World Leader in Modular Torque Limiters. Product Catalog

Transcription

1 World Leader in Modular Torque Limiters Product Catalog

2 Contents Torque Limiting Clutches page General Information 1 Where to Install / Selection 2 Safety Element Torque Limiters 3 Features and Benefits / How to Select and Order 4 Safety Element Modules 5 Extruder Applications 8 Gear Coupling Applications 11 Water and Waste Water Applications 12 Mining Applications Contact Brunel: Other Applications 16 Torque Limiting Clutches 23 How to Select and Order 24 Type JAB Basic Manual Reset Clutch 25 Type JAB Mounting Variations: JAF, JAS, JAP 26 Type JFV Manual Reset Clutch 29 Type JCB Automatic Reset Clutch 30 Type JBB Basic Automatic Reset Clutch 33 Power Modules PTM-3 35 Wiring Diagram 36 Specifications 37 PTM-4 38 Wiring Diagram 38 Specifications 39 Mounting Bracket 40 Current Transformer 40 Proximity Sensors Inductive Sensors 41 Engineering Information Torque Limiter Selection Checklist 45 Driven Equipment Service Factor 47 Application Formulas 51 Metric Conversion Chart 52 Warranty 53

3 Brunel Torque Limiting Clutches General Information Years Of Trouble Free Service Remove Overload Problems ±5% Repeatability Virtually No Maintenance Competitive First Cost All Metal, Totally Enclosed Gone are the problems associated with slow reaction electrical overloads and shear pins which give a wide torque variation and rapidly overheating slip clutches. Brunel Torque Limiting Clutches will save you money. The initial cost of a Torque Limiter is normally covered by the savings of down time and lost production during the first overload. Features & Benefits Torque setting accurate within ±5% is maintained indefinitely Ease of maintenance is assured by eliminating the need for continuous adjustment Bi-directional torque transmission is standard Selection of proper clutch is simplified Standard unit can be installed on dual direction drive system Multiple springs control torque release setting Increased dependability of drive Larger range of torque setting is available to meet your specific application All metal totally enclosed construction Longer life in contaminated environment Operator safety improved with enclosed springs Drive torque is transmitted through tapered jaws on all standard type JA models Positive drive-no slip, minimal backlash Timing of drive system is assured A single Brunel type JA clutch will also function as: (1) Dog Clutch (2) Overload Release Clutch Eliminate the need for two separate clutches Reduce system cost, complexity and size Automatic and complete disengagement on overload is standard on the JA and JFV4 models No torque is transmitted, thus preventing damage and machine downtime due to overload Typical Applications Automatic Door Openers Automatic Furnaces Or Ovens Bakery Equipment Bottling Equipment Conveyors Drying Drums Extruders Film Packaging Machines Food Processing Equipment Machine Tools Mining Equipment Mixers PTO Drives Packaging and Labelling Machinery Paper Machinery Printing Presses Pump Drives Rolling Mills Rubber Processing Machines Textile Machinery Tractor PTO Driven Winches Transfer Machines Special Machinery Washing Machines Waste Water Pumps Woodworking Machinery Reduced overall length Reduce the space required and the cost of your drive system Easy to reset Because no spring compression or ball alignment is required Type JC and JB are standard with automatic reset Operator can reset his own machine, avoiding production delays 1

4 Brunel Torque Limiting Clutches Where to Install / Torque Limiter Selection In most drive systems there are several alternate locations where the Brunel clutch can be installed (fig. 1). The preferred position is at the driven shaft. This location places the overload protection clutch at a point in the drive system where actual load torque can be accurately monitored. Alternate locations in the drive system as shown in Figure 1 are usually subject to greater variation in torque loads due to the reduction ratios within the drive system. The preferred mounting location will provide better control of the overload release torque thus preventing unnecessary release at torques below safe operating levels due to system inertia and starting torque peaks. Preferred position Conveyor head shaft Figure 1 Chain drive Alternative positions Gear box Motor Reduction Gearing When Brunel Torque Limiting Clutches are installed on large ratio reduction gear boxes care must be taken since it may not be practical to set a torque limiter mounted on the input shaft low enough to provide the proper torque protection on the output shaft. The large reduction ratio will also decrease the accuracy of the output release torque setting if the clutch is located on the input shaft. High Inertia Drive Systems When selecting Torque Limiting Clutches for use in high inertia drive system, the location of the clutch must be between the high inertia load (flywheel, large pulley or gear, etc.) and the driven mechanism. Locating the Brunel overload release clutch in this position will protect the driven mechanism from the large inertia forces. Optional Features Single Position Re-engagement For use where timing of machine is required. Available for Type JA. (Standard on JC and JB models.) Torque Limiter Selection Types JA, JB, & JC For release torques up to 48,000 lb in Decide on manual or automatic reset. Choose a position as near as possible to the expected overload (see diagram). Calculate the torque setting required at that position. This can be determined from the motor power, r.p.m. and gearing ratio to the driven load or from the maximum permissible torque for drive components such as compressive stress on keys. It is the weakest component that requires protection. Make allowance for motor starting torques (generally twice normal running torque). Having calculated an approximate setting for the release torque, final adjustments can be made on site. Check from tables that shaft, sprocket or pulley, etc. can be accommodated. Selection Example Model Type JAF This specifies: Manual reset clutch capable of 1000 lb ft torque complete with flexible coupling for shaft-to-shaft application. To enable us to deal efficiently with your inquiry, we ask you to supply the following facts:- Type of application and environment conditions R.P.M. of drive Release torque required Length and diameters of shafts Space available between shaft ends Overall space available - length and diameter limitations Type and sizes of accessories, i.e. sprocket, pulley, etc. Any special requirements such as shifter flange, neoprene seals, etc. Light Duty Springs For systems requiring very low torque levels and greater range of adjustment sensitivity. Single Direction Overload Release For applications where heavy braking is applied. Type JA only. Dual Level Torque Setting For heavy overrunning applications which require normal release torque setting in one direction and a lower torque release setting in the opposite direction. Type JA only. 2

5 Brunel Safety Element Torque Limiters Torque Limiting Modules Brunel Torque Limiting Modules have been specifically designed to provide overload protection for applications where very high torques are transmitted and to extend the range covered by Brunel Type JA units. The modular system provides facilities for virtually unlimited torque capacity and lends itself to many transmission applications chain, belt and gear drives, or shaft-to-shaft gear or flexible coupling drives. The maximum release torque depends on the number and size of Torque Limiting Modules that can be incorporated, and the size of the unit that can be accommodated within the confines of the installation. Internally & externally adjusted modules provide repeatability better than ±5%, however externally adjusted modules are preferred when the application is required to operate within minimal variations between static & dynamic disengagement. Construction The Brunel Torque Limiting Module is constructed from the finest quality materials. Many of the vital components are made from high quality tool steels, through hardened to Rockwell C62, and precision ground to close tolerances. Normal Operation The flanges X and Y are driven by a large steel ball 2, located in the detent pocket 1, which is retained by a plunger 3. This in turn is retained axially by means of a system of angled races 6,8 biased by pressure from the Belleville springs 5, acting on a circle of balls 7. Disengagement On overload, relative angular movement between flanges X and Y imparts a tangential force (Fu) on the large steel ball, forcing it clear of the detent pocket back against the plunger. This in turn causes the plunger to be forced through the circle of balls overcoming the spring loading on the angle races. In this position, the balls are resting on the large diameter of the X Fu Y Disengaged plunger, and once this condition is reached the flanges are completely free to rotate independently. A suitable switch can be incorporated in the assembly to switch off the drive motor or operate a warning device when the Torque Limiting assembly disengages. Resetting is a simple matter of first re-aligning the flanges X and Y and then tapping each module plunger back with a soft mallet to allow the circle of balls to return to their original position and the large steel ball to return to its location in the detent pocket. Detent Pockets Internally & externally adjusted modules can have through hole or blind hole detents (see diagrams left and on page 5). The type of detent is dependent upon the design constraints. All modules are required to be preloaded. In the case of the through hole module this is done by tightening the set screw at the base of the detent pocket. In the case of the blind hole module this is done by the means of shims under the module. Selection To apply the modules in the form of a torque limiter, it is necessary to determine the quantity of modules needed for the required torque capacity at a specific radius from the axis of rotation. No. of Modules = M Torque (lb in) = T Tangential Force = Fu Mounting Radius of Modules = RAD M = T Fu x RAD T = M x Fu x RAD 3

6 Brunel Safety Element Torque Limiters Features and Benefits / How to Select and Order The Brunel Safety Element Torque Limiters have been specifically designed to offer overload protection on applications where very high torques are transmitted, and so extend the range covered by the standard Brunel units. Gone are the problems associated with slow reaction electrical overloads, shear pins which give a wide torque variation, and rapidly overheating slip clutches. Features and Benefits Complete disengagement on overload No torque transmission after overload release All metal, totally enclosed Long life in harsh environments; completely enclosed torque transmitting components Easy to reset Reduces downtime, lost production, saves time and money; the safety elements can be reset in minutes; eliminate searching for misplaced shear pins; can be reset by the operator Tamperproof torque adjustment Virtually eliminates increasing the capacity of the drive by unauthorized personnel without the use of special tools, shims, springs, spacers, etc. Quick and complete disengagement Eliminates problems associated with slow reaction electrical overload sensing devices, shear pins (which give a wide torque range) and rapidly overheating slip clutches Positive drive/no slip Eliminates damaging heat build up and maintains equipment timing while engaged Torque setting accuracy maintained indefinitely Ease of maintenance is assured by eliminating continuous adjustments for wear and fatigue Through hardened, chromium tool steel, torque transmitting components Virtually eliminates wear on these critical components Precision Belleville springs Ensure accurate and repeatable release torque setting Spring loaded, ball detent torque transmission Eliminates problems with sheared pins fatigue Eliminates the problems associated with substitute shear pin materials Modular element design/four basic sizes of elements Enables a design suited to your torque requirements, at a competitive price The accuracy and repeatability can allow for downsized motors, reducers, etc. because there is no need for large service factors; the safety elements can be designed in for protection, and the power transmission equipment sized to do the job properly and efficiently How to Select and Order Because of the custom and highly technical nature of this design, please consult Brunel with full application data. We will guide you in the selection and ordering of these units. 4

7 Brunel Safety Element Torque Limiters Internally Adjusted Modules G F D E K H H 1 C J B A X Y Engaged Brunel Tangential Force Fu Dimensions in mm and inches P/N lb N A B C D E F G H H 1 J K JSE ,250 10, JSE ,000 17, JSE ,000 48, JSE , , Note: Internal design features may vary between sizes Externally Adjusted Modules D E H Adjustment Adjustment of the tangential force Fu, can be made by adjusting the spring housing (9), so altering the spring force. G J H 1 Ensure that on assembly any clearance between the driving ball and detent pocket is eliminated by adjusting the quantity of shims (8) under the clamp face of the module. C B A 8 9 Brunel Tangential Force Fu Dimensions mm and in P/N lb N A B C D E G H H 1 J JSE ,250 10, JSE ,000 17, JSE ,900 26, JSE ,000 67, N/A Note: Internal specifications may vary between sizes Consult factory for special application 5

8 Brunel Safety Element Torque Limiters Externally Adjusted Disconnect Modules G H 1 H D E F Adjustment Adjustment of the tangential force (Fu), can be made by removing the security cover 1 from the mounting flange and adjusting the housing 2, so altering the spring force. C B A This procedure discourages tampering by unauthorized personnel. 2 1 Brunel Tangential Force Fu Dimensions in mm and inches P/N lb N A B C D E F G H H 1 JSE ,250 10, JSE ,000 17, JSE ,100 27, Note: Internal design features may vary between sizes Externally Adjusted Disconnect Modules Features and Benefits Very accurate release torque repeatability with minimal variation between static and dynamic release. Versatile installation allows for the torque limiter center section to be removed without the need to move the motor or gearbox. Individual modules are preset to provide the required release torque. Any maintenance of the modules is a straightforward operation. A simple removal operation allows for module recalibration without having to replace the complete unit. By holding spare modules in stock already preset to the required release torque keeps downtime to an absolute minimum. Manual reset of the torque limiter can only be carried out when the drive is at rest. Resetting is achieved by realigning the two halves of the unit and then lightly tapping each module fitted, with a soft mallet. Lubrication of the unit is via easy access grease nipples. Proximity sensor targets are included to provide the means to switch off the drive after an overload occurs. While each torque limiter assembly is normally factory preset, if required site adjustments can be carried out, a setting chart with instructions is provided for this purpose. Please note a security key is required and adjustment should only be carried out by an authorized person. Accurate release torque repeatability Simple fast manual re-engagement Low-cost maintenance The preferred protection for many extruder manufacturers 6 P/N: JSE1-0025

9 Brunel Safety Element Torque Limiters Torque Limiting Modules Brunel Torque Limiting Modules have been specifically designed to provide overload protection for applications where very high torque s are transmitted, and to extend the range covered by Brunel Type JAB units. The modular system provides facilities for virtually unlimited torque capacity and lends itself to many transmission applications chain, belt and gear drives, or shaft-to-shaft gear or flexible coupling drives. The maximum release torque depends on the number and size of Torque Limiting Modules that can be incorporated, and the size of the unit that can be accommodated within the confines of the installation. Internally & Externally adjusted modules provide repeatability better than 5%, however Externally adjusted modules are preferred when the application is required to operate within minimal variations between static & dynamic disengagement Engaged Fu Disengaged Construction The Brunel Torque Limiting Module is constructed from the finest quality materials. Many of the vital components are made from high quality tool steels, through hardened to Rockwell C62, and precision ground to close tolerances. Normal Operation The flange connection is driven by a large steel ball (2), located in the detent pocket (1), which is retained by a plunger (3). This in turn is retained axially by means of a system of angled races (5,7) biased by pressure from the Belleville springs (4), acting on a circle of balls (6). Disengagement On overload, relative angular movement between the flanges imparts a tangential force (Fu) on the large steel ball, forcing it clear of the detent pocket back against the plunger. This in turn causes the plunger to be forced through the circle of balls overcoming the spring loading on the angle races. In this position, the balls are resting on the large diameter of the plunger, and once this condition is reached the flanges are completely free to rotate independently. A suitable switch can be incorporated in the assembly to switch off the drive motor or operate a warning device when the Torque Limiting assembly disengages. After first ensuring that the drive is isolated, resetting is a simple matter of first realigning the flanges and then tapping each module plunger back with a soft mallet to allow the circle of balls to return to their original position and the large steel ball to return to its location in the detent pocket. Detent Pockets Internally & externally adjusted modules can be through hole or blind hole detent fixing (See diagrams on opposite page). The type of detent fixing is dependant upon the design constraints. The mechanical clearance in the Module assembly should be eliminated by preloading the detent pocket (1) against the driving ball (2). Selection To apply the modules in the form of a torque limiter it is necessary to determine the quantity of modules needed for the required torque capacity at a specific radius from the axis of rotation. No. of modules = Torque (Nm) x 1000 Fu (N) x radius (mm) x K K = 0.65 for General Applications. K = 0.5 for Steelwork Applications. 7

10 Brunel Safety Element Torque Limiters OETL - Original Extruder Torque Limiter Externally Adjustable / Disconnectable Module *(EAD) Features & Benefits Modular Design Simplifies Maintenance User can replace Safety Elements (the working components) without removing clutch from shaft Clutch can be removed (dropped out) without moving motor back Module Designs Available Standard Internally Adjustable Modules Externally Adjustable Modules *(EA) Torque adjustment by micrometer graduations Tamper proof externally adjustable design Disconnectable Modules *(D) Disconnect motor for testing of motor function and torque limiter function Tamper proof internally adjustable design Externally Adjustable / Disconnectable Modules *(EAD) Incorporates both features above Simple Manual Reset -- without reversing drive Precision Ball Detent/Belleville Spring Design (+0 to -10% repeatability) Adaptable to All Drive Configurations Eflex Coupling Standard, Other Types Available Large Torque & Bore Capacity Turning bar holes standard Brunel Safety Element Torque Limiters have been protecting industrial power transmission systems around the world since The Extruder Safety Element SE Series Torque Limiters are designed specifically for the precision requirements of twin screw extruder applications. They are totally enclosed and made exclusively of steel (except coupling flex elements & seals). The wearing parts in the Safety Element Modules are D-2 tool steel thru hardened to Rc 62 minimum. Tapered roller bearings are incorporated in the design for long life, and are regreaseable through a grease fitting and grease relief valve. Modular construction provides design flexibility and simplified maintenance. Safety Elements are precision Belleville spring loaded, single ball detent design. A unique over-center mechanism insures complete disengagement on overload and simple, fast manual re-engagement. Safety Element Torque Limiters completely disengage on overload thus preventing damage and down time to the equipment. When applied on motor output shafts of twin screw extruder drive systems, the SE Torque Limiter protects the reducer and twin screws from potential damage upon overload. 400HP Twin Screw Extruder Clutch Coupling Between Motor and Reducer 900HP Twin Screw Extruder Clutch Coupling 8 * part number suffix

11 Brunel Safety Element Torque Limiters For Extruder Applications Proximity Sensor Targets (to Sense Disengagement) N O Axial movement on overload M A C D E F G H K I J L B Brunel - Extruder Torque Limiter Dimensions (millimeters/inches) Torque Torque Dimensions in mm and inches Limiter Brunel Range Max. Bore Max. Bore DBSE Size P/N lb in A B C D E F G H I J 1 JSE MAEAD 3,540-11, JSE1-0128MAEAD 9,650-30, A JSE1-0129MAEAD 11,284-36, B JSE1-0129MBEAD 22,568-59, A JSE2-0241MAEAD 23,895-76, B JSE2-0241MBEAD 47, , Torque Safety Max. Installation Max. Operating Limiter Brunel Element Eflex Gap Misalignment Misalignment Weight Size P/N Size / Qty K L M N O Angular Parallel Angular Parallel lb. mm / in mm / in mm / in mm / in 1 JSE MAEAD JSE.5 / JSE1-0128MAEAD JSE1 / A JSE1-0129MAEAD JSE1 / B JSE1-0129MBEAD JSE1 / A JSE2-0241MAEAD JSE2 / B JSE2-0241MBEAD JSE2 / Consult factory for special application 9

12 Brunel Safety Element Torque Limiters UEP Ultimate Extruder Protection Torque Limiters w/torsional Couplings Brunel Corporation has through extensive experience developed the Ultimate Extruder Protection device affording reliable protection for twin screw extruders. Based on over 30 years experience in arduous applications particularly in the steel industry has led to the development of the UEP Brunel Modular Torque Limiter which has become the industry standard for twin screw extruder machines. B M R T D E Q S K P C L Ratings and Dimensions Brunel P/N Maximum Preset Torque Nm/lb-in Minimum Preset Torque Nm/lb-in Maximum Speed RPM Coupling Size Module Size Quantity of Modules JSE A RB JSE.5 2 JSE1-0237A RB JSE1 2 JSE1-0238A RB JSE1 2 JSE1-0238B RB JSE1 4 JSE1-0239B RB JSE1 4 JSE1-0300C RB JSE1 6 Dimensions mm and in Rigid Hub Q Brunel P/N B C D E T S L Min Bore JSE A JSE1-0237A JSE1-0238A JSE1-0238B JSE1-0239B JSE1-0300C Max Bore Flex Coupling K M P Min Bore R Max Bore Weight kgs/lbs

13 Brunel Safety Element Torque Limiters For American Gear Coupling C F H, I A G B The SE Series are manual reset, modular ball detent torque limiters. They are mounted between coupling halves, or U-joint flanges or other arrangements. The module construction allows assemblies of unlimited torque capacity, protecting the largest drive lines made. E D Model Number SE1025 SE1030 SE2035 SE2040 SE2045 SE2050 SE2055 Gear Coupling Sze Size of Module JSE1 JSE1 JSE2 JSE2 JSE2 JSE2 JSE2 Quantity of Modules A - Pitch Circle Diameter of Modules Minimum Release Torque (lb in) 17,700 26,600 46,050 61,400 90, , ,800 Maximum release Torque (lb in) 92, , , , , , ,500 Recommended Max. Setting (lb in) 60,100 90, , , , , ,000 B - Torque Limiter Outside diameter C - Torque Limiter Width D - Overall Width E - Breakout Extension F - Flange Gap G - Gear Clpg Bolt Circle Diameter H - Tapped Hole Size 5/8" 5/8" 3/4" 3/4" 3/4" 7/8" 7/8" I - Number of Tapped Holes Shipping Weight (lbs) Model Number SE3060 SE3070 SE3080 SE3090 SE30100 SE30110 SE30120 Gear Coupling Sze Size of Module JSE3 JSE3 JSE3 JSE3 JSE3 JSE3 JSE3 Quantity of Modules A - Pitch Circle Diameter of Modules Minimum Release Torque (lb in) 231, , , , , ,600 1,171,900 Maximum release Torque (lb in) 1,301,300 1,480,900 2,154,600 2,954,500 3,770,000 5,385,400 6,597,200 Recommended Max. Setting (lb in) 845, ,900 1,400,500 1,920,400 2,450,500 3,500,500 4,288,200 B - Torque Limiter Outside diameter C - Torque Limiter Width D - Overall Width E - Breakout Extension F - Flange Gap G - Gear Clpg Bolt Circle Diameter H - Tapped Hole Size 7/8" 1" 1.25" 1.25" 1.25" 1.5" 1.5" I - Number of Tapped Holes Shipping Weight (lbs) Consult factory for special application 11

14 Brunel Safety Element Torque Limiters For The Fresh Water and Waste Water Treatment Industry Features & Advantages Modular Ball Detent/Disc Spring Design All Major Components 316 Stainless Steel Four Safety Element Styles Available 1) Externally Adjustable 2) Disconnectable (Tamperproof) 3) Standard (Tamperproof) 4) Externally Adjustable Disconnectable All Wearing Surfaces D-2 Tool Steel through hardened to Rc62 min. Complete Disengagement on Overload Simple Manual Reset Multiple O Ring Seals Adapts to All Drive Configurations Large Torque & Bore Capacity Brunel Safety Element Torque Limiters have been protecting industrial power transmission systems around the world since The Waste Water Safety Element SE Series Torque Limiters are designed specifically for the outdoor, corrosive waste water environment. They are made of 316 stainless steel throughout with the exception of D-2 ( Rc 62) tool steel working parts in the safety element, O ring seals and PTFE bearings. The internal parts are packed with grease and are externally regreaseable. Eight O ring seals prevent contaminants from entering the unit while a grease vent allows added grease to escape. Modular construction provides design flexibility and simple maintainability. Safety elements are precision Belleville spring loaded, single ball detent design. A unique over-center mechanism ensures complete and bidirectional disengagement on overload and simple, fast manual re-engagement. Four types of Safety Elements: standard, disconnectable, externally adjustable and externally adjustable disconnectable are available and are interchangeable on the base unit. Safety Element Torque Limiters completely disengage on overload thus preventing damage and down time to the equipment. When applied on reducer output shafts in rectangular settling tank drive systems, the SE Torque Limiter protects the reducer, drive chain, drag chain and flight bars. They can also be applied on screw conveyor drives or other sludge collection systems that have potential for jamming. 12

15 Brunel Safety Element Torque Limiters Engineering Data A B E J G H (Axial Movement on Overload) X C K F D Externally Adjustable L Externally Adjustable Disconnectable Style Disconnectable Style (Tamperproof) Standard Safety Element (Tamperproof) BRUNEL Torque Limiter P/N: JSE1-0201EA, S/N 1288 BRUNEL Corporation Wichita Falls, TX (940) M Section X-X X Brunel Safety Torque Safety Dimensions in inches Part No. Element Range Element Min H78 Series Qty. lb in Style A B C D max. E F G H J K L M Sprocket JSE ,540 Standard Qty ,500-15,080 Disconnect /8-16 Tooth External Adj Ext. Adj. Disc JSE ,080-11,000 Standard Qty ,160-22, 000 Disconnect /2-13 Tooth External Adj Ext. Adj. Disc JSE ,400-15,000 Standard Qty ,800-30,000 Disconnect /8-16 Tooth 3 10,200-45,000 External Adj ,600-60,000 Ext. Adj. Disc Item Description Qty. Item Description Qty. Item Description Qty. 1 Module Carrier Hub 1 9 PTFE Bearing /4" -28 x 5/8" S.H.C.S. 4 2 Detent Pocket Plate 1 10 PTFE Bearing Ring 1 18 Grease Fitting 1 3 Retaining Plate 1 11 PTFE Thrust Pad 1 19 Grease Relief Valve (1/8 NPT) 1 4 JSE External Adjust SE 1 12 Blanking Plate 1 20 Detent Pocket 1 5 5/16" -24 x 5/8" S.H.C.S Blanking Plate Seal 1 21 Pointer ( Alignment) 1 6 "O" Ring Seal 1 14 Stainless Steel S.H.C.S. 6 or 8 22 "O" Ring Seal 1 7 "O" Ring Seal 1 15 Stainless Lock Washer 6 or 8 8 5/16" -24 x 1/2" socket set screw 2 16 Stainless Flat Washer 6 or 8 Consult factory for special application 13

16 Brunel Safety Element Torque Limiters Applications Torque Limiting Module Unit for Helicopter Rotor Test Rig 12 off JSE3 Cam Disconnect Modules on a mm PCD Maximum Preset breakout torque = 281,950 lb ft Minimum Preset breakout torque = 188,109 lb ft Maximum operating speed = 275rpm Modules can be disconnected with the cam facility so that a lower number of modules are engaged. The breakout torque will be reduced proportionally. Although the following arrangements show Brunel Torque Limiting Modules used for torque limiting applications, it is also possible to use them for linear motion thrust or pull limiting, such as on presses, feeders etc. If preferred, the Torque Limiting Modules can be supplied as separate items for incorporation in the customer s own drive design. We would be pleased to consider your problem. Torque Limiting Module Unit Fitted to Morbark Wood Grinding Machine Provided to protect the Diesel Engine, u-joint and the rotary cutter head. Various sizes of unit supplied ranging from 46,900 to 195,000 lb in depending on release torque requirement. 16

17 Brunel Safety Element Torque Limiters Applications hp, rpm horizontal grinder Torque Limiter, engine with PTO drives through multiple belt sheave to driven sheave that houses application specified Brunel Torque Limiter mounted directly on mill shaft. When the Torque Limiter releases, it disconnects all the inertias of the engine, belts and sheaves from adding damage to the mill. Wood Hog (Hammermill Grinder) Torque Limiter Wood Hog in Service Tub Grinder Wood Grinder Torque Limiter located between PTO output shaft and u-joint driving hammermill. Morbark Tub Grinder hp rpm 226, ,100 lb. in. Wood Hog Torque Limiter Torque Limiter located in driven sheave on mill shaft. Morbark Wood Hogs hp 47, ,000 lb. in. 17

18 Brunel Safety Element Torque Limiters Applications Modular Torque Limiter Assembly for Waste Water Treatment Plants Specifically designed to operate in the corrosive areas of Sewage Treatment Plants, these units incorporate a number of special features to ensure their suitability for this hostile environment. The units are manufactured with all external components produced in 316 Stainless Steel and incorporate multiple sealing to prevent the ingress of contaminants, grease valves are provided to enable periodic re-lubrication. Various sizes of units are available up to a maximum release torque of 60,000 lb in. F.E. Weymouth Filtration Plant Metro Water District of Southern CA Notingham Water Treatment Plant Cleveland OH Red Hook WPCP - NYC DEP 18

19 Brunel Safety Element Torque Limiters Applications Extruder and Mixer SETL's Brunel SE Type Torque Limiter Assembly used in the Plastics Industry This unit is combined with a Brunel pin & bush coupling on the drive of a twin screw plastic extruder. The unit is fitted to protect the extruder screw from damage due to overload. Similar Twin Screw Extruder Application Brunel SE Type Torque Limiter Assembly used in the Plastics Industry This unit is combined with a Brunel double engagement gear cardan shaft assembly and is installed in the drive of a plastics mixer. The modular design of the SE units permits virtually unlimited release torque capacity. This unit is set to release at 92,000 lb in. 19

20 Brunel Safety Element Torque Limiters Mining Applications Ball Mill Torque Limiter with Parking Brake (5,000 kw motor 1,000 rpm) Optional Designs Using Renold HiTec Coupling JSE Crusher Torque Limiter TO SUIT APPLICATION TO SUIT APPLICATION JSE Crusher Torque Limiter with Counter Shaft 20

21 Brunel Safety Element Torque Limiters Steel Mill Applications Steel Mill Torque Limiters Timken Steel #3 Tube Mill Assel Bar Inserter Drive Torque Limiter Torque Setting = 999,960 lb-in at 100 RPM Gear Coupling with 6 x JSE3 Elements Installed on a Universal Shaping Mill Stand Drive. Release Torque: 2,743,500 lb-in Morgan Construction Co. - Worcester MA, Used at: U.S. Steel, Fairfield, AL Application: Tube Mill Mandrel rack system. S.E.T.L. in combination with Kopflex gear clpg Example of Hollow Shaft Motor Application 21

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23 Brunel Torque Limiting Clutches Torque Limiters Brunel Torque Limiters eliminate the problems associated with slow reaction electrical overload devices, shear pins which give a wide release torque variation, or slip clutches which may rapidly overheat. Brunel products can save you money - the initial cost is frequently more than covered by the saving in down-time even on the first overload. Protect plant and transmission against overload Full bi-directional operation in any plane All metal, totally-enclosed construction Virtually no maintenance Provide years of trouble-free service Low Initial cost Many of our torque limiters have been designed and manufactured to meet customers specific operating requirements. If you have any specific requirements please contact Brunel Corporation for assistance. Bores and Keyways Standard bores and keyways are manufactured to H8 and Js9 tolerances to BS4500: 1969, both in Metric and Imperial dimensions. Maintenance During assembly all units are packed with a 3% Molybdenum Disulphide (MoS 2 ) grease BP Energrease L21 M. Because of their unique fully enclosed design all units need only be stripped and re-packed with grease every two years. However, under extremely adverse conditions of environment and duty please consult Brunel Corporation. Running in Oil All Brunel units can be run in oil if required without affecting performance. Typical Applications Manual Reset Type JA: Conveyors, machine tools, woodworking and paper machinery, pumps, textile machinery, test rigs, packaging machinery, quarrying plant, Post Office machinery, extruders, automatic furnaces and ovens. Automatic Reset Type JB & JC: Conveyors, bakery equipment, indexing drives, packaging, bottling and labelling machines, printing presses and special-purpose machines. Power Take-Off Protection Type JFV: Vane, lobe, screw and centrifugal pumps. Vane and lobe blowers, please contact Brunel Corporation for further details. 23

24 Brunel Safety Element Torque Limiters How to Select and Order How To Select Select Manual Reset or Automatic Reset type overload release clutch to suit your specific application. Choose a position in your drive system for the Torque Limiting Clutch. See page 2 for guidance. Calculate the torque setting required for the position selected. Calculate the maximum permissable torque for the drive components after considering torsional stress in shafting, stress on keys and keyseats, torque capacity of couplings, chains, gears, belts, etc. It is the weakest component in the system that requires protection. or Determine the torque setting based on motor horsepower, drive speed and reduction ratios. horsepower x 5250 drive torque (lb ft) = RPM* or Determine the maximum permissable driven load based on conveyor belt or chain tension. *RPM - at point where torque limiter is applied An allowance for starting torque may be required depending on the location of the clutch in the drive. At the motor shaft, peak torque of approximately twice normal running torque is possible. At locations away from the motor, peak torques will be dampened by system inertia, tending to reduce the effect of motor peak starting torque. Field conditions will also tend to change the calculated torque values. Keep in mind that each torque limiting clutch is adjustable and the final overload release torque setting may have to be adjusted on the job to meet your specific application requirements. With the approximate torque required select the right size and type clutch. Check the clutch selected to make sure the shaft, key, sprocket, pulley, etc. requirements of your application can be accommodated. How To Order Please supply the following information with your order: Quantity: The number of clutches needed. Type & model/bore and keyseat. Example: JAB7 2.00" bore with 1/2 x 1/4 Kws. Torque Setting When combination units are selected supply additional data as required below: For coupling combination supply bore and keyseat for coupling and torque limiter. For sprocket or pulley combination supply complete sprocket or pulley data. Advise torque setting if factory setting is required. Special requirements such as shifter ring, neoprene seals, vertical mounting, etc. must be specified. If bore and/or keyseat sizes other than standard tolerances or shaft fits are required, please specify dimensions completely, including tolerances. The best way to deal with the above variables is to make some allowance when selecting the torque setting required. 24

25 Brunel Torque Limiting Clutches Type JAB - Manual Reset Release Torque: 10 to 4000 lb ft, 14 to 5500Nm Technical Features Complete disengagement on overload Simple one screw torque adjustment Positive drive - no slip Rapid easy reset Torque setting maintained indefinitely Release action can operate a warning device or limit switch Robust and compact design May also be used as a lever operated clutch Bush Bearing Type JAB Ball Bearing Type JAB For particularly dusty conditions such as cement works we offer neoprene seals. Please specify when ordering. Important - Use switch plate and limit switch to quickly shut down drive on break-out to avoid damage to bearing. For prolonged periods of running disengaged, ball-bearing mounted units must be used. For higher speed applications consult Brunel Corporation. Application The clutch can be installed in any drive system, safeguarding against sudden surges or gradual build-up of torque. Modifications are possible to provide manual lever operation of the clutch while retaining the overload release feature. Single direction release and one position reset can also be provided. Normal Running The drive is transmitted from the hub 1 through the splined ring 2 via the tapered jaws 3 to the rotating jaw ring 4. The jaws are held together by spring pressure acting through two angled races (5 and 6) and a crowded circle of balls 7 located by a step on the hub. Disengagement On overload, the tapered jaws are thrust apart, moving the splined ring 2 and lifting the balls 7 over the step on the hub, thus instantly disengaging the drive, leaving rotating jaw ring 4 free to rotate on bearing 10. Torque Adjustment The release torque settings are made by adjusting the control ring 9 so altering the spring forces. The adjusting ring is locked in position by a set screw 8. Re-engagement To re-engage, the tapered jaws are aligned using reference marks and the sliding assembly pushed along the hub until the balls snap back into their original position. This requires no further spring compression and is easily accomplished. For remote resetting the body can be supplied with a flange to suit a resetting mechanism. See diagram below. Installation Clutches can be supplied pilot bored or finish bored and keywayed. The hub may be fitted to either shaft and the flange can be connected to a flexible coupling or can carry a sprocket or pulley. Typical arrangement of Type JAS fitted with shifter ring which can also be optionally used to operate a limit switch. Clearance must be sufficient to allow for clutch disengagement 25

26 Brunel Torque Limiting Clutches Type JAB - Manual Reset Release Torque: 10 to 4000 lb ft, 14 to 5500Nm (Overload Movement) K H HOLES TAP J EQUISPACED E D A F B G C 1 Lower release torques can be achieved. Consult Brunel Corporation. 2 Dimensions G and axial movement on overload also apply to Types JAR, JAF, JAS and JAP. 3 Tolerance on spigot diameter B is f7 to BS 4500: Applicable to all variants except JAP Type. Engaged Disengaged Release Torque 4 Dimensions in mm and inches Min 1 Max Maximum Weight Nm Nm Speed 3 2 kg Model lb ft lb ft rpm A B C D E F G max G min H J K lb JAB / / JAB / / JAB / / JAB / / JAB / / Type JAB Type JAB with ball bearing mounting G OFF H HOLES ON A J PCD E A C D B (Movement on Overload) F 4 Dimensions in mm and inches Max Max Speed Model Bore rpm A B C D E F G H J JAB / / / JAB / / / JAB / / / JAB / / / Consult factory for special application 26

27 Brunel Torque Limiting Clutches Type JAR Type JAB combined with rigid coupling L OFF BO LTS J D E SPIGOT A B H MAX G MAX C K F Release Torque Dimensions in mm and inches Min Max Weight Nm Nm G H kg Model lb ft lb ft A B C D E F Max Max J K L lb JAR JAR JAR JAR JAR Type JAF Type JAB combined with Eflex flexible coupling L OFF BO LTS J D A B H G C K F E GAP BETWEEN FLANGES Release Torque Dimensions in mm and inches Min Max Weight Nm Nm G H H kg Model lb ft lb ft A B C D E F Max Max Min J K L lb JAF JAF JAF JAF JAF Consult factory for special application 27

28 Brunel Torque Limiting Clutches Type JAS Type JAB combined with chainwheel D Duplex and Triplex sprockets will usually be supplied bushed to run on customer s shaft for additional support. G MAX C Release Torque Min Max Dimensions in mm and inches Smallest standard sprocket (number of teeth) Nm Nm Model lb ft lb ft C D G 3 /8 " pitch 1 /2 " pitch 5 /8 " pitch 3 /4 " pitch 1" pitch JAS JAS JAS JAS JAS Type JAP Type JAB combined with pulley B A G MAX C Release Torque Min Max Dimensions in mm and inches Nm Nm Max A Model lb ft lb ft Speed Min B C G JAP Dimension JAP Dependant to suit upon Customers JAP Pulley 210 Pulley Diameter 8.27 Requirements JAP Consult factory for special application 28

29 Brunel Torque Limiting Clutches Type JFV PTO Drive Manual Reset F Re-engagement Release G - UNF Tap H - Quantity 4 E D A B C Technical Features Pointer to show direction of Re-engagement Bolt Pattern.080 Pilot Depth Prevents Expensive Transmission Damage By Automatically Disengaging On Overload Simple Adjustment 40 Easy Reset Flange Mates With Standard Series Universal Joints Maximum Speed 3000 rpm 40 Grease Lubricated Release Torque Adjustable Up To 560 Ib ft Maximum Fully Sealed Against The Environment Of A PTO Drive Series 1310, 1350, 1410, 1480, 1550 Release Torque Dimensions in mm and inches Min Max Universal Bolt Weight Nm Nm Max. Joint Pilot Dia. Circle Dia. kg Model lb ft lb ft Bore Series A B C D E F G H lb / JFV or / / / or / / / or / / Installation The hub is mounted on the drive shaft of the PTO using a push fit and key. When installing, do not hammer the flange face 1. Mount universal joint to flange using socket head screws. Release Torque Setting The clutch can be supplied set to your specified torque. To increase the setting, turn the adjusting nut 2 clockwise; to decrease, counterclockwise. Do not unscrew beyond the flush position where the zero marks coincide. To Reset When the clutch operates and disengages the drive, first locate and clear the cause of the overload. To reset, rotate the flange 1 to align the raised screw 3 in the housing with the set screw 4 in the hub. Hold the flange and, with a pry-bar, turn slightly in the direction of the arrow. Maintenance Clutches are grease-packed on assembly with a molybdenum disulphide base of grease. A grease fitting is provided for routine maintenance. Consult factory for special application 29

30 Brunel Torque Limiting Clutches Type JCB Automatic Reset Release Torque: 10 to 150 Ib ft, 14 to 210Nm F D H HOLES ON J PCD K DEEP E 3 SWITCH ACTUATING PLATE A B G MAX C L Technical Features Instant release at pre-set torque Smooth hold-out for one revolution Means for motor switch-off Automatic self-engagement on restart without loss of phasing 2.54mm (.100 ) OVERLOAD MOVEMENT 1 Release Torque 4 Dimensions in mm and inches Min. Max. Max Weight Model Nm Nm Speed 3 G Kg lb ft lb ft rpm A B C D E F Max H J K L lb JCB / / JCB / / Lower release torques can be achieved. Consult Brunel Corporation. 2 Tolerance on spigot diameter B is F7 to BS 4500: For higher release torques use Type B on page Standard tolerances on keyways is JS9 and on bores H8 to BS 4500: Applicable to all variants. Normal Running The drive is transmitted between the hub flange 1 and the housing 2 by the balls 3, spring-loaded into the pockets on the flange face. Disengagement On overload, the balls are displaced axially through the housing, further compressing the springs. Once out of their pockets, the balls roll on the face of the hub flange for one revolution before re-engaging and synchronizing the drive. Torque Adjustment The release torque is set by tightening nut 4 thus increasing the spring pressure. After setting, the nut is locked with a set screw and plug. Installation Clutches can be supplied pilot bored or finish bored and keywayed. The hub may be fitted to either shaft and should be located against a shoulder to resist the resetting spring force and locked by means of set screw in the hub flange. The drive flange may be replaced by a sprocket, pulley, etc., or connected to a coupling. See pages 31 and 32. Application This type of protection is ideally suited to drives such as wrapping and packing machinery where it is essential to restart in the correct sequence and where access for manual resetting is not available. Type JC clutches should always be used with a limit switch to bring the drive to rest within a few revolutions thus preventing possible damage by continual releasing and resetting. Consult factory for special application 30

31 Brunel Torque Limiting Clutches Type JCR Type JCB combined with rigid coupling K OFF BOLTS D A B E MAX G MAX C F This arrangement will not accommodate any misalignment. H Release Torque Dimensions in mm and inches Min Max Weight Nm Nm E G kg Model lb ft lb ft A B C D Max F Max H K lb JCR JCR Type JCF Type JCB combined with Brunel Eflex flexible coupling K OFF BOLTS ON J PCD A B H MAX G MAX C D (GAP) F E Release Torque Dimensions in mm and inches Min Max Weight Nm Nm G H kg Model lb ft lb ft A B C D E F Max Max J K lb JCF JCF Consult factory for special application 31

32 Brunel Torque Limiting Clutches Type JCS Type JCB combined with sprocket B Duplex and Triplex sprocketswill usually be supplied bushed to run on customer s shaft for additional support. G MAX C A For sprockets smaller than listed, an adapter is used. Details available on request. For sprockets smaller than listed, an adapter is used. Details available on request. Release Torque Dimensions in mm and inches Smallest standard sprocket (number of teeth) Min. Max. Model Nm Nm lb ft lb ft A B C G Max. 3 /8 " pitch 1 /2 " pitch 5 /8 " pitch 3 /4 " pitch 1" pitch JCS JCS Type JCP Type JCB combined with pulley B E MIN G MAX C A Pulleys to suit the following belts can also be supplied:- standard V section, flat, poly V, and timing or toothed. For pulleys smaller than listed, an adapter is used. Details available on request. Release Torque Min Max Dimensions in mm and inches Nm Nm E G Model lb ft lb ft A B C Min Max JCP To suit JCP To suit Consult factory for special application 32

33 Brunel Torque Limiting Clutches Type JBB - Automatic Reset Release Torque: 50 to 1000 Ib ft, 70 to 1356Nm H Overload movement 6 HOLES TAP J EQUISPACED mm Technical Features Instant release at pre-set torque Note: Ball bearing standard on model Ball bearing or bronze bush on model 550 depending on application requirement. C D B E A Smooth hold-out for one revolution Means for motor switch-off F Automatic self-engagement on restart without loss of phasing G Also available fitted with pulley (JBP) Rigid Coupling (JBR) Release Torque 1 Dimensions in mm and inches Min Max Max Weight Nm Nm Speed kg Model lb ft lb ft rpm A B C D E Max E Min F G H J lb JBB f / JBB f / Normal Running The drive is transmitted between the hub flange 1 and the drive flange 2 by the balls 4, spring-loaded into the pockets on the ball detent ring 3 secured by dowels. Disengagement On overload, the balls are displaced axially through the hub flange, further compressing the springs. Once out of their pockets, the balls roll on the face of the hub flange for one revolution before reengaging and synchronizing the drive. Torque Adjustment The release torque is set by tightening nut 5 thus increasing the spring pressure. After setting, the nut is locked by a set screw. Installation Clutches can be supplied pilot bored or finish bored and keywayed. The hub may be fitted to either shaft and should be axially constrained against a shoulder to resist the resetting force and locked by means of a set screw onto the shaft key. The drive flange may be connected to a flexible coupling or can carry a sprocket or pulley. Application This type of protection is ideally suited to drives where it is essential to restart in the correct sequence and where access for manual resetting is not available. 1 Applicable to all variants. Note: Type JBB clutches should always be used with a limit switch to bring the drive to rest within a few revolutions thus preventing possible damage by continual releasing and resetting. Consult factory for special application 33

34 Brunel Torque Limiting Clutches Type JBS Type JBB combined with chainwheel G B E A Ball bearing standard on Model JBS7. Ball bearing or bronze bush on Model JBS6 depending on application requirement. Duplex and Triplex sprockets will usually be supplied bushed to run on customer s shaft for additional support. For sprockets smaller than listed, an adapter is used. Details on request. Release Torque Dimensions in mm and inches Smallest standard sprocket (number of teeth) Min. Max. Model Nm Nm lb ft lb ft A B E Max E Min G 3 /8 " pitch 1 /2 " pitch 5 /8 " pitch 3 /4 " pitch 1" pitch JBS JBS Type JBF Type JBB combined with Brunel Eflex flexible coupling L NO OFF BOLTS C D J G F B K H E A Release Torque Dimensions in mm and inches Min. Max. Weight Model Nm Nm Kg lb ft lb ft A B C D E Max E Min F G H Max H Min J K L lb JBF JBF Consult factory for special application 34

35 Brunel Power Modules PTM-3 Programmable Load Monitor for any Electric Motor Limits Torque Fast Reliable Easy to Install Protect Equipment from: Overloads, Jams and Excess Torque Underloads, Run-dry, Cavitation Phase Loss, Phase Reversal, or Undervoltage. INDUSTRIAL CONTROL EQUIPMENT PTM-3-4XL & PTM-3-4XLC 8FA 2 Monitor: Viscosity, Flow, Torque, Wear Power Consumption, Load Profiles Power Factor, Energy Usage Equipment, Drivetrain, Process Data Acquisition from Desktop PC View Real-Time & Plot: Watts, Amps, Volts, Power Factor, Frequency, HP, % Loads, Peak Loads. Remotely Set: Trip Levels, Delays Typical Applications: Pumps - blockage, run-dry cavitation protection Mechanical drives - Immediate recognition of overload or underload Conveyors and feeders - blockage protection Grinding mills - feeder control and blockage protection Benefits: Absolutely limits torque to levels that you set. Detect trouble & provide early warning Protect machine, tools, & process Optimize machine adjustments & improve process quality Reduce downtime & maintenance Increase equipment output Signal beginning or end of process Features: Front Panel programming & Actual Load Display Up to three alarm limits Analog or Digital output Program and monitor unit remotely from PC Accurate power transducer input for PLC/PC Controllers Infra-red remote programming (optional) 35

36 Brunel Power Modules PTM-3 Programmable Load Monitor for any Electric Motor Typical Wiring Diagram PTM-3 & PTM-3-4XL POWER SENSOR MODULE (PSM) ANALOG OUTPUT LINKS 0-10V or 4-20mA WARNING DANGEROUS VOLTAGES DISCONNECT FROM MAIN SERVICE BEFORE PERFORMING ANY WORK. INSTALLATION MUST BE PERFORMED BY QUALIFIED PERSONNEL TWISTED SHIELDED PAIR ANALOG OUTPUT AN- MOTOR VOLTAGE INPUT AN+ L3 L2 L1 CURRENT INPUT (L1) (COM) EXTERNAL POWER SOURCE V AC FUSE "T" 315mA, 250V L N E BLACK RED 120V AC MOTOR T1 T2 T3 L1 L2 L3 * External C.T. req'd Over 8 amps (locked rotor amps) CPT (Control Power transformer) CIRCUIT BREAKER 3 PH ORMAIN FUSED DISCONNECT 3ph, or 600 Volts A1 C1 Starter Contactor Coil A2 *Note: current input to PTM must be from phase note used by CPT POWER TRIP MODULE (PTM) TRIP LEDs PF ENERGIZE ON TRIP DE-ENERGIZE ON TRIP RELAY RELAY 1 2 RELAY 3 NO1 NC1 COM1 NO2 NC2 COM2 NO3 NC3 COM3 FAIL + RESET UNDERLOAD, OVERLOAD MOTOR CUTOUT OR ALARMS External Reset "Phase Fail" Opto-Isolated NPN Transistor 100mA, 24V Max. 36

37 Brunel Power Modules PTM-3 Specifications 7.87 (200mm) TRIPS POWER MODULE SET 3.54 (90mm) 4.72 (120mm) Power Supply Motor Voltage Internal Current Transformer Frequency Range VAC 50-60Hz, 5W max. Single and Three Phase: 600V max. 5Amps max. (L1)for >5A use a standard external 5A secondary current transformer VFD Compatible Hz Accuracy Voltage ±2%, Current ±3%, Power ±5% Analog Output 0-10V or 4-20mA (max. load 450) Reaction Time Display Displayed Values Trip Relays Trip Delays Trip Hold Start Delay Phase Loss Output Enclosure Dimensions Environment 23ms actuation time or 19ms release time 3 LED digits, 14.2 mm high, red Load calibrated to read 100 at normal running load Status messages start, stop, phase failure Set-up values (i.e. trip levels). Motor power, current and voltage Three Form C Relays, contacts rated 28VDC or 120VAC, 240VAC (May be switched to energize or de-energize on trip) 0-25s in 0.1s increments ON/OFF select, pushbutton reset, terminals for external reset contacts 0-250s (0-9.9s in 0.1s increments; > 10s in 1s increments) Opto-isolated NPN transistor, 100mA 24V max. (Changes state if phase failure, 10% voltage drop, or phase sequence changes) NEMA 4X/IP66 Polycarbonate box with hinged clear cover. Enclosure can be drilled, sawed or punched on bottom, sides or back for wiring access. Options: DIN rail adapter G or 35mm top hat, open frame L mounting bracket 200mm(H) x 120mm(W) x 90mm(D) Outside dimensions 7.87" 4.72" 3.54" NEMA 4X / IP66, -4 F to +140 F (-20 C to +60 C) 37

38 Brunel Power Modules PTM-4 Load Monitor INDUSTRIAL CONTROL EQUIPMENT 8FA 2 Features: Most cost-effective motor load protection. TYPICAL WIRING DIAGRAM PTM-4 Smallest unit available. Measures the motor active power. Internal Current Transformer. 1, 2, 4 & 8A motor current ranges. 3 PH MAIN 600V 60Hz Max. CIRCUIT BREAKER OR FUSED DISCONNECT External CT required if over 8 amps locked Rotor * L1 L2 L3 A1 T1 T2 T3 C1 A2 MOTOR Single or three-phase motors. Auto-Cal feature sets load reading to 100% with the motor running at normal load, together with default trip levels and hysteresis. Simple set-up of trip levels: greater than 100% = overload, less than 100% = underload. Easy cloning of units. Diagnostic displays for Volts, Amps & Power. Intuitive display with simplified adjustment of parameters. *Note: Current Input to PTM-4 Must be taken from phase not used by CPT (Control Power Transformer) EXTERNAL POWER SOURCE V AC CPT 120V AC Nominal CT+ RS CT- L1 L2 L3 1 2 V A P/Reset A- A+ C R1 R2 N L Starter Contactor Coil WARNING DANGEROUS VOLTAGES DISCONNECT FROM MAIN SERVICE BEFORE PERFORMING ANY WORK. INSTALLATION MUST BE PERFORMED BY QUALIFIED PERSONNEL Remote Trip Reset Double Pole Double Throw monentary pushbotton A- Analog Output Load A+ meter RS A+ for 4-20mA out A- for 1-10V out Remote reset of latched relays. Analog output option: (4-20mA or 0-10V). A1 Warning Light C1 A2 Remote Trip Inhibit RS A+ for 4-20mA out A- for 1-10V out Infra-red remote programming (optional) C1 Relay C RI Normally Closed C R2 Normally Open 38

39 Brunel Power Modules PTM-4 Load Monitor Specifications 1 2 V A P/Reset (117mm) (78mm) (45mm) Power Supply VAC 50-60Hz, 5VA max. Motor Voltage 600VAC max. Motor Current Programmable: 1A, 2A, 4A, 8A. Ranges (or >8A use an external 5A secondary current transformer). Frequency 45-65Hz Display Three 7 segment digits, 0.4in high, high intensity red. Displayed Values Running: Load: (calibrated to read 100). Stopped: Peak Load. Status messages: Start, Stop. Set-up: Trip Levels, Start & Trip delays, Hold ON/OFF Diagnostics: Peak Load, Volts (RMS), Amps (RMS), Watts or kw (auto-ranging), Relays 2 contacts rated 28VDC or 120VAC, 240VAC. (Relay 1-NC, Relay 2-NO) Trip Delays 0-25s in 0.1s increments. Trip Hold (latch) ON/OFF select, pushbutton Reset, terminals for external Reset contacts Start Delay 0-250s (0-9.9s in 0.1s increments) Analog Output Option 0-10V or 4-20mA, max. load 450 Ohms (jumper selectable). Enclosure 1.772in (45mm) width x 3.071in (78mm) height x 4.606in (117mm) depth - Noral/Lexan - Gray (RAL 7035). Wire sizes Upper terminals: 2x2.5 2 mm (AWG 14) or 1x4 2 mm (AWG 12). Lower terminals: 1x2.5 2 mm (AWG 14). Mounting 35/36mm DIN rail. Optional front panel adapter, or NEMA 4X enclosure. Environment Operating temperature: -4 F to F (-20 C to +50 C) 39

40 Brunel Power Modules PTM-4 Mounting Bracket Brunel Current Transformer CT Model Current Transformer General Purpose Compact Units, UR/cUR Recognized Dimensions (inches) Part Number (without brackets) Window Size (inches) Current Rating (Amperes) VA 60 Hz VA 400 Hz Accuracy (At Rated Current) Rating Factor 30 C Ambient.20 Diameter Mounting Hole (2) A H1 CT Model A B C D E B E C D CT-50 50: =2% 1.0 CT-60 60: =2% 1.0 CT-75 75: =2% 1.0 CT-80 80: =2% 1.0 CT : =1% 1.0 CT /8 120: =1% 1.0 CT : =1% 1.0 CT : =1% 1.0 CT : =1% 1.0 CT : =1% 1.0 CT : =1%

41 Brunel Proximity Sensors Inductive Sensors Extruder Proximity Sensors Housing Style Part Number Features 18 mm - Embeddable Rotational SpeedMonitor, Potted-In Cable SensingRange (mm) Output IPSM185DC Uprox 5 3-Wire DC PNP 30 mm - Embeddable Rotational Speed Monitor, Potted-In Cable IPSM3010DC Uprox 10 3-Wire DC PNP Waste Water Proximity Sensors Housing Style - Rectangular Part Number Features Embeddable Sensing Range (mm) 14 mm - Embeddable/Nonembeddable, Potted-In Cable IP Output Housing Style Part Number Features Shielded 30 mm - Mini Quick-Disconnect Sensing Range (mm) Output Configuration Switching Frequency (Hz) IP3010NO Stainless Steel Yes 10 N.O. 15 IP3010NC Stainless Steel Yes 10 N.C. 12 Note 1: No ground pin on 12mm. Attach housing to ground. Note 2: Load can be switched to pin 2. 41

42 Brunel Proximity Sensors Inductive Sensors Waste Water Proximity Sensors Housing Style Part Number Features 30 mm - Embeddable, minifast Connection IP3015 Extended Range SensingRange (mm) Output 15 2-Wire AC/DC Short-Circuit Protected Housing Style Part Number Features Sensing Range (mm) 30 mm - Embeddable, Potted-In Cable IP Wire AC/DC Short-Circuit Protection Output IP Wire AC/DC Accessories Right Angle Cable for Quick-Disconnect Style Sensors Part Number Length (feet) 1.56 Green Black RAC3 3 RAC6 6 RAC Red 3 2 White 42

43 Brunel Proximity Sensors Inductive Sensors High Speed Inductive Proximity Sensors Housing Style Part Number Features SensingRange (mm) Output 12 mm - Embeddable, eurofast Connection HSIP1204 Stainless Steel 4 3-Wire DC PNP 18 mm - Embeddable, eurofast Connection HSIP1805 Stainless Steel Front Cap 5 3-Wire DC PNP 30 mm - Embeddable, eurofast Connection HSIP3010 Stainless Steel Front Cap 10 3-Wire DC PNP Switches Housing Style Part Number Features Zero Speed Switch ZSS1R1 Speed Monitor - Single channel for over/under speed detection with start-up override, 120Vac. Synchronization Monitor SYNCMON1 K-System intrinsic safety barriers- Universal Logic Control - Single channel for speed, frequency, timer and syncronization applications with display, 24Vdc/120/ 240Vac with display. 43

44 Brunel Proximity Sensors Inductive Sensors High Speed Inductive Proximity Sensors DC Sensor Power Supply Power Supply Dimensions Part Number Supply Voltage Sensor Connection Supply/Output Cable DCPOWERSPLY V AC 60 Hz 5-Pin Pigtail Euro-Style QD 5-Pin Mini QD Pulse Stretcher Smart Plug Dimensions Part Number Features PULSESTRETCHER Red LED dispaly Quick Disconnect Cordset Style Part Number Features Length (inches) Used With 5-Pin Euro-style Cordset Double Ended DBLCS-5 Pin Euro Female Straight/ Male Straight 20 Flex Power Module Expandable I/O Module 5-Pin Mini-Style 5-Pin Cable Female Straight/Unterminated 72 AC Power Supplies 44