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Binsfeld TorqueTrak Revolution User Manual

Torque and power monitoring system
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TorqueTrak Revolution
Torque and Power
Monitoring System
User's Guide
866001-9_J

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Summary of Contents for Binsfeld TorqueTrak Revolution

  • Page 1 TorqueTrak Revolution Torque and Power Monitoring System User’s Guide 866001-9_J...

  • Page 2: Table Of Contents

    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...

  • Page 3: System Overview

    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 Ring.

  • Page 4: System Components

    System Components Rotating Shaft Collar Stationary Power Ring (with Transmitter Module) Sends power to the Rotating Clamps to shaft with bolts provided. Collar and receives data signal Houses Transmitter Module which from the Rotating Collar converts strain gage signal to digital code.

  • Page 5: Controls And Connections Overview

    Controls and Connections Overview Signal Output Terminals Torque Config Switches Power Config Switches 1 = Torque Output HI (+I) 1 = Pos FS torque 1 = Pos FS power 2 = Torque Output LO (-I) 2 = Neg FS torque 2 = Neg FS power 3 = Power Output HI (+I) 1&2 = Zero torque...

  • Page 6: Controls And Connections

    Controls and Connections Power Input The Master Control Unit operates on 11-16 VDC (standard) or 115VAC or 230VAC (optional). Power connections are made via a removable three-position screw terminal block as shown below. WARNING: Supply voltage (up to 230VAC) is live in the Master Control Unit even when the Main Power switch is off! Use caution when accessing internal controls.

  • Page 7: Torque Output Signal

    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...

  • Page 8: Torque Signal Calibration Controls

    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.
  • Page 9 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.
  • Page 10 7&8 Used to set frequency response of torque signal (i.e. select cut-off frequency for low pass filter) as follows: Switch 7 Switch 8 Cut-off Frequency 1000 Hz 12 Hz 1.5 Hz 0.1 Hz Factory Default: All switches in the OFF position. Torque Signal Configuration Switches Figure 4 - Torque Signal Configuration Switches - 9 -...

  • Page 11: Power Output Signal

    Power Output Signal The 4-20 mA shaft power output signal is accessed from a removable eight-position screw terminal block on the upper-most board in the Master Control Unit. Power signal scaling and configuration switches are described below. Power Signal Output Terminals Terminal 3 = Power Output Current Loop (+I) Terminal 4 =...

  • Page 12: Power Signal Calibration Controls

    - position 4 x10 - position 9 x1 - position 0 IMPORTANT: Power supply to the TorqueTrak Revolution must be cycled Off, then back On, to make effective any changes to the RPM Factor switch setting. Note: The power signal gain (sensitivity) is dependent upon and proportional to the torque gain.
  • Page 13 Switch Function when switch is ON (Factory Default: All OFF): Generates positive full scale power output signal (20mA) Generates negative full scale power output signal (4 mA) 1&2 Generates zero power output signal (12 mA) Full Scale Power Output Range: 4-20mA with dipswitch #3 ON (up) 12±8mA with dipswitch #3 OFF (down) Reverses the polarity of the power signal...
  • Page 14 When switch #3 is activated the output signal at zero power changes from 12 mA to 4 mA and simultaneously the signal gain is doubled. When Switch #5 is OFF, the power output signal is calculated and updated 6 times per shaft revolution (i.e. whenever the RPM sensor is triggered).

  • Page 15: Speed (Rpm) And Direction Output Signals

    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 (+I) Terminal 6 =...
  • Page 16 NOTE: The maximum load resistance of any one of the TorqueTrak Revolution output current loops is 500 ohms. This means the system can drive the 4-20 mA output signal into resistances of 0 to 500 ohms. To calculate the distance the signal can travel, add the input resistance of the device you plan to “drive”...

  • Page 17: System Status Indicator Lights

    System Status Indicator Lights There is one Main System Status Indicator light located outside the Master Control Unit at the base of the Power Ring and five secondary system status indicator lights inside the unit. See Appendix C: Error Codes & Troubleshooting for indicator details. Main System Status Indicator Red light is on solid if no...

  • Page 18: Transmitter Status Indicator Light

    Transmitter Status Indicator Light The green light embedded in the cover of the transmitter module (located on the back side of the Rotating Collar) is the Transmitter Status Indicator Light. Transmitter Status Indicator Light Figure: Transmitter Status Indicator Light When the Transmitter Status Indicator Light is on solid, the transmitter module is receiving sufficient power from the rotating coil and is sending out viable digital data.

  • Page 19: Installation Procedure

    Installation Procedure 1. If not already installed, attach strain gage(s) (or other sensors) to shaft being measured. (See Appendix D: Strain Gage Application for simplified instructions.) 2. For 4-piece Rotating Collars and Power Rings, pre-assemble half-sections using hardware and instructions provided. Make sure 4-piece collar sections are assembled in the correct order, otherwise speed and power sensing features will not function properly.
  • Page 20 4. After collar is bolted on the shaft, place jumper wires (provided) in the screw terminal connectors at each collar junction as shown in Figure 9 and tighten securely. 5. Assemble one half of Power Ring to Master Control Unit using hardware provided.
  • Page 21 11. Slide Remote Shunt switch to ON (Main System Status light will flash). Measure Torque Signal current. Reading should be approximately 16 mA. Slide Remote Shunt switch to OFF position. (Main System Status light will return to on solid.) Slide main power switch to OFF. 12.

  • Page 22: Set Up Procedure

    Set Up Procedure The power output signal from the Revolution System is generated using the measured torque value (from the strain gage) and the measured shaft speed (RPM). System setup requires four basic steps: Step 1: Calculate the nominal full scale torque range Step 2: Select an appropriate full scale power level Step 3: Calculate the corresponding RPM Factor Step 4: Set the RPM Factor switches...
  • Page 23 Full Scale Note that these are the nominal torque and power scales that apply before any User Calibration Adjustments are made. The TorqueTrak Revolution System is now ready to record data at the nominal gain and offset settings. - 22 -...
  • Page 24 Example: Given a solid steel shaft with (shaft diameter, measured) = 2.5 inches GF (gage factor from gage package) = 2.045 (Transmitter sensitivity) = 1 mV/V Trans (estimated max power level) = 800 hp Full Scale (377.60)(2.50 in) ------------------------- = 2,885 ft-lb Full Scale (2.045) 800 hp x 5252...
  • Page 25 Example: 100 pounds weight on a 1-foot moment-arm equals 100 foot-pounds “known Torque-Input.” Observe the Current-Output of the TorqueTrak Revolution system. Sensitivity of the entire system is equal to the Torque-Input per Current- Output. Take two or more points of reference using different known Torque-Input values as confirmation of the ”Sensitivity”...

  • Page 26: Appendix A: Revolution Specifications

    0.75 inches (19 mm) Rotating Collar Material: Cast nylon Size: (see appropriate drawing) http://www.binsfeld.com/index.php/tech_info/TTR_dimensioned_drawings/ Master Control Unit and Power Ring Output Signals: Four independent current output signals: 1. Torque: 4-20 mA nominal, scalable (usable from 0-24 mA) 2. Shaft power: 4-20 mA nominal, scalable (usable from 0-24 mA) 3.
  • Page 27 Input Power: 11-16 VDC standard; 2A max, 0.5A nominal (115VAC or 230VAC option available) Output Connections: Screw Terminals Size and Weight - Master Control Unit: 6 x 6 x 4 inches (15 cm x 15 cm x 10 cm) 6 lbs (2.72 kg) Size and Weight - Collar: Outer Diameter: (see appropriate drawing) Revolution Torque &...

  • Page 28: Appendix B: Torque Calibration Calculations

    (e.g. gage factor) and the Revolution transmitter gain setting (preset at the factory and documented below). For easy calculations, use the calculator found at our website. http://www.binsfeld.com/calculators/ttrevo_range/ Calculate Nominal Full Scale Torque, T (ft-lb) Full Scale To calculate the nominal full scale torque, ±T...
  • Page 29 For metric applications with D and D in millimeters and T Full Scale in Newton-meters the general equation is: – D )()(E)(4)(D Trans (N-m) Full Scale (GF)(N)(16 x 10 )(1+)(D Where E = 206.8 x 10 N/mm Example: Given a solid steel shaft with (shaft diameter, measured) = 2.5 inches GF (gage factor from gage package) = 2.045 (transmitter sensitivity) = 1 mV/V...

  • Page 30: Appendix C: Error Codes & Troubleshooting

    Appendix C: Error Codes & Troubleshooting Indicator Condition Main Status (Red LED) On solid * No errors Fast flash a) Remote Shunt Switch is on b) One or more system errors present Stator (Green LED) On solid * Electrical power (voltage) to system is in range Fast flash Electrical power (voltage) to system is too high Slow flash...
  • Page 31 In error mode, output signals = 24 mA. Fast flash rate = 4 Hz; Slow flash rate = 2 Hz * Indicates normal (error free) mode Common Error Modes and Suggested Corrective Actions If an error is present, the Main System Status Indicator will flash and the system will display an error code briefly (another 10-15 seconds) before the startup cycle repeats.
  • Page 32 Using the BS900 Bridge Simulator for Troubleshooting A BS900 Bridge Simulator is shipped with each Revolution system inside the Master Control Unit. The Bridge Simulator is very useful for isolating the cause of a suspect data signal as it "simulates" a properly installed strain gage. By disconnecting the actual strain gage and temporarily connecting the Bridge Simulator to the ribbon cable from the Rotating Collar the user can quickly determine if the suspect...

  • Page 33: Appendix D: Strain Gage Application

    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.
  • Page 34 PREPARING THE GAGE FOR MOUNTING 5. 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.
  • Page 35 7. Gage should now be positioned. Once again, lift the gage end of the tape at a shallow angle to the surface until the gage is free of the surface. Continue pulling the tape until you are approximately 1/8” – 1/4” beyond gage.
  • Page 36 11. 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.
  • Page 37 - 36 -...

  • Page 38: Warranty And Service Information

    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.

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