Milltronics Mfa-4p User manual

MFA-4P

MOTION FAILURE ALARM

Instruction Manual October 2001

MOTION FAILURE ALARM

Safety Guidelines

Warning notices must be observed to ensure personal safety as well as that of others, and to

protect the product and the connected equipment. These warning notices are accompanied

by a clarification of the level of caution to be observed.

Qualified Personnel

This device/system may only be set up and operated in conjunction with this manual.

Qualified personnel are only authorized to install and operate this equipment in accordance

with established safety practices and standards.

Warning: This product can only function properly and safely if it is correctly transported,

stored, installed, set up, operated, and maintained.

Note: Always use product in accordance with specifications.

Copyright Siemens Milltronics Process

This document isavailable inbound version and in

electronic version. We encourage users to

purchase authorized bound manuals, or to view

electronic versions as designed and authored by

Siemens Milltronics Process Instruments Inc.

Siemens Milltronics Process Instruments Inc. will

not be responsible for the contents of partial or

whole reproductions of either bound or electronic

versions.

While we have verified the contents of

this manual for agreement with the

instrumentation described, variations

remain possible. Thus we cannot

guarantee full agreement. The

contents of this manual are regularly

reviewed and corrections are included

in subsequent editions. We welcome

all suggestions for improvement.

Technical data subject to change.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

Contact SMPITechnical Publications atthe following address:

Technical Publications

Siemens Milltronics Process Instruments Inc.

1954 Technology Drive, P.O. Box 4225

Peterborough, Ontario, Canada, K9J 7B1

Email: techpubs@milltronics.com

For the library of SMPI instruction manuals, visit our Web site: www.milltronics.com

PL-298 MFA-4p Page 3

Table of Contents

Table of ContentsTable of Contents

Table of Contents

Specifications

SpecificationsSpecifications

Specifications................................

................................................................

..................................

....

.. 5

55

5

Installation

InstallationInstallation

Installation ................................

................................................................

.......................................

..............

....... 7

77

7

Dimensions......................................................................................................................................................8

NEMA 4 Enclosure – Main Amplifier..................................................................................................8

MFA-4p Open Style.......................................................................................................................................9

Main circuit board....................................................................................................................................9

Layout

LayoutLayout

Layout

Main Amplifier........................................................................................................................................ 10

Interconnection

InterconnectionInterconnection

Interconnection................................

................................................................

.............................................................

..........................................................

............................. 11

1111

11

MSP-1, 3, or 9 Probe........................................................................................................................ 11

MSP-12 Probe with IMA ................................................................................................................ 11

MSP-12C ............................................................................................................................................. 11

XPP-5 ................................................................................................................................................... 12

Table: Cable length from RMA or IMA to Main Amp ........................................................ 12

Wiring

WiringWiring

Wiring ................................

................................................................

.............................................

..........................

............. 13

1313

13

MFA-4P Main Amp Wiring for Automatic Start Delay................................................................ 13

Schematic Diagram - Remote Mounted / Pre-amplifier............................................................. 14

Schematic Diagram MFA-4 Main Amplifier................................................................................... 15

Operating Principles

Operating PrinciplesOperating Principles

Operating Principles................................

................................................................

.....................................................

..........................................

..................... 17

1717

17

MFA-4p.......................................................................................................................................................... 17

Probe.............................................................................................................................................................. 17

Pre-Amplifier (IMA and RMA) ................................................................................................................ 18

Main Amplifier............................................................................................................................................. 18

Calibration .................................................................................................................................................... 19

Pre-amble ................................................................................................................................................ 19

Main Amplifier ....................................................................................................................................... 19

Underspeed............................................................................................................................................. 19

Overspeed ............................................................................................................................................... 20

Signal Generator Interface...................................................................................................................... 21

Probes

ProbesProbes

Probes................................

................................................................

.............................................

..........................

............. 23

2323

23

Mini Sensing Probe MSP-1 ..................................................................................................................... 23

High Temperatures MSP-3...................................................................................................................... 23

Stainless Steel Probe MSP-9.................................................................................................................. 24

Mounting Details .............................................................................................................................. 24

Standard MSP-12....................................................................................................................................... 25

MSP-12C ....................................................................................................................................................... 25

Hazardous Locations XPP-5.................................................................................................................... 26

PL-298 MFA-4p Page 4

Interconnection Diagram for the XPP-5.......................................................................................... 27

Mounting Details ........................................................................................................................................ 28

Applications

ApplicationsApplications

Applications ................................

................................................................

...................................

......

... 29

2929

29

Bucket Elevators......................................................................................................................................... 29

Shafts............................................................................................................................................................. 30

Belt Conveyors............................................................................................................................................ 30

Screw Conveyors ....................................................................................................................................... 30

Non-Ferrous Window .......................................................................................................................... 31

Bucket Elevator........................................................................................................................................... 32

Rotating Shaft of Rotary Feeder............................................................................................................. 32

Drive Sprocket on Rotary Feeder........................................................................................................... 33

Screw Conveyor Flights............................................................................................................................ 33

End Bearing on Screw Conveyor........................................................................................................... 34

Troubleshooting

TroubleshootingTroubleshooting

Troubleshooting ................................

................................................................

............................................................

........................................................

............................ 35

3535

35

Index

IndexIndex

Index................................

................................................................

................................................

................................

................ 37

3737

37

PL-298 MFA-4p Page 5

Specifications

Power

•115 Vac 50/60Hz, 5 VA

•230 Vac 50/60Hz, 5 VA

•±10% rated voltage

Output

•2 Form C (D.P.D.T.) fail-safe dry contacts

Resistive Rating:

•10 A @ 115/230 V AC

•10 A @ 24 V DC

Repeatability

•+/- 1%

Temperature coefficient (setpoint variance)

•0.01%/°F (0.018%/°C)

Setpoint adjustment range

•2 to 3,000 PPM (Pulses per Minute)

Dynamic range

•0 to 7,200 PPM

Equipment

EquipmentEquipment

Equipment Ambient Temperature Range

Ambient Temperature RangeAmbient Temperature Range

Ambient Temperature Range Approx wt.

Approx wt.Approx wt.

Approx wt.

Main amplifier open style -40 to 140°F (-40 to 60°C) 2 lb (1 kg)

Main amplifier NEMA 4 -40 to 140°F (-40 to 60°C)

(internal to enclosure) 11 lb (5 kg)

RMA -40 to 140°F (-40 to 60°C) 5 lb (2.3 kg)

MSP-12, MSP-12C -40 to 140°F (-40 to 60°C) 3 lb (1.4 kg)

XPP-5 -40 to 140°F (-40 to 60°C) 4 lb (1.8 kg)

MSP-1 -60 to 180°F (-50 to 80°C) 1 lb (0.5 kg)

MSP-3 -60 to 500°F (-50 to 260°C) 3 lb (1.4 kg)

MSP-9 -60 to 500°F (-50 to 260°C) 4 lb (1.8 kg)

PL-298 MFA-4p Page 6

Specifications

PL-298 MFA-4p Page 7

Installation

The main amplifier (and RMA if applicable) is best mounted in an area that is clean, dry,

vibration free, non-hazardous, within the ambient temperature range, and non-corrosive

to the electronics or its enclosure. The door should be accessible for viewing and to

allow calibration of the main amplifier.

Note: Do not mount amplifiers in direct sunlight.

The probe should be mounted and onto a vibration free structure and using the

mounting flange. The gap between probe and target should be enough so that there is

no danger of the target damaging the probe. The probe environment must be within the

probe's ambient temperature range and non-corrosive to the probe's body. Refer to

Applications drawings on page 29.

Note: Installation and wiring must be in accordance with all governing regulations.

Where possible, use flexible conduit. The probe components should be interconnected

via flexible conduit. This allows for easier removal or adjustment of the probe and

mounting flange assembly.

PL-298 MFA-4p Page 8

Installation

Dimensions

NEMA 4 Enclosure –Main Amplifier

Note: Use punch to make holes in the enclosure.

160mm

(6.325")

131mm

(5.138")

82mm

(3.225")

240mm

(9.455")

228mm

(8.975")

Mounting Holes

4.3mm/0.170"

dia. 4 places Suitable location for

Conduit Entrance

Lid Screws Enclosure

NEMA 4

polycarbonate

15mm

(0.59")

6mm

(.0.25")

PL-298 MFA-4p Page 9

Installation

MFA-4p Open Style

Main circuit board

221mm

(8.688")

139mm

(5.453")

202mm

(7.935")

149mm

(5.875")

71 mm

(2.8”)

6 –32 thread

9 mm (0.375")

PL-298 MFA-4p Page 10

Installation

Layout

Main Amplifier

PL-298 MFA-4p Page 11

Interconnection

MSP-1, 3, or 9 Probe

Main Amplifier

Maximum cable length from probe to RMA is 30m/100ft of shielded cable, 18 ga. wire.

See table below for cable lengths from RMA to main group.

MSP-12 Probe with IMA

Main Amplifier

Shielded cable not required. Wire can be run in conduit common to motor supply or

control wiring. Connection to probe leads can be made under probe cap. See table

below for lengths from probe at main amp.

MSP-12C

Main Amplifier

Shielded cable not required. Wire must be done in conjunction with approved conduit,

boxes and fittings and to procedures in accordance with all governing regulations. See

table below for lengths from probe at main amp.

Refer to Layout on page 10

for Main Amplifier Wiring.

Relays are shown in

de-energized state:

Contacts are reversed

under normal

operation.

Relays are shown in

de-energized state:

Contacts are reversed

under normal

operation.

Relays are shown in

de-energized state:

Contacts are reversed

under normal

operation.

RMA

Refer to Layout on page 10

for Main Amplifier Wiring.

Refer to Layout on page 10

for Main Amplifier Wiring.

PL-298 MFA-4p Page 12

Interconnection

XPP-5

Main Amplifier

Shielded cable not required. Wire must be done in conjunction with approved conduit,

boxes and fittings and to procedures in accordance with all governing regulations. See

table below for lengths from probe at main amp.

Table: Cable length from RMA or IMA to Main Amp

Wire gauge

Wire gaugeWire gauge

Wire gauge Length in feet

Length in feetLength in feet

Length in feet Length in metres

Length in metresLength in metres

Length in metres

22 2500 760

18 5000 1520

12 25000 7600

Relays are shown in

de-energized state:

Contacts are reversed

under normal

operation

Refer to Layout on page 10

for Main Amplifier Wiring.

PL-298 MFA-4p Page 13

Wiring

MFA-4P Main Amp Wiring for Automatic Start Delay

Notes:

1. Interlocks and Safety Pull Switches are not shown.

2. If START is initiated by programmable logic controller, closure time may be too

brief to allow MFA-4p contact to latch. In this case, program a timer contact into

the circuit.

3. CSA requires a 10A, or less, fuse to protect contacts. For 240V AC, protect the

contacts with a 1500 VA transformer as well.

Should the Time Delay feature on start-up not be required, power should be applied

continuously from a separate source and the pot turned to zero. This is usually

necessary for automatic up-stream start up of conveying devices after the down-stream

drive has reached its operation speed.

PL-298 MFA-4p Page 14

Wiring

Schematic Diagram - Remote Mounted / Pre-amplifier

PL-298 MFA-4p Page 15

Wiring

Schematic Diagram MFA-4 Main Amplifier

PL-298 MFA-4p Page 16

Wiring

PL-298 MFA-4p Page 17

Operating Principles

MFA-4p

The MFA-4p Motion Failure Alarm detects an increase or decrease in the speed of

rotating, reciprocating, or conveying equipment. It consists of a probe, pre-amplifier

(remote or internal to probe), and main amplifier.

Pulses generated from the probe are continually compared to the adjustable setpoint. If

the pulse rate is lower than the setpoint, the alarm relay operating in a faiI-safe mode

will de-energize, indicating failure. The relay will not energize until the pulse rate

increases above the setpoint.

Probe

The Milltronics probes work on the principle of Faraday’s Laws of Electromagnetic

Induction. When a ferromagnetic object enters the probe’s permanent magnetic field, it

distorts the flux causing it to cut the coil windings and generate a voltage. This voltage is

proportional to the strength of the magnet and the number of wire turns in the coil

(constant in the Milltronics probes) and the speed at which the ferrous target passes

through the flux. The generated voltage is also inversely proportional to the square of

the distance between the target and the probe.

The relationship between speed and gap of a standard probe:

FIG. A.

2”x1”x2”

ferrous block

FIG. B

2”x2”x1”

ferrous block

FIG C

2”x1”x1”

ferrous block

(1 inch = 25.4 mm & 1 foot = 305mm)

PL-298 MFA-4p Page 18

Operating Principles

The resultant line indicates the threshold tolerance of the accompanying MFA-4p

electronics. For example, in Fig. a, a 4" (100mm) gap requires a minimum velocity of

about 65 ft/minute (20m/minute), and with a velocity of 2 ft/minute (0.61m/minute), a

maximum gap of l/4" (6mm) is possible.

Note: 1 inch = 25.4mm & 1 foot = 0.305m

This graph was plotted from tests using four ferrous blocks set equidistantly on a 16"

diameter circle on a non-ferrous disc.

The physical shape of the ferrous target generally becomes important at low velocities

or large gaps. At these points, tests indicate that a cubic shape gives the best results

due to the sudden change it causes in the magnetic field.

An increase in block size beyond 2" X 2" X 1" (50x50x25mm) is generally not as effective

as minimizing the gap, except at very low velocities.

The Milltronics Mini Sensing Probe, MSP-1, is approximately ¼of the size of the

standard probe with about 1/8 the sensitivity.

By dividing all operating values by 0.125, the specifications of the MSP-1 are obtained.

For example, with a gap of .5" (12mm), the minimum velocity is approx. 200 ft/min.

(60m/min,), and with a velocity of a 2 ft/min. (0.6m/min), a maximum gap of .125" (3mm) is

possible.

Because of the many environments in which motion sensors are required, Milltronics

manufactures probes for low temperature, high temperature, corrosive, and Class I, II,

and III applications.

Pre-Amplifier (IMA and RMA)

The pre-amplifier accepts the voltage pulses generated by the probe and converts them

into noise immune current pulses. Current levels are 12mA low and 45mA high. It comes

internally mounted in the probe or in an enclosure for remote mounting.

Internally mounted pre-amplifiers are called IMAs. Remote mounted Pre-amplifiers are

called RMAs.

Main Amplifier

The main amplifier provides a short circuit protected, +24V DC unregulated supply to the

pre-amp. In the event that the interconnecting wiring is shorted, output current from the

main amp is automatically limited and the on-board alarm relay is de-energized to

indicate failure.

The output current pulses from the pre-amp are super imposed onto the DC current

supply. These are monitored by Probe LED 1, which is illuminated at the rate of the

incoming pulses and is useful for positioning the probe. The rate at which the pulses are

received by the main amplifier is compared to a setpoint reference signal from the time

base generator. Although two pulses within range are required to energize the relay, as

PL-298 MFA-4p Page 19

Operating Principles

long as the frequency of the incoming pulses exceeds the setpoint frequency (or is less

than that of the setpoint in the case of overspeed detection), the main amplifier keeps

the alarm relay energized. The reference generator is frequency adjustable by the

Pulses Per Minute (PMP) jumper and potentiometer. The alarm relay will de-energize

after two time constants of the setpoint when the frequency of the incoming pulses falls

below that of the setpoint (or exceeds that of the setpoint in the case of overspeed

detection). The relay status is indicated by Relay LED 2, which is illuminated when the

relay is energized (normal).

The MFA-4p has a 0 to 60 second time delay feature, allowing the monitored device to

accelerate to normal running speed before monitoring begins. This feature is activated

when power is applied to the MFA-4p in parallel with the motor starter contactor coiI.

The time delay circuit simulates normal operating conditions for the amount of time as

set by the Start Delay potentiometer, keeping the alarm relay energized. If the

monitored device does not reach normal speed before the set time period, the relay wiII

de-energize giving an alarm condition. This feature is not applicable in the overspeed

detection mode.

Calibration

Pre-amble

The probe and pre-amplifier require no calibration.

Interconnect probe, pre-amp, and main amplifier as shown in the Interconnection

diagrams on pages 11 and 12.

Connect main amplifier to power as shown in the Schematic Diagram MFA-4 Main

Amplifier shown on page 15.

Note: To help the calibration procedure, short N.O. contacts of relay to prevent motor

shut-down (terminals 1 to 2 and/or 4 to 5). This allows the system to run uninterrupted

until an operating setpoint is established.

Main Amplifier (Refer to Main Amplifier layout on page 10)

1. Operate monitored equipment at its normal operating speed.

2. Confirm that Probe LED 1 is pulsing at a regular frequency.

3. Set Start Delay fully counterclockwise (CCW) to 0seconds.

Underspeed

1. Set Pulses Per Minute (PPM) jumper to X 100 position.

2. Turn PPM potentiometer fully clockwise (CW) to 30.

PL-298 MFA-4p Page 20

Operating Principles

3. Determine incoming pulse rate by slowly turning PPM pot CCW until relay LED 2 goes

on. As the main amp requires 2 pulses within range before energizing relay, Iow PPM

applications (e.g. 2 PPM) may require stepping of pot at appropriate time intervals. If no

response is obtained by 3(below this stability suffers), reset pot fully CW and set jumper

to X 10 and then X 1 if required and repeat this step.

4. When Relay LED 2 goes on, indicating the incoming pulse rate, turn pot CCW slightly

past this point to obtain an operating setpoint that allows for normal fluctuations due to

load and voltage variations. Thus, for 50 % of full speed, set pot (and jumper if required)

to halfway between incoming pulse rate of normal speed and 0 PPM.

5. Set Start Delay by adjusting pot so that equipment being monitored can attain normal

operating speed before LED 2 can turn off.

Overspeed

1. Set PPM jumper to X 1 position.

2. Set PPM potentiometer fully CCW to 0.

3. Determine incoming pulse rate by slowly turning PPM pot CW until Relay LED 2 goes on.

Because the main amp requires 2 pulses within range before energizing relay, low PPM

applications (e.g. 2 PPM) may require stepping of pot at appropriate time intervals. If no

response is obtained, re-set pot fully CCW and set jumper to X 10, and then X 1 if

required and repeat this step.

4. When Relay LED 2 goes on, indicating the incoming pulse rate, turn pot CW slightly past

this point to obtain an operating setpoint that allows for normal fluctuations due to load

and voltage variations.

Remember: If N.O. contacts were shorted as described in final note of

calibration preamble, remove them now as calibration is complete.

Milltronics MFA-4P User manual

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