ATEX Instructions SMARTSafe TM XR12 With 222mm Rotor

Transcription

1 TEX Instructions SMRTSafe TM XR12 With 222mm Rotor 8901 E. PLESNT VLLEY ROD INDEPENDENCE, OHIO TELEPHONE: (1) FX: (1) E-MIL: WE: Modular Sensor & Rotor DESCRIPTION The vtron Model XR12 SMRTSafe is an incremental encoder for hazardous atmosphere applications (also known as tachometer or rotary pulse generator), allowing operation down to zero RPM. It provides a specific number of electrical Pulses Per Revolution (PPR) that are proportional to a shaft s revolution. The XR12 SMRTSafe encoder is a bearingless, couplingless, modular design, providing unequaled reliability and mechanical performance. CUTION The XR12 is designed for use in hazardous applications which require protection from gas or dust ignition for safe operation. Proper selection, wiring and installation procedures are essential to ensuring safe conditions. The XR12 Encoder consists of two parts: a rotor and a removable sensor module designed to be imbedded within or mounted on OEM machines. The XR12 utilizes magnetoresistive sensors. This proven technology is ideal for rugged environments since it is immune to many contaminants that cause optical encoders to fail. ll of the XR12 electronics are potted, providing full protection against liquids. The outputs are protected against short circuits and wiring errors. n vtron XR12 SMRTSafe encoder has a two-phase output (,) 90 out of phase, with complements (, ), ( Quad Output), and a marker pulse with complement (, ). The XR12 removable sensor assembly has a diagnostic package that includes daptive Electronics and a Fault-Check output. With this package, the SMRTSafe encoder can maintain itself, and let you know if there is a problem before the problem causes unscheduled downtime. DPTIVE ELECTRONICS perfect duty cycle consists of a waveform whose high and low conditions are of the same duration (50%/50%). It is possible over time for the duty cycle and edge separation to change due to component drift, temperature changes, or mechanical wear. The daptive Electronics extend the life of the XR56 by constantly monitoring and correcting duty cycle and edge separation over time. The XR12 has been evaluated to be compliant with IEC :2007, IEC :2011, EN :2009, EN :2012, SEN :2007 and SEN :2005 (Certificates of conformity: TRC12TEX0002X, TRC12TEX 0003X, IECEx TRC X, and IECEx TRC X.) THE XR12 IS CERTIFIED FOR USE IN: Group II, Category 2 (TEX one 1), Gas Group IIC potentially explosive atmospheres when marked CE 0539 Ex II 2 GD, Ex ib IIC T4 Gb -40 C < Tamb < 80 C and used with an vtron isolator marked CE 0539 Ex [II 2 GD] [Ex ib IIC Gb] -40 C<Tamb<80 C. Group II, Category 3 (TEX one 2), Gas Group II_* potentially explosive atmospheres when marked CE Ex II 3 GD, Ex ic IIC* Gc T4-40 C<Tamb<80 C *see chart in specification section and used with a power supply that limits voltage and current per the chart in the specification section. Group II, Category 3 (TEX one 22), Dust group IIIC potentially explosive atmospheres when marked CE Ex II 3 GD, Ex ic IIIC T 200 C Dc -40 C<Tamb<80 C. See installation section for electrostatic charging hazard instructions and other limitations. INSTLLTION WRNING Installation should be performed only by qualified personnel. Safety precautions must be taken to ensure machinery cannot rotate and all sources of power are removed during installation. Equipment Group II, Category 2 (one 1), Gas group IIC, Dust group IIIC (TEX one 21): vailable as a system only including XR12 with line driver option 5 and an vtron Isolator module XR1 (P/N 35134). System parameters are: Um= 250V Uo (open circuit voltage) = 7.14VDC max. Io (short circuit current) = 420m max. Co (system capacitance) = 13.5uF max. Lo (system inductance) = 0.15mH max. Encoder parameters are: Ui (input voltage) = 7.14VDC max. Ii (fault current) = 420m max. Ci (internal capacitance) = 11.9uF max. Li (internal inductance) = 0mH max. The isolator XR1 can be supplied as a separate module for location in a safe area or in an explosion proof box on a short flexible cable tethered to the encoder. Equipment Group II, Category 3 (one 2), Gas group IIC, Dust group IIIC (TEX one 22): Requires an XR12 with line driver option 7 and a SELV (Energy Limited) or equivalent power supply which limits voltage and current to the values in the table in the specifications. If current limit is not inherent in the power supply a separate fuse between the power supply and encoder can be used to limit current. Group II, Category 2 (TEX one 21), Dust Group IIIC potentially explosive atmospheres when marked CE 0539 Ex II 2 GD, Ex ib IIIC T200 C Db -40 C<Tamb<80 C and used with an vtron isolator marked CE 0539 Ex [II 2 GD] [Ex ib IIIC Db] -40 C<Tamb<80 C. XR12 1

2 NOTE: Isolators, encoders and cable must be selected and installed in accordance with the latest edition of IEC/EN and IEC/EN Cable characteristics must comply with IEC/EN and IEC/EN and for zone 1 applications total system capacitance between the isolator and encoder (including cable) must be less than Co-Ci. Total system inductance between the isolator and encoder must be less than Lo-Li. The equipment is intended for a fixed installation and should be mounted so as to avoid electrostatic charging. The XR12 is not considered as a safety device and is not suitable for connection into a safety system. The XR12 construction materials contain less than 6% magnesium by mass. These materials are not considered as able to trigger an explosion in normal operating modes in accordance with the requirements for category 2 or 3 equipment. These materials are not known to react with any explosive atmospheres to which the XR12 may be subject. It is however the responsibility of the end user to ensure that the XR12 is selected correctly for the potentially explosive atmosphere in which the equipment is to be put into service. The XR12 installation is similar to V5 GENERL The sensor must be located accurately to properly center it on the rotor and provide the correct sensor-to-rotor air gap without permitting contact between the stationary sensor and spinning rotor. xial shaft float or endplay must be less than +/ inch. CUTION Do not strike or pound the sensor or rotor. INSTLLTION HRDWRE Equipment needed for installation Supplied: XR12 Sensor 1. Washer, Spring Lock (4) 2. Soc. Hd. Cap Screw x 0.75 (4) Rotor Rotor installation hardware kit nti-seize Compound (copper) Thread Locker (blue) Not Supplied: Dial Indicator Vernier Caliper 2mm Hex Wrench (T-Handle style) (set screw style rotors only) 5/32 Hex Wrench SENSOR LOCTION RELTIVE TO ROTOR The sensor must be properly located to sense the rotor, and the rotor-sensor orientation must be correct so that the incremental and marker tracks are correctly sensed. The mounting diagrams (p10 & p11) show the sensor pocket used to orient and align the sensor to the rotor, as well as the tapped screw holes to secure the sensor to the mounting bracket. The instructions below assume a properly designed and located mounting bracket in place on the machine. 1. Slide the rotor onto the shaft to be sensed. 1a. For cam screw style rotors, ensure the cam screw side of the rotor labeled this side out is oriented to the side of the sensor with the LED. (The black potted side of the sensor should orient to the side of the rotor without fasteners). 1b. OR For set screw style rotors, ensure the set screw side of the rotor labeled this side in is oriented to the black potted side of the sensor (not the LED side). 2. Slide the rotor into position axially, using the machined face of the sensor as a reference. The rotor must be positioned correctly +/ [2.54mm]. Secure the rotor using either the set screws with thread locker, or by tightening the cam screws. 3. Using a PLSTIC shim (only), check the sensor-to-rotor gap; should be nominally [1.14mm]. For best performance and resistance to debris, the nominal gap should be +/ [+/-0.127mm]. If the sensor gap is not correct, adjust the location of the mounting bracket as required. 4. Secure the sensor to the mounting bracket using 4 screws. WIRING INSTRUCTIONS WIRING CUTION e sure to remove power before wiring the encoder. e sure to ground the cable shield: vtron recommends grounding the shield at the isolator module for one 1 applications or in the drive cabinet for one 2 applications. Cable should not be grounded multiple places. n intrinsic safety ground is required at the XR1 Isolator Module. CUTION SMRTSafe encoders include a local ground lug for customer convenience and encoder frame grounding if required to meet local electric code requirements or site operator protection standards. This is NOT the required XR1 intrinsic safety ground connection required for hazard protection against ignition of explosive atmospheres for zone 1 and zone 21 applications! Wiring diagrams are shown in the following pages. CUTION one 1 and one 21 applications utilize the XR1 isolator which requires an intrinsic safety ground to provide hazard protection. Failure to connect this ground, or providing an inadequate safety ground path could result in an spark/ignition hazard which can result in property damage, injury, or even death. Wiring diagrams are shown for one 1 and one 2 applications. For bidirectional operation of the encoder, proper phasing of the two output channels is important. Phase channel leads typically phase channel for clockwise shaft rotation as viewed from the anti-drive or accessory end of the motor (encoder mounting end). See pinout and phasing tables for exceptions. NOTE Wiring option G provides a pinout compatible with Northstar TM encoders, with a cable shield connection on pin 10. Note that this option does not ground the shield. CORRECTIVE CTION FOR PHSE REVERSL 1. Remove Power. 2. Exchange wires on cable, either at encoder cable end or at speed controller end (but not both). a) Single Ended 2 Phase Wiring (see wiring diagram) Exchange and at the use end of the wires. b) Differential 2 Phase Wiring (see wiring diagram) Exchange either with in the phase pair OR with in the phase pair but NOT both. 3. pply power and verify encoder feedback is correct. Interconnection cables specified in the wire selection chart are based on typical applications. Cable must be selected and installed in accordance with IEC/EN and IEC/EN Physical properties of cable such as abrasion, temperature, tensile sstrength, solvents, etc., are dictated by the specific application. General electrical requirements are : stranded copper, 20 through 16WG (Industrial EPIC connector type options can use 14 WG). Each twisted wire pairs overall shielded with braid or foil with drain wire,.05uf of maximum total uutual or direct capacitance, outer sheath insulator. See specifications for maximum cable length. Stranded 20 WG wire should not be used for cable runs greater then 61 meters. If 20WG is used with EPIC type connector options the wire ends should be tinned. See wiring diagram for examples of alarm output wiring. XR12 2

3 MINTENNCE GENERL This section describes routine maintenance for the vtron XR12 Encoder. For support, contact vtron s field service department at For emergency after hours service contact us at The XR12 SMRTSafe circuitry includes a diagnostic package that includes daptive Electronics and a Fault-Check output. FULT-CHECK fter power-up and the rotor position is checked by the sensor, the Fault-Check LED will turn green. If the adaptive electronics reach their adjustment limit for any reason, the Fault-Check alarm and LED will notify the drive and operator of an impending failure. The LED will turn red if the daptive Electronics reach their adjustment limit. This output occurs before an actual failure, allowing steps to be taken to replace the unit before it causes unscheduled downtime. For units other than one 1 Units, Fault-Check annunciation is available as an alarm output through the connector (one 2 configuration only) and as an integral LED. TROULESHOOTING If the drive indicates a loss of encoder/tach fault and the XR12 fault-check LED is not illuminated, check the encoder power supply. If power is present, check polarity; one indicator of reversed power supply is that all outputs will be high at the same time. If the drive indicates encoder fault, but the LED shows GREEN, then check the wiring between the drive and the encoder. If the wiring appears correct and in good shape, test the wiring by replacing the XR12 sensor module. If the new module shows GREEN, and the drive still shows encoder loss/tach fault, then the wiring is faulty and should be repaired or replaced. If the alarm output and/or LED indicate a fault (RED): 1. Check the rotor axial position relative to the sensor. 2. Check the air gap between the sensor and the rotor using a plastic shim (do not use metal). It should be [1.02mm-1.27mm]. 3. Ensure the sensor is mounted at 90 degrees to the rotor. If the alarm output and/or LED indicate a fault (RED) on a properly mounted XR12 sensor and the rotor is properly located, replace the XR12 sensor. n oscilloscope can also be used to verify proper output of the XR12 encoder at the encoder connector itself and at the drive/controller cabinet. If the outputs show large variations in the signals at steady speed (jitter or accordion effect, see figure below), check rotor position. If the rotor position is correct, the motor or shaft may be highly magnetized. Replace any magnetized material nearby with non-magnetic material (aluminum, stainless) (shafts, etc). SENSOR REMOVL To remove the sensor remove the qty 4 screws holding the sensor to the mount. Take care that the sensor does not fall from the frame and crash into the rotor. Damage to the sensor or rotor could result. ROTOR REMOVL Remove the rotor by hand, taking care not to damage the outer magnetized ring. If the rotor can not be removed by hand, use the lifter screw holes: thread in (2) 1/4-20 screws evenly until they contact a stationary surface. Turn each screw 1-3 more turns, and the rotor should break free. DO NOT PPLY HET TO THE ROTOR. PHSE PHSE VRITION > ± 15% XR12 3

4 XR12 Sensor Part Numbers Model Line Driver PPR Connector Options Modifications XR12 5- one 1/one 21 (5-7V in, 5V X- none L- 240 Q- 500 Y D none F- 60 N- 256 R out) for use with XR1 isolator 004- Super Magnetic Shielding G- 100 P- 300 S one 2/one 22: 005- Special 97mm Rotor H- 120 E- 360 V special 5-24V in, 5-24V out J (see special manual) 4xx- Special PPR (see table) 9xx- Special Cable Length (xx=ff/0.3m) 018- Includes isolator Industrial Connector G- (Northstar TM Pinout) with Plug P- with Plug Connector Options one 1 & 21 Remote Protection and ones 2 & 22 ones 1 & 21 Local Protection Mounted on Encoder ody 3 Cable XR1 in EX ox 10 pin MS Other Twist Lock Other without Plug - with Plug & clamp R- Twist Lock Mini MS with Plug 4- Terminal box S- Mini MS with Plug W- Leads only Flameproof Conduit ox w/o Gland M25 Flameproof Conduit ox w/ TEX rated Gland Special PPR Option Code PPR N/ XR12 4

5 ELECTRICL. Operating Power (Vin) 1. Volts... See Line Driver Options 2. Current m, each output, no load. Output Format 1. 2O// & Comp...,,, (differential line driver) 2. Marker:... 1/Rev, C. Signal Type... Incremental, Square Wave, 50 +/-10%... Duty Cycle. D. Direction Sensing... O/ leads O/ for CW rotation as... viewed from the back of the tach... looking at the non-drive end of... the motor. E. Transition Sep... 15% minimum F. Frequency Range... 0 to 165,000 Hz G. PPR H. Line Driver Specs:... See table I. Connectors:... See connector options on page 1 K. INTEGRL LED INDICTOR... GREEN - Power On, Unit Ok... RED - larm On MECHNICL. Rotor Inertia Oz. In. Sec. 2. cceleration RPM/Sec. Max. C. Speed: ** RPM Max. D. Weight:... 4 lbs. [ 2 kg.] E. Sensor to Rotor ir Gap (nominal): " [1.14mm] Tolerance: "/-0.005" [+0.13/-0.13mm] F. Rotor xial Tolerance... +/-0.100" [+/-2.54mm] ** Maximum RPM may be limited for PPR > 2500 contact factory with your application. SPECIFICTIONS LINE DRIVER OPTIONS Electrical Specifications 7 Isolator XR1 5 Units Input Voltage VDC Nom Output Voltage 5-24 (5-7 to Encoder) 10.6 Output Signals 5 VDC Line Driver 7272 IXDF Output Resistance Typ ohms Maximum Peak Current m Maximum verage Current m Voh Typ VIN VIN-1 VDC Vol Typ VDC Cable Drive Capacity Protection larm Reverse Voltage 5-12V 24V feet yes yes yes Short Circuit yes yes yes Transient yes yes yes Marker +V(out)* larm* LED Output voltage equal to input voltage. Open collector, normally off, goes low on alarm, sink 100m max, 50VDC max Green=power on, Red=larm One per revolution. Pulse width approximately 1/128 of a revolution *larm not available with line driver option 5, from isolator XR1, nor on connector option G (Northstar TM compatible pinout) ENVIRONMENTL Cast aluminum sensor and rotor Fully potted electronics, protected against oil and water spray V-Ring seals provided on through shaft covers Operating Temperature: to 80 C, 0-100% condensing humidity. See description section for information on hazardous location environments. Parameter Isolator Encoder Um 250V - Ui V Li - 440m Pi - 0.4W Ui Ii IIC II 250m 15V 25V CI Ci UF Li - 0mH Uo 7.14V - Io 440m V 1.8uf Po 0.4W - Lo 1.5mH 5 12V Co 13.5uF one 2 Power Supply Limits Lo/Ro - one 1 Table of entity parameters XR12 5

6 Through Shaft Rotors SPRE MECHNICL PRTS FOR V125 Outboard Covers Shaft ore Set Screw Imperial (US) Sizes Rotor Code Rotor Part Flat Thru-Shaft Cover Seal ONLY 1.375" TH TH " TJ TJ " TL TL " TM TM " TN TN " TQ TQ " TP TP " TR TQ " TT TT " T T " TV TV " TW TW " TY TY " T T " T T " T T " TC TC " T T " TD TD " TE TE " T T " TG TG " T T " T8* T N 7.875" T9* T N** N * T8 and T9 do not permit a thru-shaft seal Standard Stator housing kit w/mounting hardware **D41838 Special 7.875" through-shaft housing only, no hardware Sensor pad cover plate w/hardware XR12 6

7 WIRING DIGRMS ONE 1 HRDOUS RE LOCL PROTECTION SFE RE Ex ox ENCODER 1'(.3M) to 5'(1.5M) Cable Tether LINE DRIVER OPTION 5 CONNECTOR OPTION 5 OR Volts Out Volts In + gnd gnd ISOLTOR P/N Typical Cable 1000'(300M)max 18WG, Individually Shielded Twisted Pair + Overall Shield Rockbestos EXNE 125 Type P- P/N: 4TSP18 WG - K K K K K K GND 0V + Ub+ +E Customer Equipment 2 Phase Differential Volts Out Intrinsic Safety Gnd ONE 1 HRDOUS RE REMOTE PROTECTION SFE RE ENCODER Typical Cable 500'(150M)max 18WG, 4 Twisted Pair + Overall Shield elden P/N 9554 or lpha P/N 2244C Typ Volts Out Volts In + gnd gnd ISOLTOR P/N Intrinsic Safety Gnd - K K K K K K GND 0V + Ub+ +E Customer Equipment 2 Phase Differential Volts Out See ttached for Connector Option Pin Outs Phasing is defined as the direction of rotation for which phase leads as Option Channel Phasing 0V Gnd lm+ +Vin lm viewed from the back of the Encoder Code Code 10 Pin MS vtronpinout, CW Pin # D E C F G H I J 10 Pin Terminal lock 4 CW Pin # Pin MS Mini Twist Lock R, S CW Pin # F C NC D H J K NC 10 Pin, Industrial, vtron Pinout P CW Pin # Pin, Industrial, Northstar Pinout G CW Pin # NC NC 10 Wire Cable W CW Color LK GRN LU ORG RN RED YEL GR WHT VIO Signal XR12 7

8 WIRING DIGRMS ONE 2 HRDOUS RE DIFFERENTIL 2 PHSE WIRING SFE RE Typical Cable 500'(150M)max ENCODER LINE 18WG, Twisted Pair + Overall Shield DRIVER OPTION 7 See ached for Connector Opon Pin Outs 2 Pair 3 Pair 4 Pair 5 Pair elden lpha 2242C 2243C 2244C 2245C - K K K K K K GND 0V Ub+ +E Customer Equipment 2 Phase Differenal 5-24* Volts Out ONE 2 HRDOUS RE SINGLE ENDED 2 PHSE WIRING SFE RE Typical Cable 500'(150M)max ENCODER LINE 18WG, Twisted Pair + Overall Shield DRIVER OPTION 7 See ached for Connector Opon Pin Outs 2 Pair 3 Pair 4 Pair 5 Pair elden lpha 2242C 2243C 2244C 2245C - GND 0V + K Ub+ +E + K K v alm 5-24* Volts Out Customer Equipment ONE 2 HRDOUS RE SINGLE ENDED 1 PHSE WIRING SFE RE ENCODER LINE DRIVER OPTION 7 See ached for Connector Opon Pin Outs Typical Cable 500'(150M)max 18WG, Triad + Overall Shield elden lpha 3 Conductor 9365 M K Ub+ +E - GND 0V Customer Equipment 5-24* Volts Out *SEE SPECIFICTIONS FOR ONE 2 POWER SUPPLY LIMITTIONS Refer to Installation and Specification Sections for Requirements and Limitations XR12 8

9 SMRTSafe pplication Examples pplies to all Model XR5 Encoders except connector styles G, R, S. LRM OUTPUT CONNECTION vtron SMRTSafe encoders provide an alarm signal if maintenance is required under specific circumstances. green LED indicates power on and proper operation, red indicates alarm on. Following are application examples provided to help install the alarm output. Example 1. larm output using +V(OUT). +V(OUT) is equal to +V, the encoder power supply. ENCODER FUNCTIONL DIGRM LINE DRIVER NOTE 1 Q5 MMFT6661 CR8 LCK RED { GREEN YELLOW LUE GRY ORNGE WHITE OUTPUT OPTIONS W ROWN VIOLET, P, D G E H C I F J GND FUNCTION COMMON +V (Encoder Power) Ø Ø Ø Ø MRKER MRKER COMPLEMENT 50 m MXIMUM 300 OHM MIN. Vcc OUT COM 4-16 VDC SOLID STTE RELY Example 2. larm Output Using Separate * VDC Power Supply and Relay. ENCODER FUNCTIONL DIGRM OUTPUT OPTIONS W, P, FUNCTION COMMON LINE DRIVER NOTE 1 CR8 LCK RED { GREEN YELLOW LUE GRY ORNGE WHITE D G E H C I V (Encoder Power) Ø Ø Ø Ø POWER SUPPLY MRKER MRKER COMPLEMENT - 24 VDC VC ROWN VIOLET F J 5 10 RELY Q5 MMFT6661 GND SINK 100 m MXIMUM, WITHSTND 50 V MXIMUM REFERENCED TO COMMON *See specifications for one 2 power supply limits XR12 9

10 OUTLINE DIMENSIONS ND OPTION DETILS 1.42 (36.0) (927.0) MIN (927.0) MIN OPTION "R" OPTION "S" 0.53 (13.5) OPTION "W" 0.53 (13.5) 1.97 (50.0) 3.67 (93.2) ssembled 1.66 (42.2) 0.53 (13.5) OPTION "" ULKHED CONNECTOR ONLY OPTION "" WITH MTING PLUG & CLE GROMMET XR12 10

11 OUTLINE DIMENSIONS ND OPTION DETILS 4x n0.219 THRU vø0.460 TO DEPTH SHOWN (2.10) ± ± ± [57.4] I N U D U TO V 1.69 [43.0] 4.31 [109.4] 3.83 [97.3] Option 4 Options P & G These instructions have been reviewed and the product evaluated as suitable for our application. Company Name uthorized Company Representative Title Date SMRTSafe is a trademark of vtron Industrial utomation, Inc. Features and specifications subject to change without notice. vtron standard warranty applies. ll dimensions are in inches [mm] E. PLESNT VLLEY RD., INDEPENDENCE, OH 44131, U.S.. (1) FX (1) REV: 03/25/13 XR12 11