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Electro-Sensors TR400-C Installation & Operation Manual

Programmable process ratemeter
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Model TR400-C
Programmable Process Ratemeter
Installation & Operation Manual

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  • Page 1 Model TR400-C Programmable Process Ratemeter Installation & Operation Manual...
  • Page 2 Model TR400-C Programmable Process Ratemeter Installation & Operation Manual Part Number: 990−000510 Revision E Electro-Sensors®, Inc. 6111 Blue Circle Drive Minnetonka, MN 55343-9108 Contact us at: Local: 952-930-0100 National: 1-800-328-6170 Fax: 952-930-0130 Web: www.electro-sensors.com Sales: sales@electro-sensors.com Support: sales@electro-sensors.com...

  • Page 3: Introduction To This Manual

    TR400-C. Who should use Keep in mind that the function of the TR400-C installed in a mechanical process is to this manual monitor speed; therefore, it must be installed by qualified personnel only. This...

  • Page 4: How This Manual Is Organized

    • Section 1: Warnings and Cautions, discusses personal injury possibilities and potential damage to equipment. • Section 2: Installation, discusses installing the TR400-C into a panel and the Explosionproof sensor. • Section 3: TR400-C, Explosion-Proof Sensor Wiring and DIP Switches, discusses recommended wiring practices, wiring, and configuring the DIP Switches.

  • Page 5: Table Of Contents

    TR400-C DIP switches ........................21 4 ............................... 23 ECTION TR400-C S ......................23 ARAMETERS Introduction ............................ 23 TR400-C parts and functions ......................24 TR400-C set-up parameters ......................26 5 ............................... 27 ECTION TR400-C P ........................27 ROGRAMMING Introduction ............................ 27 Programmable variables.........................
  • Page 6 Switch input test ..........................42 4-20mA / 0-10Vdc analog output test .................... 43 System slowdown test ........................45 Reset the variables ......................... 46 A: S ....................... 47 PPENDIX PECIFICATIONS TR400-C Ratemeter ........................47 907 Hall-effect explosionproof sensor ................... 48 ..............................49 NDEX Rev E...

  • Page 7: Section 1

    Introduction This section discusses warnings and cautions to guard against the possibility of injury to persons and damage to equipment. Since the TR400-C monitors the speed of various mechanical systems, observe all warnings and cautions that pertain to the mechanical systems as well.

  • Page 8: About Warnings And Cautions

    Important Read the warnings and cautions in this section before attempting to install, set up, or notice operate the TR400-C and its associated hardware. Warnings and cautions appear in this section and throughout this manual. Definitions Warnings are given when there is the possibility of injury to persons.

  • Page 9: Warnings

    S1−Warnings & Cautions Warnings Warning Always turn the power source OFF before wiring the TR400-C. Failure to observe this warning could result in an electrical shock or damage to the equipment. Warning During a Stop condition, any slight movement of the shaft or magnetic disc could activate the control relay and start the motor.

  • Page 10: Cautions

    Failure to observe this caution could result in improper sensor operation. Caution The TR400-C standard uses 115 Vac, 6 VA @ 60/50 Hz, with 230 Vac as an option. Make sure you know the correct supply voltage before applying power to the TR400-C. Failure to observe this caution could result in damage to the TR400-C.

  • Page 11: Section 2

    Section 2 TR400-C Installation Introduction This section discusses unpacking and installing the TR400-C into a panel. In this section These are the topics: Topic See Page Installation overview Installing the TR400-C About the Hall-Effect Explosion-Proof sensor Installing the Explosion-Proof sensor...

  • Page 12: Installation Overview

    S2−TR400-C Installation Installation overview Warning The TR400-C is a programmable process ratemeter and must be installed by qualified personnel only. Failure to observe this warning could result in an injury to persons or damage to equipment. Unpacking the After unpacking the TR400-C, Explosion-Proof Sensor and Pulser Disc save the...

  • Page 13: Installing The Tr400-C

    Slide the TR400-C into the cutout. Replace the mounting bracket and tighten the screwsdo not over tighten. See Figure 1. Note: Allow a minimum of 1.5 inches of clearance on all sides of the TR400-C (all dimensions are in inches). Insert Mounting Bracket 3.10"...

  • Page 14: About The Model 907 Hall-Effect Explosion-Proof Sensor

    S2−TR400-C Installation About the model 907 Hall-Effect Explosion-Proof sensor Sensor The model 907 Hall-Effect Explosion-Proof sensor ∗ has an XLB−3 enclosure that is description C.S.A. approved and UL rated for Class I Group D; Class II Group E, F, G; and Class III.

  • Page 15: Installing The Explosion-Proof Sensor

    S2−TR400-C Installation Installing the Explosion-Proof sensor Installation The Explosion-Proof sensor is supplied with a slotted mounting bracket. Sensors should be installed so that the centerline of the magnets pass in front of the centerline of the sensor as the disc rotates. The centerline on the magnetized area of the disc should be 1¾...

  • Page 16: About The Pulser Disc

    S2−TR400-C Installation About the Pulser Disc Pulser disc The heavy-duty pulser disc is nylon. The disc is designed with magnets of alternating description polarity (N-S-N-S) imbedded in the face of the disc on the outside edge or outside circumference. See Figure 4. The disc is mounted onto the end of the shaft where the magnets serve as targets for the 907 sensors, which switches because of exposure to the changing magnetic poles.

  • Page 17: Installing The Pulser Disc

    S2−TR400-C Installation Installing the pulser disc Installation To install the pulser disc, do the following: Step Action All pulser discs have a center hole dimension of 0.196 inch. To mount the disc to the shaft, use a #21 drill bit to drill a center hole in the shaft’s end to a depth of 0.5 inch.
  • Page 18 S2−TR400-C Installation Purposely Left Blank Rev E...

  • Page 19: Section 3

    Section 3 TR400-C Wiring & DIP Switches Introduction This section discusses electrical information concerning the TR400-C, including wiring practices, wiring schematics, and DIP Switch settings. In this section These are the topics: Topic See Page Recommended wiring practices TR400-C wiring schematics...

  • Page 20: Recommended Wiring Practices

    Recommended wiring practices Warning Recommended wiring practices must be followed when wiring industrial equipment such as the TR400-C. Failure to follow the recommended wiring practices listed below could result in an injury to persons or damage to equipment. Wiring The following is a list of recommended wiring practices for installing industrial practices equipment.

  • Page 21: Tr400-C Wiring Schematics

    Caution Do not wire the TR400-C to 230 Vac unless it has been specially built for that voltage. The standard voltage setting is 115 Vac. Failure to observe this caution could result in damage to the TR400-C.
  • Page 22 S3−TR400-C Wiring & Dip Switches TR400-C wiring schematics, continued Warning During a Stop condition, any slight movement of the shaft or magnetic disc could activate the control relay and start the motor if the Motor Auxiliary, Normally Open Contact (MS Aux n.o.) is not wired in series.
  • Page 23 S3−TR400-C Wiring & Dip Switches TR400-C wiring schematics, continued 120VAC 480VAC 120VAC 120VAC gure 7b Slowdown PLC Wiring Schematic (Motor Starter and Timer) Rev E...

  • Page 24: Ac Power And Channel A Input Signal Power

    AC power and Channel A input signal power AC power The TR400-C standard comes set-up for 115 Vac, 6VA at 50/60 Hz. An external wiring 1/16 amp slow-blow fuse must be provided by the customer. AC power will tie to TB1−1, Line, and TB1−2, Neutral.

  • Page 25: 4-20Ma / 0-10Vdc Analog Output Wiring

    S3−TR400-C Wiring & Dip Switches 4-20mA / 0-10Vdc analog output wiring 4-20 mA/0-10 The 4-20mA/ ∗ 0-10 Vdc analog output supports a maximum load resistance of 500 VDC analog ohms. The analog output plus (+) signal is at TB1−5, and the negative (-) signal is at output TB1−4, as shown in Figure 9.

  • Page 26: Channel A Input Signal Sensor Wiring

    S3−TR400-C Wiring & Dip Switches Channel A input signal sensor wiring Caution Never use shielded cable with extra conductors. Extra conductors can act as antennas, picking up electrical noise. Failure to observe this caution could result in improper sensor operation.

  • Page 27: Tr400-C Dip Switches

    S3−TR400-C Wiring & Dip Switches TR400-C DIP switches Sensor DIP The sensor DIP Switches are located on the bottom of the TR400-C, as shown in switches Figure 11. Sensor input and switch information is shown in Table 2. Table 2: Sensor Input Configuration DIP Switches Input Channel A TB2−7...
  • Page 28 S3−TR400-C Wiring & Dip Switches Purposely Left Blank Rev E...

  • Page 29: Section 4

    Section 4 TR400-C Set-Up Parameters Introduction This section discusses information about the TR400-C operations panel and set-up parameters. In this section These are the topics: Topic See Page TR400-C parts and functions TR400-C set-up parameters Rev E...

  • Page 30: Tr400-C Parts And Functions

    (9) keys. See Figures 12a and 12b. The letters in Figures 12a and 12b represent each part on the front panel of the TR400-C. The Parts and Functions table 3 describes the function of each of the parts.
  • Page 31 S4−TR400-C Set-Up Parameters TR400-C parts and functions, continued Figure 12b: TR400-C Front Panel Description Table 3: TR400-C Panel Parts and Functions (continued) Part Function The REV key is used as a keypad test key in Diagnostics Mode only. The ENTER key is used in Program Mode to set the value of a variable after...

  • Page 32: Tr400-C Set-Up Parameters

    S4−TR400-C Set-Up Parameters TR400-C set-up parameters Set-up The TR400-C comes from the factory set for NPN open-collector operation. In most parameters applications, when using a standard hall effect sensor with the model 255-pulser disc, you only need to program a few variables. For example, RPM (Revolutions Per Minute) and PPR (Pulses Per Revolution): •...

  • Page 33: Section 5

    Section 5 TR400-C Programming Introduction This section discusses information about programming the TR400-C. In this section These are the topics: Topic See Page Programmable variables How to select a variable and view its data Keypad keys used to access and program variables How to select and change a variable’s numerical value...

  • Page 34: Programmable Variables

    S5−TR400-C Programming Programmable variables Variables Table 4 describes the programmable variables for the TR400-C. Table 4: TR400-C Programmable Variables Var # Variable Name Description See Page Pulses Per Revolution. Time relay is held energized at startup regardless of Start Delay setpoint status Holds the set point value for output “1”...

  • Page 35: How To Select A Variable And View Its Data

    DIAG Figure 14: TR400-C Placed in Program Mode Displaying Variable 07 Note: The TR400-C will remember the last variable selected and changed until the TR400-C is powered Down. After powering up the TR400-C, the display will show Pr01 the first time you enter Program Mode.
  • Page 36 S5−TR400-C Programming How to select a variable and view its data, continued Viewing To view the data for variable 07, do the following: variable data Step Action Press the ENTER key to go to the data-entry level; the display will show 0150, which is the default value for variable 07, output 1, with the 1’s...

  • Page 37: Keypad Keys Used To Access And Program Variables

    RIGHT ARROW, UP ARROW, DOWN ARROW, DECIMAL, and ENTER keypad keys. The REV and DIAG keys are inactive when the TR400-C is in Program Mode. Figure 17 shows only the keys used to program the variables. Table 5 describes the keys and their functions.

  • Page 38: How To Select And Change A Variable's Numerical Value

    Note: You can use the following 7-step procedure to select any variable, change its value, and save the results. Note: You can select a variable and change its value when the TR400-C is actively monitoring or when it is idle.
  • Page 39 S5−TR400-C Programming How to select and change a variable’s numerical value, continued Changing the To change the PPR from 8 to 16 for variable 02, press each key the number of times value shown in the three (3) steps below, while viewing the results on the display.

  • Page 40: Rate And Signal Parameters

    S5−TR400-C Programming Rate and signal parameters Overview The TR400-C has the ability to display rates as “Speed”, using variables 01, 02, and 03. Variable 02 PPR is programmable; variables 01 and 02 are fixed. Variables 01, The values for Maximum Revolution Per Minute (RPM) and Pulses Per Revolution...

  • Page 41: Relay Outputs And Start Time Delay

    S5−TR400-C Programming Relay outputs and start time delay Overview Variables 13, 10, and 07 establish the functional operating parameters for the relay outputs (fixed on Cargill units) Variable 13, The relay output Function sets the function of the relay outputs.
  • Page 42 S5−TR400-C Programming Variables 08, & Output Delay Times are used to set the amount of time the set-point condition must 11, relay exist before the output will respond. The default value for these variables is one half output-delay second (0.5) second. The range is 0-1.0 seconds.

  • Page 43: Programming The Analog Output

    S5−TR400-C Programming Programming the analog output Overview The 4-20 mA or ∗ 0-10 Vdc range is specified with variables 15 and 16. The output is linear between the two specified values. Variable 19 is used to set the analog output response time.

  • Page 44: Programming The Display Features

    S5−TR400-C Programming Programming the display features Variable 26, This variable configures how the display appears. Leading Zero The display appearance bit assignments are as shown below: Blanking and Segment Display Characters intensity Leading Zero blanking  makes the leading zeros dark or not lit.

  • Page 45: Section 6

    TR400-C Diagnostics Introduction Diagnostics are used to test the functionality of the TR400-C. When the DIAG key is pressed, the TR400-C will display “dIAg,” and all of the LEDs except the KEY ERR LED will light. The LEDs will remain on until you exit Diagnostics Mode.

  • Page 46: Keypad And Display Test

    S6−TR400-C Diagnostics Keypad and display test Overview The keypad diagnostic tests the functionality of each key and bit position on the display. Keypad and To perform the keypad test, do the following: display test Step Action Press the DIAG key.

  • Page 47: Relay Output Test

    S6−TR400-C Diagnostics Relay output test Overview The relay output diagnostic tests the functionality of the relays. Relay output To test the relay outputs using the built in diagnostic while not running, and when test the TR400 is not locked, do the following:...

  • Page 48: Switch Input Test

    S6−TR400-C Diagnostics Switch input test Overview The Switch Input diagnostic tests the TR400’s ability to recognize switch inputs tied to TB1−1. When a closed switch is tied to TB2, screw tap 1, 2, or 3, the corresponding bit position will toggle to “1.”...

  • Page 49: 4-20Ma / 0-10Vdc Analog Output Test

    S6−TR400-C Diagnostics 4-20mA / 0-10Vdc analog output test Overview The Analog Output diagnostic puts the TR400 into Pot Output Mode, which permits you to adjust the 4-20 mA 12-bit isolated, or the 0-10 Vdc outputs. The same ∗ hardware and procedure are used regardless of the option. There is a direct correlation between current/voltage and speed.
  • Page 50 S6−TR400-C Diagnostics 4-20mA / 0-10Vdc analog output test, continued Step Action Press the DOWN ARROW key and the display will appear, as shown in Figure 23. Display Characters Percent Symbol 00 – 99 Range Figure 23: 4−20 mA or 0−10 Vdc Output Display in Percent Turn the Offset Pot until the mA meter reads 4 mA or voltmeter reads 0 Vdc.

  • Page 51: System Slowdown Test

    S6−TR400-C Diagnostics System slowdown test Overview The system slowdown test, tests the functionality of the system as a whole. System To run the slowdown test on the system you must have the system up and running. slowdown test The system must be above both the shutdown and alarm setpoints. This test does not require the user to change the setpoints.

  • Page 52: Reset The Variables

    S6−TR400-C Diagnostics Reset the variables Overview When necessary, the TR400-C’s variables can be reset to factory default, using the default function. Resetting To Reset the variables, do the following: variables Step Action Press the DIAG key. Press the REV key; the display will appear as shown in Figure 24, restoring the factory defaults.

  • Page 53: Appendix A: Specifications

    Appendix A: Specifications TR400-C Ratemeter Power Description Input Power • 115 Vac, 6VA @ 50/60 Hz, requires external fuse 1/16 amp slow- blow • 230 Vac, 6VA @ 50/60 Hz, requires external fuse 1/32 amp slow- blow Sensor Input Switch selectable NPN Open Collector 2200 ohm pull-up to 12 Vdc, 2.5 volts trigger level...

  • Page 54: 907 Hall-Effect Explosionproof Sensor

    Appendix A: Specifications 907 Hall-effect explosionproof sensor Power Description Supply Requirements 5-24 Vdc @ 10 mA Output Type NPN Open Collector Current Sink 25 mA Maximum Maximum Frequency 20 kHz Temperature Range -40ºC to +60ºC Gap Distance 3/8 ±1/8 inch Maximum Dist.

  • Page 55: Index

    18, 47 pulser disc, 11 wiring, 15, 18, 19 sensor dimensional drawing, 8 AC Switch Inputs TR400-C, 7 test, 42 unpacking TR400-C, 6 Analog Outputs 0-10 Vdc, 43 4-20 mA, 43 Appendix A Offset and Span Pots, 44 specifications...
  • Page 56 10 output (2), 35 power, 8, 18, 48 11 relay output 2 delay time, 36 Sensors 12 relay output 2 on time, 36 electro-sensors standard type, 21 13 relay output function, 35 Set Point 15, 4 mA output, 37 values, 26, 35...
  • Page 58 Electro-Sensors®, Inc. 6111 Blue Circle Drive Minnetonka, MN 55343-9108 Contact us at: Local: 952-930-0100 National: 1-800-328-6170 Fax: 952-930-0130 Web: www.electro-sensors.com Sales: sales@electro-sensors.com Support: tech@electro-sensors.com...

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