BUCKET ELEVATOR & BELT CONVEYOR MONITORING SYSTEM

INSTALLATION / OPERATION GUIDE WDC3NV46C

Revision 2 - December 2009

This guide must be used in conjunction with the ofcial Watchdog Elite installation operation manual that is supplied with the product.

www.go4b.com USA: (309) 698-5611 UK: +44 (0) 113 246 1800 France: +33 (0) 3 22 42 32 26 Germany: +49 (0) 700 224 24091

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1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 4 4.1

INTRODUCTION General Motion Sensing Misalignment Sensing Temperature Sensing Serial Communications Installation Standard Watchdog Elite System Diagram Determining Left and Right Side of Bucket Elevator Watchdog Elite Block Diagram Watchdog Elite Control Unit Dimensions SPECIFICATIONS The Control Unit Electrical Ratings (Table A) System Parameters (Table B) NTC Bearing Temperature Sensor (Table C) Touchswitch Belt Alignment Sensor (Table D) Proxswitch Belt speed Monitor (Table E) INSTALLATION GUIDE Control Unit Installation of Bearing Temperature Sensors Typical Touchswitch Mounting Positions on a Bucket Elevator Touchswitch Mounting Positions on a Bucket Elevator with a Knee / Idler Pulley Touchswitch Mounting Positions on a Tail / Boot Section of a Bucket Elevator Touchswitch Mounting Positions on a Open Belt Conveyor Touchswitch Mounting Positions on a Enclosed Belt Conveyor Hazardous Locations General Installation Tips Quick Tips Installation and Wiring - Hazardous Locations Installation of Bearing Temperature Sensors Installation of Touchswitches Control Wiring Diagram for Watchdog Elite Control Wiring Diagram for Multiple Watchdog Elite Units to One Set of Alarms Sensor Wiring Diagram (No Knee or Idler Pulleys) Sensor Wiring Diagram (Knee or Idler Pulleys) OPERATING INSTRUCTIONS First Time Use and Initial Calibration

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5 5.1 5.2 5.3 5.4 5.5 6 7 8

TESTING Testing the Control Unit Test Settings Underspeed Testing and Full Test Testing the Touchswitch Testing the NTC Bearing Temperature Sensor WATCHDOG ELITE AND SENSOR TROUBLESHOOTING GUIDE WARNING MESSAGE DISPLAYED ON WATCHDOG ELITE LCD TECHNICAL SUPPORT

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1 INTRODUCTION
1.1 General The Watchdog Elite system is a user-programmable, microprocessor controlled bucket elevator and belt conveyor monitor. The control unit accepts signals of belt speed, belt alignment and bearing temperature from sensors mounted on the bucket elevator or belt conveyor and is able to sound an alarm and provide shutdown control of the elevator or conveyor, and feeding system, when a potentially hazardous condition is detected. Microprocessors and electronics are housed in a self-contained wall-mounting control unit. 1.2 Motion Sensing - General Features The Watchdog accepts input pulses from a boot or tail shaft mounted P800 proximity sensor. The Watchdog compares the speed given by these input pulses with a preset value, (the calibrated speed) and is able to affect an alarm or shutdown if there is a deviation from the Calibrated speed of more than the programmed percentage. These percentages are fully user-selectable. A digital display of speed is provided on the front panel of the Watchdog which can be scaled as required by a programmable Scale Factor. The Watchdog also accepts a signal from the motor starter which will initiate a programmable start-up timer. During this startup time the speed is monitored and if insufcient acceleration is detected, (e.g. due to a blockage) a stop signal will be generated to shut down the elevator leg or conveyor. A full test feature is also provided on the Watchdog Control Unit. This test feature displays the programmed percentages and actively tests the internal and external alarm and shutdown circuits. 1.3 Misalignment Sensing - General Features Four Touchswitch sensors are mounted on the elevator (two at the head or drive end and two at the boot or tail end) in order to detect a misaligned belt. Upon detecting a belt misalignment the Watchdog control unit provides an alarm signal for external alarm horn sounding and automatic feed equipment shutdown and after a short time delay, automatic shutdown for the elevator or conveyor. NOTE: An additional pair of Touchswitches can be installed when knee/idler pulley/belt misalignment is to be monitored. 1.4 Temperature Sensing - General Features The Watchdog has inputs for up to six temperature sensors. Each of the boot/tail shaft bearings and head/ drive bearings can be tted with a temperature sensor to detect overheating. The temperature sensors have a user adjustable switching temperature, which if exceeded, causes an alarm for external alarm horn sounding and automatic feed equipment shutdown followed by an elevator or conveyor shutdown if the condition persists. Additionally, the control unit displays the temperature of the bearings. NOTE: An additional pair of temperature sensors can be installed when knee/idler bearings are to be monitored. 1.5 Serial Communications - General Features The Watchdog can be connected to a Host computer or PLC via a serial link (RS422/485) which enables remote two-way communication with the Watchdog and connection to the available PC based Log/Print/PM software 1.6 Installation When installing the Watchdog system we strongly advise that you employ the services of a certied and licensed electrician, who is familiar with installation of electronic controls. If assistance is required in obtaining an installation electrician please contact us and we will recommend an electrical contractor.

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1.7 Standard Watchdog Elite System Diagram for Bucket Elevator Legs

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1.8 Determining Left & Right Side of Bucket Elevator

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1.9 Watchdog Elite Block Diagram

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1.10 Watchdog Elite Control Unit Dimensions

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2 SPECIFICATIONS
2.1 The Control Unit - WDC3NV46C A polycarbonate enclosure houses the electronics, the displays, and the terminal connectors. The watchdog contains two printed circuit boards. A lower board accommodates the power supply circuitry, output relays and opto-isolators for the input signals. The upper board is mounted in the hinged lid and houses the microprocessors and the circuitry associated with the display and touch buttons. The two boards are connected by a short ribbon cable. In normal use there are no adjustments required inside the case, all settings being performed via the front panel touch buttons.

CAUTION
DO NOT REMOVE COVER WHILE CIRCUITS ARE LIVE. REPLACE COVER AND TIGHTEN SCREWS BEFORE APPLYING POWER.
2.2 Electrical Ratings TABLE A
Electrical Supply Power Consumption Starter Interlock Input Alarm Relay Contacts Stop Relay Contacts 100 to 260 VAC or 24 VDC (WDC3NV46C) 12 Watts Maximum 110 V +/- 10% 50/60 Hz 2.5 mA or 220 V +/- 10% 50/60 Hz 5 mA or 24 VDC 1 Pole Changeover 240 VAC, 10 A Max. 1 Pole Changeover 240 VAC, 10 A Max.

Additional relay contacts for under speed, misalignment, and bearing temperature are available with the optional PLC interface board. Probe Inputs Probe Supply Approvals 24 VDC Approx. 24 VDC Approx. (1A) CSA Class II Div 2 Groups F and G (USA) CSA Class II Div 1 Groups E, F and G (Canada)

2.3 System Parameters The Watchdog is normally supplied with its programmable parameters preset to default values. Table B shows these values. Each unit is supplied with an Engineers access code to enable on site programming. TABLE B
Parameter Underspeed Alarm Underspeed Stop Over Calibrated Alarm Speed Over Calibrated Stop Speed Start Up Delay Number of Touchswitches Number of NTC Bearing Sensors Hot Bearing Temperature Alarm Units % % % % Seconds Degree F Default Settings 10 20 10 20 10 4 4 140

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2.4 NTC Bearing Temperature Sensor - WDB20V3C WARNING: Refer to bearing temperature sensor installation and operation manual. The temperature Sensor is designed to screw into the bearing housing in a grease nipple hole or other tapped hole and will detect the temperature of the bearing housing. The sensor contains a negative temperature coefcient (NTC) Thermistor. The system fails to safe, as if the wire is broken at one of the sensors, or a wire is shorted, an alarm signal is generated. A two conductors PVC covered 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. TABLE C - BEARING SENSORS WDB20V3C
Switching Temperature Resistance at (21C) 70F Resistance at (60C) 140FResistance at (100C) 212F Sensing Voltage Max. Current Mounting Thread Conduit Entry Cable Weight Approvals 140F (user adjustable in Watchdog control unit) 12000 Ohms Approx. 2500 Ohms Approx. 680 Ohms Approx. 24V DC Approx. 8ma 1/8 NPTF 1/2 NPT 2 Conductors 9 ft. (3 Mtr.) Long 7 oz. (0.2 Kg) CSA Class II Div 1 Group E, F, and G (USA & Canada)

Bearing Temperature Sensor Overview: Can accommodate between 0 and 6 WDB20V3C series NTC bearing sensors The sensors are connected to the Watchdog through the normal temperature sensor connections Temperature accuracy +/- 2F display in whole numbers only Temperature alarms can be individually set for each sensor and are factory set for 140F The temperatures are calculated as an average reading over 5 seconds Three alarms are generated, over temperature, open circuit sensor, and short circuit sensor. The alarm relay will operate 10 seconds (by default) after the detected alarm The stop relay will operate between 180 and 1 second (default is 60 seconds) after the detected alarm (persistent alarm detection) unless immediate stop on HOT bearing has been set Alarms remain on the display until the fault/over temperature problem is removed. Fail safe operation (open / short detected) The temperature data can be read through the Watchdogs serial port
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2.5 Touchswitch Belt Misalignment Sensor TS2V4C WARNING: Refer to Touchswitch installation and operation manual. The Touchswitch is an electromechanical limit-switch with no moving parts, which detects tracking and misalignment problems on bucket elevators and conveyors. When a belt mis-aligns or a pulley moves over and contacts the sensor, the built in solid-state electronic circuitry detects the lateral force of the belt or pulley and activates a voltage free relay contact. This relay contact is used to immediately alarm and shutdown the machine. TABLE D - Touchswitch TS2V4C
Supply Power Consumption LED Indication Adjustment Output Body Construction Face Construction Conduit Entry Cable Weight Approvals 24 VDC 50 mA Red LED indicates unit is powered up and relay is energized Factory set to 8 lb. (3.6 Kg) approx. Voltage free changeover relay contact rated at 5A 250 VAC, non-inductive Pressed seamless steel with epoxy paint Hardened and annealed stainless steel 1/2 NPT 6 conductors 10ft long (only 4 conductors used with the Watchdog) 3 lbs. CSA Class II Div 1 Group E, F, and G (USA & Canada)

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2.6 Proxswitch Belt Speed Monitor P8001V34FC WARNING: Refer to Proxswitch installation and operation manual. The P800 Proxswitch is a Class 2, Division 1 approved inductive proximity sensor, which works on the damped oscillator principle. No contact is made between the sensor and the object being monitored. The P800 will detect a ferrous object at 1/2 and a non-ferrous metal object at a distance of 5/16.
TABLE E - Proxswitch P8001V34FC Supply Indication Output Max Input Speed Sensitivity Temperature Minimal Current Body Construction Conduit Entry Cable Weight Approvals 10 to 30 VDC Red and Green LEDs for target detection NPN / PNP transistor rated at 30 VDC 100 mA max. 250 Hz (15,000 ppm) Detect up to 8 mm 5F to 122F 1 mA Molded Polycarbonate / ABS mix 1/2 NPT 4 conductors 6 ft. Long 1 lbs. CSA Class II Div 1 Group E, F, and G (USA & Canada)

P800 Proxswitch

P800 Proxswitch Shown Installed on a Shaft using 4Bs Whirligig Universal Target / Bracket / Guard

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3 INSTALLATION GUIDE
3.1 CONTROL UNIT The control unit should be installed in a suitable location away from excessive heat, moisture and vibration and mounted at an eye level position so that the display and warning lights can be easily seen. There should be sufcient space to open the hinged lid for wiring.

The Control Unit can be susceptible to static voltage. Connection of a clean ground to terminal 16 is essential for optimum performance. Prior to this connection, static handling precautions should be taken.

ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL AND NATIONAL ELECTRICAL CODES AND SHOULD BE UNDERTAKEN BY AN EXPERIENCED AND PROFESSIONAL, QUALIFIED ELECTRICIAN.
The certication of this product does not permit the drilling/punching of additional cable entry holes into the body of the enclosure. To do so will void both certication and warranty and may cause serious injury or death. ACCESSORIES

Flashing Lamp Part #FL1V1 (120 VDC) Part #FL1V34 (12 to 24 VDC) Note: General purpose use only!

Audible Alarm Horn Part #H350120 (Horn) Part #H350WP (Weather Proof Housing) Note: General purpose use only!

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3.2 Installation of Bearing Temperature Sensor

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3.3 Typical Touchswitch Mounting Positions on a Bucket Elevator When mounting on the head section of a leg or belt conveyor try to catch the belt and the pulley. On a leg mount Touchswitch just above the center line of the head shaft on the discharge side of the pulley when possible. Sometimes this is not possible due to inspection doors or X-pacs etc. They can be mounted on the top or up side of the head pulley if these are encountered. Try to mount Touchswitches so they are accessible from the head section walkway.

TOUCHSWITCH MUST BE INSTALLED ABOVE THE HEAD SHAFT BETWEEN THE 9 OCLOCK AND 3 OCLOCK POSITION AND AS CLOSE TO THE 3 OCLOCK AS POSSIBLE. NOTE: FOR INCREASED PROTECTION, MORE TOUCHSWITCHES CAN BE ADDED TO THE HEAD. NOTE: MOUNT PAIR OF TOUCHSWITCHES DIRECTLY ACROSS FROM EACH OTHER ON RIGHT AND LEFT SIDE OF BUCKET ELEVATOR.

MOUNT TOUCHSWITCH ON UPSIDE OF LEG (IF POSSIBLE) AT THE HIGHEST POINT THAT THE BOOTSHAFT CAN BE ADJUSTED TO. NOTE: FOR INCREASED PROTECTION, MORE TOUCHSWITCHES CAN BE ADDED TO THE BOOT.

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3.4 Touchswitch Mounting Position on a Bucket Elevator with a Knee / Idler Pulley When mounting on the head section of a leg or belt conveyor try to catch the belt and the pulley. On a leg mount Touchswitch just above the center line of the head shaft on the discharge side of the pulley when possible. Sometimes this is not possible due to inspection doors or X-pacs etc. They can be mounted on the top or up side of the head pulley if these are encountered. Try to mount Touchswitches so they are accessible from the head section walkway.

TOUCHSWITCH MUST BE INSTALLED ABOVE THE HEAD SHAFT BETWEEN THE 9 OCLOCK AND 3 OCLOCK POSITION AND AS CLOSE TO THE 3 OCLOCK AS POSSIBLE. NOTE: FOR INCREASED PROTECTION, MORE TOUCHSWITCHES CAN BE ADDED TO THE HEAD. NOTE: MOUNT PAIR OF TOUCHSWITCHES DIRECTLY ACROSS FROM EACH OTHER ON RIGHT AND LEFT SIDE OF BUCKET ELEVATOR.

MOUNT TOUCHSWITCHES AT KNEE PULLEY TO DETECT BELT AND PULLEY MISALIGNMENT.

MOUNT TOUCHSWITCH ON UPSIDE OF LEG (IF POSSIBLE) AT THE HIGHEST POINT THAT THE BOOTSHAFT CAN BE ADJUSTED TO. NOTE: FOR INCREASED PROTECTION, MORE TOUCHSWITCHES CAN BE ADDED TO THE BOOT.

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3.5 Typical Touchswitch Mounting Positions on Tail / Boot Section of a Bucket Elevator

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2009 4B Components Ltd. NOTE: TOUCHSWITCH MOUNTING BRACKETS WILL NEED TO BE FABRICATED TO WITHSTAND THE FORCE OF A MISALIGNED BELT. NOTE: MOUNT PAIR OF TOUCHSWITCHES DIRECTLY ACROSS FROM EACH OTHER ON LEFT AND RIGHT SIDE OF CONVEYOR. NOTE: ON TAIL PULLEYS OF OPEN BELT CONVEYORS THAT ARE TAKE UP PULLEYS MOUNT THE TOUCHSWITCH BRACKET OFF OF BEARING MOUNTING BOLTS WHEN POSSIBLE. NOTE: MOUNT TOUCHSWITCHES INLINE WITH BOTH THE PULLEY AND BELT WHEN POSSIBLE. NOTE: WHEN CONVEYOR HAS IDLER PULLEY INSTALL ADDITIONAL TOUCHSWITCHES AND BEARING SENSORS.

RIGHT SIDE

3.6 Touchswitch Mounting Positions on a Open Belt Conveyor

LEFT SIDE

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NOTE: MOUNT PAIR OF TOUCHSWITCHES DIRECTLY ACROSS FROM EACH OTHER ON LEFT AND RIGHT SIDE OF CONVEYOR. ON HIGH ROLLER TAIL SECTION MOUNT TOUCHSWITCHES ALIGNED WITH TOP SIDE OF BELT ON MOVEABLE SECTION JUST IN FRONT OF VERTICAL ANGLE AHEAD OF TAIL PULLEY.

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NOTE: FOR INCREASED PROTECTION ADDITIONAL TOUCHSWITCHES MAY BE ADDED TO THE HEAD AND TAIL.

LEFT SIDE

3.7 Touchswitch Mounting Positions on a Enclosed Belt Conveyor

RIGHT SIDE

PLACE TOUCHSWITCHES ANYWHERE BETWEEN 6 OCLOCK AND 12 OCLOCK IN FRONT OF HEADSHAFT.

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3.8 Hazardous Locations The Watchdog and sensors have been designed for use in certain hazardous locations, where the hazard is known to be Ignitable Dust. Watchdog Control Unit type WDC3NV46C is approved for use in: - CSA Class II DIV1 Groups E, F & G (Canada) - CSA Class II DIV2 Groups F & G (USA) The Touchswitch TS2V4C is approved for use in: - CSA Class II DIV1 Groups E, F & G The Temperature Sensor Probe WDB20V3C is approved for use in: - CSA Class II DIV1 Groups E, F & G The Proxswitch P8001V34FC is approved for use in: - CSA Class II DIV1 Groups E, F & G 3.9 GENERAL INSTALLATION TIPS: A Watchdog system is equipped to monitor only one bucket elevator or belt conveyor. Normally the internal power supply will be used to power the sensors required by the system. You must use a shielded cable for sensor wiring. Use Belden 5508FE (10 conductor shielded 22 AWG) Do not leave Touchswitches physically installed for an extended period of time before calibrating and bringing the Watchdog into service. Extended continuous belt /splice rub can damage the sensors. The Watchdog power and sensor cables should be installed in a conduit or cable tray without other cables. If it is not possible to install the cable in this way you should ensure that the cable is not installed in an area where electrical interference can be a problem. High voltage cables, high current cables, high frequency cables such as Variable Frequency Drives and microwave driers are all potential sources of interference for the Watchdog system and you should avoid using existing cabling routes if they contain any of the above. Label all wires to aid commissioning and fault nding. Disconnect and insulate all unused wires to avoid shorting to conduit or other wires. Do not install the Watchdog cables or control unit near radio transmitter aerials or cellular telephone repeaters. Ground the Belden 5508FE shield wire to the Watchdog end of the cable only. You must not allow the shield wire to come into contact with a ground source at any other points as this could signicantly increase electrical noise by inducing ground currents. Do not drill extra holes into the Watchdog control unit. This will void the warranty of the product and may affect the approval rating of the enclosure.

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3.10 Quick Tips Quick Tip # 1 When using Touchswitches, ensure that you cut a 2-1/4 diameter hole through the machine casing, centered on the edge of the belt. The hole should be cleaned and de burred to avoid the Touchswitch puck binding and giving false misalignment alarms. Quick Tip #2 The Watchdog requires a motor interlock input voltage signal across terminals 6 and 7. This signal controls the starting and stopping of the equipment under normal conditions. The voltage should be present when the equipment is running, and not present when the equipment is stopped. Quick Tip #3 Before powering the system, measure the resistance to check that the DC supply wires are not shorted to each other and that the +24VDC is not touching any conduit. Quick Tip #4 When using NTC (WDB20V3C) bearing temperature sensors, leave the default setting for the HBS zones at 0 in the Engineer Set-UP. Press A & C at the same time to enter the NTC menu to set the number of bearing sensors that you have installed (Either 4 or 6). Quick Tip #5 Conduit systems can channel water due to ingress and condensation directly to sensors and sensor connections which over time will adversely affect the performance of the system. As such, the installation of low point conduit drains is recommended for all sensors (see example below).

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3.11 Installation and Wiring - Hazardous Locations Consult the National Electrical Code prior to installation. Always use dust/liquid tight exible metal conduit with approved ttings to protect the sensor cables. Use rigid metal conduit to protect the cables from the sensors to the control unit. 3.12 Installation of Bearing Temperature Sensors: The following are guidelines and suggestions for installing bearing temperature sensors. The installer must take responsibly that the sensors are installed in a fashion that can detect bearing temperature as quickly and accurately as possible. All lockout and hotwork procedures must be followed. The NTC bearing sensor has a 1/8 NPT tting with the sensor just at the base of the threads. This is where the heat is detected, so the closer this is to the actual heat source (bearing) the better detection capability this sensor will have. These sensors are designed for the bearings existing grease zerk to be removed and the sensor screwed directly into the grease zerk hole. The NTC sensor is supplied with a grease zerk installed in it. On the majority of bearings the sensor can be directly installed. Some bearing designs require an extension be added to the sensor. When an extension is added, add the very minimum length to keep the bearing sensor as near the bearing as possible. Often times a female to male coupling can be used; this is about as short of an extension that can be purchased. It is recommended to purchase these in brass, as brass will transmit heat fairly well. Sometimes the threaded tting in a bearing maybe 1/4 or 3/8 NPT. When this is encountered, a reduce bushing will need to be used. Use only one reduce bushing to get from bearing tting size to the 1/8 female. This will help to keep the sensor closer to the bearing. When connecting liquid tight to Bearing Temperature Sensors, limit the length to NEC requirements. However, when installed on an adjustable pulley or section be certain enough liquid tight is installed so all adjustments can be utilized. There is also an NTC lug style temperature sensor available that is interchangeable with the screw in sensor. It maybe found that on some applications this is the style of sensor that will be able to detect heat the quickest.

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Temperature Sensor Installation Photos

WDB20V3C bearing temperature sensor shown installed on a tail bearing of an enclosed belt conveyor.

WDB20V3C bearing temperature sensor shown installed on a head bearing of a bucket elevator.

WDB70V3C lug style temperature sensor shown installed on bearing housing.

WDB70V3C lug style temperature sensor shown installed on enclosed belt conveyor casing.

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3.13 Installation of Touchswitches: This following are guidelines and suggestions for installing Touchswitches. The installer must take responsibly that the Touchswitches are mounted in a position to be able to detect a belt misalignment condition and or a pulley misalignment condition, whichever it maybe. All lockout and hotwork procedures shall be followed. The Touchswitch hole should be cut into the housing with a 2-1/4 hole saw. You can mount the Touchswitch with 2 of the 4 ange holes, provided they are across from one another. The Touchswitch needs to be mounted on a at surface, preferably with the conduit entrance (1/2) at the 3 oclock to 9 oclock position to minimize the entrance of water thru the conduit threads. Use 1/4 x 1-1/4 round head machine bolts with lock washers to mount them with the round head inside the leg or conveyor housing, there shall not be any screws or bolts sticking inside of the leg or conveyor housing. When placing ange shims on Touchswitch make certain belt and or pulley contacts Touchswitch face before it can contact any internal surface of leg or conveyor housing. It is best not to be any further away from the pulley then 1- 1/4 to 1-1/2 to the face of the Touchswitch. Make certain both sides are the same distance from pulley. When mounting on the head section of a leg or belt conveyor try to catch the belt and the pulley. On a leg mount Touchswitch above the center line of the head shaft on the discharge side of the pulley when possible. Sometimes this is not possible due to inspection doors or X-pacs etc. They can be mounted on the top or up side of the head pulley if these are encountered. Try to mount Touchswitches so they are accessible from the head section walkway. Be sure to mount Touchswitches straight across from one another. On a conveyor head section mount Touchswitches forward of the head shaft in order to catch the head pulley and belt if either should become misaligned. On a leg boot mount Touchswitch on the up side of the tail pulley if there are no obstructions. If obstructions are encountered the down side of the pulley will work but be sure to have the switches mounted directly across from one another. When mounting on the boot of a leg, mount Touchswitch above center line of boot shaft at the boot shafts highest possible position. Note were shaft is, measure how much higher it can possibly travel or be adjusted, mount Touchswitch that much higher than the shaft is sitting. You will not be able to catch the leg boot pulley in all positions with a Touchswitch. On enclosed belt conveyor tail sections mount Touchswitches to catch top side of belt on movable section just in front of vertical angle just ahead of tail pulley. You will not be able to catch the tail pulley with a Touchswitch on a enclosed belt conveyor due to the ippers on the pulley. Some tail sections have a stud welded to the side of housing just outside of the ippers to mount a lug type temperature sensor. When installing Touchswitches on the tail section of enclosed belt conveyors some tail section adjustment will be sacriced. When mounting Touchswitches on open belt conveyors usually brackets will need to be fabricated. These brackets must be built rigid enough to take pressure from a misaligned belt. It is best if these can be mounted so the Touchswitch can detect if the pulley and or the belt has shifted. On tail pulleys of open belts that are take-up pulleys, it is good if the Touchswitch bracket can be mounted off of the bearing mounting bolts. This allows the Touchswitch to move with the pulley when belt adjustments are made. When connecting liquid tight to Touchswitches, limit the length to NEC requirements. However, when installed on an adjustable pulley or section be certain enough liquid tight is installed so all adjustments can be utilized. When connecting Touchswitches, the green and orange wires in the cable will not be used. Cut both of these wires near the cable jacket, cut one longer than the other and tape them to isolate them from any power or ground. The orange wire has 24 VDC on it when the Touchswitch is powered and activated. The green wire is connected directly to ground inside the Touchswitch. This will cause problems if the wires contact each other, power, or ground.

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TOUCHSWITCH INSTALLATION PHOTOS Open Belt Conveyors

Touchswitch installed on take-up pulley of an open belt conveyor.

Touchswitch installed at the tail of an open belt conveyor.

Enclosed Belt Conveyor and Bucket Elevator

Touchswitch installed at the drive end of an enclosed belt conveyor (inside view).

Touchswitch installed on a bucket elevator.

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3.14 Control Wiring Diagram for Watchdog Elite

NOTE: ALARM AND STOP RELAYS ARE SHOWN ENERGIZED IN THE NORMAL RUNNING CONDITION.

NOTE 1: AUTOMATIC SHUTDOWN CONTROL SIGNAL TO FEED EQUIPMENT.

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3.15 Control Wiring Diagram for Multiple Watchdog Elite Units to One Set of Alarms
NOTE: ALARM AND STOP RELAYS ARE SHOWN ENERGIZED IN THE NORMAL RUNNING CONDITION.

NOTE 1: AUTOMATIC SHUTDOWN CONTROL SIGNAL TO FEED EQUIPMENT.

NOTE: ALARM AND STOP RELAYS ARE SHOWN ENERGIZED IN THE NORMAL RUNNING CONDITION.

NOTE 2: AUTOMATIC SHUTDOWN CONTROL SIGNAL TO FEED EQUIPMENT.

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3.16 Watchdog Sensor Wiring Diagram (No Knee or Idler Pulleys)

WITH TOUCHSWITCH BELT MISALIGNMENT SENSORS, P800 PROXSWITCH AND BEARING TEMPERATURE SENSORS.

WATCHDOG ELITE

WATCHDOG ELITE SENSOR WIRING TERMINALS

NOTE: TOUCHSWITCHES SHOWN IN NORMAL OPERATING STATE. WARNING: INSULATE THE ORANGE WIRE ON THE TOUCHSWITCH. THIS WIRE IS NOT TO BE USED. NOTE: REFER TO WATCHDOG AND TOUCHSWITCH INSTRUCTION MANUALS FOR COMPLETE INSTALLATION INFORMATION. NOTE: LEFT AND RIGHT SIDES ARE DETERMINED WHEN FACING THE DIRECTION THE BUCKET ELEVATOR OR CONVEYOR DISCHARGES.
BOOT / TAIL ALIGNMENT SENSORS

HEAD / DRIVE ALIGNMENT SENSORS

HEAD / DRIVE PULLEY HOT BEARING SENSORS

BOOT / TAIL PULLEY HOT BEARING SENSORS

SPARES

Sensor 1 2 3 4 5 6 7 8 9 10 11 12 13

Location Left Head / Drive Pulley Right Head / Drive Pulley Left Boot / Tail Pulley Right Boot / Tail Pulley Not Used Not Used Left Head / Drive Pulley Right Head / Drive Pulley Left Boot / Tail Pulley Right Boot / Tail Pulley Not Used Not Used Boot / Tail Shaft

Function Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment N/A N/A Bearing Temperature Bearing Temperature Bearing Temperature Bearing Temperature N/A N/A Motion / Underspeed

NOTE: CABLE TYPE IS BELDEN 5508FE WITH 10 CONDUCTORS EACH 22 AWG, SHIELDED. OVERALL OUTER DIAMETER IS 0.23 INCHES. PURPLE AND GREY CONDUCTORS ARE SPARES. THE SHIELD IS TO BE CONNECTED TO GROUND (TERMINAL #1) AT THE WATCHDOG ONLY.

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3.17 Watchdog Sensor Wiring Diagram (Knee or Idler Pulleys)

WITH TOUCHSWITCH BELT MISALIGNMENT SENSORS, P800 PROXSWITCH AND BEARING TEMPERATURE SENSORS.

WATCHDOG ELITE

NOTE: TOUCHSWITCHES SHOWN IN NORMAL OPERATING STATE. WARNING: INSULATE THE ORANGE WIRE ON THE TOUCHSWITCH. THIS WIRE IS NOT TO BE USED. NOTE: REFER TO WATCHDOG AND TOUCHSWITCH INSTRUCTION MANUALS FOR COMPLETE INSTALLATION INFORMATION. NOTE: LEFT AND RIGHT SIDES ARE DETERMINED WHEN FACING THE DIRECTION THE BUCKET ELEVATOR OR CONVEYOR DISCHARGES.

WATCHDOG ELITE SENSOR WIRING TERMINALS

HEAD / DRIVE ALIGNMENT SENSORS

BOOT / TAIL AND KNEE / IDLER ALIGNMENT SENSORS

HEAD / DRIVE PULLEY HOT BEARING SENSORS

BOOT / TAIL PULLEY HOT BEARING SENSORS

KNEE / IDLER PULLEY HOT BEARING SENSORS

Sensor 1 2 3 4 5 6 7 8 9 10 11 12 13

Location Left Head / Drive Pulley Right Head / Drive Pulley Left Boot / Tail Pulley Right Boot / Tail Pulley Left Knee / Idler Pulley Right Knee / Idler Pulley Left Head / Drive Pulley Right Head / Drive Pulley Left Boot / Tail Pulley Right Boot / Tail Pulley Left Knee / Idler Pulley Right Knee / Idler Pulley Boot / Tail Shaft

Function Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment Belt / Pulley Misalignment Bearing Temperature Bearing Temperature Bearing Temperature Bearing Temperature Bearing Temperature Bearing Temperature Motion / Underspeed

NOTE: CABLE TYPE IS BELDEN 5508FE WITH 10 CONDUCTORS EACH 22 AWG, SHIELDED. OVERALL OUTER DIAMETER IS 0.23 INCHES. PURPLE AND GREY CONDUCTORS ARE SPARES. THE SHIELD IS TO BE CONNECTED TO GROUND (TERMINAL #1) AT THE WATCHDOG ONLY.

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4 OPERATING INSTRUCTIONS
The equipment should have been installed and wired in accordance with the Installation Instructions and in accordance with National and Local Codes. 4.1 First Time Use & Initial Calibration The Watchdog is normally supplied UNCALIBRATED. When the unit is rst connected to its supply this is indicated by a message on the display, Not Calibrated! See Manual! At this time the Alarm lamp should be ashing and the Alarm relay pulsing. WARNING: Prior to calibration and throughout the calibration process, ensure that the belt is tight and that there is no grain being moved by the elevator / conveyor. Proceed as follows: (i) Go to the Main Menu by touching button C (green) once. Select the Calibration option by touching button B (yellow) to move the cursor to CALIB. (ii) Select CALIB by touching button C (green). Enter the 3-character Calibration access code (A,B,C) that was supplied with the unit. If the code is accepted the LCD will indicate Start Elevator to Calibrate. (iii) Operate the START button on the motor starter. This provides an interlock signal to the Watchdog (terminals 6 and 7) which will cause the Alarm and Stop relays to be energized and allow the machine to start. Alarm lamp will continue ashing. (iv) The display will indicate the start up delay time. When the start up delay has expired the Alarm lamp will extinguish and the Calibration procedure will start. (v) The Calibration procedure takes about 16 seconds, the progress being indicated on the display as a percentage. The Watchdog will measure the rate of input signals and store an average value of speed (the Calibrated speed) in memory. (vi) When the Calibration procedure is complete the unit will go into normal operation. Any change of speed or misalignment or temperature beyond the preset levels will now cause the appropriate ALARM and STOP action. WARNING: A full system test should be undertaken before the elevator is used in normal operation.

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5 TESTING
5.1 Testing the Control Unit To perform a test, go to the main menu by touching the button C (red). Select TEST from the main menu. Two options will be displayed, Test Settings and Full Test. 5.2 Test Settings When selected, the test will show the value of the calibrated speed and the actual alarm and stop trip speed settings in pulses per minute on the speed display and the trip percent- ages on the message display. This test can be performed at any time whether the machine is running or stationary, as the relays do not operate from this test function and the normal running of the machine is unaffected. 5.3 Underspeed Testing and Full Test WARNING: This test will deactivate the alarm and shut down relays which will shut down the elevator. The elevator must be empty and clear of all products when performing this test. When the full test is selected, the engineers access code BBBB will be requested. When the access code is entered, the settings will be displayed as the Test Settings, and in addition the alarm relay and then the alarm and stop relays will be de-activated, thus verifying the relays and external wiring. It is recommended that these tests are performed on a regular basis in order to verify correct working of the system, the external wiring, and related components. Abort test by touching button A. WARNING: A full test should be performed on a regular basis and should be included in the preventative maintenance program for the elevator. Also, visually inspect the system wiring, sealtite, junction boxes and conduit, making sure that all ttings are tight and secure. 5.4 Testing the Touchswitch: Observe that the red LED on the sensor housing is on and the belt or pulley is not touching the sensor. Slowly turn the test knob clockwise by hand, until the LED goes out. Check that the correct Green Pulsed LED on the Watchdog goes off and that alarms and shutdowns work as expected. Turn the test knob back to its original position (about 1/4 turn) and make sure that it is loose. Observe that the LED is now on. Periodically test the sensor and system, and visually inspect the contact surface of the sensor and the sealtite, the wires, junction box and conduit. 5.5 Testing the NTC Bearing Temperature Sensor: Observe and note the temperature readings on the Watchdog display and/or the PC Log / Print / PM software. Freeze spray each bearing sensor in turn and observe a reduction in temperature for each sensor. Check that the sensor location matches up with the correct location on the Watchdog display and/or the PC Log / Print / PM software. After a few minutes, observe that the temperature returns to normal. Periodically test the sensor and system, and visually inspect the sensor, the sealtite, the wires, junction box and conduit.

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6 WATCHDOG ELITE AND SENSOR TROUBLESHOOTING GUIDE

FAULT CAUSE REMEDY Check ribbon cable connection on bottom PCB Remove terminal strip, remove sensor wires one at a time Check fuses and make sure you have appropriate power 24VDC Check for hot bearing Check for correct set up Call 4B Call 4B Check for plugged belt Check green LEDs on lid Check P800 LED is ashing Check Whirligig to see if still tight on shaft Check for 24VDC at P800 Check to see if orange wire is insulated on Touchswitches Check motor starter interlock wiring at terminals 6 and 7 Call 4B Check motor starter interlock wiring at terminals 6 and 7 Call 4B Re-calibrate after checking belt tension and do not introduce grain! Check belt alignment Check hole diameter is 2-1/4 inches and is de-burred. Check Touchswitch is centered in the hole Loosen knob (rotate counterclockwise 1/4 turn until loose) Check 24 VDC to Touchswitch Check orange wire is insulated

Blank and ashing screen

External sensor short

Hot bearing alarm

Hot bearing or incorrect set up Soft start

Stop Condition / Starting Fault

No Pulses

Stop relay open

Interlock problem

Leg will not start Elevator stopped ready to run Over Speed

Interlock problem

Incorrect calibration Belt misaligning Touchswitch Binding against leg casing

Touchswitch signalling an alarm condition and / or red led is out on Touchswitch

Test knob active No Power

DANGER: Exposed buckets and moving parts will cause severs injury or death. In all cases, immediately stop the elevator before investigating any problem. Ensure that all lockout and tag-out procedures are adhered to.
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7 WARNING MESSAGE DISPLAYED ON WATCHDOG ELITE LCD

TEXT ON LCD Not Calibrated Start Elevator Hot Bearing HBS #x Open Circuit HBS #x Over Range Misalignment Upper / Lower Underspeed Alarm Delay in Seconds Overspeed Alarm Delay in Seconds or Overspeeding Internal Fault Code n Power Fail Stop Condition Stop Condition Underspeed Fault Stop Condition Over Calibration Fault Stop Condition Persistent Alarm Stop Relay Open Speed n Motor Running Speed n CAUSE Watchdog Not Calibrated Calibrate option has been selected from menu Bearing at Sensor x has exceeded temperature Bearing sensor faulty or wiring faulty Bearing sensor faulty or wiring faulty Belt is misaligned at top or bottom Elevator belt is slipping ACTION (Where Required) Calibrate Watchdog Start elevator to calibrate Check the bearing at Sensor x Check bearing sensor and wiring at Zone x Check bearing sensor and wiring at Zone x Check elevator belt Check Touchswitch Check the belt tension

Incorrect Calibration Watchdog internal fault Supply voltage out of limits Elevator or conveyor failed to accelerate Elevator speed was below preset value Elevator speed was above preset value One or more alarm conditions have persisted Waiting for motor to stop Normal running

Check the belt speed Contact 4B Check supply voltage is within tolerance Check elevator leg Check motor starting circuitry Check condition of soft start system Check belt tension Check belt speed Check belt tension Check belt speed Check and remedy problem None None

DANGER: Exposed buckets and moving parts will cause severs injury or death. In all cases, immediately stop the elevator before investigating any problem. Ensure that all lockout and tag-out procedures are adhered to.

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8 TECHNICAL SUPPORT

CALL 4B USA TECHNICAL HOTLINE WITH ANY QUESTIONS 24 HOURS A DAY 309-698-5611

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