micro-trak Shaft-Trak User manual

1
Installation and Operation Instructions
Shaft-Trak TM -P/N 50209
CONSOLE END VIEW
Console easily adjusts for
side or dashboard mounting.
Rubber washers
Carriage bolts
Mount knobs
Drill ¼” (7mm)
holes for bolts,
or “ (5mm)
holes for self-
tapping screws.
316
Bolts
Lockwashers
and nuts
Shaft-Trak™
RUNNING
RUNNING
STOPPED
STOPPED
123
456
Illustration 1 Illustration 4Illustration 3Illustration 2
OVERVIEW
The Shaft-Trak™ is a Go/NoGo monitor and senses that rotation less than 45
RPM is a stopped or “NoGo” condition and rotation greater than 45 RPM is an
active or “GO” condition. Each shaft or bin is monitored independently of the
others. A GREEN LED light indicates that the respective shaft rotation or bin
level is acceptible. When monitored shaft RPM falls below the minimum of 45
RPM or the level of product in a bin drops below the bin sensor level, the RED
LED will flash and an audible alarm will sound (audible alarm is switchable).
After 45 seconds, the RED LED and alarm will turn off. The system is designed
to be used with either the standard Micro-Trak sensor (black housing) or the
Micro-Trak gear tooth sensor (red housing). Bin level sensors are infrared
optical type.
INSTALLING CONSOLE
Console/Bracket - See Illustration 1
Select a mounting location that is convenient to reach and
highly visible to the operator. DO NOT INSTALL IN A POSITION
THAT OBSTRUCTS THE VIEW OF THE ROAD OR WORK AREA.
Avoid locations that expose the console to direct sunlight, high
temperature, strong chemicals or rain.
Place the mounting bracket in selected location, mark holes, drill
1/4” (7mm) holes and mount bracket with bolts, lockwashers
and nuts provided. (Use self-tapping screws if not practical to
use bolts.) See Illustration 2.
Place rubber washers on carriage bolts and push the bolts
through the bracket holes from the inside out. Loosely attach
the mount knobs onto the bolts. Place console over carriage bolt
heads and tighten knobs to secure the console. See Illustration 3.
The console bracket can be mounted on either a horizontal or
vertical surface. See Illustration 4.
Shaft-TrakTM
On/O switch for audible alarm
Mount
knob
Console
bracket
Console
body
Mount
knob
Shaft & Bin Monitor System

2
Installation and Operation Instructions
Shaft-Trak TM -P/N 50209 (cont)
USING BIN LEVEL SENSORS
Either row of sensor indicators - 1-3 and/or 4-6 can be operated in either shaft sensing mode or bin level sensing mode. To enable Bin Level
sensing, simply insert included magnet in lower molded pocket on side of plastic console case - see Illustration 8 below. Peel o
protective paper from the 2-sided tape and press rmly to secure. It is critical that the SOUTH pole side with dashed line faces the console body.
Installation instructions for the bin level sensors (P/N 50226) are included with the Bin Level Sensor Kit - P/N 01544.
Illustration 8
Insert magnet here to
enable bin indication
on sensors 1, 2, and 3.
The dashed side of the
magnet must face the
console body.
Insert magnet here to
enable bin indication
on sensors 4, 5, and 6.
The dashed side of the
magnet must face the
console body.
Sensors 1, 2, and 3 Sensors 4, 5, and 6
45° max
Sensor
(black body)
Magnet
3/8” nuts
Bracket must
be rigidly
mounted
Sensor assembly must not
be mounted more than
45° from perpendicular
¼” to ½” air gap
S
S
Plastic Cable Tie
Shaft
NOTE: Magnets can be placed closer than 1” apart
if magnet with opposite polarity is
placed between them.
South South
1 2
1” minimum
S
N
INSTALLING SHAFT SENSORS
Locate the following parts
• Shaft sensor cable (black housing) • Magnets • Cable ties
(Your unit may have factory-installed magnets and/or sensors,
the following illustrations may not apply)
Mount magnet with SOUTH pole (dashed line) facing tip of
sensor. Some installations may require more than one magnet
per shaft. The magnets provided by Micro-Trak are marked with
a dashed line on the SOUTH pole side of the magnet.
See Illustration 5.
INSTALLATION: For proper operation, the magnets must be
evenly spaced around the shaft. The magnets must be at least 1”
apart. See Illustration 6.
NOTE: magnets may be attached with a cable tie or adhered
with epoxy or other high quality adhesive. When using
adhesive, thoroughly clean the area of dirt and oil. Use
of cable ties or other mechanical attachment is highly
recommended.
Mount the shaft sensor directly over the path of the rotating
magnets. For the shaft sensor to operate properly, the spacing
between the magnets and the tip of the sensor must always
remain constant. Before permanently mounting any parts, verify
that the mouting location will meet the specs. See Illustration 7.
Note that magnets can be closer than 1” apart only if another
magnet with opposite polarity is mounted between each of the
south-faced magnets. NOTE: Observe magnet polarities.
Illustration 7
Illustration 6Illustration 5

3
Table 1
OPERATION
No calibration or set-up is required.
The Shaft-Trak TM console constantly monitors all of the shaft and
bin sensors independently. If shaft rotation is greater than minimum
RPM, or a bin level senses product, Shaft-Trak will indicate with a
green LED for that particular sensor.
Each time power to the Shaft-Trak TM is turned on, all of the red lights
will flash for approximately one minute, or until any or all bin levels
are okay or shafts have exceeded 45 RPM (if only using one magnet).
If a particular shaft exceeds the minimum RPM, its corresponding
green light will turn on and the red light will turn off. If bin levels
are okay, the green bin level indicators will turn on immediately. If
any shaft does NOT reach the minimum RPM within one minute of
power-up, or if a bin is empty, both lights for that sensor will turn
off. This avoids unnecessary lights flashing if a sensor channel is not
being used.
If a lower minimum RPM is needed, simply add magnets, per Table 1.
If the shaft RPM of any of the active (green lights on) shafts drops
below 45 RPM (one magnet), or a bin level is low, the corresponding
red light will flash to alert the operator that the shaft has effectively
stopped or the bin is empty. The audible alarm will also sound (if
enabled). The red light will continue to flash as long as the shaft RPM
or the bin level is low, (for a maximum of one minute). If the shaft
RPM remains below the minimum RPM, or the bin level remains low,
at the end of the one minute period, it will turn both lights off until
that shaft rotates at more than the minimum RPM again - or until the
bin has been filled.
Carefully route switch
cable to a 12VDC source
BLACKto Ground
Attach RED wire to
12VDC terminal or lead that is
“hot” with ignition on.
4-amp in-line fuse (NOT PROVIDED) required for unprotected circuits
Illustration 9
Illustration 10
Number of Magnets Approximate
Min RPM Number of Magnets Approximate Min RPM
1 45 5 9
2 22½67½
3 15 10 (or molded shaft sensor) 4½
4 11¼
Installation and Operation Instructions
Shaft-Trak TM -P/N 50209 (cont)
Sensor Harness
See schematic (below and system drawing - Illustration 10 below. The
branch cable P/N 14473 is color-coded with cable ties to match shaft or
bin sensors with corresponding indicators on console.
Electrical Installation
Shaft-Trak TM must be connected to a 12-volt DC negative ground electrical system. Using your test light, locate a terminal or wire connected to your
ignition switch which is “hot” when the ignition is turned on and “dead” when the ignition is off. A 12V outlet adapter may be used if desired.
Locate the power cable on the main wiring harness. See Illustration 9.Connect the RED wire to the contact point you have located. (A 4-amp in-line
fuse is required for unprotected circuits.) Attach the BLACK wire (ground) to a screw or bolt on the equipment frame. Be sure there is clean metal-to-
metal contact. The terminal connectors have been supplied for your convenience. You may wish to substitute other types of connectors or make a
direct solder connection. In routing cable to console, avoid areas where the cable may be subjected to abrasion or excessive heat.
A
B
C
D
E
F
G
H
J
K
10-PIN M/P SHROUD
RED TIE
A
B
C
A
B
C
A
B
C
A
B
C
A
B
C
A
B
C
3-PIN
M/P 150
TOWER
3-PIN
M/P 150
TOWER
3-PIN
M/P 150
TOWER
3-PIN
M/P 150
TOWER
3-PIN
M/P 150
TOWER
3-PIN
M/P 150
TOWER
SIGNAL
POWER SHAFT
1
GROUND
SIGNAL
POWER SHAFT
6
GROUND
SIGNAL
POWER SHAFT
5
GROUND
SIGNAL
POWER SHAFT
4
GROUND
SIGNAL
POWER SHAFT
3
GROUND
SIGNAL
POWER SHAFT
2
GROUND
84”
WHT
WHT
BLK
BLK
RED
RED
RED
RED
RED
RED
ORG TIE
YEL TIE
GRN TIE
BLU TIE
GRY TIE
WHT
BLK
RED
WHT
BLK
RED
WHT
BLK
RED
WHT
BLK
RED
WHT
BLK
RED
WHT
BLK
RED

4
TROUBLESHOOTING COMPONENTS
CONSOLE: Make sure the console is in the desired mode (Shaft
or Bin). Either set of 3 inputs (1-3 or 4-6) can be operated in either
SHAFT mode or BIN mode by inserting or removing magnets as
shown on page 2.
It is easy to tell which mode each set of inputs is operating in
when the console is turned on: if a set of inputs is set up for BIN
mode and all sensors are disconnected, all of the GREEN lights will
light. If set up for SHAFT mode, and all sensors are disconnected,
all of the RED lights will flash.
HARNESS: The harness can be checked using an ohmmeter or
continuity tester. The main wiring diagram shows the pin out of all
connectors.
ELECTRICAL INTERFERENCE: Erratic operation of the system
may be the result of electrical interference from ignition wires or
inductive loads (electrical clutch, fan solenoid, etc.) Always try to
route wires as far away from suspect areas as possible. If problems
occur, you may need to relocate the console and/or wiring harness,
or install a noise suppressor.
POWER: Check power source with a test light. If there is no power,
trace cable toward battery looking for breaks. Also check any fuses
or circuit breakers that supply power to the console.
ACCESSORY POWER: The shaft/bin cables have an accessory
power wire. Check for 12 volts between B (white) and C (black) of
the 3 pin connectors. If power is not present, make sure the ac-
cessory power wire is not open or shorted to ground or to another
wire. If this wire has a problem the console may exhibit erratic
behavior or not function at all.
SHAFT SENSORS: Improper connection or voltage could dam-
age sensors. The Micro-Trak standard sensor (black housing)
works similar to a reed switch, but requires power in order to
function. The internal circuit “closes” when near the south pole
(dashed side) of a magnet and is otherwise “open”.
Ground pin C (black) and connect 12 volts to pin B (white) of the
sensor cable. Connect the positive lead (red) of an ohmmeter or
continuity tester to pin A (red) and the negative lead (black) of the
ohmmeter or continuity tester to pin C (black) of the sensor cable.
Holding the tip of the sensor up to the south pole (dashed side) of
a magnet should result in a very low resistance (around 300 ohms).
Taking the sensor away from the magnet should result in a very
high resistance (infinite).
This troubleshooting procedure can also be used for the Micro-
Trak gear tooth sensor (red housing) with the following change;
use a piece of ferrous metal, like a screwdriver tip, to test the sen-
sor. It has an internal magnet to activate the sensing circuit.
Installation and Operation Instructions
Shaft-Trak TM -P/N 50209 (cont)
Copyright © 2019 Micro-Trak Systems • P/N 50209 • 021519
BIN LEVEL SENSORS: Ground pin C (black) and connect clean
12 volts to pin B (green) of the sensor cable. Connect the positive
lead (red) of an ohmmeter or continuity tester to pin A (red) and the
negative lead (black) of the ohmmeter or continuity tester to pin C of
the bin level sensor cable.
If the Bin Level Sensor is “blocked”, the output will show high
(infinite) resistance, and if the sensor is “unblocked” the result will
be low (300-500 ohm) resistance. Make sure the back of the sensor
is covered by the black foam pad; if light enters from the back of
the sensor, it will not “see” blockage. Use your hand or other solid
object to block both “eyes” on the sensor and the resistance should
go high.
CONSOLE INPUTS: If there is no response from any of the follow-
ing tests, refer to the main wiring diagram on the previous page to
locate the next connector in line toward the console and repeat the
test at that connector. If there is a response at that connector, the
problem may be in the cable between the two connectors (or the
connectors themselves).
SHAFT INPUT: Disconnect the shaft sensor from the extension
harness. Check for 12 volts between pins B (white) and C (black) of
the extension harness. Using a clip lead or other jumper wire (such
as a per clip bent in a “U”), rapidly short together pins A (red) and C
(black) of the 3-pin connector. The corresponding green light on the
console should light.
BIN INPUT: Disconnect the bin sensor from the main harness. The
corresponding green light on the console will light. Check for 12
volts between pins B (white) and C (black) of the sensor cable being
tested. Using a clip lead or other jumper wire (paper clip bent in a
“U”), short together pins A (red) and C (black) of the 3- pin connector.
The green light will turn off and the corresponding red light will flash
for one minute or until the short is removed.
REPLACEMENT PARTS LIST FOR SHAFTTRAK
Part Number Description
01544 Bin Level Sensor Kit
13181 Console Mount Kit, Base
13221 Cable, 10’ 10-pin M/P (optional)
13222 Cable, 15’ 10-pin M/P (2)
13223 Cable, 20’ 10-Pin M/P (optional)
13224 Cable, 25’ 10-pin M/P (optional)
13205 Cable, 5’ 3-pin M/P Extension (optional)
13206 Cable, 10’ 3-pin M/P Extension (optional)
13207 Cable, 15’ 3-pin M/P Extension (optional)
13208 Cable, 20’ 3-pin M/P Extension (optional)
14381 Console, Shaft-Trak Standard
14471 Molded Shaft Sensor w/ 5’ cable
14473 Shaft-Trak 6-sensor Branch Cable, 7’