximum current at 0.9 amps. 6

7 8- ELECTRICAL CONNECTION Four wires are used to connect probe to PSU. Max. Cable length is 100 meters between MMS-WA-5 and PSU. Client supplied cable extension between MMS-WA-5 and PSU shall be 4 wires overall shield AWG-18. SU WA Standard connections Alternate connections (8 wires cable 22 gauge) RED is 24 vdc RED is 24 vdc BLACK is 0 vdc BLACK is 0 vdc WHITE is Relay supply WHITE is Relay supply GREEN is LED supply NOT A GROUND BLUE is LED supply SHIELD (normally not connected) ALL OTHERS (normally not connected) For the EXP use removable connector Signal for Relay & LED are 24-vdc sourcing. Shield shall be connected to earth ground if cabling is more than 100 feet long (30meters), or if cabling is placed near high current AC line. Probe is protected against reversed polarity. Probe is fused with limited current fuse of 0.9 amps with auto reset. Outputs from Relay & LED are capable of current inrush up to 20 amps and are spike protected. Important installation note: Care must be taken not to overtighten probes 1/2 conduit connection, otherwise internal damage to circuitry may occur. Hold the ½ coupling when screwing in conduit or other connectors. Do not hold probe. 9- TROUBLE SHOOTING 9.1 Probe does not work properly. Check fuse on PSU-010 and output voltages. With energized probe check for LED illumination (flashes). Check wiring polarity. 9.2 LED blinks even if no movement of spiral present. Check around probe for any other moving objects. Note: SENSOCONTROLLER must be stationary during normal operation or when testing. Metallic object in your pocket such as coins or keys may occasionally interfere with operation of probe as they may be mistaken for passage of spiral. 9.3 Probe does not stop conveyor when spiral is stopped. Check if other objects are moving in sensing area of probe as they may be interpreted as passage of spiral. Check if LED is blinking. Check wiring. Replace probe. 7

8 WARRANTY: BELCATEC DESIGN INC. WARRANTIES MOTION MASTER PRODUCTS TO BE FREE OF MANUFACTURING DEFECTS FOR A PERIOD OF ONE YEAR FROM DATE OF INSTALLATION WHEN USED AS INTENDED. SHOULD PRODUCT BECOME DEFFECTIVE DURING THAT TIME IT WILL BE REPLACED FREE OF CHARGE. SHIPPING COSTS WILL BE BORNE BY PURCHASER. APPLICATION NOTES WA-5 SU-5 & EXP-5 probe may be connected directly to output/input of PLC; current required from output (18 to 24 VDC or dry contact with supply) of PLC is only 150ma + current required for inputs. When probe has stopped due to failure of rotation it is required to cut it supply to reset lockout. When speed is very low or ferromagnetic part is small adding small permanent magnet (40 ghosts) on rotating part will help detection of rotation. Distance of detection may be reduced if trough is in steel. Positive detection has been observed with a 5/16 inches steel trough at medium speed. Installing probe near gear reducer will influence probe; try to put it as far as 30 inches from any moving parts or electric motor or power cables. Detection is using displacement of magnetic lines from probe and cannot be shielded. Though not mandatory we suggest you to buy our PSU-010 with PSU-EXT to make connections in your control panel. See specifications. Detection is all around probe. Probe must be put in direction of movement of material. Sensibility may be decreased if probe is placed other ways. 8

9 TYPICAL INSTALLATIONS: Alternate installation on trough lid is to use double side tape to hold unit in place. 9

10 For Submersible SU-5 or EXP-5 Motion Master SensoController Installation Detail - proposed location for Submersible MM Sensocontrollers Drill 2 pipe-size U- Bolt hole dia & spacing Secure wiring to hold down cross bar with heavy duty tie-wraps or other clamps. 2 PIPE SIZE S.STL. U-Bolts or J-Bolts supplied by conveyor 3 c/c Peripheral Sensing Area 4 x 1 hold down bar 3/8 Shaftless Spiral 3/8 3/8 MMS - SU-1 3 OD x 6 lg SLURRY FLOW Concrete slab mild steel trough inbeded in concrete 10

11 EXP-5 Connecting box is supplied with a 5 positions plug. Plug accept wires of 12 gauge Center of plug is case ground and do not need to be connected if binding post is used Left side of plug are used for 0VDC & 24VDC Right side of plug are used for Relay output 24VDC and LED signal 24 VDC Following drawing shows connector position for EXP-5 11

12 Following figure show typical connection to include in electric control panel PLC CONNECTIONS SCHEMAS Last revised Janvier