Binsfeld TorqueTrak Revolution User manual

Binsfeld Engineering Inc. (+01)231-334-4383 www.binsfeld.com 866005iB Page 1
TorqueTrak Revolution Installation Guide
Tools Required:Digital multimeter, solder and soldering iron,
5/8”, 9/16” and 11/16” socket wrenches,
1/8”, 5/32” and 1/4” hex wrenches, and wire strippers
Step 2:
Secure Rotating Collar to Shaft
-Assemble the Collar on the shaft
near the gage with lead wires
toward the gage.
USE CARE WITH CONNECTORS
-Secure the Collar with bolts
provided after applying antiseize
compound to the threads.
-Tighten alternate bolts evenly
until gap between the halves is
as shown above.
Step 3:
Mount Master Control Unit
-Mount Master Control Unit
(MCU) to a mounting bracket so
that the back edge of the
Mounting Block is aligned with
the back surface of the Collar.
-Remove the MCU cover.
-Connect power supply to Power
Input connector (green) and
connect to the mating terminal
inside MCU.
Step 1:
Install Strain Gage Sensor
- Glue gage to shaft at least 1 inch
(2.5 cm) from the Rotating Collar
per manufacturer’s instructions.
- Do not attach Revolution lead wires
to strain gage at this time.
(shaft)
Step 5:
Verify System Operation
-Slide the Main Power switch to ON.
-After 10 seconds, verify that Main System
Status and Star Bridge lights are on solid.
(If Main System Status light is flashing or
Star Bridge light is not on, see
Troubleshooting Guide on back.)
-Connect ammeter to Torque Signal
Output Terminals (1 & 2) inside MCU.
-Measure Torque Signal current (mA).
Reading should be approximately 12 mA.
-Slide Remote Shunt switch inside MCU to
ON. (Main System Status light will flash.)
-Measure Torque Signal current (mA).
Reading should be approximately 16 mA.
-Slide Remote Shunt switch inside MCU to
OFF. (Main System Status light on solid.)
Star Bridge
Resistor Set
Strain Gage Sensor
(jumper wire)
Step 6:
Connect Signal and Gage WIres
-Remove star bridge from lead
wires and discard.
-Solder leads from collar to gage
as shown.
-Connect permanent signal leads
to Signal Output connector
(black) and connect to the
mating terminal inside MCU.
(edge view)
0.100” (2.5 mm)
no gap between
connectors
0.020” (0.5 mm)
Main System
Status Indicator
Light
Mounting
Block
Step 4:
Install Stationary Power Coil
-Assemble the Power Coil to
the Mounting Block with
screws provided.
-Verify that the Power Coil is
aligned with the Collar before
proceeding. Adjust the Collar
or MCU position if necessary.
CAUTION: For successful operation
there should be no metal (other than the
shaft) within 1” (2.5 cm) of the Power Coil

Binsfeld Engineering Inc. (+01)231-334-4383 www.binsfeld.com 866005iB Page 2
TorqueTrak Revolution Troubleshooting Guide
WARNING: Supply voltage (up to 230VAC) is live inside the Master Control Unit (MCU) even when the Main Power
switch is off! Use caution when accessing internal controls.
When the TorqueTrak Revolution is first powered up, it cycles through the startup sequence, lasting 10-15 seconds.
During startup mode, all of the Indicator lights flash in unison. If all system checks are positive, the Main System Status
light on the outside of the control box remains on solid, and the system is ready for operation.
Normal Operating Mode (no errors)
Indicator
Condition
Main System Status (red light outside MCU)
On solid
Stator (green light inside MCU)
On solid
Rotor (green light inside MCU)
On solid
Data (green light inside MCU)
On solid
Range (red light inside MCU)
Off
If an error is present, the Main System Status light will flash and the system will display an error code briefly (another 10-
15 seconds) before the startup cycle repeats. Below are the most common error modes and potential corrective actions.
Error Mode: Power supply voltage to system is incorrect
Indicator
Condition
Suggested Corrective Action
Main System Status
Fast flash (4 Hz)
1. Supply the correct voltage to the MCU (see manual
for details)
Stator
Flashing (2 or 4 Hz)
Error Mode: Weak inductive interface
Indicator
Condition
Suggested Corrective Action
Main System Status
Fast flash (4 Hz)
1. Make certain the Rotating Collar connectors are not
damaged and are completely engaged
2. Check alignment of the Rotating Collar within the
Power Ring: the back surface of the Collar should
align with the back edge of the Mounting Block
3. Make certain the Power Coil is not shorted to the
MCU enclosure by water or other conductive
material
4. Remove any surrounding metal other than the shaft
within 1 inch (2.5 cm) of the Power Coil
5. Verify that Rotating Coil voltage is about 120 mVAC
(probe the two terminal dots on the outer surface of
the Coil Boards attached to the Rotating Collar)
6. Verify voltage is about 35 mVAC across the outer
set of attachment screws to the Mounting Block
7. Clean the mating surfaces of the Power Ring and
tighten all the mounting screws
Stator
On solid
Rotor
Slow flash (2 Hz)
Data
Off or flickering
Error Mode: Strain gage problem
Indicator
Condition
Suggested Corrective Action
Main System Status
Fast flash (4 Hz)
1. Verify the excitation voltage to the gage is 2.5 VDC
(or light on Star Bridge should be on solid when
connected in place of the gage)
2. Check solder connections and wiring to the gage
3. Balance the gage to reduce the offset or apply a
new gage
Stator
On solid
Rotor
On solid
Data
On solid
Range
On solid