PPI SMART ROLL Guida alla risoluzione dei problemi

OPERATION & MAINTENANCE

SMART ROLL & SMART MONITOR

READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION

Smart Roll Selection Guide ............................................................................3

Selecting how many pulses per revolution for the Smart Roll.........................................3

Selecting the Smart Roll Mounting Option and Location .............................................3

Selecting which Smart Monitor to use ..............................................................3

Installing and Mounting the Smart Roll .................................................................4

Clean Side Return Mounting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Setting up the pivot/hinge..........................................................................4

Test Fit the Mounting Assembly ....................................................................5

Final Installation of the Mounting Assembly .........................................................5

Pivot / Hinge Option 1: Welding pivot rod to conveyor frame .........................................6

Pivot / Hinge Option 2: Use of mounting brackets ...................................................6

Clean Side Return Smart Roll Diagram & Parts List..................................................7

Wiring the Smart Roll..................................................................................8

Wiring the Smart Monitor..............................................................................9

Smart Monitor Set-up ................................................................................ 12

Trip Point Set-up.................................................................................. 12

Ramp-up Timer Set-up............................................................................ 12

Testing Procedure ................................................................................ 12

Adjust Ramp-up Timer after Smart Monitor is Installed and Wired into Control Circuit ............... 12

Using a PLC ......................................................................................... 13

What is a Pulse? ..................................................................................13

What is the Pulse Duration and calculating Pulse Duration? ........................................ 14

What if the pulses are too fast for my electronics? .................................................. 14

Converting pulses to belt speed? .................................................................. 14

Frequently Asked Questions:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Appendix .............................................................................................17

Universal Mount Smart Roll ........................................................................17

Universal Mount Smart Roll Mounting Instructions: ..................................................17

Universal Mount Smart Roll Wiring: .................................................................17

Universal Mount Smart Roll Diagram & Parts List:.................................................. 18

Troughing Smart Roll ............................................................................. 19

Troughing Smart Roll Mounting Instructions: ....................................................... 19

Troughing Smart Roll Wiring: ...................................................................... 19

Troughing Smart Roll Diagram and Parts List:......................................................20

Return Smart Roll ................................................................................. 21

Return Smart Roll Mounting Instructions: .......................................................... 21

Return Smart Roll Wiring: ......................................................................... 21

Return Smart Roll Diagram & Parts List: ...........................................................22

Smart Roll Sensor Wiring Diagrams and Specifications .............................................23

Additional Smart Monitors.........................................................................24

Part number 37545 Smart Monitor 120VAC 4-20mA output .........................................24

Part number 47268 Smart Monitor 9-36 VDC ......................................................26

Part number 47269 Smart Monitor 220VAC 4-20mA output.........................................28

Part Numbers.....................................................................................30

Smart Monitor Part Numbers ......................................................................30

Clean Side Return Smart Roll Part Numbers .......................................................30

Universal Mount Smart Roll Part Numbers .........................................................30

Troughing Equal Smart Roll Part Numbers ......................................................... 31

Flat Return Smart Roll Part Numbers ..............................................................32

TABLE OF CONTENTS

SMART ROLL SELECTION GUIDE

The Smart Roll needs to be used with a Smart Monitor, PLC, or similar device that can monitor the pulses and select a desired output.

Read the complete manual and understand all wiring, pulse selection, and mounting instructions prior to installation. Refer to the sections

Pulse Selection and Frequently Asked Questions of this manual. If necessary contact a PPI Applications Engineer.

The Smart Roll and Smart Monitor should be installed by trained personnel using appropriate safety practices per the National Electric

Code, including electrical disconnect and lockout practices reference ANSI Z244.1. This device is not intended for use in hazardous areas

as defined by the NEC articles 500-504. Intrinsically Safe Smart Rolls and Smart Monitors are not presently available. Follow all procedures

for power disconnect, lockout-tagout, mechanical blocking, etc. to ensure safety.

SMART ROLL SELECTION GUIDE

SELECTING HOW MANY PULSES PER REVOLUTION

FOR THE SMART ROLL

The PPI Smart Roll is a preset sensor switch. As the roll rotates,

an electrical circuit is opened and closed to create pulses. It is

available in options of 1, 2, or 6 pulses per revolution. The most

commonly used is the 2 pulse option. Belt speed, roll diameter,

and electronics capabilities are selection considerations. Using

the lowest number of pulses per revolution will maximize the time

duration of each pulse. The Clean Side Return SAD5CSRSB-2PL4

is the most versatile and most commonly used Smart Roll. Table 1.1

is based on using a Smart Monitor and the Clean Side Return Smart

Roll using a 5 inch diameter roll. The actual speed limitations may

differ from these limits depending on the roll diameter and electronics.

SELECTING THE SMART ROLL MOUNTING OPTION AND LOCATION

The Smart Roll is available in 4 mounting options, and can fit most locations on a conveyor.

1. Clean Side Return (CSR) – Preferred

2. Universal Mount – An 11.125” long roll in a mounting bracket with two slots for mounting.

3. Return Roll positions in CEMA C and D sizes. Belt widths from 24-60 inches.

4. Troughing Idler (wing roll only) positions in CEMA C and D sizes. Belt widths from 24-60 inches.

In order for the Smart Roll to provide reliable feedback follow these guidelines:

• The roll must maintain belt contact at all times. Areas with high vibration should be avoided.

• Avoid areas where material can build up on the roll. This can increase the roll diameter

and cause errors.

• Select an area and location where the Smart Roll will be best protected from abuse.

• PPI typically recommends the Clean Side Return (CSR) mounting option.

• The next best option is typically the Universal Mount.

• Mounting the Smart Roll in a troughing frame or return position should be considered

as a last option.

• The CSR is the most commonly used Smart Roll (see picture). This Operation and Maintenance

Manual uses this model when explaining the installation and wiring.

SELECTING WHICH SMART MONITOR TO USE

Several models of the Smart Monitor are available. The most commonly used is part number 37543

Smart Monitor 120VAC. This Operation and Maintenance Manual uses this model when explaining

the installation and wiring.

• 37543 Smart Monitor 120VAC; Relay Contacts

• 37545 Smart Monitor 120VAC 4-20mA output

• 47268 Smart Monitor 9-36 VDC; Relay Contacts

• 47269 Smart Monitor 220VAC 4-20mA output

Attention must be given to the location of the Smart Roll so that it is always in contact with the belt. Failure to mount properly may void

warranty and could cause damage to conveyor belt and other components.

# PULSES

SPEED FEET

PER MINUTE

MIN

SPEED

FPM

MAX

RANGE APPLICATION

6 5 700 Low Feeders/Metering

2 10 2000 Normal Normal

1 20 4000 High High Speed

TABLE 1.1 – Smart Roll Speed Limitations

Please note, care must be taken to avoid scraped, pinched, or crushed

wiring. Wires that are scraped, pinched, or crushed during shipping,

handling or installation will void the warranty.

Installing the Clean Side Return (CSR) Smart Roll is shown to the right.

This is the most commonly used Smart Roll. For mounting the Universal,

Trougher or Return Smart Rolls see the appendix.

CLEAN SIDE RETURN MOUNTING INSTRUCTIONS

Setting up the pivot/hinge

Typically, the CSR is mounted on the clean side of the belts return run

using a ¾ inch diameter rod as a pivot or hinge. Figure 2.1 shows a typical

installation for a Clean Side Return Smart Roll on the clean side of the

return run of the belt. Care must be taken to select a location allowing

free movement of the CSR hinge, see Figure 2.2. Mounting the CSR in

locations restricting free movement of the roll and/or mounting arm may

cause premature failure and void the warranty. CSR should not be used on

a reversing belt. The angle from the belt to the CSR mounting arm should

not exceed 45 degrees as shown in Figure 2.2. Proper orientation with belt

travel direction, as shown, is critical. Severe roll and/or belt damage

may occur if mounted incorrectly.

Two options are shown for mounting the CSR Smart Roll. Option 1 is

welding the pivot shaft to the conveyor frame work and option 2 is

using mounting brackets bolted to the frame work. Diagrams for the

pivot/hinge options are shown at the end of this section.

Option 1: At the conveyor mounting location, measure the distance

between the conveyor framework where the ¾ inch diameter shaft

will be attached. Cut the shaft to length, removing burrs, and all

sharp edges.

Option 2: At the conveyor mounting location, measure the distance

between the conveyor framework where the holes will be located for

the mounting brackets. This measurement will determine which mounting

bracket hinge option to use.

Options 1 & 2: Insert the ¾ inch diameter shaft through the CSR hinge

point. Center the shaft with the hinge point, and install one retaining collar

on each end of the shaft as shown in Figure 2.3. Turn shaft collars so set

screws are aligned and lightly tighten the set screws.

FIGURE 2.1: Clean Side Return roll in a typical installation. Optional

CSR mounting hardware shown. Conduit and wire tire not included.

FIGURE 2.2: CSR Mounting

FIGURE 2.3: CSR Mounting Accessories test fit in CSR hinge point.

CSR Mounting Accessories sold separately.

INSTALLING AND MOUNTING THE SMART ROLL

Test Fit the Mounting Assembly

Option 1: Test fit the CSR and Mounting assembly in the conveyor

framework before doing the final installation. Place the CSR and Mounting

assembly in conveyor framework as shown in Figure 2.4. Be sure the

travel direction and path of the wire and/or conduit is correct, and that the

set screws are accessible. The Smart Roll should be in the center of the

belt. Check to make sure the roll is free to rotate and mounting arm is

free to pivot through its full range of motion. If there are any obstructions,

move the CSR and Mounting assembly out of the way and make the

necessary adjustments.

Option 2: Install both mounting brackets to the conveyor framework. One

bracket will be installed on each side of the belt with slots facing upward

and toward the center of the belt. Holes might be needed in the structure

for attaching the brackets.

Option 1 & 2: Move both collars to within 1/8 inch of CSR hinge and

tighten securely.

Final Installation of the Mounting Assembly

Option 1: Prepare the site for welding the ¾ inch diameter shaft to the

conveyor framework by providing adequate protection for the belt and

other components. Welding to be performed by qualified individuals

trained to AWS, or equivalent. PPI is not capable of being aware of all site

specific and industry welding requirements for an application, and cannot

be held liable for non-compliant installations. Proper weld ground location

is critical to prevent damage to bearings and sensor inside the Smart Roll.

These components will not tolerate welding current through them and will

be permanently damaged. Improper ground placement will void warranty.

Figure 2.5 shows a typical welding set-up. Weld ground is placed in a

location keeping the flow of current away from the roll. Keep the belt

splice at least six inches away from the Smart Roll to further reduce the

chance of welding current damage.

When welding is completed remove welding protection, clamps, welding

ground, and any other objects used in installation. Clean weld area and

provide paint or other protective coating per accepted site practice.

Option 2: With the ¾ inch diameter rod installed in the CSR hinge, slide

the slots at the ends of the rod into the slots on the brackets. On each

end of the shaft install the teardrop shaped end clip over the end of the

shaft. Then install the screw into the hole in the end clip and bracket. This

is a self-threading screw; take care not to strip the threads on the screw

or the hole in the bracket.

FIGURE 2.4: Test fit of CSR and Mounting Accessory assembly in

conveyor framework, typical both sides.

FIGURE 2.5: Permanent attachment of 3/4 inch shaft to framework.

Component protection for welding has been removed for clarity.

PIVOT / HINGE OPTION : WELDING PIVOT ROD TO CONVEYOR FRAME

PIVOT / HINGE OPTION : USE OF MOUNTING BRACKETS

ASSEMBLIES

CARBON STEEL

ASSEMBLY PART #

STAINLESS STEEL

ASSEMBLY PART #

42971 42971S4

42972 42972S4

COMPONENTS 4 FEET LONG – CARBON STEEL

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter x 4’ long rod 43180

2 2 Shaft Collar SC0012

COMPONENTS 7 FEET LONG – CARBON STEEL

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter x 7’ long rod 43181

2 2 Shaft Collar SC0012

COMPONENTS 4 FEET LONG – STAINLESS STEEL

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter x 4’ long rod 43180S4

2 2 Shaft Collar - Stainless Steel SC0012S4

COMPONENTS 7 FEET LONG – CARBON STEEL

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter x 7’ long rod 43181S4

2 2 Shaft Collar SC0012S4

COMPONENTS – CARBON STEEL RODS

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter rod TABLE

2 2 Shaft Collar SC0012

3 2 1-1/2” End Stand 15001

4 2 C End Clip 31790

5 2 #12-3/8” Self Tapping Screw 31880

COMPONENTS – STAINLESS STEEL RODS

ITEM QTY DESCRIPTION PART #

1 1 3/4” diameter rod TABLE

2 2 Shaft Collar SC0012S4

3 2 1-1/2” End Stand 15001

4 2 C End Clip 31790

5 2 #12 x 3/8 Self Tapping Screw 31880

ASSEMBLIES WITH RODS – STAINLESS STEEL

ASSEMBLY

PART #

SHAFT

PART #

SHAFT

LENGTH (HC) BE LT

WIDTH

CSR-24S4 43521S4 28.625 33.0 24

CSR-30S4 43522S4 34.625 39.0 30

CSR-36S4 43523S4 40.625 45.0 36

CSR-42S4 43524S4 46.625 51.0 42

CSR-48S4 43525S4 52.625 57.0 48

CSR-54S4 43526S4 58.625 63.0 54

CSR-60S4 43527S4 64.625 69.0 60

CSR-66S4 43528S4 70.625 75.0 66

CSR-72S4 43529S4 76.625 81.0 72

CSR-78S4 43670S4 82.625 87.0 78

CSR-84S4 43671S4 88.625 93.0 84

CSR-90S4 43672S4 94.625 99.0 90

CSR-96S4 43673S4 100.625 105.0 96

ASSEMBLIES WITH RODS – CARBON STEEL

ASSEMBLY

PART #

SHAFT

PART #

SHAFT

LENGTH (HC) BE LT

WIDTH

CSR-24 43521 28.625 33.0 24

CSR-30 43522 34.625 39.0 30

CSR-36 43523 40.625 45.0 36

CSR-42 43524 46.625 51.0 42

CSR-48 43525 52.625 57.0 48

CSR-54 43526 58.625 63.0 54

CSR-60 43527 64.625 69.0 60

CSR-66 43528 70.625 75.0 66

CSR-72 43529 76.625 81.0 72

CSR-78 43670 82.625 87.0 78

CSR-84 43671 88.625 93.0 84

CSR-90 43672 94.625 99.0 90

CSR-96 43673 100.625 105.0 96

CLEAN SIDE RETURN SMART ROLL DIAGRAM & PARTS LIST

ASSEMBLY COMPONENTS

ITEM QTY DESCRIPTION PART #

1 1 Smart Roll TABLE

2 1 CSR Bracket 40820

3 1 D End Clip 47117

4 2 #12-3/8” Self Tapping Screw 31880

5 1 B End Clip 31800

6 1 Hex Bushing 34461

7 1 90º Elbow Conduit Access Port 34452

8 1 Strain Relief Fitting 40824

CSR SMART ROLLS

ROLL Ø ASSEMBLY PART # ROLL ONLY PART #

5.5 SAD5CSRSB – 1PL4 SAD5TE30SB – 1PL4

5.5 SAD5CSRSB – 2PL4 SAD5TE30SB – 2PL4

5.5 SAD5CSRSB – 6PL4 SAD5TE30SB – 6PL4

6.5 SAD6CSRSB – 1PL4 SAD6TE30SB – 1PL4

6.5 SAD6CSRSB – 2PL4 SAD6TE30SB – 2PL4

6.5 SAD6CSRSB – 6PL4 SAD6TE30SB – 6PL4

1. Disconnect and lockout power before starting wiring procedure.

The CSR Smart Roll is provided with a ½ inch 90° elbow conduit access port and a strain relief. The Smart Roll cable is 2 wire, 22

AWG, PVC jacket, PVC insulation, and 6 feet in length. No set-up is required to the sensor inside the Smart Roll. It is factory set and

maintenance free.

DO NOT apply voltage directly across the wires of the Smart Roll Sensor, permanent damage may result. The Smart Roll is designed to

be used with a Smart Monitor, PLC, or similar device.

DO NOT use an incandescent light bulb as a load. An overload will occur due to extremely high cold current.

DO NOT operate without a load. A dead short will result which may cause irreparable damage.

DO NOT directly operate a motor with the sensor. Always use a relay or other appropriate device.

2. At this point a 2 wire cable needs to be routed from the control box housing the Smart Monitor to the Smart Roll. It is recommended to

use minimum of 22 AWG shielded cable. Shielded cable eliminates electromagnetic interference (EMI). It is advisable to route the wires/

conduit for the Smart Roll away from electrical power conduit as the electrical power may cause electromagnetic interference (EMI) in the

signal from the Smart Roll. If EMI is present the signal from the Smart Roll may not make it to the Smart Monitor or PLC. This will result in

the Smart Monitor or PLC getting faulty readings.

Conduit from the control box to the Smart Roll offers more protection to the cable. Any nick, gouge, or cut in the cable wiring could

prevent the sensor signal from reaching the Smart Monitor.

If flexible conduit is used then the strain relief is not needed and can be removed. PPI recommends the wires or flexible conduit be

routed along the side of the CSR bracket and towards the hinge point. This will allow for free motion of the hinge. Be sure the wires or

conduit will not hinder the pivoting of the smart roll.

PPI is not capable of being aware of all site and industry electrical requirements for an application, and cannot be held liable for

non-compliant installations. The product has been designed to be capable of meeting many requirements, and a qualified individual should

review the connection plan prior to installation. Connection of conduit to 90° elbow conduit access port does not meet intrinsically safe

requirements.

DO NOT PULL THE WIRES CONNECTED TO THE SMART ROLL. Pulling wire from inside the roll will cause damage and void warranty. Be

sure to protect the wire near elbow threads and all corners, as this may damage the wire/insulation.

3. Remove the cover from the 90° elbow conduit access

port and route the Smart Roll wires and the wires from

the control box through the conduit opening in the 90°

elbow access port and out the rectangular opening.

4. Attach the conduit to the 90° elbow access port.

5. Attach the Smart Roll wires to the wires from the control

box. Cut wires to proper length to fit in junction box. DO

NOT apply power to the sensor at this time. The Smart

Monitor or PLC provides the power for the Smart Roll.

To avoid damage, verify the circuit meets the sensor

specifications shown in Section A4 prior to applying

power.

6. Reinstall junction box lid and tighten screws to secure.

FIGURE 3.1: 90° Elbow Conduit Access Port.

WIRING THE SMART ROLL

The Smart Monitor provides an under speed switch by monitoring 6-3,000 pulses per minute

(PPM) and has a user-programmable 0-30 second ramp-up timer. The Smart Monitor is

designed to be located in an electrical panel or O.E.M. control box. A removable plate allows for

mounting to a DIN rail. The digital display shows the current PPM in real time. This eliminates

setting “guesswork” by constantly showing the actual PPM being monitored.

The digital display shows “RPM” next to the monitored speed. This can be misleading with a 2 or

6 pulse Smart Roll, as the monitor is actually displaying pulses per minute (PPM).

As with any electrical equipment, the Smart Monitor should be installed by trained personnel

using appropriate safety practices per the National Electric Code, including electrical disconnect

and lockout practices reference ANSI Z244.1.

This device is not intended for use in hazardous areas as defined by the NEC articles 500-504.

Intrinsically Safe Smart Monitors are not presently available.

Several models of the Smart Monitor are available. This section will show wiring for the 120VAC

model part number 37543.

Specification – 37543 Smart Monitor 120VAC

• AC Input: 120 VAC 10 W

• Fuse Protected: 1 amp

• Speed Range: 6-3000 pulses per minute

• Relay Contacts: DPDT 5 amp @ 120VAC

• Safety Delay: 1 second

• Response Time: 1 second or less

Additional models of the Smart Monitor are available.

Specifications for these are shown in the appendices:

• Part number 37545 Smart Monitor 120VAC 4-20mA output

• Part number 47268 Smart Monitor 9-36 VDC

• Part number 47269 Smart Monitor 220VAC 4-20mA output

1. Mount the Smart Monitor inside and existing control panel or other suitable

protective enclosure. See Figure 4.1 for Smart Monitor mounting dimensions.

2. Disconnect AC power before proceeding with installation.

3. Table 4.2 shows connection details for the terminal strip.

FIGURE 4.1: 37543 Smart Monitor dimensions.

TERMINAL CONNECTION

FRONT

1NO CONNECTION

2NO CONNECTION

3NO CONNECTION

4NO CONNECTION

5NO CONNECTION

6NO CONNECTION

7Sensor Input (+)

8Sensor Input Common (-)

BACK

9N/C (2)

10 Common (2)

11 N/O (2)

12 N/C (1)

13 Common (1)

14 N/O (1)

15 AC Input (N)

16 AC Input (H)

FIGURE 4.2:

37543 Smart Monitor terminal connections.

WIRING THE SMART MONITOR

4. Figure 4.3 shows a sample wiring diagram of how the Smart Monitor can be wired into your system. If you are familiar with PPI’s older

Smart Monitor see Figure 4.4 comparing the wiring diagrams on the next page.

5. Connect Smart Roll wires to terminals 7 and 8. Polarity of the wires is not important.

6. Connect the wiring for the 120 VAC to terminals 15 and 16 to power the Smart Monitor.

The Smart Monitor provides the power for the Smart Roll through terminals 7 and 8.

7. Terminals 9 through 14 are customer contacts to be used for system control.

8. Remove lockouts and apply power to the Smart Monitor.

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