PPI SMART MONITOR, Operation & Maintenance Manual

Page 1: ...OPERATION MAINTENANCE SMART ROLL SMART MONITOR READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION ...

Page 2: ...14 What if the pulses are too fast for my electronics 14 Converting pulses to belt speed 14 Frequently Asked Questions 15 Appendix 17 Universal Mount Smart Roll 17 Universal Mount Smart Roll Mounting Instructions 17 Universal Mount Smart Roll Wiring 17 Universal Mount Smart Roll Diagram Parts List 18 Troughing Smart Roll 19 Troughing Smart Roll Mounting Instructions 19 Troughing Smart Roll Wiring ...

Page 3: ...D LOCATION The Smart Roll is available in 4 mounting options and can fit most locations on a conveyor 1 Clean Side Return CSR Preferred 2 Universal Mount An 11 125 long roll in a mounting bracket with two slots for mounting 3 Return Roll positions in CEMA C and D sizes Belt widths from 24 60 inches 4 Troughing Idler wing roll only positions in CEMA C and D sizes Belt widths from 24 60 inches In or...

Page 4: ... Severe roll and or belt damage may occur if mounted incorrectly Two options are shown for mounting the CSR Smart Roll Option 1 is welding the pivot shaft to the conveyor frame work and option 2 is using mounting brackets bolted to the frame work Diagrams for the pivot hinge options are shown at the end of this section Option 1 At the conveyor mounting location measure the distance between the con...

Page 5: ... aware of all site specific and industry welding requirements for an application and cannot be held liable for non compliant installations Proper weld ground location is critical to prevent damage to bearings and sensor inside the Smart Roll These components will not tolerate welding current through them and will be permanently damaged Improper ground placement will void warranty Figure 2 5 shows ...

Page 6: ...L RODS ITEM QTY DESCRIPTION PART 1 1 3 4 diameter rod TABLE 2 2 Shaft Collar SC0012S4 3 2 1 1 2 End Stand 15001 4 2 C End Clip 31790 5 2 12 x 3 8 Self Tapping Screw 31880 ASSEMBLIES WITH RODS STAINLESS STEEL ASSEMBLY PART SHAFT PART SHAFT LENGTH HC BELT WIDTH CSR 24S4 43521S4 28 625 33 0 24 CSR 30S4 43522S4 34 625 39 0 30 CSR 36S4 43523S4 40 625 45 0 36 CSR 42S4 43524S4 46 625 51 0 42 CSR 48S4 435...

Page 7: ...0 5 1 B End Clip 31800 6 1 Hex Bushing 34461 7 1 90º Elbow Conduit Access Port 34452 8 1 Strain Relief Fitting 40824 CSR SMART ROLLS ROLL Ø ASSEMBLY PART ROLL ONLY PART 5 5 SAD5CSRSB 1PL4 SAD5TE30SB 1PL4 5 5 SAD5CSRSB 2PL4 SAD5TE30SB 2PL4 5 5 SAD5CSRSB 6PL4 SAD5TE30SB 6PL4 6 5 SAD6CSRSB 1PL4 SAD6TE30SB 1PL4 6 5 SAD6CSRSB 2PL4 SAD6TE30SB 2PL4 6 5 SAD6CSRSB 6PL4 SAD6TE30SB 6PL4 2 3 4 1 5 8 7 6 4 ...

Page 8: ...ld prevent the sensor signal from reaching the Smart Monitor If flexible conduit is used then the strain relief is not needed and can be removed PPI recommends the wires or flexible conduit be routed along the side of the CSR bracket and towards the hinge point This will allow for free motion of the hinge Be sure the wires or conduit will not hinder the pivoting of the smart roll PPI is not capabl...

Page 9: ...ls of the Smart Monitor are available This section will show wiring for the 120VAC model part number 37543 Specification 37543 Smart Monitor 120VAC AC Input 120 VAC 10 W Fuse Protected 1 amp Speed Range 6 3000 pulses per minute Relay Contacts DPDT 5 amp 120VAC Safety Delay 1 second Response Time 1 second or less Additional models of the Smart Monitor are available Specifications for these are show...

Page 10: ...the next page 5 Connect Smart Roll wires to terminals 7 and 8 Polarity of the wires is not important 6 Connect the wiring for the 120 VAC to terminals 15 and 16 to power the Smart Monitor The Smart Monitor provides the power for the Smart Roll through terminals 7 and 8 7 Terminals 9 through 14 are customer contacts to be used for system control 8 Remove lockouts and apply power to the Smart Monito...

Page 11: ...11 Figure 4 4 Installation cross reference for old and new Smart Monitors ...

Page 12: ...to highlight RAMP 2 Momentarily depress the SET button to highlight the timer in seconds 3 Use the up down arrow buttons to increment the timer from 0 seconds up to a max of 30 seconds The selection will time out and reset after approximately 15 seconds with no new input When satisfied press and hold the SET button the timer setting will highlight then return to normal TESTING PROCEDURE 1 A test f...

Page 13: ...he sensor If the switching of the sensor pulses is faster than the sampling rate of the equipment errors may occur Marginal cases may have erroneous speed output from missed pulses and extreme cases may cause a complete lack of output WHAT IS A PULSE As the roll rotates it opens and closes an electrical circuit to create pulses a preset number of times per revolution One pulse is defined as one co...

Page 14: ... 5 diameter Smart Roll without lagging switch to a roll with of lagging to make the Smart Roll 5 5 diameter or switch to a 6 diameter Smart roll with or without lagging CONVERTING PULSES TO BELT SPEED The following equation can be used to convert Smart Roll pulses to belt speed D Roller Outside Diameter including lagging in inches count Number of pulses counted in the sampling time period Time Sam...

Page 15: ...t can test the Smart Roll sensor IS IT POSSIBLE TO TEST THE ROLL AFTER IT IS INSTALLED ON THE CONVEYOR Yes Using a sensor tester mentioned above the Smart Roll must be disconnected from the Smart Monitor or PLC whichever is being used before the sensor tester is connected WHY DOES PPI NOT RECOMMEND USING A CLEAN SIDE RETURN SMART ROLL WITH REVERSING BELTS When the belt and material reverse the Sma...

Page 16: ...ng the Smart Monitor in Section 4 Wiring the Smart Monitor The ramp up timer will only keep the relay energized when the Smart Monitor first receives power When 120 VAC is applied to the power cable the timer function will energize the control relay After the time has elapsed the relay will de energize unless the belt is running above the set speed UNIVERSAL MOUNT SMART ROLL MOUNTING INSTRUCTIONS ...

Page 17: ...e Smart Roll is designed to be used with a Smart Monitor PLC or similar device DO NOT use an incandescent light bulb as a load An overload will occur due to extremely high cold current DO NOT operate without a load A dead short will result which may cause irreparable damage DO NOT directly operate a motor with the sensor Always use a relay or other appropriate device At this point a 2 wire cable n...

Page 18: ...L MOUNT SMART ROLL DIAGRAM PARTS LIST 2 3 4 1 5 8 7 6 4 FIGURE 3 1 90 Elbow Conduit Access Port ASSEMBLY COMPONENTS ITEM QTY DESCRIPTION PART 1 1 Smart Roll TABLE 2 1 Universal Mount Frame 38040 3 1 D End Clip 47117 4 2 12 3 8 Self Tapping Screw 31880 5 1 B End Clip 31800 6 1 Hex Bushing 34461 7 1 90º Elbow Conduit Access Port 34452 UNIVERSAL MOUNT SMART ROLLS ROLL Ø ASSEMBLY PART ROLL ONLY PART 5...

Page 19: ...read it onto the shaft TROUGHING SMART ROLL WIRING 1 Disconnect and lockout power before starting wiring procedure The Smart Roll is provided with a inch 90 elbow conduit access port The Smart Roll cable is 2 wire 22 AWG PVC jacket PVC insulation and 6 feet in length No set up is required to the sensor inside the Smart Roll It is factory set and maintenance free DO NOT apply voltage directly acros...

Page 20: ...To avoid damage verify the circuit meets the sensor specifications shown in section A4 prior to applying power 6 Reinstall junction box lid and tighten screws to secure 7 Proceed to Section 4 Wiring the Smart Monitor FIGURE 3 1 90 Elbow Conduit Access Port ASSEMBLY COMPONENTS ITEM QTY DESCRIPTION PART 1 1 Smart Roll TABLE 2 1 Hex Bushing 34461 Provided with Smart Roll 3 1 90º Elbow Conduit Access ...

Page 21: ...f the Smart Roll into the drop bracket using the D end clip and self tapping screw 7 Align the Smart Roll so it is square and horizontal with the centerline of the conveyor frame Tighten bolts on the drop brackets to the conveyor frame RETURN SMART ROLL WIRING 1 Disconnect and lockout power before starting wiring procedure The Smart Roll is provided with a inch 90 elbow conduit access port The Sma...

Page 22: ...or or PLC provides the power for the Smart Roll To avoid damage verify the circuit meets the sensor specifications shown in section A4 prior to applying power 6 Reinstall junction box lid and tighten screws to secure 7 Proceed to Section 4 Wiring the Smart Monitor RETURN SMART ROLL DIAGRAM PARTS LIST See Flat Return Smart Roll Part Numbers in section A6 FIGURE 3 1 90 Elbow Conduit Access Port ASSE...

Page 23: ...tection 220 mA Off State Leakage Current 1 7 mA Minimum Load Current 3 0 mA Inrush Current 1 0A 30ms 15 Duty Cycle Time Delay Before Availability 60 ms Power On Effect Per IEC 947 5 2 Transient Protection Per EN 60947 5 2 Operating Temperature 25 C to 70 C 13 F to 158 F Repeatability 2 of Rated Operating Distance Temperature Drift 10 A4 SMART ROLL SENSOR WIRING DIAGRAMS AND SPECIFICATIONS BU BN LO...

Page 24: ...the arrow keys select the desired range from the list 3 With the correct range highlighted depress and hold the set button for approximately 4 seconds The display will now change back to normal operation with the new RPM range shown on the screen NOTE If you do not make a selection within approximately 10 seconds the display will go back to normal operation and keep the existing speed range NOTE T...

Page 25: ...y adding additional targets to the roller or shaft a lower RPM range can be obtained The following examples will show how to calculate the speed range for 4 four targets INPUT FREQUENCY 60 4 TARGETS ACTUAL RPM Examples 0 166 Hz 60 4 2 49 RPM 1 33 Hz 60 4 19 95 RPM 2 50 Hz 60 4 37 50 RPM CONCLUSION By changing the number of targets on the roller or shaft different speed ranges can be obtained from ...

Page 26: ...10s place digit Use up down arrow buttons as before to change the number and once set momentarily depress the SET button to begin setting the 1st and final digit Review your settings for accuracy If a digit needs to be adjusted momentarily depress the SET button one or more times to get to the proper digit then use the up down arrows to switch number and when satisfied press and hold the SET butto...

Page 27: ...ton until the equipment start up sequence has been initiated the display of the Smart Monitor will be powered on RAMP will be highlighted and the control relay REL will be ON energized Release the SET button then use the up arrow button to increment the ramp up timer to the desired number of seconds max of 30 Depress and release the SET button to write the new ramp up timer setting in to the Smart...

Page 28: ...sing the arrow keys select the desired range from the list 7 With the correct range highlighted depress and hold the set button for approximately 4 seconds The display will now change back to normal operation with the new RPM range shown on the screen NOTE If you do not make a selection within approximately 10 seconds the display will go back to normal operation and keep the existing speed range N...

Page 29: ...y adding additional targets to the roller or shaft a lower RPM range can be obtained The following examples will show how to calculate the speed range for 4 four targets INPUT FREQUENCY 60 4 TARGETS ACTUAL RPM Examples 0 166 Hz 60 4 2 49 RPM 1 33 Hz 60 4 19 95 RPM 2 50 Hz 60 4 37 50 RPM CONCLUSION By changing the number of targets on the roller or shaft different speed ranges can be obtained from ...

Page 30: ...Lagging 5 5 11 125 All SAD6CSRSB 1PL4 1 PULSE 1 4 Lagging 6 5 11 125 All SAD6CSRSB 2PL4 2 PULSE 1 4 Lagging 6 5 11 125 All SAD6CSRSB 6PL4 6 PULSE 1 4 Lagging 6 5 11 125 All UNIVERSAL MOUNT SMART ROLL PART NUMBERS PART NUMBER PULSES PER REVOLUTION LAGGING THICKNESS DIAMETER ROLL LENGTH BELT WIDTH SAD5UMSB 2PL4 2 PULSE 1 4 Lagging 5 5 11 125 All SAD6UMSB 2PL4 2 PULSE 1 4 Lagging 6 5 11 125 All SAD5U...

Page 31: ...agging 5 5 17 625 48 SAD5TE54SB 6PL4 6 PULSES 1 4 lagging 5 5 19 750 54 SAD5TE60SB 6PL4 6 PULSES 1 4 lagging 5 5 21 750 60 PART NUMBER PULSES PER REVOLUTION LAGGING THICKNESS ROLL DIA ROLL LENGTH BELT WIDTH SAD6TE24SB 1P 1 PULSE no lagging 6 0 8 938 24 SAD6TE30SB 1P 1 PULSE no lagging 6 0 11 125 30 SAD6TE36SB 1P 1 PULSE no lagging 6 0 13 250 36 SAD6TE42SB 1P 1 PULSE no lagging 6 0 15 438 42 SAD6TE...

Page 32: ...THICKNESS ROLL DIA ROLL LENGTH BELT WIDTH SAD6FL24SB 1P 1 PULSE no lagging 6 0 27 375 24 SAD6FL30SB 1P 1 PULSE no lagging 6 0 33 375 30 SAD6FL36SB 1P 1 PULSE no lagging 6 0 39 375 36 SAD6FL42SB 1P 1 PULSE no lagging 6 0 45 375 42 SAD6FL48SB 1P 1 PULSE no lagging 6 0 51 375 48 SAD6FL54SB 1P 1 PULSE no lagging 6 0 57 375 54 SAD6FL60SB 1P 1 PULSE no lagging 6 0 63 375 60 SAD6FL24SB 2P 2 PULSES no lag...