T400E

MANUAL

(Model T4004V4CAI & T4004V46CAI)

Important: This document should be read carefully before commencing installation

Rev1.1 March. 2006

CONTENTS

A

B

C

INTRODUCTION

1 SPECIFICATIONS

1.1

CONTROL UNIT

1.2

BEARING TEMPERATURE SENSORS

2 INSTALLATION INSTRUCTIONS

2.1

CONTROL UNIT

2.2

BEARING TEMPERATURE SENSORS

3 ELECTRICAL WIRING

5

4 OPERATING INSTRUCTIONS

4.1

THE TEST FUNCTION

4.2

NORMAL OPERATION

4.3

HOT BEARING ALARM

4.4

ALARM MUTE

4.5

HOT BEARING STOP (SHUT DOWN)

4.6

RESTARTING

FAULT FINDING

DRAWINGS

BLOCK DIAGRAM AND SENSOR WIRING

SUPPLY AND RELAY WIRING

FITTING OF TEMPERATURE SENSOR TO BEARING

2

3

Approvals

Zones of use of T400 Elite:

CAT II 1D for use in Zone 20. Areas as defined in BS EN 50281-1-2

CAT II 2D for use in Zone 21. Areas as defined in BS EN 50281-1-2

CAT II 3D for use in Zone 22. Areas as defined in BS EN 50281-1-2

Certification Markings:

1180 II 1D T125° -20°C to +50°C IP66 Baseefa04ATEX0130X

1180 II 2D T125° -20°C to +50°C IP66 Baseefa04ATEX0131X

Class II Division 1 Groups E, F & G (Canada Only)

Class II Division 2 Groups F & G (USA Only)

Power dissipation in Watts

ATEX category 1D : 6 Watts

ATEX category 2D : 12 Watts

To Open the Lid:

1.

Disconnect power (isolate ALL circuits)

2.

Untighten the lid securing screws

3.

Carefully open the lid ensuring that the gasket is not damaged and remains in place

To Close the Lid:

1.

Check that the gasket is correctly fitted into the box groove and is undamaged.

2.

Tighten the lid screws.

3.

Check that the lid and box are correctly mated.

Special conditions for safe use:

WARNING: Static Hazard - Clean only with a damp cloth.

4

T400 ELITE HOT BEARING MONITOR

INTRODUCTION

The T400 ELITE is a microprocessor controlled unit which is able to accept signals of hot bearings in 8 zones and is able to cause alarm and shutdown of the machine when hot bearings are detected. The control unit is housed in a self-contained wall-mounting enclosure, and the sensors are separate items for mounting on the bearings. The T400

ELITE will operate from 100 to 240 VAC ±10% or from 10 to 30 VDC depending upon the model chosen.

1.

SPECIFICATIONS

1.1

The Control Unit

A plastic enclosure houses the electronics and terminal connectors. The unit contains a printed circuit board to accommodate power supply circuitry, output relays, microprocessor and terminals. A short ribbon cable is connected to the lid of the enclosure where the indicator lamps are mounted. Two ‘touch buttons’ are mounted on the lid to allow the unit to be tested during operation, and to mute the alarm relay.

Electrical Supply

(T4004V46)

-

-

Electrical Supply

(T4004V34)

-

Power Consumption -

Alarm Relay Contacts

Stop Relay Contacts

-

-

100 to 240 VAC ±10% 50/60Hz (Zone 22 only)

10 to 30 VDC

10 TO 30 VDC (Zone 21)

10VA/10 WATTS

1 Pole normally open 8A@ 250VAC

1 Pole normally open 8A@ 250VAC

Sensor Inputs

Sensor Supply

Terminals

Protection

-

-

-

-

-

-

PTC thermistor

** DC Current 100 ma maximum

Power 4mm² 14 AWG max

Signals 2.5mm² 16 AWG max Plug In

ATEX CE Ex II 2D T125°C, II 3D T125°C

CSA CL II DIV 1 GPs E, F & G (Canada)

Height

Width

Depth

Fixing Centres

Cable Entry

Weight

-

-

-

-

CSA CL II DIV 2 GPs F & G (USA)

9.7”, 246mm

7.4”, 188mm

4”, 102mm

-

-

-

8.75” high x 4” wide, 222mm x 102mm

2 Holes 11/8” DIA, 28mm, ¾” CONDUIT

3lbs, 1.3Kg

** The actual voltage will be +24 for model T4004V46A and between +10 and +30 volts for model T4004V34A depending on the supply to the unit.

5

Status Indicator Lamps

-

-

-

-

Viewed through front panel

POWER

HOT BEARING 1

HOT BEARING 2

-

-

-

-

-

-

HOT BEARING 3

HOT BEARING 4

HOT BEARING 5

HOT BEARING 6

HOT BEARING 7

HOT BEARING 8

Touch Switches

-

-

ALARM

MUTE

-

1.2

Bearing Temperature Sensors

TEST

1.2.1 Bearing Temperature Sensor – WDB14V3F

The temperature Sensor is designed to screw into the bearing housing in a grease nipple hole or other tapped hole and will detect excessive temperature of the bearing housing.

The brass body of the sensor contains a positive temperature coefficient (PTC) thermistor which has a fixed switching temperature. Below this temperature, the thermistor has a low resistance and above this temperature it has a very high resistance. All of the sensors in each zone on the bearings are connected electrically in series so that if any one of them exceeds its switching temperature the total resistance exceeds the trip resistance of the control unit. The system fails to safe, as if the wire is broken at one of the sensors, an alarm signal is generated. A two core plus shield cable is permanently attached to the sensor body. A grease nipple is provided in the body of the sensor to allow greasing of the bearing in the normal manner.

SWITCHING TEMPERATURE -

RESISTANCE AT 60°C

RESISTANCE AT 100°C

-

-

176°F + 10°F (80°C + 5°C)

(Other temperatures are available)

250 Ohms max

2000 Ohms Min

SENSING VOLTAGE

SENSING CURRENT

FIXING THREAD

CABLE

WEIGHT

-

-

-

-

-

Protection.

Ex II 1 D Txx°C BAS01 ATEX 1191X

CSA Class II Division 1

30V DC maximum

5ma maximum

1/8” NPT

2 Core + shield 0.75mm² 10ft (3Mtr.) Long

7 oz. (0.2Kg)

Txx°C is replaced by the actual maximum temperature of the chosen sensor.

6

2 INSTALLATION INSTRUCTIONS

Warning

: Always lock-out and tag-out the machine prior to installation and setup.

Wiring: All Wiring Must Be In Accordance With Local and National Electrical

Codes and Should Be Undertaken By an Experienced and Professional, Qualified

Electrician.

2.1

The Control Unit

The Control Unit box should be installed in a suitable control or starter switch room and mounted at an eye level position so that the warning lights can be readily seen. The box should have sufficient space to open the lid for wiring and adjustment. An audible alarm, hooter or visual indicator lamp can be installed in or outside of the control room.

The Control Unit is susceptible to static voltage. Connection of a clean ground to terminal 31 is essential for optimum performance. Prior to this connection, static handling precautions should be taken.

Enclosure Installation:

a.

The IP66 rating of the enclosure must be maintained when used in Zone 20 and 21 dust environment. You must use the correct cable, glands and sealing arrangement and in accordance with the installation codes detailed in BS EN 60079 and EN 50281 b.

Where other certified components are used as part of the assembly or installation procedure, the user must take in to account any limitations which might be listed on the relevant certificates. c.

The box is supplied with 2 x 27.5mm (1⅛”) pre drilled holes in the bottom face. The user may add only 2 x 27.5mm (1⅛”) clearance holes per face. The holes may be placed anywhere on the box face but the centre line between adjacent holes must be no less than 54mm (2¼). There must be at least 12.7mm (½”) of material from the inside edge of the box. All unused entry apertures must be sealed using component certified stopping plugs Hawke International type 375 or 387. The end user must install component or apparatus certified stopping plugs and cable glands in strict accordance with the manufacturer’s instructions. d.

The enclosure must not be modified in any way without reference to Wheat

Electronics, as this will invalidate the certification, except where used in certain Zone

22 applications. e.

All wiring must be carried out in accordance with relevant codes of practice and / or instructions (BS EN 600079-14, EN50281). f.

The voltage and current and maximum power dissipation shown on the box label must not be exceeded. g.

The wiring installation must extend to within 1 mm of the metal face of the terminal. h.

All leads must be insulated for the appropriate voltage.

7

i.

Not more than 1 single or multiple strand cable is to be connected to any terminal unless multiple conductors have previously been joined in a suitable manner (e.g. boot lace ferrule) such that they present a single connection point to the terminal. j.

A parallel shaft screwdriver of the correct size should always be used when tightening terminals.

2.2

Bearing Temperature Sensors (Grease through type)

The standard temperature sensors, which are pre-set at 176°F (80°C) are screwed into the grease holes of the bearings for the elevator leg head pulley, boot pulley and jockey pulley, where fitted. If any of the sensors exceeds its switching temperature, a signal is sent to the control unit and will cause an alarm signal, eventually resulting in shutdown.

Each sensor has a greasing by-pass and is installed in the bearing as Drawing ‘C’.

3 ELECTRICAL WIRING

Refer to Drawings A & B

Mount a conduit junction box within 10ft (3 metres) of each sensor – generally one junction box can be used for a pair of sensors. Connect the sensor cable to the junction box using sealing glands and protect the cable from damage. If flexible conduit is to be used, a conduit adaptor is available to attach to the sensor. Connect the junction box back to the control unit. We strongly recommend the use of shielded wires when wiring the sensors to the control unit. When terminating conduits at the control unit, ensure ground continuity by using a suitable bushing.

Any Bearing Sensor inputs which are unused must be connected to +volts at the control unit.

When installing the equipment in an area which is likely to be hazardous from Ignitable

Dusts, use liquid tight conduit and fittings and follow all local codes.

Terminal (Shield) is used to provide a continuous shield connection for the communications cable and is not grounded in the T400

Terminal 1 and 2 (A+ and B-) are used for the RS485 serial communications bus

(HotBus). Care should be taken to ensure that the connections are observed. Incorrect connection can result in loss of communications between nodes.

WARNING: under no circumstances must the power supply connection be allowed to come into contact with these terminals; to do so would result in the failure of the communications interface.

Terminals 3 and 4 (+ and 0V) are used to provide a 24 DC supply to the HotBus network node when required. This supply can be disabled by switch SW2 and is protected by F5.

Terminal 5 is provides for an 0 volt connection

Terminal 6 is used for temperature sensor 1 input

Terminal 7 is used for temperature sensor 2 input

8

Terminal 8 is used for temperature sensor 3 input

Terminal 9 is used for temperature sensor 4 input

Terminal 10 is used to provide +24 VDC power to the temperature sensors

Terminal 11 is used to provide +24 VDC power to the temperature sensors

Terminal 12 is used for temperature sensor 5 input

Terminal 13 is used for temperature sensor 6 input

Terminal 14 is used for temperature sensor 7 input

Terminal 15 is used for temperature sensor 8 input

Terminal 16 is provides for an 0 volt connection

Terminal 17 no connection

Terminal 18 no connection

Terminal 19 is used for remote MUTE+ connection

Terminal 20 is used for remote MUTE- connection

Terminals 21 and 22 are no connection

.

Terminals 23 and 24 are a volt free Alarm contact for Alarm relay A rated 250 VAC @ 8

Amp non inductive.

Terminals 25 and 26 are no connection

Terminals 27 and 28 are a volt free Stop contact for Stop relay A rated 250 VAC @ 8

Amp non inductive.

Terminals 29 and 30 are for the AC power supply. This is only fitted when the T400 is to be used in a Zone 22 application. The AC supply can be between 100 and 250 Volts

50/60 HZ.

Terminal 31 is used for a ground (earth) terminal when using a mains power supply or an

0 VDC terminal when using a separate DC power supply.

Terminal 32 is used when powering the T400 from a separate 12/24 VDC power supply

(10 to 30 vdc rated)

Fuses:

It is very important to observe the fuse ratings used on the T400 elite. The following

fuse ratings MUST apply.

F5 must have a maximum rating of 200ma when used in a CAT 2D (Zone 21) installation.

F5 has a recommended maximum rating of 200ma when used in a CAT 3D (Zone 22) installation.

F5 is used to limit the current available to the internal electronics and terminals 3 and 4.

F6 is used to protect the AC power supply and should have a 1.0 Amp rating. This fuse is only required when used in Zone 22 installations.

9

In order to maintain the product certification, these fuses MUST be replaced with equivalent fuses at the same rating. Failure to do so will invalidate the certification and any warranties which may exist. The sensor supply (terminals 10 and 11) is limited by a self resetting 100ma fuse. This fuse may get warm especially when close to the trip current. If the current exceeds trip level it may be necessary to allow time for the fuse to cool down before operation can re-commence, this is normal practice.

4 OPERATING INSTRUCTIONS

4.1

The TEST function

4.1.1

Normal Test

The T400 ELITE is equipped with a self test function, initiated by the test touch button on the lid of the control unit. When the button is touched sensor 7 lamp flashes and then the following automatic test is initiated as the touch is released.

1.

All lamps illuminate – sensor 7 lamp continues to flash

2.

After 5 seconds all lamps return to their pre-test conditions

This test can be performed when the system is running or stopped and tests the correct function of the microprocessor and of all lamps.

4.1.2

Extended Test

If the Normal Test is initiated as in 4.1.1 and if the test touch button is touched again, while sensor 7 lamp is flashing, the extended test operates as follows:

1.

All lamps illuminate – sensor 7 lamp continues to flash

2.

Touching the test sensor again

3.

Sensor 7 and 8 lamps flash together for a further 5 seconds (8 seconds total time)

4.

The ALARM RELAY and STOP RELAY are inverted (off becomes on and on becomes off) and sensor 7, sensor 8 and the alarm led flash together.

5.

After 3 seconds all lamps and relays return to their pre test conditions

If this test is performed when the system is not running, the Alarm will sound but the

STOP RELAY will have no effect on the equipment. If this test is performed when the equipment is running, the Alarm will sound and the STOP RELAY will stop the equipment! This test should be performed on a regular basis to check the safety of the installation.

The touch button has been designed to ignore the first 0.5 seconds of touch; this is to reduce the possibility of accidental activation. Once activated as indicated by the led adjacent to the touch pad, removing the finger deactivates the button, if you leave your finger in place, the touch button will only remain active for approximately 2 seconds before automatically de-activating again. The touch button continuously recalibrates in order to eliminate the effects of static, dust or moisture build up on the surface.

10

4.2

Normal Operation

If all Hot Bearing Sensors are ‘cold’, all eight HOT BEARING indicator lamps will be off. The ALARM indicator lamp and ALARM relay will be off. The STOP relay will be energised.

4.3

Hot Bearing Alarm

If a Hot Bearing Sensor becomes ‘hot’, the associated HOT BEARING indicator lamp and ALARM lamp will illuminate. After approx 2 seconds, the ALARM relay will energise. If the Hot Bearing Sensor then becomes ‘cold’, the HOT BEARING indicator lamp, ALARM lamp and ALARM relay will de-energise.

If more than one Hot Bearing Sensor becomes ‘hot’, all associated HOT BEARING indicator lamps will illuminate. Only when all Hot Bearing Sensors become ‘cold’ will the ALARM lamp and ALARM relay de-energise.

4.4

Alarm Mute

If the ALARM lamp and ALARM relay are energised because of a Hot Bearing, the

ALARM may be muted (turned off) by the following methods. If a finger is placed on the MUTE target, the ALARM lamp begins to flash, the ALARM relay de-energises and all HOT BEARING indicator lamps which were illuminated will flash. Alternatively, if a voltage is applied to the MUTE input terminals, the same MUTE action will occur. If the

Hot Bearing Sensors become ‘cold’, the flashing indicator lamps will de-energise.

If, during a MUTE condition, a further bearing sensor becomes ‘hot’, the associated HOT

BEARING indicator lamp will illuminate, the ALARM lamp and relay will energise leaving the original muted HOT BEARING indicator lamps flashing. A further MUTE operation would flash all associated HOT BEARING indicator lamps.

4.5

Hot Bearing Stop (Shut Down)

If a HOT BEARING condition is detected, and if the ALARM indicator lamp is on

(whether muted or not) for more than 3 minutes, the STOP relay will de-energise. If the

ALARM condition is cleared in less than 3 minutes, the STOP relay will not de-energise but the amount of alarm time will be ‘remembered’. If the ALARM condition occurs again immediately, the ‘shut down timer’ will continue from where it last stopped until the 3 minutes is completed. If the ALARM condition does not occur again immediately, the ‘shut down timer’ will time backwards, reducing the amount of time ‘remembered’ until the timer reaches zero. Consequently, if the alarm condition is intermittent, but no single interval of alarm exceeds 3 minutes, the persistence of alarms can eventually result in a STOP condition.

4.6

Restarting

If the machine has stopped because of a hot bearing condition as in 4.5 the lamps described above will remain flashing indefinitely. As soon as the hot bearings have cooled the flashing lamps will be cancelled, and the ALARM and STOP relays will be reset.

11

CHECKLIST

For problems after initial start-up

1.

2.

3.

4.

5.

Is there excessive interference on the electrical power supply? Power conditioners and surge (spike) suppressor may have to be fitted.

Has the wiring for the Sensors been routed away from power cables? See paragraph 3.

Is the T400 Elite circuit properly grounded?

Is the Micro-processor control unit overheating, if so mount in temperaturecontrolled environment of maximum temperature 104°F (40°C).

Check that high powered ‘Walkie Talkie’ radios are not operated immediately near the T400 Elite control unit or Sensors as this will affect the performance.

12

5. FAULT FINDING CHART

SYMPTOM

Hot Bearing LED on

CAUSE

Sensor not operating

Control Unit does not illuminate

Wiring Fault

Sensor connected to wrong

Hot Bearing LED on

Control Unit on continuously

Wrong Hot Bearing LED on unit illuminates

Alarm LED on

Relay off terminals

Wiring fault

Sensor fault

Unused input

Sensor connected to wrong input

Bearing is HOT

Stop condition occurred

Machine fails to start Wiring fault

REMEDIAL ACTION

Replace Sensor

Check wiring

Check wiring

Check sensor

Connect to +v

See drawing ‘A’

Check Bearings

Alarm condition for more than 3 minutes

Check wiring

BRAIME ELEVATOR COMPONENTS LIMITED

Web: http://www.braime.com

♦

Email: [email protected]

4B COMPONENTS LTD

Web: http://www.go4b.com

♦

Email: [email protected]

SETEM

Web: http://[email protected]

♦

Email: [email protected]

Tel. (33) 03 22 42 32 26 ♦ Fax. (33) 03 22 42 37 33

4B SUDAMERICA S.A.

Web: http://www.go4b.com

♦

Email: [email protected]

Tel. (54) 114 702 2364 ♦ Fax. (54) 114 701 5075

Manufactured by Don Electronics Limited.

Woodside Estate, Low Lane, Horsforth, LEEDS LS18 5NY.UK.

Tel +44(0)845 130 4798

Web: www.donelectronics.co.uk

13

Clear

Yellow

Shield

Clear

Yellow

Shield

Clear

Yellow

Shield

Clear

Yellow

Shield

Clear

Yellow

Shield

(LINK TO +24)

(LINK TO +24)

Clear

Yellow

Shield

Clear

Yellow

Shield

5 0v

6 IN1

7 IN2

8 IN3

9 IN4

10 +24

11 +24

12 IN5

13 IN6

14 IN7

15 IN8

16 0v

14

Terminals 21,

22, 25 and 26 are not used on this model.

19 20 23 24 27 28 29 30 31 32

No Connection

Terminals 21,

22, 25 and 26 are not used on this model.

No Connection

15

16