S&S SYSTEMS

S&S SYSTEMS 303, Markaz Apartments, Srinagar Colony P.O, HYDERABAD - 500 073.

Manufacturers of Process Instruments & Systems

SPEED TRANSMITTERS & SIGNAL CONVERTERS AND REVERSE ROTATION MONITORING SYSTEMS

040 23748721, 98491 35071, snssystems@rediffmail.com

INSTALLATION AND OPERATING MANUAL

IOM - E 010 NOVEMBER, 1999 ISSUE 1

REVERSE ROTATION MONITORING SYSTEM

( SPLIT VERSION )

ADVICE

This publication should be read in its entirety before performing any operation. Failure to understand and

follow these instructions could result in serious personal injury and / or damage to the equipment.

In case this equipment needs repair or adjustment, contact S&S SYSTEMS. It is important that servicing be performed only by trained and qualified service personnel. S&S SYSTEMS will not be held responsible, if the equipment is tampered by unauthorized personnel.

GUARANTY

If at any time within one year of shipment, but not thereafter, it is proved that any part of the equipment furnished by us was defective when shipped by us, we will repair or replace the same free of charge. Notice of this claim must be made to us within one year after delivery. Our liability is limited to replacement of such defective parts or equipment. There are no guarantees or warranties expressed or implied other than those herein specifically mentioned.

CAUTION

This instrument contains electronic components that are susceptible for damage by static electricity. Proper handling procedures must be observed during the removal, installation, or other handling of internal circuit boards or devices.

Page : 1 of 16

COMMITTED TO PROVIDE COMPREHENSIVE SERVICE TO INDUSTRY THROUGH CONTINUOUS IMPROVEMENT IN QUALITY.

CONTENTS

1. INTRODUCTION 3 PURPOSE 3 DESCRIPTION .. 3 PRINCIPLE OF OPERATION 3 SPECIFICATONS 4

2.

INSTALLATION

4

GENERAL 4 RECEIPT OF EQUIPMENT 4 INSTALLATION . 4 START UP ADJUSTMENTS 6

3.

OPERATION

8

4.

MAINTENANCE ..

11

LISTS AND ILLUSTRATIONS

1. CONNETION SCHEMATIC DIAGRAM .. 6 2. BLOCK DIAGRAM, RPM INDICATOR . 8 3. BLOCK DIAGRAM, DIRECTION MONITOR 9 4. FUNCTIONAL BLOCK SCHEMATIC DIAGRAM . 10 5. RPM INDICATOR PCB ASSEMBLY 11 6. DIRECTION MONITOR PCB ASSEMBLY ... 12 7. DIMENSIONS OF ENCLOSURES 13 9. PROXIMITY SWITCH DIMENSIONS . 13

10. PARTS LIST 14 11. RECOMMENDED SPARES 14 12. TROUBLE SHOOTING RPM INDICATOR .. 15 13. TROUBLE SHOOTING DIRECTION MONITOR 15 14. WIRING SPLIT VERSION RRMS .. 16

1. INTRODUCTION 1.1 PURPOSE

Instructions for operation and maintenance in this manual apply to Models RRMS SRI 01 W, RPM INDICATOR and RRMS SDM 01 W, DIRECTION MONITOR, members of REVERSE ROTATION MONITORING SYSTEM, in split version.

1.2 DESCRIPTION

RPM INDICATOR indicate s RPM of any rotating object, with a transmission output of 4 20 mA DC. It also contains a Power Failure warning relay. DIRECTION MONITOR indicates direction of rotation and has relay outputs corresponding to the direction, enabling a control action to be taken on reversal of direction.

Both are housed in separate Weather Proof Enclosures, suitable for wall or panel mounting . The Protection

is IP 65, as per IEC 529. The enclosure s are approved by ERTL (WEST), ERTL, STQC DIRECTORATE.

Each unit has a sensing part and a signal conditioning part. RPM INDICATOR has one sensor and DIRECTION MONITOR has two sensors. The sensors are two -wire intrinsically safe NAMUR type Proximity Switches . Hence the Switches can be installed in hazardous areas also , with suitable isolators.

The signal conditioning part in RPM INDICATOR processes signals from the sensor, to indicate RPM and provide 4 - 20 mA DC output for transmission. Power Failure wa rning is given by a relay. An Amber LED indicates proper functioning of the RPM measuring sensor, identified as A.

The signal conditioning part in DIRECTION MONITOR processes signals from the sensors, to indicate the direction of rotation, forward or reverse, on green and red LEDs respectively. In addition, relay contacts, changing as per the direction of rotation are provided. They can be used to close discharge valves, start AOPs and activate alarms in control room and field on reverse rotation. Thus Reverse rotation can be prevented and the damage to the bearings can be minimized. Further, proper functioning of the direction sensing switches, identified as B and C is indicated by separate Green and Red LEDs respectively.

At power on, default direction indication may be either forward or reverse. On rotation, the system latches to the appropriate direction. At zero speed, the preceding direction is indicated as a precaution .

1.3 PRINCIPLE OF OPERATION

RPM INDICATOR

The Proximity Switch, A, generates a pulse, for every target it senses. Depending on the speed, a frequency proportional to RPM is obtained, which is converted into a DC voltage and a DC current. The DC voltage drives a 4 Digit LED Display, indicating RPM . The current is transmitted out . Span and zero trimpots facilitate calibration to the desired range of RPM.

DIRECTION MONITOR

First pulse detection is used to sense the direction of rotation. The two Switches B and C are mounted adjacent to each other so that the influence of a target on them is displaced by 90 . The first pulse resets the triggering stages , no matter from which sensor. The second pulse is evaluated in the subsequent switching amplifiers, activating output stages based on direction of rotation, driving two DPDT relays , giving out four sets of change over contacts corresponding to the direction of rotation.

1.4 SPECIFICATIONS

ITEM RPM INDICATOR DIRECTION MONITOR

POWER SUPPLY 230 / 110 V AC OR 24 V DC

UNINTERRUPTED SOURCE (TO BE INITIALLY SPECIFIED)

230 / 110 V AC OR 24 V DC

UNINTERRUPTED SOURCE (TO BE INITIALLY SPECIFIED)

INPUT SIGNAL Pulses from Proximity Switch Pulses from two Proximity Switches

LOCAL INDICATIONS 1. RPM on 4 Digit Display 2. Switch Status on Amber LED

1. Direction of Rotation on LEDs Green Forward, Red Reverse

2.Switch Status on LEDs Green B, Red C

OUTPUT SIGNALS 1. 4-20 mA DC proportional to RPM (In either directions) , Load - 600

2. Power Failure Relay, DPDT, Contact Rating : 5A, Potential free

4 sets of Relay Contacts for direction of rotation Contact Rating : 5A, Potential free Max. Voltage : 230 V AC/110 V DC

RPM RANGE 0-20,000 RPM Max., ( 4-20 ma DC calibrated to any range

SIGNAL CONDITIONING UNITS

They should be mounted close to the rotating mechanism. The following precautions are to be taken.

1. The targets on the rotating objects must be well within the sensing ranges of the Proximity Switches. 2. Connections from B and C, must be done carefully so that they are not interchanged. 3. Width of the target should be double the width of the Proximity Switch selected. 4. Cables should be run through conduits, to avoid physical damage. 5. Polarity of the switches should be maintained as reversal may damage the instruments.

TERMINATION DETAILS

Chassis Plate, on which the PCBs are mounted, has a sticker containing this information.

PROXIMITY SWITCH TERMINATIONS IN : Brown

5 mm Min

CONNECTION SCHEMATIC DIAGRAM

RADIAL MOUNTING OF PROXIMITY SWITCHES - EXAMPLE

B Forward

C Reverse

Min. 2 mm DIRECTION MONITOR

B C RRMS SDM 01 W

ROTATING OBJECT

3.5 mm gap POWER IN DIRECTION OUTPUTS

.

A

RPM INDICATOR

RRMS SRI 01 W

.

POWER FAIL OUTPUTS

POWER IN 4 20 mA DC OUTPUT

AXIAL MOUNTING OF PROXIMITY SWITCHES - EXAMPLE

Min. 2.5mm C Max. 4.0mm TO DIRECTION MONITOR

B ROTATING OBJECT

TARGETS, 2 Nos.

0.

4.0 mm Max

A

TO RPM INDICATOR

Targets could be projections on wheel, flat metallic stri ps mounted on bolts or even the bolts themselves.

START UP ADJUSTMENTS EQUIPMENT REQURED: 1. DIGITAL MULTIMET ER, 2. TACHOMETER

RPM INDICATOR

This is set to the range specified in the order. If there is any difference between the RPM indicated and the actual RPM, it can be adjusted using the two sets of span & zero trimpots on the Frequency to Current Converter and Indicator portions of the Signal Processor PCB.

Switch on power to the instrument and wait for 15 minutes. It should read 0 U/Min RPM. Measure the current output. It should be 4 mA DC. If it is not, adjust the ZERO trimpot[102] of the F/I Converter portion . Start the coupling and run at its full speed. Confirm that the speed is steady, with a tachometer. At Full Speed, the current should be 20 mA DC. If it is not, adjust the SPAN trimpot[104] of the F/I Converter portion . Stop the coupling. If the current is not 4 mA DC, adjust the ZERO trimpot. Again, run the coupling at its full speed and measure the current. If it is not 20 mA DC, adjust the SPAN trimpot. Repeat these steps till there is no need of adjustments. If it is not possible to run at full speed, any speed above half the full speed may be used. Desired current at this random speed may be calculated as following. Suppose the speed as indicated by the tachometer is S. Let the Full Scale Speed be F.

Desired Current output at S = (S/F) 16 + 4 mA DC

If F = 7,500 RPM, S = 5,500 RPM Desired Current at S= (5,500/7,500)16 + 4 15.7333 = mA DC

VERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT AVAILABLE

For this, a frequency measuring millimeter is required. The RPM INDICATOR converts input frequency into proportional DC Voltage and Current. The input frequency depends on speed. So, RPM can be calculated from input frequency. The above procedure can then be followed to tally current and indication. Let F be 7,500 RPM. Let there be 6 Targets. The Switch generates one pulse for every target. For 6 Targets, it generates 6 pulses per revolut ion. For 7,500 Revolut ions, 7,5006=45,000 pulse are

Generated. If full speed is 7,500 RPM, 45,000 pulses are generated per Minute. Pulses Per Minute 60 = Pulses Per Second, the Input Frequency. So, Input Frequency corresponding to 6,000 RPM is given by 45,000 60 = 750 Hz. By measuring the Input Frequency, speed can be calculated based on this relation.

If the Input Frequency thus measured is 550 Hz, then the Speed is ( 550 750) 7,500 = 5,500 RPM . Further calculations of desired current for this speed of 5,500 RPM can be done as outlined earlier.

RPM from Input Frequency = (Input Frequency Full Scale F frequency) Full Scale RPM

Full Scale Frequency = (Full Scale RPM No. of Targets on Pole wheel) 60

actual, simply interchange the connections of B and C. At Power On, as default, red or green LED corresponding to Reverse or Forward direction may glow. Rotate the shaft till targets come under the Switches. Make sure that green LED for B and red LED for C glow respectively. Adjust the gap between targets and switches so that the respective LEDs just start to glow. This maximizes the gap ensuring proper sensing. The switches should be tightened here. Then rotate the shaft in forward (normal) direction. Green LED glows when targets pass the switches and remains ON until the direction is normal. Rotate the shaft in reverse direction. Red LED glows and remains ON until the direction is reverse.

3. OPERATION

Dividing the total system into simple functional blocks explains the operation.

RPM INDICATOR

1. Power Supply and Power Failure Relay Drive 2. RPM measurement and transmission 3. Indicator

BLOCK DIAGRAM OF RPM INDICATOR

MAINS POWER INPUT FROM PROXIMITY

230 V AC SWITCH A

1 2

POWER SUPPLY DC POWER RPM MEASUREMENT

AND AND POWER FAIL RELAY DRIVE TRANSMISSION

POWER FAIL

VOLTAGE

RELAY OUTPUTS OUTPUT TO DRIVE

CURRENT OUTPUT

INDICATOR 4 20 mA DC

3 INDICATOR (4 DIGIT LED)

SHOWING RPM

1. POWER SUPPLY & POWER FAILURE RELAY DRIVE BLOCK

Mains power is converted into different DC voltages to operate other blocks. The AC Voltage is stepped down, rectified and filtered. The DC Voltages obtained are regulated. 12 V DC energizes a DPDT Relay. Short between NC & COM indicates power fail ure. A gets power from this block.

2. RPM MEASUREMENT AND TRANSMISSION BLOCK

This receives signal from A . Every target induces a pulse in the Switch. For 8 targets, 8 pulses are induced per revolution. If the Full Scale RPM is 6,000 , number of pulses induced per minute is

6,0008=48,000. Converting into Frequency, we get 48,000 60 = 800 Pulses Per Second or Hz. This Frequency is converted into 0.4 -2.0 V DC and 4-20 mA DC. Current is transmitted. DC Voltage drives local indicator. Span/Zero trimpots facilitate Calibration. Proper functioning of A , is indicated by an Amber LED.

3. INDICATOR BLOCK

This contains a 4 Digit, Seven Segment LED Display circuit, on which the RPM is displayed. 0.4 - 2.0 V

DC from the previous block is input to this. Span /Zero trimpots permit adjustment of RPM.

DIRECTION MONITOR

1. Power Supply Block 2. Direction Sensing and Relay Drive Block

BLOCK DIAGRAM OF DIRECTION MONITOR

MAINS POWER

230 V AC

1 POWER SUPPLY

DC POWER INPUT FROM PROXIMITY SWITCH B

INPUT FROM PROXIMITY SWITCH C

2 DIRECTION SENSING

AND

DIRECTION RELAY DRIVE

DIRECTION RELAY OUTPUTS

1. POWER SUPPLY

This receives mains power and converts it into different DC voltages to operate other functional blocks. The AC Voltage is stepped down, rectified and filtered. The DC Voltages thus obtained are regulated to give stable DC voltages. This also gives Power to Proximity Switches, B and C.

2. DIRECTION SENSING AND RELAY DRIVE BLOCK This receives signals from B and C. It contains circuitry to detect and indicate the direction of rotation. There are only four possibilities for both the switches, as far as sensing the targets is concerned.

1. B sensing and C not sensing 3. B not sensing and C sensing 2. Both B and C sensing 4. Both B and C not sensing

These conditions are true for one direction. When the direction changes, the above condi tions also change accordingly. The first pulse resets the triggering stages and the second pulse is processed in the subsequent switching stages, driving Green and Red LEDs as per the sequence in which the conditions mentioned above are met. This is interp reted as either Forward or Reverse Direction. Two DPDT Relays are connected in the circuit so that they are energized when the Direction of Rotation changes from Reverse to Forward. This means that a short between NO and COM always indicates Forward Direction of Rotation and a short between NC and COM indicates Reverse Direction of Rotation. Proper functioning of the Proximity Switches B and C is indicated by Green and Red LEDs respectively. They glow for every pulse they receive from the respective switches.

FUNCTIONAL BLOCK DIAGRAM OF REVERSE ROTATION MONITORING SYSTEM

L + 12 V 5 V -5 V

DC VOLTAGE N

G

12 V

REGULATORS

POWER FAIL

RELAY CONTACTS

SENSOR A

+ Comparator F V ADC Display RPM

Indication

V I 4-20mA DC Output

+ Comparator

SENSOR B First Pulse Forward

Detection Logic

+ Comparator

SENSOR C Reverse

1 2

U2

4 . MAINTENANCE

The Reverse Rotation Monitoring System does not normally require any maintenance other than occasional

verification of its accuracy. However the following aspects should be taken c are as part of routine maintenance.

1. It should be ensured Proximity Switches have their targets well within the specified Sensing Range . 2. T here is no accumulation of dust or other metallic particles on surfaces of the Switches or the targets. 3. All the terminations are right and tight.

Verification of Accuracy can be done as outlined in the start -up adjustments .

In DIRECTON MONITOR, there is only a single PCB Assembly, designated as the Signal Processor PCB

Assembly. In RPM INDICATOR, an additional Power Supply PCB is there. The following Information and drawings are for the sake of Ide ntification of individual Components on the PCB Assemblies only and not meant for either servicing or repair. Any malfunction in the system shall be notified to the supplier for getting replacement.

Whenever the lids of the Instruments are opened, care sh ould be taken to tighten all the screws equally while putting back the lids. Cable Glands should be tightened properly after taking the cables into the Enclosures. Otherwise the Degree of Ingress Protection is affected.

RPM INDICATOR

PCB ASSEMBLY DRAWING RPM INDICATOR

U4

6 U7 U6 U5

4 5 TB1 3

U1

TB3 U3

TB2

There are six trimpots altogether. Purpose and function of each trimpot is described below.

1. Zero Adjustment Current (4 mA at 0 RPM ) 2. Span Adjustment Current (20 mA at Full Scale RPM) 3. Cut off Adjustment Display Value 4. Span Adjustment Display value 5. Zero Adjustment Display Value 6. Clock Frequenc y Adjustment

COMPONENT DESIGNATIONS AND DETAILS

TB1 : Terminal Block, 5 Position Termination Details as given below.

1 : + 5 V DC 2 : Circuit Common (Ground) 3 : < 5 V DC 4 : Switch Input + 5 : Switch Input < (Ground)

TB2 : Terminal Block, 2 Position Termination Details as given below. 1 : + 12 V DC 2 : Circuit Common (ground)

TB3 : Terminal Block, 2 Position Termination Details as given below. 1 : Current Output < 2 : Current Output +

Dot in Terminal Blocks indicates Pin No. 1 U1 U7 : ICs. The rest are Transistors, Diodes, Zeners, Capacitors, Resistors and Displays

DIRECTION MONITOR

PCB ASSEMBLY DRAWING DIRECTION MONITOR

U6 F U3 B

R U5 C

U4

BR1

K1 K2 T1

There are no adjustments. T he LED Indications are as given below.

DIRECTIONS SWITCH STATUS

FORWARD GREEN SWITCH B - GREEN REVERSE RED SWITCH C - RED

DIMENSIONS OF ENCLOSURE

All Dimensions are in mm

120 96

90

215 200 230

88

6.5, 4 Holes, for mounting

Chloroprene Round Seal

M201.5 WP IP 65 CABLE GLAND FOR OUTPUTS

M201.5 WP IP 65 M121.5 WP IP 65 CONDUIT GLANDS CABLE GLAND FOR POWER SUPPLY FOR PROXIMITY SWITCH CABLES INLET

PROXIMITY SWITCH DIMENSIONS Type : NJ 4 12 GM N

8 72

M12 1 Cable, 5 Meters Long

Brown (+), Blue () 11 Sensing Range : 4 mm

Metal Free Zone 2 Nuts, 18mm A/F, 4mm Thick

Page : 6 of 6

PARTS LIST

ITEM NO.

1.

ITEM

RPM INDICATOR

QUANTITY

1 No.

1.1 Proximity Switch Type : NJ 4 12 GM N 1 No. 1.2 RPM INDICATOR Enclosure 1 No. 1.2.1 Signal Processor PCB (RPM INDICATOR)

Diodes, Capacitors, Transistors , Resistors, ICs, 1 No. A/R

1.2.2

LED, Displays, Terminal Blocks, Wires, Trimpots Power Supply PCB

1 No.

Transformer, Diodes, Regulators, Capacitors , A/R

1.2.3 Bridge Rectifiers, Terminal Blocks, Relay Two part Terminal Strip Assy. 1 No.

1.3 Mounting Plate External 2 Nos. 1.4 Mounting Plate Internal 1 No. 1.4.1 Termination Details Sticker 1 No.

1.4.2 Serial Number Sticker 1 No. 1.4.3 M3/35 Spacer 2 Nos 1.4.4 M3/40 Spacer 2 Nos.

1.4.4 M3/6 Screw Spacer 2 Nos. 1.5 Cable Glands M20/1.5 2 Nos. 1.6 Conduit Gland M12/1.5 1 No.

1.7 Blind Plug M12/1.5 1 No. 1.8 Mounting Hard ware A/R 2. DIRECTION MONITOR 1 No.

2.1 Proximity Switches Type : NJ 4 12 GM N 2 Nos 2.2 DIRECTION MONITOR Enclosure 1 No.

2.2.1 Signal Processor PCB (Direction Monitor) Transformer, Relays, Fuse, IC Bridge Rectifiers, IC Voltage Regulators,

1 No.

2.2.2

Diodes, Capacitors, Transistors, Resistors, ICs, LEDs, Terminal Blocks, Wires Two part Terminal Strip Assy.

A/R

1 No.

2.3 Mounting Plate External 2 Nos. 2.4 Mounting Plate Assembly Internal 1 No. 2.4.1 Termination Details Sticker 1 No.

2.4.2 Serial Number Sticker 1 No. 2.4.3 M3/40 Spacer 2 Nos. 2.4.4 M3/45 Spacer 2 Nos.

2.5 Cable Glands M20/1.5 2 Nos. 2.6 Conduit Gland M12/1.5 2 Nos.

2.7 Mounting Hard ware A/R

RECOMMENDED SPARES

PROXIMITY SWITCHES 1 Set (3Nos.) RPM INDICATOR UNIT 1 No. DIRECTION MONITOR UNIT 1 No.

TROUBLE SHOOTING RPM INDICATOR

ITEM PROBLEM CAUSE REMEDY

1. None of the LEDs glow 1. AC Power input may not be O K. 2. 12 VDC not coming 3. Correct the terminations.

Check with new sensor

2. No Indication of Speed 1. Proximity Switches are not OK 2. 3mmGap between Switches and

Targets.

Check with new Switches Adjust the gap between 1 -3mm.

Correct the terminations.

3. Speed Indication does

Not respond to change in actual speed.

1. Proximity Switches are not OK 2. 3 mm gap between sensor and target

3. Termination of Brown at < and Blue at + ( Switch wires )

4. 12 V DC not coming 5.

Check with new Switches Adjust the gap between 1 -3mm.

Correct the terminations.

Replace Power Supply PCB.

Replace 7812 regulator

4. Indication is dull 12 V DC not coming from Regulator Replace 7812 regulator

5. Current output not coming .

Frequency to voltage converter ic might be bad.

Replace LM2917 IC[U1] in bottom board

NOTE: If any other words in display please once off and on.

12 V DC most important to total instrument.

If have any problem in instrument, Please check 12 V DC with multimeter in at TB1

In 12 and 13 pins.

CUSTOMER ORDER NUMBER RATED RPM CALIBRATED RANGE

VOITH TURBO PRIVATE LIMITED.

POP - 05 - 1132

DATE : 18 - 05 - 2005 0 6,000 RPM 0 6,000 RPM

4 20 mA DC

SS WE RRMS SV 01

L 240 V AC N POWER G SUPPLY

1 2 3 1 2 3

9 15 12

8 14 11

DIRECTION 10 DIRECTION 16 DIRECTION RPM 13 POWER FAIL OUTPUTS MONITOR OUTPUTS INDICATOR OUTPUTS

12 18 15

11 17 14

13 19 16

4 5 6 7 5 6 8 9

Bn Bu Bn Bu Bn Bu

+ + + +

POLE WHEEL

*

A 4 20 mA DC B C OUTPUT

NOTES : 1. MODEL NUMBER RPM INDICATOR : RRMS SRI 01 W DIRECTION MONITOR : RRMS SDM 01 W

2. POWER SUPPLY : 230 V AC, 50 Hz 5%, FROM UPS 3. PROXIMITY SWITCHES DESIGNAT ION : A RPM, B & C DIRECTION

SWITCHES B & C SHOULD BE INSTALLED ADJACENT. 4. DIRECTION SIGNAL CONTACT OUTPUT : RELAYS ENERGISED FORWARD,

RELAYS DEENERGISED REVERSE 5. EXTERNAL INDICATORS WITH MARK, ARE NOT IN OUR SCOPE.

Page : 16 of 16

S&S

SYSTEMS

S&S SYSTEMS

303, Markaz Apartments, Srinagar Colony P.O,

HYDERABAD 500 073.

DRAWING TITLE

WIRING SPLIT VERSION RRMS DRAWING NUMBER : SS WE RRMS SV 01

DRAWN SRIVALLI DATE 14 01 2001

REV. 0 CHECKED SESHU DATE 15 01 2001