Model WKN-142T TRANSDUCER INSTRUCTION MANUAL

Transcription

1 MANUAL No E1.0 Published in Apr Revised in Jan WKN SERIES Model WKN-142T TRANSDUCER INSTRUCTION MANUAL Carefully read and understand this manual before using the product. After reading this manual, store it in a safe location so that it can be referenced readily as required.

2 Preface Thank you for purchasing the WKN series WKN-142T transducer. This instruction manual (referred to as this manual hereafter) explains handling instructions and cautions regarding the WKN series WKN-142T transducer (referred to as this unit hereafter).

3 Preface Important Information Carefully read and understand this manual before using this unit. Store this manual in a safe location so that it can be referenced readily as required. If you have any questions regarding this manual or this unit, contact your dealer. When using this product, it is necessary to be knowledgeable about not only the contents of this manual, but also regarding the instrumentation and equipment connected with this unit. For safety, it is necessary to have standard knowledge regarding safety in addition to the contents described in this manual. The WKN series uses a variety of noise tests to evaluate EMC (electro-magnetic compatibility). However, since the following environmental conditions will cause fluctuations in EMC characteristics, it is important to ensure the stability of the system according to the cautionary instructions found in this manual. - Volume of noise produced - Temperature and humidity - Equipment layout When combining this unit with other instrumentation or equipment and then selling or transferring ownership as an assembly, always make sure to attach this manual as well and provide it to the end user. When disposing of this product, make sure to follow all local laws and regulations. This unit is comprised of the following devices. - WL-142K Sensor (referred to as WL Sensor hereafter) - WW-142K Extension cable (referred to as WW Extension cable hereafter) - WKN-142T Transmitter (referred to as WKN Transmitter hereafter) During use, it is necessary to build the system structure according to the instructions in this manual. For system structure examples, refer to page 14. This manual contains some explanations for parts of other separately sold equipment, in order to explain their attachment to this unit. The illustrations of parts that are sold separately in this manual may differ from their actual appearance. Any company names and product names listed in this manual are the trademarks or registered trademarks of their respective companies. Shinkawa Sensor Technology, Inc. owns the copyright to this manual. Unauthorized publication of this content, and any and all copying/duplication of the content are prohibited. 1

4 Preface Exclusion from liability Shinkawa Sensor Technology, Inc. shall not be liable for any damages or injuries arising from not following the instructions indicated in this manual, or from carelessness or neglect while handling this unit or during its installation. Compensation shall not be made for any damage, injury, or loss that occurs as a direct or indirect result of the incorrect use, improper use, modification, or disassembly of this product. Shinkawa Sensor Technology, Inc. will not take any responsibility for any items not listed in this document and in the warranty, including the guarantee of product merchantability, guarantee for specific objectives or specifications, or for violation of patents, whether they are expressed or implied. The warranty for this unit is at the end of this manual. If a breakdown occurs in this unit, repairs will be performed according to this warranty. Shinkawa Sensor Technology, Inc. will not take any responsibility for any and all results from using parts other than those recommended by our company. Confirmation of this unit and package items Shinkawa Sensor Technology, Inc. performs strict quality control and quality inspections to provide reliable products. When this unit first arrives, please check that it is the correct ordered product, that there was no damage to it during its transportation, and that all accessories (ordered items) are provided in the package. If there is damage to this unit or missing accessories (ordered items), contact your dealer immediately. 2

5 Index Page Important notice...1 Exclusion from liability...2 Confirmation of this unit and package items...2 Chapter 1 Safety Information Warning Symbols Cautions when handling...4 Chapter 2 Introduction Objectives of this unit Measurement principles Specifications Specifications of this unit WL Sensor specifications WW Extension cable specifications WKN Transmitter specifications Recommended specifications for the signal transmission cable Outer dimensions and part nomenclature WL Sensor WW Extension cable WKN Transmitter System configuration example...14 Chapter 3 Installation Installation environment WKN Transmitter installation environment WL Sensor installation environment WKN Transmitter installation Installation WKN-142T Installation WKN-142T WL Sensor installation Gap adjustment Wiring connections WW Extension cable connection (When using the WW Extension cable) WL Sensor connection Connection of signal transmission cable Wiring Current output calibration Mechanical method Test input method Confirmation after completing connection Set gap voltage confirmation...33 Chapter 4 Maintenance/Inspection Periodic inspection Unit life Troubleshooting...36 Chapter 5 Characteristics data Standard static characteristics (Target material: JIS SCM440)...38 Index Appendix Cable wiring/laying

6 Chapter 1 For safe usage Chapter 1 Safety Information Read this section carefully to use this product safely. 1.1 Warning Symbols In this document, rules that must be followed in order to prevent injuries or financial losses to customers, and for the safe usage of this unit, is labeled with the following markings. Make sure to understand the contents of these cautions and make sure to follow their instructions. Warning Symbol WARNING CAUTION Meaning This symbol is used to warn against the possibility of serious or fatal injury. Always follow the instructions to ensure safety. This symbol is used to caution against the possibility of injury. Always follow the instructions to ensure safety. ATTENTION This symbol is used to draw attention to the possibility of property damage. Always follow the instructions to prevent damage to equipment. Point The Point is used to emphasize important items or to provide useful information. 1.2 Cautions when handling Be sure to observe the following instructions for safe use of this unit. Prohibited actions WARNING Never disassemble or modify this unit. And do not use this unit under conditions outside the standards specified in the specifications. Doing so may lead to failures of this unit, fires, or personal injuries. ATTENTION Do not use transceivers and other radio equipment/cellular phones near this unit. If this unit or signal cables are exposed to electromagnetic waves, this unit may not satisfy the precision indicated in the specifications. 4

7 Chapter 1 For safe usage Rules to follow WARNING When installing this unit, be sure to follow the procedures described in Chapter 3 Installation. If the procedures indicated are not followed, it may lead to failures of this unit, fires, or personal injuries. ATTENTION Before operating this unit, be sure to read the instruction manuals for instruments and equipment connected with this unit. The person handling this unit must have specialized knowledge regarding instrumentation and other devices related to this unit. Before touching this unit, be sure to touch a metal section near by to discharge any static electricity. The device may be damaged if exposed to static electricity from a person s body. Do not perform insulation resistance measurements or voltage endurance tests at locations other than those with the insulation resistance and voltage endurance specifications indicated. Doing so may damage this unit. When performing a megger test (insulation test) of the signal transmission cable, always disconnect the cable from this unit and equipment connected with this unit. When reconnecting the cable after a megger test, short the cable to ground first before connecting the cable to discharge any electric charge. Connecting cables in a charged condition to this unit or equipment connected with this unit may damage this unit. In order to prevent system malfunctions in the case that this unit breaks down, add interlock features to the system. If any one of the following conditions occurs, stop using this unit and contact your retailer. Continuing the usage in an abnormal condition may result in fires or failures. - When there is a strange odor coming from this unit. - When this unit is heating up abnormally. - If this unit is dropped - If the casing of this unit is damaged Store this unit in a location away from direct sunlight, under the following conditions. Do not store in a location exposed to high temperatures and/or humidity, or where corrosive gasses are present. - Temperature: -34 to 100 C - Humidity: 30 to 95 %RH (No condensation) - Corrosive gasses: Hydrogen sulfide gas, NO x gas and chlorine gas etc. 5

8 Chapter 2 Introduction Chapter 2 Introduction 2.1 Objectives of this unit Model WKN-142T 2-Wire Thrust Transducer is most suitable measuring system for thrust position of rotating machinery and the system consists of WL Sensor, WW Extension cable and WKN Transmitter. It detects displacement (gap) between sensor and observed material (target) precisely without physical contact with target by the eddy current principle, and outputs voltage proportioned to gap from gap out of terminal block and BNC connector. Thrust position can be measured by 4 to 20 ma output as consumption of current loop. This unit is not designed for use in any other applications. 2.2 Measurement principles The gap between the WL Sensor and the target is found according to the following principles. If an approximately high frequency current is supplied from the oscillator in this unit to the WL Sensor, a high frequency magnetic field is created at the WL Sensor. By the interlinkage of high frequency magnetic flux in the target, an eddy current will flow on the target surface. When the eddy current flows on the target surface, a magnetic field is created at the target side, and the sensor impedance will change. The output of the oscillator (voltage amplitude) changes by the change in the sensor impedance. The output of the oscillator is detected, and the distance vs. output voltage is made linear by a linearizer electrically. Therefore, if the following relationships are identified in advance, it is possible to find the gap between the WL Sensor and the target by measuring the sensor impedance: Relationship between the WL Sensor and the target gap Relationship of the sensor impedance 6

9 Chapter 2 Introduction 2.3 Specifications Specifications of this unit SPECIFICATIONS 4 to 20 ma OUTPUT RANGE 4 to 20 ma OUTPUT CONVERSION ACCURACY MAX. LOAD RESISTANCE NOT-OK FUNCTION CALIBRATION MATERIAL LINEAR RANGE* SCALE FACTOR* SCALE FACTOR ERROR* LINEARITY* OUTPUT IMPEDANCE* TEMPERATURE RANGE OF TRANSMITTER TEMPERATURE RANGE OF SENSOR AND EXTENSION CABLE RANGE OF TEMPERATURE AT EXPLOSION PROOF CONSTRUCTION RELATIVE HUMIDITY RANGE POWER SUPPLY VOLTAGE SENSOR TIP DIAMETER CABLE DIAMETER CONNECTOR DIAMETER SYSTEM CABLE LENGTH TRANSMITTER SIZE Current Output -0.6 to 0 to +0.6 mm or to 0 to mm (-25 to 0 to +25 mils) ±1.5 % of Full Scale Range (From test signal input pin to current output) 43.5 (Vps-12) Ω (Vps=Power supply voltage) Current output : 3.6 ma or less. Not-OK condition : Open or short of sensor, Outside of linear range. Delay time to resume ; 2 to 3 seconds after Not-OK condition is removed. GAP Output JIS SCM440 FLAT (AISI 4140 equivalent ) 1.4 mm (Gap : 0.3 to 1.7 mm) 7.87 mv/µm 7.87 mv/µm ±6.5 % typ. (including interchangeability errors) Step : 200 µm, Target : 30 mm dia. Within ±30 µm (typ.) of 7.87 mv/µm straight line (including interchangeability errors) 10 kω (It is calibrated at load impedance 10 MΩ) System Operating : 0 to 70 C (32 to 158 F) Storage : -34 to +100 C (-29 to +212 F) Operating : -34 to +177 C (-29 to +350 F) (Connector : Max. 125 C (257 F)) Storage : -34 to +177 C (-29 to +350 F) (Connector : Max. 125 C (257 F)) CSA,ATEX : 0 to +70 C (Sensor, Ext. Cable & Transmitter) 30 to 95 %RH (non condensing) 12 to 35 VDC Approx. 5.5 mm (0.217 inch) dia. Approx. 2.7 mm (0.106 inch) dia. Approx. 7.1 mm (0.280 inch) dia. 5 m or 7 m WKN-142T - -1 (L) 90 mm (W) 40 mm (H) 46.2 mm (3.54 in) (1.57 in) (1.82 in) WKN-142T - -2 (L) 90 mm (W) 74 mm (H) 45.2 mm (3.54 in) (2.91 in) (1.78 in) Mass : Approx. 200 g (0.44 lb) APPLICABLE WIRE 0.2 to 1.5 mm GAUGE 2 (1.0 mm 2 recommended) *The above specifications apply at 25 C with 24 VDC power supply and SCM440 (AISI 4140 equivalent) steel flat target. 1. CALIBRATION MATERIAL MODEL WKN-142T 2-wire Thrust Transmitters are calibrated with JIS SCM440 (AISI 4140 equivalent) flat surface (more than 15 mm dia.). It is not calibrated with any other target. 2. CONNECTOR ISOLATION, etc. The connector connecting the sensor cable and the extension cable shall be insulated with the attached insulation sleeve (transparent shrink tube) or fluoro resin insulation tape. The vinyl-insulating tape shall not be used, which may cause the wiring trouble in the case of the temperature more than 80 C. The connector shall not be located in the oil environment. The oil penetration to cable through the connector may cause the sensitivity change, due to the change of the cable capacitance. 3. MEGGER TEST OF SIGNAL CABLE If megger test is made on the signal cable (2-wire shielded cable), be sure to discharge the charged electric load before connecting the cable to transmitter. If this caution is not adhered the transmitter could be damaged. 4. WIRING BETWEEN GAP OUT TERMINAL AND EQUIPMENT a). Non-grounding type equipment Connect directly with coaxial cable within 3 meters long. b). Grounding type equipment Use an isolator between the transmitter and the equipment. Use coaxial cable within 3 meters long between the transmitter and the isolator. 5. INSTALLATION ENVIRONMENT Not available for rainwater at out door use and for occurring place of corrosive gasses. It may cause the sensitivity change and insulation down. Other NOTICE Geothermal specification (Additional Spec. Code: /GEO) is not applicable. CONFIGURATION WL Sensor WW Extension Cable Connector System Cable Length:5 m (16 ft) or 7 m (23 ft) WKN-142T Transmitter 7

10 Chapter 2 Introduction WL Sensor specifications WL-142K05 - / NB1 Armor Thread size Unthreaded length* (L1) Case length* (L2) Cable length (L3) Non-incendive A T L With M1 M8 X 1 10 mm step, 0 to 230 mm 10 mm step, 20 to 250 mm m (Without Fluoro resin M2 M10 X 1 e.g.) 06=60 mm, L1 L2-20 mm e.g.) 25=250 mm m coating) U1 1/4-28 UNF-2A 0.1 in step, 0 to 9.2 in 0.1in step, 0.8 to 9.9 in m With U2 3/8-24 UNF-2A e.g.) 04=0.4 in, L1 L2-0.7 in e.g.) 35=3.5 in m (With Fluoro resin coating) Without * inch for UNF-2A thread mm for M thread 1 CSA: ClassⅠDiv.2 Gr.A,B,C,D ATEX: EEx na ⅡT WW Extension cable specifications WW-142K - / NB1 Armor Cable length Non-incendive A With (Without Fluoro resin coating) m T With (With Fluoro resin coating) m L Without m m 1 CSA: ClassⅠDiv.2 Gr.A,B,C,D ATEX: EEx na ⅡT WKN Transmitter specifications WKN-142T - - / NB1 System cable length Output range Mounting plate Non-incendive 1 5 m to 0 to +0.6 mm 1 35 mm DIN Rail mounting plate 2 7 m to 0 to mm 2 Screw mounting plate (-25 to 0 to +25 mils) 1 CSA: ClassⅠDiv.2 Gr.A,B,C,D ATEX: EEx na ⅡT4 Terminal Arrangement Terminal no. Signal 1 POWER + 2 POWER 3 COM 4 GAP OUT

11 Chapter 2 Introduction Name plate (Front) (Back) 2-wire Thrust Transmitter Remove label for ZERO and SPAN adjust! CAUTION Grounded AC powered equipment can cause false alarm Do not connect it to GAP OUT MEASURE CAL TEST PIN ZERO IN COM SPAN Logo, Model Code and Ser No ma COM GAP OUT PWR +12 TO +35 VDC A Model code B System cable length A B C WKN-142T2-1 7 m System Thrust : -0.6 to +0.6 mm Tag No. ********** Ser. No. ********** D E C D E Output range Tag No. Ser. No. 9

12 Chapter 2 Introduction Recommended specifications for the signal transmission cable Use a commercially sold cable to connect this unit and equipment connected with this unit. A CVVS 2 core shielded cable (straight) is recommended, but if it is not available, a 2 line multiple core cable for light electrical instruments (individually shielded) can be used. Recommendation cables of sizes AWG. No.18 (1.0 mm 2 ). Cable name Recommended Note CVVS 2 core shielded cable (straight) Conduit pipe Recommendation: Copper tape shield (core wire; soft copper wire) (Normally, silver plated braid) Use conduit pipe (cable rack) for wiring. Shield wire 2 line multiple core cable for light electrical instruments (individually shielded) Conduit pipe Outside shield Recommendation: Outer shield is aluminum tape, copper tape shield The multi pair cable can contain a mixture of vibration signals and displacement signals. However, vibration signals for a high amplitude vibration can affect other vibration signals and displacement signals negatively, and these need to be wired on a separate cable. Shield wire ATTENTION Do not use unshielded cables or non-pair shielded multi core cables as the measured values could be affected by external noise. Divide wiring for the pulse signal (phase marker and rotation) with the wiring for other vibration and displacement signals. Avoid running signal transmission cables together with control and power cables. Install all cables in conduit pipes or on cable racks. After the megger test of the signal cable, discharge the charged electric load before connecting the cable. If this caution is not adhered to, the transmitter and connecting equipment could be damaged. 10

13 Chapter 2 Introduction 2.4 Outer dimensions and part nomenclature WL Sensor WL-142K05L Dimensions : mm (inch) 3 Ref. (0.12 Ref.) WL-142K05A Dimensions : mm (inch) (0.12 Ref.) WL-142K05T Dimensions : mm (inch) (0.12 Ref.) L1:Unthreaded length L2:Case length L3:Cable length 11

14 Chapter 2 Introduction WW Extension cable WW-142KL Dimensions : mm (inch) WW-142KA Dimensions : mm (inch) WW-142KT Dimensions : mm (inch) L:Cable length 12

15 Chapter 2 Introduction WKN Transmitter WKN-142T - -1 Name plate Gap out Dimensions : mm (inch) Sensor connector Logo, Model code and Ser. No. Terminal block DIN rail Mounting plate WKN-142T - -2 Dimensions : mm (inch) Screw Mounting plate 13

16 Chapter 2 Introduction 2.5 System configuration example This unit is designed to fulfill the specifications when used under the following configuration. Point Always combine the components of this unit (WL Sensor, WW Extension cable, and WKN Transmitter) so that it will be configured as follows. If this unit is not configured as shown below, or if the WW Extension cable is not used in combining the WL Sensor and WKN Transmitter, the output characteristics will differ dramatically. WL Sensor WW Extension WKN Transmitter WL Sensor WW Ex. Cable System length WKN Transmitter 0.5 m 4.5 m 5 m WKN-142T1 WKN-142T System combination 0.5 m 6.5 m 7 m WKN-142T2 1.0 m 4.0 m 5 m WKN-142T1 1.0 m 6.0 m 7 m WKN-142T2 5.0 m - 5 m WKN-142T1 7.0 m - 7 m WKN-142T2 14

17 Chapter 3 Installation Chapter 3 Installation WARNING Installation work, wiring and connections must be performed by a person with knowledge in instrumentation. Always perform grounding. Never apply power until all wiring work and connection work has been completed. If this is not followed there is a possibility of electrocution. ATTENTION Before touching this unit, be sure to touch a metal section near by to discharge any static electricity. The device may be damaged if exposed to static electricity from a person s body. Before applying power, make sure that all wiring is properly connected. There is a possibility of damage to this unit and fire if improperly connected. Locate this unit away from motors and relays. Install the sensor cable, extension cable and input/output signal cables away from power system and control system cables. Noise occurring from the motor or relay can adversely affect this unit. We recommend using separate wiring ducts. For each relay used near this system, devices related to this system or signal cables connecting the system and these devices, install a surge killer. In order to prevent the system from its malfunction when the system fails, provide the systematic interlock function. Do not pull or bend the WL Sensor cables and WW Extension cables with excessive force. The conductor in the cable may become cut off. The allowable tension of the WL Sensor cables and WW Extension cables is 98.1N (10kgf). The allowable bend radius is as follows. Without armored cable: 30 mm With armored cable: 50 mm With fluoro resin coating armored cable: 75 mm After completing installation work, confirm the attachment conditions of this unit. Point For information regarding typically recommended cable wiring, and installation methods, refer to the Appendix: Cable wiring/laying ( Page 39). Noise filter Noise transmitted through in each cable may be rejected to some extent by inserting a ferrite core in the cable (note 1).If the cable passes through noisy surroundings, it is recommended that such a noise prevention device is used. 15

18 Chapter 3 Installation (note 1) ZCAT : TDK 3.1 Installation environment WKN Transmitter installation environment Install the WKN Transmitter in a location that satisfies the following environmental and install conditions. Environmental conditions Ambient temperature : Must be in a range between 0 to 70 C when devices are operating. Ambient humidity : Must be in a range between 30 to 95 %RH (no condensation) when devices are operating. Vibration conditions : Must be 10 m/s 2 or less at 10 to 150 Hz. Ambient environment : Not available for rainwater at out door use, and for occurring place of corrosive gasses such as hydrogen sulfide, NOx gas, and chlorine, and conductive particles such as iron dust and carbon. It may cause the sensitivity change and insulation down. Install conditions If there are walls or other obstacles at the cable connection surface of the WKN Transmitter, make sure to keep spacing as shown in the figure below, and take care not to bend the cable excessively. Do not locate above heat emitting objects. 60 mm 16

19 Chapter 3 Installation WL Sensor installation environment Install the WL Sensor at a location that satisfies the following environmental and install conditions. Environmental conditions Ambient temperature: Must be in a range between -34 to 177 C (Connector: Max.125 C) when devices are operating. Vibration conditions: Must be 10 m/s 2 or less at 10 to 150 Hz. (If the sensor vibrates, an accurate measurement cannot be made.) Other environmental conditions are the same as the content described in WKN Transmitter installation environment ( Page 16). Installation conditions Do not install at a location exposed to rain or other moisture. It can lead to reduced sensitivity of the WL Sensor, and reduced insulation. A target surface area of 15 mm dia. centered on the WL Sensor is required. When placing other WL Sensors next to each other, separate the sensor tops by 25 mm or more. If they are placed too close together, the WL Sensors will interfere with each other. The WL Sensor must be installed on a surface with adequate rigidity, that will not be affected by an outside vibration. If the WL Sensor vibrates, an accurate measurement will not be possible. For shapes and dimensions around the WL Sensor, refer to the installation example 1-3 below. 15 mm 25 mm or more 25 mm or more If a piece of metal other than the target is near the WL Sensor, an accurate reading will not be possible. If it is unavoidable to install the WL Sensor in the methods of installation examples 4 to 7, check the characteristics at the attachment completed conditions. Installation example 1 (most recommended) Dimension X is bigger than 8 mm. WL sensor Installation example 2 (recommended) Dimension X is bigger than 8 mm. Dimension Y is to be 15 mm or more. 17

20 Chapter 3 Installation Installation example 3 (recommended) After constructing as shown in installation example 2, the area shown by the shaded line in the illustration is filled with resin or other insulating material. Installation example 4 If dimension X is less than 8 mm, it will be affected by the attachment plate. Installation example 5 If dimension Y is less than 15 mm, it will be affected by the attachment plate. Installation example 6 If the attachment plate around the sensor top is chamfered, it will be affected by the attachment plate. Installation example 7 If the target and the sensor top are not parallel (dimension X1 and X2 are not the same), it will affect the reading. Installation example 8 If dimension X is 0.3 mm or less, measurement will not be possible. The area 0.3 mm or less is a non-sensitive area. The characteristics of output (V) and gap (mm), are as shown in the graph on the right. 18

21 Chapter 3 Installation 3.2 WKN Transmitter installation The WKN Transmitter installation method differs according to the model. Secure the required spacing described in the installation conditions, and attach properly. The model number is shown on the label on the WKN Transmitter. For WKN-142T - -1 ( Page 19) For WKN-142T - -2 ( Page 20) Installation WKN-142T - -1 For the WKN-142T - -1, it will be an attachment to a 35 mm DIN rail. Install according to the following procedures. 1 Hook the upper tabs on the back of the WKN Transmitter onto the DIN rail. DIN rail 2 Push the WKN Transmitter into the DIN rail until a click is heard from the slide lock. If it does not fit onto the DIN rail well, pull on the slide lock, and push the WKN Transmitter against the DIN rail. Upper tab 3 Make sure that the upper tabs and the slide lock are securely fixed onto the DIN rail. Slide lock DIN rail Point It is possible to remove the WKN Transmitter by pushing down on the slide lock with a flat tip screwdriver. 19

22 Chapter 3 Installation Installation WKN-142T - -2 For WKN-142T - -2, they will be directly mounted on the housing or panel. Point When attaching to housing or panels or mounts, make sure it is a strong flat surface. The transmitter should be put into the EMC shield enclosure, if the transmitter is installed at noisy surroundings. And the enclosure should be grounded for EMC shield grounding. Install according to the following procedures. 1 Attach the WKN Transmitter to the panel and affix with the provided 4 screws (M4 15). Tightening Torque 1.18 N m (12 kgf cm) or less. For the WKN-142T - -2, there are 4 holes on the mounting plate. Use the 70.0 mm 63.5 mm pitch holes. Screw mounting plate WKN-142T - -2 Screw 20

23 Chapter 3 Installation 3.3 WL Sensor installation The system provides a linear range of 1.4 mm (a gap of 0.3 to 1.7 mm between sensor and target) and is calibrated for JIS SCM440 (AISI 4140 equivalent) as a standard target material. The system can measure the gap in the linear range. Recommended standard setting gap is 0.9 mm. ATTENTION Do not drop or otherwise subject the WL Sensor to shock. Install and fix the sensor to keep the gap within the linear range to prevent contact with target or out of linear range. Be careful not to damage or scratch the sensor tip and target surface with thickness gauge. Take care the effect for output characteristics by the relation between target shape and sensor or installing condition with reference to ATTENTION If a piece of metal other than the target exist near the WL Sensor, an accurate reading will not be possible. 21

24 Chapter 3 Installation Gap adjustment Point After completing all wiring connections, it is possible to perform gap adjustment using a tester. In this case, make sure to fully understand the content described in this chapter and complete all connection work, then perform gap adjustment according to the procedures in Set gap voltage confirmation ( Page 33). Adjust according to the following procedures. 1 Refer to 5.1 Standard static characteristics ( Page 38), and prepare a gap gage matching the gap that will produce the desired characteristics. Consider the following items for the gap. Set the gap so that even when the target is at the nearest point to the WL Sensor, the target will still not come into direct contact with the WL Sensor. 2 3 Being careful not to scratch the sensor top and target surface, insert the gap gage between the sensor top and target. Adjust the WL Sensor to a position where the gap gage just moves freely, and affix in place with the jam nut. Tighten the jam nut with the following torque. Model WL-142K05 -M1 WL-142K05 -U1 WL-142K08 -M2 WL-142K08 -U2 Tightening torque 4.0 N m(41 kgf cm) 1.4 N m(15 kgf cm) 8.5 N m(87 kgf cm) 6.8 N m(69 kgf cm) ATTENTION Don't add excessive twist power to the cable when you install the sensor. Make sure to tighten the jam nut at the specified torque. If tightened with excessive torque, the WL Sensor may become damaged. If the tightening torque is too small, it may come loose. 22

25 Chapter 3 Installation 3.4 Wiring connections WARNING Make sure the wiring and connections are performed by a person with knowledge in instrumentation. Always perform grounding. Never apply power until all wiring work and connection work has been completed. If this is not followed there is a possibility of electrocution. ATTENTION Make sure to tighten the collar of the connector by hand. If it is tightened using a tool, the connector may become damaged. If the installation environment does not allow proper tightening by hand and there is a possibility that it may come loose, tighten by an additional 1/4 turn using a pliers after tightening by hand. Do not apply excessive force on the screws of the connector. The connector may become damaged. Do not cut the WL Sensor / WW Extension cables shorter. It may cause problems, such as not being able to perform up to specifications. Point When connecting the connectors, make sure that the cable is not twisted. If there is twisting stress on the cable, it may slowly loosen the connection. If a twisting force is applied to the direction where the collar will be loosened, twist the extension cable slightly to the opposite direction of the collar tightening direction before connecting, then connect the connector and tighten the collar. We recommend that excessive extension cables be stored in the cable storage box. If it is unavoidable to store inside the housing, do not force excessive cables into the housing. Connections are performed in the following order. 1. WW Extension cable connection (When using the WW Extension cable) 2. WL Sensor connection 3. Connection of signal transmission cable 4. Confirmation after connection completion 5. Confirmation of set gap voltage 23

26 Chapter 3 Installation WW Extension cable connection (When using the WW Extension cable) When using the WW Extension cable, connect the WL Sensor and WW Extension cable as shown below. Point The connection area of the connector must not be used in a condition where it is exposed to water or oil. If water or oil enters the connector, the cable capacity will increase, and will cause a loss in sensitivity. 1 Confirm that there are no foreign objects in the WL Sensor and WW Extension cable connectors. Foreign objects in the connector will cause faulty connections or faulty characteristics. 2 3 Insert the extension cable through the provided insulation sleeve (clear heat shrink tube). Connect the WL Sensor connector and WW Extension cable connectors, and tighten the collar by hand. Connector (jack) Insulation sleeve WW Extension cable WL Sensor connector Connector (jack) 4 Cover the insulation sleeve over the connector. Collar Insulation sleeve 5 Apply hot air on the insulation sleeve, to shrink the insulation sleeve. ATTENTION Never use vinyl tape to insulate. During extended periods of use or when the connector temperature exceeds 80 C, vinyl electrical tape may harden or the adhesive may deteriorate, leading to a dirty connector and faulty insulation. If no spare insulation sleeve is available, protect the connector with a fluorine resin tape. Recommended insulation tape: Manufacturer: Nitto Denko Corporation Product name: Nitoflon adhesive tape (903uL) Temperature spec.: -60 to +180 C 0.08 mm thickness Shinkawa s order code: 1901LEW 24

27 Chapter 3 Installation WL Sensor connection Connect the WL Sensor as follows. Connection is performed in the same manner when using a WW Extension cable. 1 Confirm that there are no foreign objects in the WL Sensor (or WW Extension cable), and in the WKN Transmitter sensor connector. Foreign objects in the connector will cause faulty connections or faulty characteristics. Collar Connector 2 Connect the WL Sensor (or WW Extension cable) connector and the sensor input connector, and tighten the collar by hand Connection of signal transmission cable Sensor connector WKN Transmitter Connect the signal transmission cable as follows. ATTENTION When using a cable that has been subject to a megger test, make sure to short the cable to ground before connecting, to discharge any electric charge in the cable. Connecting cables in a charged condition to this unit or equipment connected with this unit may damage this unit. Point We recommend using cables described in Recommended specifications for the signal transmission cable ( Page 10) between this unit and connecting equipment. Because a small signal is being transmitted, a cable that is not recommended may be subject to interference from external noise, and the measurement may become affected. We recommend that the length of the non-shielded area be kept under 100 mm. 25

28 1 2 Remove the insulation so that there is 9 mm of exposed wire, and twist the wire. Refer to the following drawing, and connect the signal transmission cable to the WKN Transmitter and connecting equipment. Connect to the terminal block of the WKN Transmitter according to the following procedures. 1. Use a flat tip screwdriver to push down the operation lever of the terminal block (the orange area). (Recommended flat tip screw driver size: W2.5 mm T0.4 mm) 2. Insert the signal transmission cable (the 9 mm of exposed wire) all the way into the cable insert port of the terminal block, until it hits the back. 3. Pull out the flat tip screwdriver from the operation lever. The signal transmission cable is locked and the connection is complete. 9 mm Chapter 3 Installation Don't solder Flat tip screwdriver Signal transmission cable Operation lever Terminal block Terminal block fixture screw Terminal Arrangement Terminal no. Signal 1 POWER + 2 POWER 3 COM 4 GAP OUT Point The terminal block is affixed by the 2 screws on the ends of the terminal block. If these screws are loosened for installation or inspection work, make sure to affix the terminal block after work is complete by tightening the screws. 26

29 Chapter 3 Installation Wiring The loop resistance is the total resistance of the power supply output, the receiver, field wiring, and any other devices placed in the loop. Use following equation to determine the maximum loop resistance: RLOOP = 43.5 x (VPS-12) Ω max. Operation outside of the operating region shown above may result in erratic system behavior. Maximum Loop Resistance (Ω) OPERATING REGION Power Supply Voltage 35 (VPS) Use the following wiring diagrams to connect the field wiring between the transmitter and the monitoring instruments. 1:+ * Assumes the receiver 250 Ω, other 30 Ω. Terminal Arrangement Terminal no. Signal 1 POWER + 2 POWER 3 COM 4 GAP OUT ** Recommended wiring is shielded. Twisted pair. 1.0 mm 2 (18 AWG) (ordered separately) Max. length = 1 km (0.62 miles) 2: :+ 2: 1:+ 2: Cable Shield ** Cable Shield ** Cable Shield ** Receiver Receiver Receiver + Common (Ground) Power Supply VPS = 18.5 to 35 VDC * * Assumes the receiver 250 Ω, other 30 Ω. Receiver Common (Ground) + + Power Supply VPS = 18.5 to 35 VDC * * Assumes the receiver 250 Ω x 2, other 30 Ω. Non-grounding type equipment Common (Ground) Non-grounding type equipment + Power Supply VPS = 24.2 to 35 VDC * 27

30 Chapter 3 Installation 1:+ * Assumes the receiver 250 Ω, other 30 Ω. 2: Cable Shield ** Receiver + Common (Ground) 1:+ 2: Cable Shield ** Receiver + + Power Supply VPS = 18.5 to 35 VDC * ** Recommended wiring is shielded. Twisted pair. 1.0 mm 2 (18 AWG) (ordered separately) Max. length = 1 km (0.62 miles) Common (Ground) Use the following wiring diagrams to connect to the GAP OUT terminals. 3:COM 4:GAP OUT Battery Powered Test Equipment (Non-grounding type equipment) With 1 MΩ Min. Isolated Input. (Output will drop approximately 1 % down.) Isolator Grounding type Equipment Battery Powered Test Equipment (Non-grounding type equipment) With 1 MΩ Min. Isolated Input. (Output will drop approximately 1 % down.) 28

31 Chapter 3 Installation Current output calibration Remove name plate. Input select pin Refer to ZERO Potentiometer Refer to Refer to Terminal Arrangement Terminal no. Signal 1 POWER + 2 POWER 3 COM 4 GAP OUT Test signal input pin Refer to SPAN Potentiometer Refer to Refer to Recommended used equipment No. Name Symbol Notes 1 DC Voltmeter V Non-grounding type equipment DC Voltmeter(With 1 MΩ Min. Isolated 2 DC Ammeter A Input) or DC Ammeter 3 Signal generator Signal generator Non-grounding type equipment Mechanical method 1 2 Set a gap between sensor and target for a 6.5±0.03 VDC signal measured between GAP OUT and COM. Adjust zero potentiometer to set the loop current to 12 ma or 3 V. Target Input select pin : MEASURE 1:+ 2: 250 Ω±0.1 % A 0.9±0.2 mm (static condition) (or 35±8 mils (static condition)) Non-grounding type equipment (Voltmeter) + 6.5±0.03VDC + V GAP OUT Voltage Within 6.5±0.03 VDC Within 12±0.05 ma Within 3±0.02 VDC A V 29

32 3 4 Set a gap between sensor and target for a full scale voltage signal measured between GAP OUT and COM. Adjust zero potentiometer to set the loop current to 20 ma or 5 V. Chapter 3 Installation Target Input select pin : MEASURE 1: + 2: 250 Ω±0.1 % A 1.5±0.4 mm (static condition) (or 60±15 mils (static condition)) + + F.S. VDC V Non-grounding type equipment (Voltmeter) Output range GAP OUT F.S. Voltage -0.6 mm to +0.6 mm Within 11.22±0.03 VDC -25 mils to +25 mils Within 11.50±0.03 VDC A Within 20±0.05 ma V Within 5±0.02 VDC Test input method Set the input select pin to "CAL". Set a gap between sensor and target in approx. 0.9 mm or 35 mils (static condition). Connect a signal genetator output to test signal input pin. Signal generator COM( ) IN(+) COM ( ) IN (+) Input select pin (MEASURE CAL) Test signal input pin 30

33 4 Set the DC test input voltage to 6.5±0.03 VDC shown, and adjust the zero potentiometer to set the loop current to 12 ma or 3V. Chapter 3 Installation ATTENTION Signal generator does not connect to ground. Signal generator COM( ) IN(+) Input select pin : CAL 1:+ A Target 2: 250 Ω±0.1 % 0.9±0.2 mm (static condition) (or 35±8 mils (static condition)) + V 5 Output range Test signal (Signal generator output) -0.6 mm to +0.6 mm Within 6.5±0.03 VDC -25 mils to +25 mils Within 6.5±0.03 VDC Set the DC test input voltage to the full scale voltage shown, and adjust the span potentiometer to set the loop current to 20 ma or 5 V. AA Within 12±0.05 ma VV Within 3±0.02 VDC Signal generator does not connect to ground. ATTENTION Signal generator COM( ) IN(+) Input select pin : CAL 1:+ A Target 2: 250 Ω±0.1 % 0.9±0.2 mm (static condition) (or 35±8 mils (static condition)) + V Output range Test signal (Signal generator output) -0.6 mm to +0.6 mm Within 11.22±0.03 VDC -25 mils to +25 mils Within 11.50±0.03 VDC AA Within 20±0.05 ma VV Within 5±0.02 VDC 31

34 Chapter 3 Installation 6 Disconnect a signal generator, and set the input select pin to "MEASURE". Input select pin (CAL MEASURE) Confirmation after completing connection Before turning on the power, check the following: Make sure that there are no loose terminals, and that all wiring is connected properly. Check that the power line for the PWR is connected to power supply of the connecting equipment terminal block. Make sure that the WKN Transmitter and WL Sensor are installed at locations where the installation environmental conditions are satisfied. Make especially sure that there are no problems with the WKN Transmitter and WL Sensor installation conditions and they are not installed at the following types of locations. - Locations with high temperatures and high humidity - Locations with a lot of dust - Locations exposed to vibration - Locations where there are metal objects other than the target near the sensor After checking all items, check the set gap voltage values. 32

35 Chapter 3 Installation Set gap voltage confirmation In the following cases, perform confirmation of set gap voltage in order to maintain the performance of this unit. When supplying power to this unit for the first time. When more than 1 year has passed from the last confirmation. When the performance of this unit has been reduced due to a problem of some sort. Check the set gap voltage using the following procedures. 1 2 Turn the power ON. In order to stabilize the output, perform warm-up for 5 minutes. (leave alone for 5 minutes). 3 Warm-up is performed in order to collect accurate data. Connect the tester (voltmeter) to GAP OUT-COM on the monitor terminal block, and read the voltage. The voltmeter to connect GAP OUT-COM terminal is portable equipment (battery powered non-grounding type equipment). Therefore, please use the voltmeter which is more than 1 MΩ input impedance. * Assumes the receiver 250 Ω, other 30 Ω. Power Supply V PS = 18 to 35 VDC * 1:+ 2: 3:COM 4:GAP OUT Voltmeter : Battery Powered Test Equipment (Non-grounding type Equipment) With 1 MΩ Min. Isolated input impedance. (Output will drop approximately 1 %.) 4 Refer to 5.1 Standard static characteristics ( Page 38), and make sure that the desired set gap voltage is indicated. Point Data indicated in 5.1 Standard static characteristics are measured for a SCM440 flat target (dia. more than 15 mm). When the target material or shapes differ, the output characteristics (gain) will differ, and it will be necessary to confirm output. 33

36 Chapter 3 Installation 5 If the desired set gap voltage is not gained, readjust the WL Sensor position using the following procedures. 1. Loosen the jam nut of the WL Sensor. 2. Adjust the WL Sensor position so that the desired set gap voltage is gained. 3. After adjustment, tighten the jam nut of the WL Sensor at the specified torque. ( Page 22). ATTENTION Always tighten the lock nut at the specified torque. ( Page 22) The above completes the installation of this unit. In subsequent operations, the measurement precision described in the specifications will be satisfied approximately 5 minutes after turning on the power. In the case that this device does not operate as per the specifications, contact your retailer. 34

37 Chapter 4 Maintenance/Inspection Chapter 4 Maintenance/Inspection The following is a description of maintenance and inspection procedures for this unit. 4.1 Periodic inspection In order to maintain performance and secure system stability of this unit, check the set gap voltage values once a year. Refer to Set gap voltage confirmation ( Page 33) for the check procedures. SENSOR APPEARANCE CONFIRMATION Dismount the sensor, and confirm scratch or wear mark of the sensor tip which is the part of black resin. When the sensor tip has scratch or wear mark, please replace it. CONVERSION OUTPUT (4 to 20mA output) CONFIRMATION. Refer to "3.4.5 Current output calibration " ( Page 29), and confirm conversion output (4 to 20 ma output) by inputting test signal. 4.2 Unit life Even if there is no apparent problem, we recommend that the product be replaced every 10 years. Point The deterioration of this unit depends on the surrounding environment, and may be even shorter than 10 years. In order to secure system stability, 10 years should be considered a guideline, and early replacement is desirable. The following is a flowchart for finding out when a replacement is required. Calibration (Static characteristic data collection) The margin for scale factor error satisfies the specifications. Yes It is possible to use. No In comparison to the data in Chapter 5 characteristics data the 10% (for scale factor, changes near the set gap) Yes Contact your retailer for adjustment. This unit can be continued to be used after adjustment. No Replacement is recommended 35

38 Chapter 4 Maintenance/Inspection 4.3 Troubleshooting Possible problems with this unit are indicated below. No. TROUBLE PROBABLE CAUSE CHECK COUNTERMEASURES 1 Gap output is 0 V and no 1) Power is not supplied. 1) Measure power supply 1) Supply power. change. voltage. 2) Is not connected 2) Refer to 3.4 Wiring 2) Connect properly. properly. connections ( Page 23), and wire correctly. 3) Faulty transmitter. 3) Replace. 2 Gap output does not change from approx. 0.2 V. 3 Gap output does not change from approx. 16 V. 4 Current output is 0 ma and no change. 5 Current ouput does not change from approx ma. 1) Sensor is too close to 1) Measure distance. 1) Adjust. target. 2) Short circuit in sensor. 2) Measure resistance. 2) Replace. Normally Sensor coil conductor approx. 4 Ω + Sensor cable conductor approx Ω/m 3) Faulty transmitter. 3) Replace. 4) A foreign substance is included in a connector. 4) To remove the foreign substance. 1) Far distance between 1) Measure distance. 1) Adjust. target and sensor. 2) Open circuit in sensor. 2) Measure resistance. 2) Replace. Normally Sensor coil conductor approx. 4 Ω + Sensor cable conductor approx Ω/m 3) Open circuit in extension cable. 3) Measure resistance. Normally; Inner conductor Approx. 0.3 Ω/m Outer conductor Approx. 0 Ω/m 3) Replace. Between inner and outer conductors Ω 4) Faulty transmitter. 4) Replace. 5) Is connector securely 5) Connect securely. connected. 1) Power is not supplied. 1) Measure power supply 1) Supply power. voltage. 2) Faulty transmitter. 2) Replace. 1) Input select pin is not setted to "MEASURE". 1) Check the input select pin. 1) Set the input select pin to "MEASURE ". Normal position MEASURE Input select pin (CAL MEASURE) 36

39 Chapter 4 Maintenance/Inspection 5 Current ouput does not change from 3.6 ma or less. 1) Sensor is too close or far to target. 2) Short or open circuit in sensor. 3) Short or open circuit in extension cable. 4) Input select pin is setted to " CAL ". 1) Measure distance. 1) Adjust. 2) Measure resistance. Normally Sensor coil conductor approx. 4 Ω + Sensor cable conductor approx Ω/m 3) Measure resistance. Normally; Inner conductor Approx. 0.3 Ω/m Outer conductor Approx. 0 Ω/m Between inner and outer conductors Ω 4) Check the input select pin. 2) Replace. 3) Replace. 4) Set the input select pin to " MEASURE ". 5) Faulty transmitter. 5) Replace. 6) Is connector securely 6) Connect securely. connected. 37

40 Chapter 5 Individual characteristics data Chapter 5 Characteristics data Static characteristics data are supplied here. Refer to the characteristics data in this chapter for determination of the gap, etc. 5.1 Standard static characteristics (Target material: JIS SCM440) Refer to Set gap voltage confirmation ( Page 33) for the check procedures. TARGET GAP 1:+ 2: 3:COM 4:GAP OUT Power Supply V PS = 18 to 35 VDC (Assumes the receiver 250 Ω, other 30 Ω.) Voltmeter : Battery Powered Test Equipment (Non-grounding type equipment) With 1 MΩ Min. Isolated input impedance. (Output will drop approximately 1 %.) GAP OUT Output Output (V) (V) GAP(mm) (mm) SCF Error (%) GAP GAP(mm) (mm) 38

41 Appendix Cable wiring/laying Appendix Cable wiring/laying The following descriptions are typically recommended issues in regards to cable wiring and laying. Cables for pulse signals (phase marker, rotation) are to be on a separate cable from vibration and variation signals. Do not mix signal transmission cables and control/power system cables. All cable constructions are to be with conduit pipe or cable racks. A single ground is installed. Cable wiring/laying example Good example Bad example 39

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43 Warranty Warranty The warranty conditions for this unit are as follows. 1. Warranty conditions for newly delivered products. The warranty period for the delivered product is 3 years (1 year for special products and software) from the time of shipment from our factory. If a failure occurs in the delivered product due to our fault during this warranty period, we will take responsibility for the replacement/repair of that product. Also, if it becomes necessary to dispatch an engineer within the warranty period, traveling expenses based on our company regulations will be charged. The repair cost at this time will be covered by our company. If one of the following conditions applies, the failure will not be covered by this warranty. (1) Improper handling or use by the customer. (2) If the cause of the problem is due to a reason other than by the fault of our company. (3) If there were modifications or repairs made by a party other than our company or persons specified by our company. (4) Handling, storage, or usage under severe environments exceeding design specification conditions. (5) Problems caused by fires, floods, earthquakes, lightning strikes and other natural disasters. (6) Consumable parts. (7) Other failures that are not at the fault of our company. The warranty here covers the delivered product only, and we will not take responsibility for any direct or indirect damages caused by the malfunction of the delivered product. Warranty periods and coverage of warranties for devices manufactured by those other than our company will be at the responsibilities and conditions of those respective manufacturers, regardless of this document. 2. Warranty conditions for repaired products The Warranty period for repaired items will be 6 months after the date of repairs for that item. Other conditions will be as 1. above. 40