Rotech systems manual

Sales and Installation Manual

ROTECH FOR RELIABILITY!

? s s e L g in h t y n Why Accept A Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

Monitoring the world since 1983

Product Selection ROTECH FOR RELIABILITY!

Monitoring the world since 1983

ess?

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Monitoring Solutions

Monitoring Solutions For Your Equipment Speed Monitoring Safety Interlocking Rotation Control

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

End Of Shaft Mounted Motion Sensors •Extremely robust

•Pulse rates from 1 to 1000

•Self contained, easy to fit

•Range of signal outputs

•Maintenance free for life

•To suit all Industrial applications

AE 1000 Standard Duty Aluminium Body

For monitoring: •Speed •Shaft Stopped •Distance •Underspeed •Direction •Overspeed •Belt Slip •Safety guards interlocking

SSE 2000

AE 2000 Heavy Duty Aluminium Body

Heavy Duty Stainless Steel Body Also available in 3000 Series Extra Heavy Duty For use in the most severe arduous environments

AE 3000

PE 4000

SS 4000 Speedswitch

Extra Heavy Duty Aluminium Body

Polypropylene Body Low Cost

Polypropylene Body Speed control trip set point in RPM adjustable over chosen speed range via internal control fitted under unit cover.

Re-Chargeable Grease Chamber

Wheel Driven Trailing Arm Motion Sensors For monitoring:

WE 5000

PWE 6000

Totally Enclosed Utilising AE series sensors

Open Frame Utilising PE 4000 series sensor

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

Screen Vibration Sensors VS 4000 Series Pulsed output Type E3 10-30 Volts DC Totally sealed solid state operation Monitoring Vibrating Screens For: * Slowdown * Stoppage * Breakage * Irregular Vibration •‘V’- Belts Damage Used with SR4000 Series speed relays or PLC, gives an alarm indication of screen problems, stops screen drive motor and/or stops infeed conveyor.

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

AUE 400

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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

Typical connection examples

Product Data sheets

10

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.

2.

3.

Select a suitable shaft to install the ‘Rotech’ unit to.

Use a 5mm drill to drill a pilot hole to a depth of 25mm into the centre of the end of the shaft.

Use a 10mm drill to open the hole to the required tapping size.

IMPORTANT Take care that the shaft is drilled centrally.

4.

5.

6.

Tap the 10mm X 25mm deep hole 12mm x 1-5.

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.

Bolt the flexible securing strap to any convenient part of the machine frame work

22

75

65

5

Securing bolt 10mm or 12mm

132 2 off M8 X 12

30

10

25

Flexible Liquid tight conduit

Flexible retaining Strap 400mm long

16mm DIA X 900mm long C/W – 20mm threaded Gland termination

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‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

5

Product Information

Commissioning & Testing

Monitoring the world since 1983

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End of Shaft Mounted Encoders Local Junction Box

Rotech motion sensor end of shaft mounting type To drive control panel Cable screened / shielded or wire armoured Securely attach retaining strap to machine framework.

Allow for movement!

Flexible Conduit

Installation 1. Drill & tap end of shaft to be monitored (refer to “Mag-con” data sheet for magnetic connector usage) 2. Remove rear cover plate from Rotech 3. 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 Rotech 5. If fitted - secure flexible restraining strap to convenient point on machine 6. Cable as per drawing above 7. Refer to appropriate Rotech data sheet for output type connections Commissioning & testing Important All wiring must be in accordance with local and national electrical codes and should only be undertaken by an experienced and professional Qualified 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 connections Voltmeter should indicate D.C. Supply voltage of between 10 and 30vdc Now Connect the voltmeter between the black and blue connections.

Rotate Rotech unit very slowly, voltmeter should indicate on/off pulses between 0vdc and the nominal Supply 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 circuit rotate 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.

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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 control panel is 1000 yards.

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

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

5. Alternative Installation An alternative method of installation is to house the Control Module/Speed Relay etc. in a slightly larger terminal box.

A mains signal (typically 110Vac) can then be switched on by the control module and then routed via 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 options available.

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.

? s s e L g n i h t y n A t p e c c A Why

8

Product Codes ROTECH FOR RELIABILITY!

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Monitoring the world since 1983

(1)

Typical Example:

(2)

(3)

(4)

Codes Explanation

(5)

AE – 60 – E2 – HD – HS

(1) Housing Type AE = Aluminium Housing (1000,2000 Series) – End of shaft mounting PE = Polypropylene Housing (4000 Series) – End of shaft mounting SSE = Stainless Steel Housing (2000, 3000 Series) – End of shaft mounting WE = 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 MA E = 3 wire 10 to 30 VDC – NPN transistor/current sink E2 = 3 wire 10 to 30 VDC – PNP transistor/current source E3 = 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 Configuration EQ = 2x 3 wire - E Type (as shown above) - Quadrature Configuration E2Q = 2x 3 wire = E2 Type (as shown above) - Quadrature Configuration W = 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 Series XHD = Aluminium/ Stainless Steel Extra Heavy Duty 3000 Series (5) Variations on Standard Units HS – High Speed Operation = Excess of 1000 RPM No Code (blank) 100 125 150 -40

= -25°C to +70°C = -25°C to +100°C = -25°C to +125°C = -25°C to +150°C = - 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 Connector RS40 = 4 pin ‘Brad Harrison’ Electrical Connector S = Special Bespoke Customer Requirements (refer to Rotech systems).

9

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Electrical Output Signal Configuration Product type – Output type dependant upon chosen pulse rate Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown ATEX

Max frequency = 2000Hz

SSE 2000/3000 Blue Type E (N.P.N) Current sink

Brown

10-30Vdc

Black

AE 1000

Max frequency = 600Hz

Blue

Type E2 (P.N.P) Current source

Brown

10-30Vdc

Black

AE 2000

Max frequency = 600Hz

Blue Brown

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

Black

Max frequency = 1000Hz

Blue

AE 3000

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source

PNP

Brown

L+

Load Blue

NPN

L-

Max frequency = 1300Hz

Brown

L+

Load

PE 4000

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

L-

Brown

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

Blue Load

Brown

WE 5000

Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Black Blue Brown Black Blue

Red

PWE 6000

Type E3 Q (Quadrature) 10-30Vdc

+ -

A Max frequency = 600Hz B CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

+ VE Supply

White

A

Green

B

Black

- VE Supply

Screen (Ground)

10

+

Channel “A” Channel “B”

Product Information

AE 1000 Series

ROTECH FOR RELIABILITY!

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Aluminium Body e s s?

L g in h t y n A t p e c Why Ac Standard Duty – End of Shaft

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

• Shaft stopped

• Distance

• Underspeed

• Direction

• Overspeed

• Belt slip

• 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

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

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Dimensions and Installation Information 18

76

43

Shown in millimetres

17

Securing bolt 10mm or 12mm

132 2 off M8 X 12

25 30

10

Flexible Liquid tight conduit 16mm DIA X 900mm long

Flexible retaining Strap 400mm long

C/W – 20mm threaded Gland termination

Electrical Outputs

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

+ + -

A B

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Product Information ROTECH FOR RELIABILITY!

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AE 2000 Series Aluminium Body Heavy Duty – End of Shaft

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.

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

FOR MONITORING: • Speed

• Shaft stopped

• Distance

• Underspeed

• Direction

• Overspeed

• Belt slip

• 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

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

www.rotechsystems.co.uk

Dimensions and Installation Information 75

65

22

Shown in millimetres

5

Securing bolt 10mm or 12mm

132 2 off M8 X 12

30

25

10

Flexible Liquid tight conduit 16mm DIA X 900mm long

Flexible retaining Strap 400mm long

C/W – 20mm threaded

Electrical Outputs

Gland termination

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

+ + -

A B

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Product Information

AE 3000 Series

ROTECH FOR RELIABILITY!

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Aluminium Body e s s?

L g in h t y n A t p e c Why Ac Extra Heavy Duty – End of Shaft

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 finish Designed 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 A wide range of number of pulses per revolution are available together with AC and DC electrical outputs FOR MONITORING: • Speed

• Shaft stopped

• Distance

• Underspeed

• Direction

• Overspeed

• Belt slip

• Safety guards interlocking

FEATURES: •Totally self contained (no guards required) •Maintenance free for maximum reliability •1 to 1000 pulses per revolution

SPRING LOADED SHAFT SEAL + RE-CHARGEABLE GREASE CHAMBER + SPRING LOADED SHAFT SEAL =

•Environment ingress‐IP67 •‐25 to +70, 100, 125, 150 deg Celsius versions available

TOTAL PROTECTION

• ATEX

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

www.rotechsystems.co.uk

Dimensions and Installation Information 19 7

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

82

75

Shown in millimetres

40

132

1 12mm Spring washer 2 12mm x 65 socket cap bolt 3 2 off ‘0’ ring seals 4 2 off grease seals 5 6 off M4 x 16mm socket cap bolts 30 6 Rear end cap 7 2 off heavy duty bearings 8 Grease chamber 9 Rotor Disc 10 10 Grease nipple 11 Seals protector Flexible retaining

25

2 Off M8 X 12 Flexible liquid tight conduit 16mm DIA X 900mm Long

Strap 400mm long

Electrical Outputs

C/W – 20mm threaded Gland termination

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

+ + -

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Product Information ROTECH FOR RELIABILITY!

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PE 4000 Series

Polypropylene Body Heavy Duty – End of Shaft

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

• Shaft stopped

• Distance

• Underspeed

• Direction

• Overspeed

• Belt slip

• Safety guards interlocking

FEATURES: •Low cost •Totally self contained (no guards required) •Maintenance free for maximum reliability •1 to 1000 pulses per revolution •Environment ingress‐IP66 •‐25 to +100 deg Celsius versions available • ATEX

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

www.rotechsystems.co.uk

Dimensions and Installation Information Shown in millimetres

6 off Plastite self Threading screws (cover removable)

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

10 Flexible liquid tight conduit 16mm DIA X 900mm Long C/W – 20mm threaded Gland termination

Electrical Outputs

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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SS 4000 Series

Polypropylene 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

• Shaft stopped

• Distance

• Underspeed

• Direction

• Overspeed

• Belt slip

• Safety guards interlocking

FEATURES: •AC/DC Supply voltages •Transistor/Relay outputs •1 to 40 pulses per revolution •Totally self contained (no guards required) •Maintenance free for maximum reliability •Environment ingress‐IP66 •‐25 to +100 deg Celsius versions available ATEX

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders

IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

www.rotechsystems.co.uk

Dimensions and Installation Information Internal View (Cover removed)

Shown in millimetres 6 off Plastite self Threading screws

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

Speed control adjustment

Flexible liquid tight conduit 16mm DIA X 900mm Long C/W – 20mm threaded Gland termination

Electrical Outputs

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

+

Brown

6 VDC or 12 VDC or 24 VDC

Output Black

Relay Output

+ Transistor Output

Blue

Output

-

Brown

10 to 30 VDC or 5 to 15 VDC

Black

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

Blue

Red Live Black Neutral Speed switch Output cable

Green N.O. Orange Common White N.C.

Supply 120/240 VAC 50/60 Hz

Output relay S.P.C.O Rated 230V 2 Amp

IMPORTANT Health and safety Rotech SS4000 series speed switches These units must only be installed and commissioned by qualified and experienced personnel.

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

If units are installed inside machine guards or in a position that could expose personnel to any danger, they should be set up and adjusted on a separate variable speed drive in a safe area, workshop, etc.

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information

SSE 2000 Series

ROTECH FOR RELIABILITY!

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Stainless Steel Body e s s?

L g in h t y n A t p e c Why Ac 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.

For Monitoring

SSE STAINLESS STEEL BODY

• Speed

• Shaft stopped

• Distance

• Underspeed

•Direction

• Overspeed

• Belt slip

• Safety guards interlocking

Product Features •Stainless steel 304/316 solid body housing •Totally self contained (no guards required) •Maintenance free for maximum reliability •1 to 1000 pulses per revolution •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 • ATEX

MAG‐CON MAGNETIC CONNECTOR For quick and easy installation of Rotech shaft mounted sensors & encoders IMPORTANT NOTE: MAXIMUM OPERATING SPEED IS 300RPM RECOMMENDED MINIMUM SHAFT DIAMETER FOR FITTING=35MM

www.rotechsystems.co.uk

Dimensions and Installation Information 7 22

Shown in millimetres

65

75

Type SSE stainless steel Body material Fixing – end of shaft 12mm Fixing bolt (10mm/16mm Optional)

M12 (standard) – ½”, 5/8” UNC, M16 optional Sealed for life – Steel – 6205 – 2RS (Optional) – Stainless steel -Polymer moulded oil

Bearings 140

30

304/316 stainless steel

Maximum operating speed

10,000 RPM

Temperature

-25°C to +70,100,125,150°C

35

10

Ingress rating Flexible liquid tight conduit 16mm DIA X 900mm Long C/W – 20mm threaded Gland termination

Flexible retaining Strap 400mm long

Electrical outputs

IP67 See table below

Electrical Outputs

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information

WE 5000 Series

ROTECH FOR RELIABILITY!

ess? Conveyor Belt Wheel Sensor L g in h t y n A t p e c Why Ac Utilising AE series sensors

Monitoring the world since 1983

For monitoring belt speed, slip & distance measurement Tough, robust and easily installed, units are designed for long and durable service in the harshest of environments.

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

•Belt Weighers •Distance/length measurement

FEATURES: •Totally enclosed & self contained trailing arm running on return side of conveyor belt •Maintenance free for maximum reliability •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 • ATEX

www.rotechsystems.co.uk

Dimensions and Installation Information Shown in millimetres

2 M10 fixing holes 580 200

Pivot bracket

110 150

Electrical Outputs

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information ROTECH FOR RELIABILITY!

PWE 6000 Series ?

ess Conveyor Belt Wheel Sensor L g in h t y n A t p e c Why Ac Utilising PE4000 Series Sensors

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For monitoring belt speed, slip & distance measurement Tough, robust and easily installed, units are designed for long and durable service in the harshest of environments.

For monitoring: •Belt speed •Belt Weighers •Distance/length measurement •Belt slip •Belt stopped

FEATURES: •Totally enclosed & self contained trailing arm running on return side of conveyor belt •Maintenance free for maximum reliability •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 • ATEX

www.rotechsystems.co.uk

Dimensions and Installation Information Shown in millimetres

580 200

2 M10 fixing holes

Solid rubber wheel Pivot bracket

160

175 135 Centre Flexible liquid tight conduit 16mm DIA x 900mm long C/w - 20mm threaded Gland termination

PE4000 series unit

Electrical Outputs

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) Type E (N.P.N) Current sink

10-30Vdc

Type E2 (P.N.P) Current source

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

Brown

Brown

Brown

Black

Black

Black

Blue

Blue

Blue

Max frequency = 600Hz

Max frequency = 600Hz

Type E4 (N.P.N + P.N.P.- 2 Wire) 10-30Vdc Bi-polar – Current sink/source Brown PNP

10-30Vdc

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

Brown

Type N (Namur) 8-2 Vdc (1KΩ) Intrinsically safe circuits 7.5 – 30 Vdc when used outside The hazardous areas

Brown

L+

Load Blue

Max frequency = 1000Hz

Brown L-

Blue

Load

ATEX

L+

Load

NPN Blue

Max frequency = 1300Hz

L-

CH “A” Leads CH “B” for clockwise rotation viewed from shaft end of encoder

Type E3 Q (Quadrature) 10-30Vdc Red + VE Supply White

A

Green

B

Black

- VE Supply

Screen (Ground)

Blue

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

Max frequency = 2000Hz Type E2 Q (Quadrature) 1 to 40 PPR inclusive

Brown Black Blue

Channel “A”

Brown Black Blue

Channel “B”

Max frequency = 600Hz

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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VS 4000 Series Screen 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

•Irregular vibration

•Slowdown

•Blockage

•Stoppage

•Drive belt slip

Features: •Totally self contained (no guards required) •Maintenance free for maximum Reliability •Dc output ‐ plc/speed relay compatible •Environment ingress ‐ IP67 •Up to 2000 VPM •‐25 to + 70 °C

www.rotechsystems.co.uk

Dimensions and Installation Information Shown in millimetres

80

To control panel

46

70

40

Local junction box

Cable screened/shielded or wire armoured Leave conduit loop to allow for movement of screen Angled sensor bracket bolted or welded to screen sideplate.

Flexible conduit 1.5 Metres

IMPORTANT Align sensor bracket in main direction of screen movement

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

Electrical connections

Brown

Supply 10 to 30 Vdc Black

Blue

Output type E3 (PNP + NPN)

Order Code:

Max frequency = 1000Hz

AV – 1 – E3 – HD

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information ROTECH FOR RELIABILITY!

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VS 4000 Series Screen Vibration Sensor Application Information

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

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

Variations in feed rates and composition of the material being fed to a screen (wet, sticky, etc.) can however in some circumstances 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 very quickly.

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 overload increases 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 almost instantaneously.

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.

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Product Information

VS 4000 Series

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Screen Vibration Sensor Application information

ROTECH VS 4000 SERIES VIBRATION SENSOR AV – 1 – E3 – HD

P.L.C PULSE OUTPUT 1 PULSE PER THROW MARK/SPACE-EQUAL

PULSED INPUT DIRECT TO PLC INPUT = PULSES TYPE E3 (N.P.N + P.N.P – 3 WIRE) 10-30Vdc BI-POLAR – CURRENT SINK/SOURCE

VIBRATION RELAY MODULE – SERIES SR 4000 c

. ..

nc no

INPUT = VOLT FREE RELAY CONTACT ON/OFF

CONVERTS PULSES INTO ON/OFF SIGNAL VIA RELAY OUTPUT CONTACTS

4 -20 mA CONVERTOR MODULE 20 mA 4

INPUT = ANALOGUE 4 – 20mA

CONVERTS INPUT PULSES INTO 4-20mA ANALOGUE OUTPUT SIGNAL

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Product Information ROTECH FOR RELIABILITY!

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Mag ‐ Con

Magnetic Connector

For quick and easy installation of Rotech shaft encoders & speedswitches No 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 unit To the mag-con 4. It is recommended that a film of silicon grease is applied to the end of the shaft before Installing 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.M Recommended minimum shaft diameter for fitting = 35mm

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Product Information ROTECH FOR RELIABILITY!

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Speed Relay’s

Selection Information Safety 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 equipment Heavy duty motion sensors/encoders together with speed relays For detecting:-

•SPEED •DIRECTION •DISTANCE •SHAFT STOPPED

•UNDERSPEED •OVERSPEED •BELT SLIP •VIBRATION

www.rotechsystems.co.uk

Product Descriptions Speed Relays Rotech Type AUE400 & SR4000 Rotech offers 2 types of speed relay modules, in the form of:Type AUE 400 Speed Relay – Advanced Series This 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 Series This 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 revolution dependant 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 E or type W motion sensor output e.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.

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information ROTECH FOR RELIABILITY!

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SR 4000 Series Speed 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.

EU directives

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.

www.rotechsystems.co.uk

Dimensions and Installation Information Shown in millimetres

Connections – DC 2/3 wire sensors

Height = 115

76

1 2 3

Neutral 110/120V 50/60Hz 220/240V 50/60Hz

4 5 6

N.O. Common N.C.

7 8 9

0VDC Input +12 VDC

10 Range 11 Links 12

AC mains power supply

1 12/24VDC-Positive 2 2/24VDC-Negative DC Power supply

Output relay rated 5A @ 250VAC / 30VDC Blue Brown

Blue 2 Wire Black Sensors Brown

3 Wire Sensors

No links = 0 to 10RPM Link 10 to 11 = 0 to 100RPM Link 10 to 12 = 0 to 1000RPM

Connections – AC 2 wire ‘W’ type sensors only

50

1 2 3

Neutral AC mains power 110/120V 50/60Hz supply Input – AC ‘W’ type 2 wire sensor

4 5 6

N.O. Common N.C.

7 8 9

0VDC Input +12 VDC

10 Range 11 Links 12

Brown Blue

Rotech motion sensor

Output relay rated 5A @ 250VAC / 30VDC

No links = 0 to 10RPM Link 10 to 11 = 0 to 100RPM Link 10 to 12 = 0 to 1000RPM

Typical installation shown for 110/120 V AC supply

AC-2 wire ‘W’ type sensor connections To Rotech Shaft motion sensors, wheel motion sensors, vibration or proximity sensors.

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

Mounting: DIN 35x7.5mm Rail Environment Ingress: IP50 Temperature: -10°C to +70°C

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

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Product Information

Automatic Start Delay

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SR 4000 Speed Relay

The following option can be included to any SR 4000 type unit. please refer to ‘Rotech systems’ for details 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 speed relay will then remain energised.

If the drive does not reach its normal running speed by the end of the 20 seconds the speed 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 below 1 RPM and remains below 1 RPM for a period of 20 seconds.

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Product Information

Commissioning & Testing

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SR 4000 Speed Relay

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.

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, etc 1.2 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 the SR 4000 is connected as in 1.2 above and the time taken to reach normal, running speed is 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.

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Product Information

Testing & Troubleshooting

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SR 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 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 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 control circuit are correct.

6. Testing the SR 4000 Speed Relay 6.1 NON– W Types (DC Sensors) Only Disconnect shaft encoder connections to terminals 7, 8 & 9 Disconnect any speed range links to terminals 10, 11 & 12 Connect a small switch or push button between terminals 8 & 9 Simulate 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 take several seconds) 6.2 “W” Types (AC Sensors) Disconnect shaft encoder connections to terminals 1 or 2 & 3 Disconnect any speed range links to terminals 10,11 & 12 Connect a small, insulated switch or push button between terminals 2 & 3 Simulate 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 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.

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Product Information ROTECH FOR RELIABILITY!

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e s s?

L g in h t y n A t p e c Why Ac

AUE 400 Series Speed Relay Advanced Series

For Rotation Monitoring 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.

EU directives

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.

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Dimensions and Installation Information Shown in millimetres

55

1 2 3 4 5 6 7 8

AC Supply AC Supply Neutral N.O. Common N.C. 10 Sec Delay

220/240V

9

A.C. Input

10 11

0-100 RPM 0-1000 RPM

Link to terminal 14 for speed range Required – no links – 0 to 10 RPM

12 13 14

0VDC Signal +12VDC

Blue Brown

15 16

+ -

110/120V 50/60Hz 50/60Hz Output relay rated 250VAC/30VDC @5a

Brown

Motion sensor input type W only

Link for start up delay Blue

2 Wire Type N

Blue Black Brown

3 wire sensors Type E,E2&E3

Opto – isolated repeat output1.2V/80 m A

Note: typical part no = AUE 416 AUE= speed relay-advanced series 4400 series 16calibrated for use with 16 pulse / rev motion sensor

75

The 10 second start delay operates every time an external switch or contact connects terminal 7 & 8 Note: start delay

Typical installation shown for 110/120 V AC supply

Alternatively with a fixed link between terminals 7 & 8, the 10 second delay will operate every time power is applied to the module

See Note 1

Note 1: Link for start up delay Note 2: Link for required speed Range Note 3: Repeat output

C1

See Note 2

Mounting Environment Ingress Temperature

-

DIN 35 x 7.5 mm RAIL IP 50 -10°C to +70°C

Rotech motion sensor

See Note 3

Repeat Output Facility

Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

Monitoring the world since 1983

Product Information

Commissioning & Testing

Monitoring the world since 1983

g L es s? in th y n A t p e c c A Why

AUE 400 Speed Relay

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.

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 be combined, 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 obtain multiple 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 400 speed 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 speed decreases below that set on the potentiometer, the “relay on” indicator extinguishes.

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Product Information

Testing & Troubleshooting

g L es s? in th y n A t p e c c A Why

Monitoring the world since 1983

AUE 400 Speed Relay

1. Important - all connections and disconnections 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 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 illuminated then speed range selected is too 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 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 & 9 Disconnect any speed range links to terminals 10 & 11.

Connect a small insulated switch or push button between terminals 1 or 2 & 9 Simulate 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.

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Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: sales@rotechsystems.co.uk

Monitoring the world since 1983