Sales and Installation Manual - Rotech · Sales and Installation . Manual . ... Screen Vibration Sensors. VS 4000 Series. ... Commissioning and testing : 6. Installation – Electrical:

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.ukFax: +44 (0)151 356 2437 Email: [email protected] Monitoring the world

since 1983

Sales and Installation Manual

Why Accept Anything Less?ROTECH FOR RELIABILITY!

www.rotechsystems.co.uk

Product Selection

Why Accept Anything Less?Monitoring the world

since 1983

ROTECH FOR RELIABILITY!Monitoring Solutions

Monitoring Solutions For Your Equipment

Speed Monitoring

Safety Interlocking

Rotation Control

End Of Shaft Mounted Motion Sensors

Wheel Driven Trailing Arm Motion Sensors

For monitoring:

•Belt slip•Belt speed measurement•Belt weighers/scales•Distance/length measurement•Belt Stopped Alarm

WE 5000Totally Enclosed

Utilising AE series sensors

PWE 6000Open Frame

Utilising PE 4000 series sensor

Rotation Monitoring Speed Relays For use with all Rotech Motion Sensors

Set trip/alarm speed directly from plant control panel

Eliminating:-• Fiddly adjustments • Removal of machine guards• Crawling under machines • Entering dangerous areas• Climbing over plant• Exposure of personnel to risk• Health & Safety Conditions

SR 4000

•Extremely robust

•Self contained, easy to fit

•Maintenance free for life

•Pulse rates from 1 to 1000

•Range of signal outputs

•To suit all Industrial applications

AUE 400

AE 3000Extra Heavy Duty

Aluminium Body

Re-Chargeable Grease Chamber

PE 4000Polypropylene Body

Low Cost

AE 2000Heavy Duty

Aluminium Body

For monitoring:•Speed•Distance•Direction•Belt Slip

•Shaft Stopped•Underspeed•Overspeed•Safety guards interlocking

AE 1000Standard Duty

Aluminium Body

Screen Vibration SensorsVS 4000 SeriesPulsed output Type E3 10-30 Volts DCTotally sealed solid state operationMonitoring Vibrating Screens For:

* Slowdown* Stoppage* Breakage* Irregular Vibration•‘V’- Belts Damage

Used with SR4000 Series speed relays or PLC, gives an alarm indicationof screen problems, stops screen drive motor and/or stops infeed conveyor.

ROTECH

products can be used whenever information onshaft speed, position, completed revolutions, etc, is required,for indication, control, interlocking, alarm initiation, etc.

SS 4000 SpeedswitchPolypropylene Body

Speed control trip set point in RPM adjustable over chosen speed range via

internal control fitted under unit cover.

SSE 2000Heavy Duty Stainless Steel Body

Also available in 3000 Series Extra Heavy Duty

For use in the most severe arduous environments

Contents

Title Page

Introduction 1

General Description 2

Installation 3

Applications 4

Installation – mechanical 5

Commissioning and testing 6

Installation – Electrical 7

Other Non – standard applications 8

Product codes explanation 9

Electrical output signals configuration 10

Typical connection examples

Product Data sheets

Heavy duty monitoring equipment for the bulk handling and processing industries

Founded in 1983 Rotech systems manufacture and supply worldwide, high quality, high reliability equipment for monitoring and measuring the speed, position and direction of rotating shafts

Rotech Systems are the worlds leading manufacturer of high quality monitoring solution products with an unparalleled reputation for reliability, durability and quality.

Major features are tough, strong, heavy duty construction, designed to operate and give years of maintenance free operation in even the harshest industrial environments, quarries, mines, etc. And simple, quick, installation.

Main applications are in the bulk handling and processing industries. Protecting conveyors, elevators, screws, crushers, mixers, etc. Anywhere where slowing down or stoppage will cause product spillage, blockage, etc. and incur downtime, lost production, cleaning up, spoilt product, etc.

Equipment Can Give Visual And/Or Audible Alarms Plus Shutdown Items Of Plant For A Speed Reduction Of Only 5% (Adjustable 5% To 90%)

Protects Against Conveyor Belt Slip, V Belt Slip, Chain Breakage, Mechanical Failure, Stoppage, Blocking, Jamming, Etc.

Industries using Rotech: food, textiles, glass, grain, power generators, fertiliser, sand, gravel, roadstone, coal, steel, ore.

Introduction

Wherever materials are transported or processed by conveyors, elevators, screws, gushers, mixers, etc, there are applications for “Rotech”. Heavy duty shaft encoders.

Food, Grain, Pharmaceuticals, Chemicals, Sand, Stone, Cement, Ore, Coal, Ash, In Factories, Quarries, Mines, Power Utilities, And Dock Installations Are All Excellent Examples.

A single conveyor may run for long periods without any problems, but not forever, the day arrives when it starts to slip or slow down and unless action is taken quickly to switch off the conveyor, crusher or plant that feeds it then a major spillage can occur.

In a large plant with many conveyors and drives the potential for problems is multiplied by every additional drive element.

1

The costs of clearing up a spillage are not simply the costs of a man with a shovel, this is the tip of the iceberg, they can include:

Damaged belts (Conveyor & Drive, “V”, Flat, Etc.).

Damaged plant & machinery.

Mechanical diggers, front loaders, etc. To clear up grain, sand, stone, ore, coal, etc.

Contamination to food, pharmaceutical, chemical, products, resulting in rejection and waste.

Whilst these costs can be considerable, they can be minor compared to the real cost.

The REAL COST is the loss in Production, Throughput and Revenue whilst cleaning up.

Hundreds, even thousands of dollars can be lost for every hour a plant us not producing product.

“Rotech heavy duty shaft sensors provide simple, low cost, high reliability protection against these problems.

General Description

The “Rotech” range of shaft monitoring equipment is comprised of a range of heavy duty motion sensors and associated speed relays.

The heavy duty shaft sensor is installed on the end of the shaft being monitored and sends and electrical signal proportional to the speed of the shaft to a suitable control unit.

The control unit can be a “Rotech” speed relay, a programmable controller, a computer, data logger device or other proprietary control equipment.

The alarm level of the control unit is set to just below the normal running speed of the shaft.

In the event of the shaft slowing below the set level, the control unit operates and can be connected to give an alarm to the operator and/or shutdown preceding items of plant.

Advantages of ‘Rotech

‘Rotech’ heavy duty motion sensors and encoders combine many unique design features to give the customer:-

•Simple installation

•High performance

•High reliability

•Price benefits

2

Installation

One hole drilled and tapped into the end of the shaft to be monitored, gives simple, uncomplicated, fast installation.

One type of unit covers all types of drives, conveyors, elevators, crushers, etc. Allowing standardisation of designs, installation and spares.

No target discs to design, manufacture and install.No sensor brackets to design, manufacture and install.No guards to design, manufacture and install.No on – plant adjustment or setting up required.

The ‘rotech’ unit is carried on the shaft and moves with it, it is unaffected by shaft end float, belt adjustment, etc.

Performance

‘Rotech’ motion sensors/encoders are digital pulse generators guaranteed accurate to within 0.5%, they cannot drift and require no checks or periodic calibration.

With pulse output rates from 1 pulse per rev to 360 pulses per rev, drive speeds from 5000 rpm down to 0.03 rpm (2 revs/hour) can be accurately and reliability measured and monitored.

Reliability

“Rotech” units are designed to operate and survive in even the toughest industrial environments, they have been particularly developed for the quarrying and mining industries, however their compact size makes them just as suitable for light industries.

Heavy duty castings, heavy duty sealed bearings and robust fully encapsulated industrialised electronics form the tough strong core of these units.

Extensive use is made of modern engineering adhesives and sealants to double up on the traditional precision assembly methods and ensure even greater reliability.

‘O’ Ring seals on end covers, grease chambers, spring loaded shaft seals and liquid tight flexible conduit and glands complete these units to give outstanding levels of protection and ensure the highest levels of reliability and operational life.

All Rotech units are totally maintenance free – sealed for life!

Price

Installed price is competitive or possibly lower than alternative methods, ultimate in operational life and reliability is an added bonus.

3

Applications

The principle application for “Rotech” heavy duty motion sensor is as a speed or slow down switch on plant and machinery.

They can be fitted to conveyor belts, elevators, conveyor screws, crushers, mixers, valves and any other plant that presents a hazard if it slows beneath its normal running speed.

They should always be installed at the end of the drive system.

On a conveyor and elevator they should be installed on the tail drum, tail roller, snub roller, gravity take up roller or any roller that is driven by the conveyor belt itself.

Any slowing down of the drive motor, gearbox, drive chains, drive belts, or the conveyor belt slipping, etc, will result in the conveyor belt and the selected drum/roller slowing down which will be detected by the encoder.

All elements of the conveyor are therefore monitored.

The heavy duty shaft sensor should, unless special circumstances apply, never be fitted to the drive roller or drum.

On conveyor screws the heavy duty shaft sensor should be installed to the non-driven end of the screen.

Other Applications

Shaft sensors can give information on the speed, angular position, direction and number of revolutions completed by a rotating shaft.

Via racks, screws, slides, etc all of these functions can be translated into linear functions.

Although its use as a speed switch is the principle application of “Rotech” heavy duty shaft sensors, they also fulfil a wide range of other applications in many types of industries.

4

Installation – Mechanical - (If the shaft end cannot be drilled please refer to Magcon fixing shown below)

1. Select a suitable shaft to install the ‘Rotech’ unit to.2. Use a 5mm drill to drill a pilot hole to a depth of 25mm into the centre of the end of the shaft.3. Use a 10mm drill to open the hole to the required tapping size.

IMPORTANT

Take care that the shaft is drilled centrally.

4. Tap the 10mm X 25mm deep hole 12mm x 1-5.5. Remove the rear cover the Motion Sensor/Encoder and using a 10mm Allen key wrench

install the unit onto the shaft. Re-fit the rear cover.6. Bolt the flexible securing strap to any convenient part of the machine frame work

As an alternative method of securing the Rotech end of shaft unit without the need for drilling the shaft, our unique ‘Magcon’ unit can be used as shown below – see product data sheets for full details.

MAG‐CONMAGNETIC CONNECTOR

For quick and easy installation of Rotech shaft mounted sensors & encoders

Flexible Liquid tight conduit

16mm DIA X 900mm long

C/W – 20mm threaded

Gland termination

Flexible retainingStrap400mm long

Securing bolt10mm or 12mm

2 off M8 X 12

22 65

5

75

132

2530

10

5



since 1983

Product Information

Commissioning & TestingEnd of Shaft Mounted Encoders

Installation1. Drill & tap end of shaft to be monitored (refer to “Mag-con” data sheet for magnetic connector usage)2. Remove rear cover plate from Rotech3. Install Rotech to end of shaft using socket cap bolt provided. Ensure bolt does not ‘bottom’ in tapped

hole, slippage may occur if shaft faces are not firmly in contact.4. Refit rear cover plate to Rotech5. If fitted - secure flexible restraining strap to convenient point on machine6. Cable as per drawing above7. Refer to appropriate Rotech data sheet for output type connections

Commissioning & testingImportantAll wiring must be in accordance with local and national electrical codes and should only be undertaken by an experienced and professionalQualified electrician.

All disconnections and connections must be made with the power supply switched off.

To test the Rotech unit it must be connected to it’s power source and associated control circuit I.E. “Rotech” speed relay, plc, Computer, etc. And for power to be switched on.

Rotech sensor output type E, E2, E3

Connect a 0 to 30vdc voltmeter between brown and blue connectionsVoltmeter should indicate D.C. Supply voltage of between 10 and 30vdcNow Connect the voltmeter between the black and blue connections.Rotate Rotech unit very slowly, voltmeter should indicate on/off pulses between 0vdc and the nominalSupply Voltage (Supply Voltage Minus 1 To 2 Vdc)

Rotech sensor type N

Connect a 0 to 10ma Multimeter in series with the blue wire connecting the Rotech unit to it’s control circuitrotate the Rotech unit very slowly, Multimeter should indicate on / off pulses of less than 1ma to greater than 3ma. See note * 1 below

Rotech sensor type W

Connect a 0 to 240vac voltmeter between the brown connection and 0 vac, verify the supply voltage is present.Now connect the voltmeter between the blue connection and 0 vac.Rotate the Rotech unit very slowly, the voltmeter should indicate on / off pulses of between 0v and the supply voltage.See note * 1 below

Note * 1* At higher speeds the meter will not respond quickly enough to the on / off pulses. It will display an average value between

The max and min levels.* The number of on / off pulses for one complete revolution should be the same as detailed in the Rotech Product data sheets

I.E. 1,10,120,360,500 etc.

Cablescreened / shielded

or wire armoured

To drive control panel

Flexible Conduit

Rotech motion sensorend of shaft

mounting type

Local Junction Box

Securely attach retaining strap

to machine framework.Allow for movement!

6

Installation – Electrical refer to page 6 for typical installation commissioning and testing information

1. Always complete the mechanical installation before commencing the electrical installation.

2. Install a suitable junction box within 300 – 600mm of the Motion Sensor/Encoder.

3. Gland – Off the flexible conduit of the Motion Sensor/Encoder in the junction box and connect the 2 or 3 wires to suitable terminals. (The flexible conduit and cable are supplied over-length they can be cut back and shortened as required)

4. Connect suitable wires and cable to route the Shaft Encoder signal back to the control panel.

Important

The maximum distance recommended between the Motion Sensor/Encoder and the controlpanel is 1000 yards.

Armoured or screened cable should be used id the cable is routed in the vicinity of powercables.

Do not route the Motion Sensor/Encoder signal through multi-core cables carrying othersignals or voltages.

5. Alternative Installation

An alternative method of installation is to house the Control Module/Speed Relay etc. in a slightlylarger terminal box.

A mains signal (typically 110Vac) can then be switched on by the control module and then routedvia multi-cores; unprotected cables etc. back to the control panel.

Electrical Connection Options

Refer to page 11 for details of Rotech motion sensors and encoders electrical output optionsavailable.

7

Other Applications

Motion Sensors/Encoders are used extensively in many different industries for a wide variety of applications.

Besides measuring the speed of a rotating shaft, they can determine direction of rotation, angular position, and the number of revolutions or parts of revolutions completed.

Using screws, slides, racks & pinions these angular functions can be translated into linear or length functions.

The following are the more popular applications that ‘Rotech’ Heavy Duty Motion Sensors/Encoders are utilised for.

Speed Indication

Used in conjunction with a Digital Panel Meter to display RPM or linear speed of a Conveyor Belt.

Length Measurement

Used in conjunction with a Counter unit and either a roller or wheel of known circumference, to measure cut-off lengths, total throughput, or to position material for a process operation.

Direction Indication

Using a ‘Rotech’ Heavy Duty Motion Sensor/Encoder with dual quadrature outputs, direction of rotation can be determined.

This is most frequently used to detect if a heavily loaded conveyor starts to run backwards.

Why Accept Anything Less?

8


Product Codes


since 1983

ROTECH FOR RELIABILITY! Codes Explanation

(1) (2) (3) (4) (5)

Typical Example: AE – 60 – E2 – HD – HS

(1) Housing TypeAE = Aluminium Housing (1000,2000 Series) – End of shaft mountingPE = Polypropylene Housing (4000 Series) – End of shaft mountingSSE = Stainless Steel Housing (2000, 3000 Series) – End of shaft mountingWE = Steel Housing - Wheel Driven Trailing Arm (Utilising AE 2000)PWE= Steel Housing – Wheel Driven Trailing Arm (Utilising PE 4000)AV = Aluminium Housing (4000 Series) – Vibration Sensor

(2) PPR Number of Pulses Per Revolution

Available pulse rates (dependant upon output type)1, 2, 4, 6, 8, 10, 12, 13, 16, 20, 30, 32, 40, 50, 60, 100, 120, 180, 240, 250, 300, 360, 500, 1000

(3) Electrical Signal Output Configuration (Incremental)

N = 2 wire – Intrinsically Safe-Hazardous Areas 8V DC 3 to 5 MAE = 3 wire 10 to 30 VDC – NPN transistor/current sinkE2 = 3 wire 10 to 30 VDC – PNP transistor/current sourceE3 = 3 wire 10 to 30 VDC – NPN/PNP transistor (Sink/Source)E4 = 2 wire 10 to 36 VDC – NPN/PNP transistor (Sink/Source) bipolar (Can be used in place of E3 Type) E3Q = 4 wire 10 to 30VDC - 2x NPN/PNP Transistor (Sink/Source - Quadrature Confguration)NQ = 2x 2 wire - N Type (as shown above) - Quadrature ConfigurationEQ = 2x 3 wire - E Type (as shown above) - Quadrature ConfigurationE2Q = 2x 3 wire = E2 Type (as shown above) - Quadrature ConfigurationW = 2 wire 20 to 240 VAC/DC (Max Switching Frequency 25Hz AC, 100 Hz DC).

For detailed technical information refer to electrical outputs on page 11

(4) Application Duty

No Code (blank) = Aluminium Standard Duty 1000 Series HD = Aluminium Heavy Duty 2000 Series or Polypropylene Housings – PE4000 SeriesXHD = Aluminium/ Stainless Steel Extra Heavy Duty 3000 Series

(5) Variations on Standard Units

HS – High Speed Operation = Excess of 1000 RPM

No Code (blank) = -25°C to +70°C100 = -25°C to +100°C125 = -25°C to +125°C150 = -25°C to +150°C-40 = - 40°C to +70°C

No Code (blank) = 12mm Thread Fixing Bolt (2000/3000 Series) 10mm Fixing Bolt (1000 Series).M10 = 10mm Thread Fixing bolt (2000 Series)M16 = 16mm Thread Fixing bolt (2000/3000 Series)

RS30 = 3 pin ‘Brad Harrison’ Electrical ConnectorRS40 = 4 pin ‘Brad Harrison’ Electrical Connector

S = Special Bespoke Customer Requirements (refer to Rotech systems).

9

Brown

Blue

ATEX

Brown

Black

Blue

Max frequency = 600Hz

Type E (N.P.N) 10-30VdcCurrent sink

Brown

Blue

Max frequency = 600HzBlack

Type E2 (P.N.P) 10-30VdcCurrent source

Brown

Blue

Max frequency = 1000HzBlack

Type E3 (N.P.N + P.N.P –

3 wire) 10-30VdcBi-polar –

Current sink/source

Type N (Namur) 8-2 Vdc

(1KΩ)Intrinsically safe circuits7.5 –

30 Vdc

when used outsideThe hazardous areas Max frequency = 2000Hz


Type W 20-240V AC/DC(1 to 30 PPR only)

Max frequency = 25Hz (AC) 1000Hz (DC)

Brown

Blue

Load

Brown

BlackBlue

Brown

Blue

Type E2 Q (Quadrature) 1 to 40 PPR inclusive

CH “A”

Leads CH “B”for clockwise rotationviewed from shaft end of encoder

Channel “A”

Channel “B”

Black

Type E3 Q (Quadrature) 10-30Vdc

Red

Green

Screen (Ground)

+ VE Supply

-

VE Supply

WhiteA

B

Black

L +

L -Blue

Brown

PNPBrown

Blue

L +

L -

Load

Load

NPN

Type E4 (N.P.N + P.N.P.-

2 Wire) 10-30VdcBi-polar –

Current sink/source


SSE 2000/3000

AE 1000

AE 2000

AE 3000

PE 4000

WE 5000

PWE 6000

Electrical Output Signal ConfigurationProduct type –

Output type dependant upon chosen pulse rate

10

+

+

-

-A

B



since 1983

ROTECH FOR RELIABILITY!

Product Information

AE 1000 SeriesAluminium Body

Standard Duty – End of Shaft



IMPORTANT NOTE:

MAXIMUM OPERATING SPEED IS 300RPM

RECOMMENDED MINIMUM

SHAFT DIAMETER FOR FITTING=35MM

The AE 1000 series of Rotech shaft mounted sensors & encoders are manufactured in an extremely

tough and durable aluminium casting with an industrial powder coated hammer blue finish

Installation is simple and easy, just one M10 or M12 threaded hole in the end of the shaft

being monitored or fitted using the unique “Mag‐con”

magnetic connector

A wide range of number of pulses per revolution are available together with AC and DC electrical

outputs

FOR MONITORING:

• Speed

• Distance

• Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed

• Safety guards interlocking

FEATURES:

•Totally self contained (no guards required)

•Maintenance free for maximum reliability

•1 to 1000 pulses per revolution

•Environment ingress‐IP67

•‐25 to +70, 100, 125, 150 deg Celsius versions

available

•

ATEX

Dimensions and Installation Information


since 1983

Electrical OutputsAvailable Pulse Rates (PPR)1,2,4,5,6,8,10,12,16,20,30,32,40,50,60,100,120,180,240,250,300,360,500,1000 (Dependent Upon Output Type)

Shown in millimetres



C/W –

20mm threaded

Gland termination



2 off M8 X 12

18 43

17

76

132

2530

10

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black

Max frequency = 1300HzMax frequency = 25Hz (AC) 1000Hz (DC)

CH “A”


Channel “A”

Channel “B”


+

+-

-

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Brown

Black

Blue

Black

Brown

Blue


Black

Type E3 Q (Quadrature) 10-30VdcRed

Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B

Type N (Namur) 8-2 Vdc (1KΩ)Intrinsically safe circuits7.5 –

30 Vdc

when used outsideThe hazardous areas

Brown

Blue


ATEX

A

B



since 1983


Product Information


Heavy Duty – End of Shaft



IMPORTANT NOTE:


RECOMMENDED MINIMUM


The AE 2000 series of Rotech shaft mounted sensors & encoders are manufactured in an extremely

tough and durable aluminium casting with an industrial powder coated hammer blue finish.

Installation is simple and easy, just one 12mm threaded hole in the end of the shaft being

monitored or fitted using the unique “Mag‐con”

magnetic connector.


outputs.

FOR MONITORING:

• Speed

• Distance

• Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed


FEATURES:






available

•

ATEX



since 1983


Available Pulse Rates (PPR)1,2,4,5,6,8,10,12,16,20,30,32,40,50,60,100,120,180,240,250,300,360,500,1000 (Dependent Upon Output Type)



C/W –

20mm threaded

Gland termination



2 off M8 X 12

22 65

5

75

132

2530

10

Electrical Outputs

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B



since 1983


Product Information


Extra Heavy Duty – End of Shaft



IMPORTANT NOTE:


RECOMMENDED MINIMUM


The AE 3000 series of Rotech shaft mounted sensors & encoders are manufactured in an extremely tough

and durable aluminium casting with an industrial powder coated hammer blue finishDesigned for areas subject to extreme operating conditions, constant water spray, high pressure washing,

severe dust or material contamination

Installation is simple and easy, just one 12mm threaded hole in the end of the shaft being monitored or

fitted using the unique “Mag‐con”

magnetic connector


outputsFOR MONITORING:

• Speed

• Distance

• Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed


FEATURES:






available

•

ATEX

SPRING LOADED SHAFT SEAL

+RE-CHARGEABLE

GREASE CHAMBER+

SPRING LOADED SHAFT SEAL

=

TOTAL PROTECTION



since 1983


1 12mm Spring washer2 12mm x 65 socket cap bolt3 2 off ‘0’

ring seals4 2 off grease seals5 6 off M4 x 16mm socket cap bolts6 Rear end cap7 2 off heavy duty bearings8 Grease chamber9 Rotor Disc10 Grease nipple11 Seals protector Flexible retaining

Strap400mm long

Flexible liquid tight conduit

16mm DIA X 900mm Long

C/W –

20mm threaded

Gland termination

2 Off M8 X 12

12mm Fixing bolt(10mm/16mm Optional)

75

132

25

8219

7

40


Electrical Outputs

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

30

10

A

B


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B



since 1983


Product Information

PE 4000 SeriesPolypropylene Body

Heavy Duty – End of Shaft



IMPORTANT NOTE:


RECOMMENDED MINIMUM


The PE 4000 series of Rotech shaft encoders are manufactured in an extremely tough and durable 30%

glass fibre reinforced polypropylene.

Installation is simple & easy, just one 12mm threaded hole in the end of the shaft being monitored or

using the unique ‘Mag‐con’

magnetic connector.

A wide range of number of pulses per revolution are available together with AC and DC electrical outputs.

FOR MONITORING:

• Speed

• Distance

• Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed


FEATURES:

•Low cost





•‐25 to +100 deg Celsius versions available

•ATEX



since 1983



12mm Fixing bolt

(10mm/16mm Optional)

Flexible liquid tight conduit16mm DIA X 900mm LongC/W –

20mm threadedGland termination

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B



Electrical Outputs

6 off

Plastite

selfThreading screws(cover removable)

10


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B



since 1983


Product Information

SS 4000 SeriesPolypropylene Body

Heavy Duty – Speedswitch

The SS 4000 series of Rotech shaft mounted motion sensors & encoders are manufactured in an

extremely tough and durable 30% glass fibre reinforced polypropylene.

Installation is simple & easy, just one 12mm threaded hole in the end of the shaft being monitored or

fitted using the unique ‘Mag‐con’

magnetic connector.

A wide range of number of pulses per revolution are available together with transistor and relay

outputs. AC and DC supply voltages available.

Speed control trip set point in RPM adjustable over chosen speed

range via internal control fitted

under unit cover. FOR MONITORING:

• Speed

• Distance

• Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed


FEATURES:



IMPORTANT NOTE:


RECOMMENDED MINIMUM


ATEX

•AC/DC Supply voltages

•Transistor/Relay outputs





•‐25 to +100 deg Celsius versions available



since 1983


Electrical OutputsAvailable Pulse Rates (PPR)1,2,4,5,6,8,10,12,16,20,30,32,40.

12mm Fixing bolt

(10mm/16mm Optional)

Flexible liquid tight conduit16mm DIA X 900mm LongC/W – 20mm threadedGland termination

Red

Black

GreenOrange

White

LiveNeutral

N.O.

Common

N.C.

Supply 120/240 VAC 50/60 Hz

Output relayS.P.C.O

Rated 230V 2 Amp

Brown

Black

Blue

Brown

Black

Blue

Relay Output

TransistorOutput

6 VDCor

12 VDCor

24 VDC

10 to 30 VDC or

5 to 15 VDC

+

+-

-

Speed switchOutput cable

IMPORTANTHealth and safety

Rotech SS4000 series speed switches

These units must only be installed and commissioned byqualified and experienced personnel.

Units must only be installed in positions where the speed adjustmentcan be carried out without exposing personnel to any danger.

If units are installed inside machine guards or in a position that could expose personnelto any danger, they should be set up and adjusted on a separate variable speed drive

in a safe area, workshop, etc.

6 off Plastite selfThreading screws

Internal View(Cover removed)

Speed control

adjustment

Output

Output

Type E3 (N.P.N + P.N.P – 3 wire) 10-30VdcBi-polar – Current sink/source



since 1983


Product Information

SSE 2000 SeriesStainless Steel Body

Ultra Heavy Duty – End of Shaft

is proud to present the new stainless

steel body ultra heavy duty range of shaft

motion sensors & encoders designed to suit the most arduous environments in:‐Food processing, pharmaceutical, offshore, chemical, mining, quarrying and many, many more!

Installation is simple and easy, just one M10 or M12 threaded hole in the end of the shaft being

monitored or fitted using the unique “Mag‐con”

magnetic connector

A wide range of number of pulses per revolution are available together with AC and DC electrical outputs.

•Stainless steel 304/316 solid body housing




•Multiple outputs AC/DC

•Simple ease of fitting‐single 12mm fixing bolt(1/2, 5/8, UNC, 16mm, hollow shaft optional)

• Environment ingress‐IP67

•‐

25°C TO +70, 100, 125, 150°C versions available

•

SSE STAINLESS STEEL BODY

Product Features

ATEX

For Monitoring

• Speed

• Distance

•Direction

• Belt slip

• Shaft stopped

• Underspeed

• Overspeed




IMPORTANT NOTE:


RECOMMENDED MINIMUM




since 1983



Electrical Outputs




Type SSE stainless steel

Body material 304/316 stainless steel

Fixing –

end of shaft

M12 (standard) –½”, 5/8”

UNC, M16 optional

BearingsSealed for life –

Steel –

6205 –

2RS(Optional) –

Stainless steel-Polymer moulded oil

Maximum operating speed 10,000 RPM

Temperature -25°C to +70,100,125,150°C

Ingress rating IP67

Electricaloutputs See table below

65

7

22 75

140

3530

10

12mm Fixing bolt(10mm/16mm Optional)

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B


Product Information


since 1983

ROTECH FOR RELIABILITY! WE 5000 SeriesConveyor Belt Wheel Sensor

Utilising AE series sensors

For monitoring belt speed, slip& distance measurement

For monitoring:•Belt speed•Belt slip •Belt stopped

FEATURES:

•Totally enclosed & self contained trailing arm running on return side of conveyor belt


•Non standard wheel diameters available

•“Rapid fix” installation kits available

•1 to 1000 pulses per revolution (multiple outputs ac/dc)

•Environment ingress - IP67

•-25 to +100 deg Celsius versions

•

Tough, robust and easily installed, units are designed for long and durable service in the harshest of environments.

•Belt Weighers•Distance/length measurement

ATEX



since 1983



Electrical Outputs

580

200

110 150

2 M10 fixing holes

Pivot bracket

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B


Product Information


since 1983

ROTECH FOR RELIABILITY! PWE 6000 SeriesConveyor Belt Wheel Sensor

Utilising PE4000 Series Sensors

For monitoring belt speed, slip& distance measurement

For monitoring:•Belt speed•Belt slip •Belt stopped

FEATURES:

•Totally enclosed & self contained trailing arm running on return side of conveyor belt


•Non standard wheel diameters available

•“Rapid fix” installation kits available

•1 to 1000 pulses per revolution (multiple outputs ac/dc)

•Environment ingress - IP66

•-25 to +100 deg Celsius versions

•

Tough, robust and easily installed, units are designed for long and durable service in the harshest of environments.

•Belt Weighers•Distance/length measurement

ATEX



since 1983



Electrical Outputs

580

200

160 135Centre

175

Flexible liquid tight conduit16mm DIA x 900mm longC/w -


2 M10 fixing holes

Pivot bracket

Solid rubber wheel

PE4000 series unit

Brown

Black

Blue


Brown

Blue


Brown

Blue



Black Black


CH “A”


Channel “A”

Channel “B”

NPN





Current sink/source



Current sink/source

L +

L -Blue

Brown

Black


Green

Screen (Ground)

+ VE Supply

-

VE Supply

White

PNP

Brown

Blue

L +

L -

Brown

Blue Load

Load

Load

A

B


30 Vdc


Brown

Blue


ATEX


+

+-

-

Brown

Black

Blue

Black

Brown

Blue


A

B


Product Information


since 1983

ROTECH FOR RELIABILITY! VS 4000 SeriesScreen Vibration Sensor

Heavy Duty

Monitoring vibrating screens for slowdown, stoppage, blockage or irregular vibration

Can be used with Rotech SR 4000 series speed relay or connection

directly to plc, computers, data

loggers, etc. Gives a signal to stop screen drive motor and/or stop in‐feed conveyor.

Tough, robust and easily installed, units are designed for long and durable service in the harshest

of environments.

For monitoring:

•Vibrating screens

•Slowdown

•Stoppage

Features:


•Maintenance free for maximum Reliability

•Dc output ‐

plc/speed relay compatible

•Environment ingress ‐

IP67

•Up to 2000 VPM

•‐25 to + 70 °C

•Irregular vibration

•Blockage

•Drive belt slip



since 1983

70

40

80

46


Cablescreened/shieldedor wire armoured

Flexible conduit

1.5 Metres

Angled sensor bracketbolted or welded to screen

sideplate.

IMPORTANT Align sensor bracket in main direction of screen movement

Leave conduit loop to allow formovement of screen

Local junction boxTo control panel

Electrical connections

Supply 10 to 30 Vdc

Output type E3 (PNP + NPN)

Order Code:

AV – 1 – E3 – HD

Brown

Blue


Black

Type E3 (N.P.N + P.N.P – 3 wire) 10-30VdcBi-polar – Current sink/source


Product Information


since 1983

ROTECH FOR RELIABILITY! VS 4000 SeriesScreen Vibration SensorApplication Information

From a pilot introduction starting in 2000, Rotech Systems now have over 200 VS 4000 Vibration Protection Systems inoperation.

Most modern screens are designed with the benefit of computer simulation and can therefore cope with a wide rangeof operational conditions.

Variations in feed rates and composition of the material being fed to a screen (wet, sticky, etc.) can however in somecircumstances result in an excessive amount of material being on the screen.

If as a result, the rate and speed of vibration of the screen slows down, even temporarily, problems can occur veryquickly.

Material continues to be fed to the screen at the normal rate but the slowdown causes the discharge rate to be reduced, a marginal overload can quickly enter a runaway situation with the material arriving at the screen causing an every increasing overload and further slowdown, the discharge rate is then further reduced and the overloadincreases exponentially.

Mechanical Failure – “V” Belt damage or the intervention of the screen drive motors electrical overload is often the first thing the operator will know that all is not well!

Overloaded screens and feeders, V belt damage, spillage, cleaning up, etc. and their associated downtime and lost production can now be a thing of the past.

Key elements in the design brief were:-Quarry environment construction to ensure long term reliability, easy installation and simple setting up.

A ‘Rotech’ vibration sensor, fitted to screen, monitors its rate of vibration and will operate an alarm or switch the in – feed conveyor off if the screen slows down.

Accuracy is such that even a drop in speed of 5% for a few milli – seconds can be detected and action taken almostinstantaneously.

On V – belt driven screens, the screen drive motor can be switched off the instant any slippage occurs, preventing costly damage to belts.

The VS 4000 Vibration sensor is housed in heavy duty aluminium housing with all internal components and cable connections fully encapsulated.

It is supplied complete with a heavy duty galvanised angle bracket that is simply bolted or welded to the side of the screen or feeder. A heavy liquid tight flexible conduit is then looped to a convenient electrical junction box and the signal

routed by standard PVCSWA cable back to the main control panel.The associated SR 4000 Speed Relay Control Module has a single dial that is turned to locate the actual running speed of the screen / feeder and then set to just below this speed.

Typically on a screen / feeder vibrating at 750 throws per minute the speed relay is set to 725, if the speed drops below this level the SR 4000 speed relay operates in less than 10 milli – second.


Product Information


since 1983

ROTECH FOR RELIABILITY! VS 4000 SeriesScreen Vibration SensorApplication information

P.L.C

ROTECHVS 4000 SERIES

VIBRATION SENSORAV – 1 – E3 – HD

PULSED INPUT DIRECT TO PLC

VIBRATION RELAY MODULE – SERIES SR 4000

CONVERTS PULSES INTO ON/OFF SIGNAL VIA RELAY

OUTPUT CONTACTS

4 -20 mACONVERTOR MODULE

CONVERTS INPUT PULSES INTO 4-20mA ANALOGUE OUTPUT SIGNAL

INPUT = PULSES

INPUT = VOLT FREE RELAY CONTACT ON/OFF

INPUT = ANALOGUE 4 – 20mA

PULSE OUTPUT1 PULSE PER THROW

MARK/SPACE-EQUALTYPE E3 (N.P.N + P.N.P – 3 WIRE) 10-30VdcBI-POLAR – CURRENT SINK/SOURCE

20 mA

4

. ..cncno


Product Information


since 1983

ROTECH FOR RELIABILITY!Mag ‐ Con

Magnetic Connector

For quick and easy installation of Rotech shaft encoders & speedswitchesNo drilling and threading of shaft required, simply attach using mag-con

Installation instructions

1. Always observe lock-out and tag-out procedures during and after installation

2. Mag-con contains a powerful magnet - do not place anything between magnet and metal - personal injury may occur.

3. Using a 10mm Allen wrench and a 25mm open ended spanner attach the rotech unitTo the mag-con

4. It is recommended that a film of silicon grease is applied to the end of the shaft beforeInstalling the mag-con

5. Attach mag-con to the centre of the shaft. (Absolute centre not necessary)

6. Consult Rotech installation instructions for further information.

7. Do not remove installed Rotech while shaft is rotating, serious injury may occur.

8. Mag-con is not compatible with stainless steel shafts.

9. This magnet will erase magnetic strips from credit cards/door keys and other magnetic sensitive items.

Note - maximum speed for mag-con is 300 R.P.MRecommended minimum shaft diameter for fitting = 35mm


Product Information


since 1983

ROTECH FOR RELIABILITY! Speed Relay’sSelection InformationSafety and Reliability

Setting and routine testing of ‘Rotech’ motion sensors is carried out quickly, and most importantly safely, within your control room environment

Routine testing is carried out by observing a series of L.E.D. Indicators for –power on – delay on – relay on – incoming signal and then simply by starting and stopping the

Appropriate drive.

Rotation monitoring for your equipmentHeavy duty motion sensors/encoders together with speed relays

For detecting:-

•UNDERSPEED•OVERSPEED•BELT SLIP•VIBRATION

•SPEED •DIRECTION•DISTANCE•SHAFT STOPPED


since 1983

Rotech offers 2 types of speed relay modules, in the form of:-

Type AUE 400 Speed Relay – Advanced SeriesThis unit includes as standard:

• Dual AC Supply 110/240VAC 50/60Hz• Single output relay S.P.C.O. – Volt free Contacts• 3 Selectable Speed Ranges – Factory Settings – 0 to 10, 100 & 1000 RPM• Selectable Start Delay – Factory Setting = 10 seconds• Input signal repeat output – open collector transistor

Type SR 4000 Speed Relay – Standard SeriesThis unit includes as standard:

• Dual AC Supply 110/240VAC 50/60Hz• Single output relay S.P.C.O. – Volt free Contacts• 3 Selectable Speed Ranges – Factory Settings – 0 to 10, 100 & 1000 RPM

Variations to Factory Settings

All Speed Relays can be calibrated to suit Rotech Motion Sensors from 1 to 1000 pulses per revolutiondependant upon the sensor type it is being used with. e.g.. 401, 410, 416, 4120, 4360, 41000 etc.

The part number can be occasionally suffixed with either ‘E’ or ‘W’ to indicate it is for use with a type Eor type W motion sensor outpute.g. AUE 404W, SR4010E etc.

The part number can also be suffixed with x2, x5, x10 (multiply by) etc. This indicates the unit has been calibrated for a higher than standard speed ranges.

This affects the ‘speed ranges’ information in the above description. Thus x2 would change ranges to; 0 to 20, 0 to 200, 0 to 2000 RPM.x5 would change ranges to; 0 to 50, 0 to 500, 0 to 5000 RPM.x10 would change ranges to; 0 to 100, 0 to 1000, 0 to 10,000 RPM.

Similarly units can be calibrated for lower than standard speed ranges.Here the part number is suffixed by /5, /10, /100 (divide by) etc. e.g. AUE 4360/100, SR4020/10 etc.Suffix /5 would change the ranges to; 0.2 to 2, 2 to 20, 20 to 200 RPM.Suffix /10 would change the ranges to; 0.1 to 1, 1 to 10, 10 to 100 RPM.Suffix /100 would change the ranges to; 0.01 to 0.1, 0.1 to 1, 1 to 10 RPM.

Standard supply voltages is 110/240VAC 50/60 Hz while 12V, 24VDC, 24VAC can be provided upon application.

Product DescriptionsSpeed Relays

Rotech Type AUE400 & SR4000


Product Information


since 1983

ROTECH FOR RELIABILITY! SR 4000 SeriesSpeed Relay

Standard Series

For Rotation Monitoring The SR 4000 series speed relay modules are intended for use with all Rotech motion

sensors, shaft encoders, wheel sensors, vibration sensors and proximity probes to detect if the speed of a rotating shaft rises or falls below a preset level.

FEATURES:

Dual Ac Supply Standard (Optional - 12/24 Volt Dc)

Easy Setting Of Required Trip/Alarm Speed Directly In Rpm

Extensive range of optional features including automatic start delay (refer to additional information on automatic start delay operation)

Multiple Ranges, Fixed Start Delay, Etc.

Three speed ranges are available on each module. Standard ranges are 1-10 rpm, 1-100rpm and 1-1000 rpm. The required range being selected by link on the terminal rail. Other modules are available with ranges covering the speeds 0.01 rpm to 20,000 rpm.

In normal operation the output relay of the module is energised if the speed of the shaft is above the set level and de-energised if speed is below the set level.

Front mounted LED’s indicate power on, relay energised, input signal status.

EU directives



since 1983

1 Neutral AC mains power2 110/120V 50/60Hz supply3 220/240V 50/60Hz

4 N.O. Output relay5 Common rated6 N.C. 5A @ 250VAC / 30VDC

7 0VDC Blue 38 Input Blue 2 Wire Black Wire9 +12 VDC Brown Sensors Brown Sensors

Typical installation shown for 110/120 V AC supply

DC 2/3 wire ‘E,E2,E3’ type sensors connections

AC-2 wire ‘W’ type sensor connections

To Rotech Shaft motion sensors, wheel motion sensors,

vibration or proximity sensors.

50

76

1 12/24VDC-Positive2 2/24VDC-Negative

DC Power supply

1 Neutral AC mains power2 110/120V 50/60Hz supply3 Input – AC ‘W’ type 2 wire sensor

4 N.O. Output relay5 Common rated6 N.C. 5A @ 250VAC / 30VDC

7 0VDC8 Input9 +12 VDC

10 Range No links = 0 to 10RPM11 Links Link 10 to 11 = 0 to 100RPM12 Link 10 to 12 = 0 to 1000RPM

Rotech motionsensor

Brown

Blue

Connections – DC 2/3 wire sensors

Connections – AC 2 wire ‘W’ type sensors only

Height = 115


10 Range No links = 0 to 10RPM11 Links Link 10 to 11 = 0 to 100RPM12 Link 10 to 12 = 0 to 1000RPM

Mounting: DIN 35x7.5mm RailEnvironment Ingress: IP50Temperature: -10°C to +70°C



since 1983

Product Information

Automatic Start DelaySR 4000 Speed Relay

The automatic start delay on the SR 4000 speed relays operates as follows:

As soon as the main drive is started and the Rotech Motion Sensor/Encoder starts to rotate the start delay is initiated.

The start delay energises the SR 4000 speed relay for a period of 20 seconds.

During this period the drive should reach its normal operating speed and the speedrelay will then remain energised.

If the drive does not reach its normal running speed by the end of the 20 seconds thespeed relay will de-energise and the drive will shut down.

The 20 second start delay will only re-operate if the speed of the drive drops below1 RPM and remains below 1 RPM for a period of 20 seconds.

The following option can be included to any SR 4000 type unit. please refer to ‘Rotech systems’ for details



since 1983

Product Information

Commissioning & TestingSR 4000 Speed Relay

1.The SR 4000 Speed Relay monitors the speed of a drive and gives a signal if the speed of the drive falls below or rises above its normal running speed, the output relay of the SR 4000 can be connected to give a variety of control functions.

1.1 The output relay can be connected to sound an alarm, bring on a warning light, etc1.2 Can be connected into the motor control circuit to switch off / trip out the drive

motor.1.3 It can be connected into the motor control circuit of a conveyor, machine, etc,

proceeding the drive to which it is fitted, to stop the delivery of material, etc to the drive that has slowed down or stopped.

1.4 With the use of additional control relays and / or timers the above functions can be combined, plus many others created.

2. Use of the automatic start up delay is optional, this feature is normally only required when theSR 4000 is connected as in 1.2 above and the time taken to reach normal, running speedis several seconds longer.

SETTING UP

1. Check that all connections are correct and any links fitted to select the running speed range.

2. Turn the potentiometer on the SR 4000 Speed Relay fully anti – clockwise.

3. Start the drive.

4. “Supply On” and “Relay On” indicators should be illuminated and “Input” indicator should be pulsing or partly illuminated.

5. Turn the potentiometer slowly clockwise until the “Relay On” indicator extinguishes.

6. Now turn potentiometer anti – clockwise until “Relay On” indicator just illuminates.

7.The SR 4000 Speed Relay is now set to de- energise if the speed of the drive decreases below that set on the potentiometer.

8. If the drive is subject to temporary short period decreases in speed that you wish to ignore, the potentiometer can be turned further anti- clockwise to say 80% or 70% etc, of normal speed, the SR 4000 Speed Relay will then only de – energise if the speed of the drive falls below this setting.

9.Test by starting and stopping the drive, when running normally “Relay On” indicator will be illuminated, observe that when the stop button is pressed, as soon as the drive speed decreases below that set on the potentiometer, the “Relay On” indicator extinguishes.

Commissioning and testing must only be carried out by a qualified and competent technician who is fully familiar with the plant to which the “Rotech” equipment is

installed.



since 1983

Product Information

Testing & TroubleshootingSR 4000 Speed Relay

IMPORTANT- All connections and dis-connections must be made with mains power supply switched off.

2. Under normal running conditions “Supply On” and “Relay On” indicators should be illuminated.

3. “Input” indicator should be observed to pulse on and off when the drive is running slowly. At higher speeds on/off pulses become blurred and indicator is illuminated but not at full brightness. When fitted to higher speed drives the input can be tested by stopping drive and observing that at final few rpm beforestopping “Input” indicator pulses on and off. When stopped “Input” indicator can be in either on or offcondition. If no input signal is observed, check connections to shaft encoder are correct, if input signal is still not observed proceed to 6.

4. If input signal is present but the SR 4000 cannot be set up correctly then proceed as follows:-

4.1 Turn potentiometer fully clockwise, if “Relay On “ indicator does not extinguish, then the speed range selected is to low, change speed range links on terminals to select a higher range.

4.2 Turn potentiometer fully anti-clockwise, if “Relay On” indicator is not illuminated then speed range selected is to high, change speed range links on terminals to select a lower range.

5. “Relay On” indicator extinguishes but does not stop drive motor, check correct connections have been made to SR 4000 relay terminals (no contacts 4 & 5) and that all external connections to motor controlcircuit are correct.

6. Testing the SR 4000 Speed Relay

6.1 NON– W Types (DC Sensors) OnlyDisconnect shaft encoder connections to terminals 7, 8 & 9Disconnect any speed range links to terminals 10, 11 & 12Connect a small switch or push button between terminals 8 & 9Simulate input pulses by switching on and off

“Input” indicator should illuminate / extinguish and “Relay on“ indicator should illuminate.Set switch to off position, “Relay On” indicator should extinguish (on low speed units this may takeseveral seconds)

6.2 “W” Types (AC Sensors)Disconnect shaft encoder connections to terminals 1 or 2 & 3Disconnect any speed range links to terminals 10,11 & 12Connect a small, insulated switch or push button between terminals 2 & 3Simulate input pulses by switching on and off“Input” indicator should illuminate / extinguish and “Relay On” indicator should illuminateSet switch to off position, “Relay On” indicator should extinguish (on low speeds this may take several seconds)

7. Satisfactory completion of the above tests indicates that the SR 4000 Speed Relay is operating correctly

If when the shaft encoder is re connected the system is still not operational, then the problem is either with the installation cables or the shaft encoder

See shaft encoder installation data sheet for information on testing shaft encoders.


Product Information


since 1983

ROTECH FOR RELIABILITY! AUE 400 SeriesSpeed Relay

Advanced Series

The aue 400 series speed relay modules are intended for use with all Rotech motion sensors, shaft encoders, wheel encoders and proximity probes to detect if the speed

of a rotating shaft rises or falls below a preset level.

For Rotation Monitoring

FEATURES:

Dual ac supply standard - (optional - 12/24 volt D.C.)

Easy setting of required trip/alarm speed directly in rpm

Three speed ranges are available on each module. Standard ranges are 1-10 rpm, 1-100 rpm and 1-1000 rpm. The required range being selected by link on the terminal rail. Other modules are available with ranges covering the speeds 0.01 rpm to 20,000 rpm.

In normal operation the output relay of the module is engerised if the speed of the shaft is above the set level and de-energised if the speed is below the set level.

An internal 10 second delay timer is fitted as standard to allow for the run up time of the drive being monitored.

An opto-isolated input signal repeat output fitted as standard.

Front mounted LED’s indicate power on, delay on, relay energised, and input signal status.

EU directives



since 1983

1 AC Supply 220/240V2 AC Supply 110/120V3 Neutral 50/60Hz 50/60Hz4 N.O. Output relay rated5 Common 250VAC/30VDC @5a6 N.C. 7 10 Sec Link for start up 8 Delay delay

9 A.C. Input

10 0-100 RPM Link to terminal 14 for speed range11 0-1000 RPM Required – no links – 0 to 10 RPM

12 0VDC Blue 13 Signal Blue 2 Wire Black 3 wire sensors14 +12VDC Brown Type N Brown Type E,E2&E3

15 + Opto – isolated 16 - repeat output1.2V/80 m A

Brown

Motion sensor inputtype W only

Blue

AUE= speed relay-advanced series4- 400 series16- calibrated for use with

16 pulse / rev motion sensor

Note: typical part no = AUE 416

The 10 second start delay operatesevery time an external switch or contact connects terminal 7 & 8

Note: start delay


Note 1:Link for start up delayNote 2:Link for required speed RangeNote 3:Repeat output

See Note 1

See Note 2

See Note 3

Typical installation shown for 110/120 V AC supply

Rotech motion sensor

Alternatively with a fixed linkbetween terminals 7 & 8, the 10 seconddelay will operate every time power is applied to the module

C1

Mounting - DIN 35 x 7.5 mm RAILEnvironment Ingress - IP 50Temperature - -10°C to +70°C

75

55

Repeat OutputFacility



since 1983

Product Information

Commissioning & TestingAUE 400 Speed Relay

1. The AUE 400 monitors the speed of a drive and gives a signal if the speed of the drive falls below or rises above its normal running speed. The output relay of the AUE 400 can be connected to give a variety of control functions.

i. The output relay can be connected to sound an alarm, bring on a warning light, etc.

ii. It can be connected into the motor control circuit to switch off/trip out the drive motor.

iii. It can be connected into the motor control circuit of a conveyor, machine, etc. preceding the drive to which it is fitted, to stop the delivery of material, etc. to the drive that has slowed down or stopped.

iv. With the use of additional control relays and / or timers the above functions can becombined, plus many others created.

2. Use of the 10 second start up delay is optional. This feature is normally only required when the AUE 400 is connected as in 1.2 above and the time taken to reach normal running speed is several seconds or longer.

3. The repeat output facility allows the input pulses from the motion sensor/ encoder to be re-transmitted to other equipment. Typical applications are speed indication, secondary input to plc, computer, etc. Analogue conversion 0 to 10VDC/4 to 20MA, etc. or connecting two or more AUE 400 modules to a single motion sensor/ encoder to obtainmultiple alarm/trip levels.

SETTING UP

1. Check that all connections are correct and that links are fitted to select the correct speed range.

2. Turn the potentiometer on the AUE 400 speed relay fully anti-clockwise.3. Start the drive and if the run-up delay facility is being used, wait 10 seconds until the

“delay on” indicator is extinguished.4. “Supply on” and “relay on” indicators should be illuminated and “input” indicator should

be pulsing or partly illuminated.5. Turn the potentiometer slowly clockwise until the “relay on” indicator extinguishes

and note setting.6. Turn potentiometer anti-clockwise until ‘relay on’ indicator illuminates, then turn

clockwise and set to approximately 90% of the above setting.7. The AUE 400 speed relay is now set to de-energise if the speed of the drive decreases below

that set on the potentiometer.8. If the drive is subject to temporary short period decreases in speed that you wish to

ignore, the potentiometer can be set to 80%, 70%, etc. of normal running speed, the AUE 400speed relay will then only de-energise if the speed of the drive falls below this setting.

9. Test by starting and stopping drive. When running normally "relay on" indicator will be illuminated. Observe that when the stop button is pressed, as soon as the drive speeddecreases below that set on the potentiometer, the “relay on” indicator extinguishes.

Commissioning and testing must only be carried out by a qualified and competent technician who is fully familiar with the plant to which

the “Rotech” equipment is installed.



since 1983

Product Information

Testing & TroubleshootingAUE 400 Speed Relay

1. Important - all connections and disconnections must be made with mains power supplyswitched off.

2. Under normal running conditions “supply on” and “relay on” indicators should be illuminated.

3. “Input” indicator should be observed to pulse on and off when the drive is running slowly. at higher speeds on / off pulses become blurred and indicator is illuminated but not at full brightness. When fitted to higher speed drives the input can be tested by stopping drive and observing that at final few rpm before stopping “input” indicator pulses on and off. When stopped “input” indicator can be in either on or off condition. if no input signal is observed, check connections to motion sensor/ encoder are correct,

4. If input signal is still not observed proceed to 6.

i. If input signal is present but the AUE 400 cannot be set up correctly then proceed as follows:

ii. Turn potentiometer fully clockwise, if “relay” on indicator does not extinguish, then the speed range selected is to low. Change speed range links on terminals to select a higher range.

iii. Turn potentiometer fully anti-clockwise, if “relay on” indicator is not illuminatedthen speed range selected is too high. Change speed range links on terminals to selecta lower range.

5. “Relay on” indicator extinguishes but does not stop drive motor. Check correct connections have been made to AUE 400 relay terminals (N.O. contacts 4 & 5) and that all external connections to motor control circuit are correct.

6. Testing AUE 400 speed relay.

i. (For DC type motion sensors/encoders only)

Disconnect motion sensor/encoder connections to terminals 12, 13 & 14.Disconnect any speed range links to terminal 10 & 11.Connect a small switch or push button between terminals 13 & 14.Simulate input pulses by switching on and off at approximately 1 second intervals.“Input” indicator should operate and “relay on” indicator should illuminate.

ii. (For AC type motion sensor/encoders-“W” type input only)

Disconnect motion sensor/ encoder connections to terminals 1 or 2 & 9Disconnect any speed range links to terminals 10 & 11.Connect a small insulated switch or push button between terminals 1 or 2 & 9Simulate input pulses by switching on and off at approximately 1 second intervals.“Input” indicator should operate and “relay on” indicator should illuminate.

7. Satisfactory completion of the above tests indicates that the AUE 400 speed relay is operating correctly.

If when the motion sensor/encoder is re-connected the system is not operational, then the problem is either with the installation cables or the motion sensor/encoder.

See appropriate installation data sheet for information on testing motion sensor/encoders.


since 1983

Documents

Sales and Installation Manual - Rotech · Sales and Installation . Manual . ... Screen Vibration Sensors. VS 4000 Series. ... Commissioning and testing : 6. Installation – Electrical: