New Receiving Addition

New Receiving Addition
JOB #370724
PO# 18-2743
DRAG CONVEYOR
SAFETY
INSTALLATION, OPERATION MAINTENANCE
INSTRUCTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS 1
SAFETY ALERT SYMBOL 2
TO THE OWNER 3
RECEIVING MERCHANDISE & FILING CLAIMS 3
LIMITED WARRANTY 3
MODIFICATIONS 3
SAFETY EQUIPMENT 3
SAFETY INFORMATION 4
GENERAL SAFETY STATEMENT 4
OPERATIONAL SAFETY STATEMENT 4
OPERATOR QUALIFICATIONS 6
SIGN-OFF SHEET 7
DRAG CONVEYOR MODELS 8
ASSEMBLY INSTRUCTIONS 10
HEAD AND DRIVE 10
TAIL 10
CHAIN / FLIGHTING 11
LINERS 11
INSTALLATION INSTRUCTIONS 12
LIFTING AND MOVING 12
COMPLETELY ASSEMBLED DRAG CONVEYOR 12
SITE ASSEMBLED DRAG CONVEYOR 12
INLETS 13
CONVEYOR FILLING 15
INTERMEDIATE DISCHARGES 16
TAKE-UP CHAIN ADJUSTMENT SCREW 18
CONVEYOR CHAIN ADJUSTMENT Read This Now 19
ULTRAMAX ANTI-PLUGGING DOOR 20
LEVELLING 21
OPERATION INSTRUCTIONS 22
START-UP FOR THE FIRST TIME 22
MAINTENANCE INSTRUCTIONS 24
LUBRICATION 25
GEARBOX INFORMATION 25
CONVEYOR CHAIN AND SPROCKET LIFE 25
EXTENDED SHUTDOWN 25
PROBLEM / CAUSE CHART 26
MAINTENANCE SCHEDULE 27
SPECIFICATION SHEETS
DRAWINGS
1
SAFETY ALERT SYMBOL
THE SYMBOL SHOWN BELOW IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS

CONCERNING YOUR PERSONAL SAFETY. WATCH FOR THIS SYMBOL AS IT POINTS OUT
IMPORTANT SAFETY PRECAUTIONS. IT MEANS “ATTENTION BECOME ALERT! YOUR
PERSONAL SAFETY IS INVOLVED!” READ THE MESSAGE THAT FOLLOWS AND BE
ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
BE ALERT! YOUR SAFETY IS INVOLVED
WARNING
Anyone who will operate or work around this equipment shall first
read this manual!
This manual must be delivered with the equipment to its owner.
2
TO THE OWNER
Your new MMS Drag Conveyor has been designed as a quality product to give years of dependable service.
The care of this equipment will greatly affect the satisfaction and service you will obtain from it. Use this
manual as a guide and observe the instructions and suggestions we have recommended. For additional
information, please contact us.
RECEIVING MERCHANDISE & FILING CLAIMS

When receiving merchandise, it is important to check both the number of parts and their description with the packing list.
All claims for freight damage or shortage must be made by the consignee within 10 days from date of delivery. In
the event of freight damage, the consignee should accept the shipment after noting the damage on the delivery docket,
reorder replacement part/s and file claim to cover loss.
LIMITED WARRANTY
All MMS products are warranted to the original consumer purchaser to be free from defects in material and
workmanship and to do the work for which intended under normal use and service, ordinary wear and tear excepted, for a
period of twelve (12) months from date of shipping for local customers and thirteen (13) months for export customers.
NOTE: To clarify the terms normal use and service and ordinary wear and tear we offer the following explanation:
The wear parts of equipment that are exposed to abrasive materials such as whole and cracked soy beans may not
qualify for warranty. It is not our intention to bypass our warranty responsibility as a supplier of your equipment
purchase. Our intent with this statement is only to draw your attention to the fact that under certain
circumstances and conditions some parts will require more frequent repair or replacement. In the event that there
is premature wear of a part both parties will discuss a fair solution.
All products must be assembled/installed to instructions provided and all safety shields and guards must be installed prior
to startup. We make no other express warranty, nor is anyone authorized to make any on our behalf. MMS will repair or
replace, at its option and free of charge, any part which proves defective in material or workmanship during the warranty
period, provided the part is returned at our request to our factory for our examination, transportation charges
prepaid. Any damage to this product as a result of misuse, abuse, neglect, accident, improper installation, alterations or
repairs, (not our own) or any other use contrary to our instructions will void the warranty. This warranty is limited to
defective parts repair and/or replacement only. Labor charges and/or damage incurred in installation, repair or
replacement are not covered by this warranty as well as incidental and consequential damages connected
therewith are excluded.
MODIFICATIONS
It is the policy of MMS to improve its products whenever possible and practical to do so. We reserve the right to make
changes, improvements and modifications on any equipment sold previously.
SAFETY EQUIPMENT
Please, remember that safety equipment provides important protection for persons working near a machine that is in
operation. Be sure ALL safety shields and protection devices are installed and properly maintained.
3
SAFETY INFORMATION
GENERAL SAFETY STATEMENT

Occupational safety is of prime concern to MMS. This manual was written with the safety of the
operator and others who come in contact with the equipment as our prime concern. The manual presents
some of the day to day work problems encountered by the operator and other personnel. We wrote this
manual to help you understand safe operating procedures for drag conveyors. We want you as our
partner in safety.
It is the responsibility of the contractor, installer, owner and user to install, maintain and operate the
conveyor in such a manner as to comply with Occupational Safety and Health Acts and with all National
and Local laws and ordinances.
In order to avoid an unsafe or hazardous condition, the assemblies or parts must be installed and
operated in accordance with the following minimum provisions.
OPERATIONAL SAFETY STATEMENT

1. Maintain a safety training and safety equipment operation/maintenance program for all employees.
2. Drag Conveyors shall not be operated unless the conveyor housing completely encloses the
conveyor moving elements and power transmission guards are in place. If the conveyor is to be
opened for inspection cleaning or observation the motor driving the conveyor is to be LOCKED
OUT electrically in such manner that it cannot be restarted by anyone however remote from the area
unless the conveyor housing has been closed and all other guards are in place.
3. After the equipment is “locked out” it is the responsibility of the person who will be carrying out
inspection, cleaning or maintenance of the equipment to check that the equipment cannot be started.
4. If the conveyor must have an open housing as a condition of its use and application, the entire
conveyor is then to be guarded by a railing or fence, in accordance with National and local laws.
5. Feed openings for shovel, front loaders or other manual or mechanical equipment shall be
constructed in such a way that the conveyor opening is covered by a grating. If the nature of the
material is such that a grating cannot be used, then the exposed section of the conveyor is to be
guarded by a railing or fence and there shall be a warning sign posted.
6. RUGGED gratings may be used where necessary. If the distance between the grating moving
elements is less than 100mm (4”), the grating opening must not exceed 12mm(1/2”) × 50mm (2”). In
all cases the openings shall be restrictive to keep any part of the body or clothing from coming in
contract with moving parts of the equipment. SOLID COVERS should be used at all other points and
must be designed and installed so that personnel will not be exposed to accidental contact with any
moving parts of the equipment.
7. All rotating equipment such as drives, gears, shafts and couplings must be guarded by the
purchaser/owner as required by applicable laws, standards and good practice.
8. SAFETY DEVICES AND CONTROLS must be purchased and provided by the purchaser/owner
as required by applicable laws, standards and good practices.
9. Do not attempt any maintenance or repairs of the conveyor until power has been LOCKED OUT.
4
10. Keep all operating personnel advised of the location and operation of all emergency controls and
devices. Clear access to these controls and devices must be maintained.
11. Frequent inspections of these controls and devices, covers, guards and equipment to ensure proper
working order and correct positioning must be performed.
12. Practice good housekeeping at all times and maintain good lighting around all equipment.
13. Do not walk on conveyor covers, gratings or guards.
14. Do not poke or prod material into the conveyor with a bar or stick.
15. Do not place hands, feet or any part of the body or clothing in the conveyor or openings.
16. Do not overload conveyor or attempt to use it for other than its intended use.
17. Always regulate the feeding of material into the unit at a uniform and continuous rate.
18. Do not attempt to clear a jammed conveyor until power has been LOCKED OUT.
19. Do not attempt field modifications of the conveyor.
20. Drag conveyor inlet and discharge openings are designed to connect to other equipment or
machinery so that the flow of material into and out of the drag conveyor is completely enclosed.
21. Before power is connected to the drive, a pre-start up check shall be performed to ensure the
equipment and area are safe for operation and all guards are in place and secure.
22. Drag conveyors are not normally manufactured or designed to handle materials that are hazardous to
personnel. These materials which are hazardous include those that are explosive, flammable, toxic or
otherwise dangerous to personnel. Conveyors may be designed to handle these materials. Conveyors
are not manufactured or designed to comply with National and Local codes for unfired pressure
vessels. If hazardous materials are to be conveyed or if the conveyor is to be subjected to internal or
external pressure, then consult MMS prior to any modifications.
23. Always operate the conveyor in accordance with these instructions and those contained on the
caution labels affixed to the equipment.
MMS insists that disconnecting and locking out the power to the motor driving the unit provides
the only real protection against injury. Secondary safety devices are available; however, the
decision as to their need and the type required must be made by the owner-assembler as we have no
information regarding plant wiring, plant environment, the interlocking of the drag conveyor with
other equipment, and the extent of plant automation.
Other devices should not be used as a substitute for locking out the power prior to removing guards
or covers. We caution that use of the secondary devices may cause employees to develop a false
sense of security and fail to lock out power before removing covers or guards. This could result in a
serious injury should the secondary device fail or malfunction.
There are many kinds of electrical devices for interlocking of equipment systems such that if the drag
conveyor in a system or process is stopped other equipment feeding it, or following it can also be
automatically stopped.
Electrical controls, machinery guards, railings, walkways, arrangement of installation, training of
personnel, etc., are necessary ingredients for a safe working place. It is the responsibility of the
5
contractor, installer, owner and user to supplement the materials and services furnished with these
necessary items to make the drag conveyor installation comply with the law and accepted standards.
It is your responsibility as an owner/operator/supervisor to know what specific requirements,
precautions and work hazards exist and to make these known to all other personnel working with the
equipment, or in the area, so that they too may take any necessary safety precautions that may be
required. Avoid any alterations to the equipment. Such alterations may create a dangerous situation
where serious injury or death may occur.
Explosion venting may be required depending on location, and / or product being
transferred through this equipment. To operate without proper explosion venting
may result in fire or explosion. Check local industrial codes and policies.
Failure to read this Operation and Assembly Manual and its safety instructions is a misuse of the
equipment.
OPERATOR QUALIFICATIONS
Operation of this drag conveyor shall be limited to competent and experienced persons. In addition,
anyone who will operate or work with this equipment must use good common sense. In order to be
qualified, he/she must also know and meet all other relevant requirements such as:
1. Some regulations may specify that no one under a certain age may operate
powered mechanical equipment. It is your responsibility to know what these
regulations are in your own area or situation.
2. The Workplace Health and Safety Act requires that all persons who supervise,
manage or operate machinery should receive appropriate training and instruction
for health and safety. Do not assume that people already know or can informally
learn about machinery safety.
3. Unqualified persons are to stay out of the work area.
4. A person who has not read and understood all operating and safety instruction is
not qualified to operate this equipment.
6
SIGN-OFF SHEET
Workplace Health and Safety requires each owner and/or employer to inform every
person working with or near this equipment as to operating procedures and safety
precautions. The sign-off sheet below is provided as a convenient means by which
to record when such information was conveyed.
DATE EMPLOYER SIGNATURE EMPLOYEE SIGNATURE
7
Round and Square Trough Drag Conveyors
Standard “U” Trough Drag Conveyor

5
4 6
3
2
1
① Head Section ( End Discharge) ② Drag Chain Tightening System ③ Anti Plugging Door
④ Trough Section ⑤ Inlet ⑥Self CleaningTail Section
Ultramax Drag Conveyor
Two Deck Drag Conveyor

Notched Paddle
Sweeper Paddle
Note: Paddles in Models above 400mm in width have notched paddles to reduce friction and noise. A
sweeper paddle(s) with NO notch is provided to ensure the conveyor properly cleans out. When changing
paddles it is important that you replace a sweeper paddle with another sweeper paddle. The sweeper paddle
is black in colour.
Bone Drag Conveyor
Paddle
Note: All models have notched paddles to reduce friction and noise. A sweeper paddle(s) with NO notch is
provided every 3m (10ft) to ensure the conveyor properly cleans out. When changing paddles it is important
that you replace a sweeper paddle with another sweeper paddle. The sweeper paddle is black in colour.
8
En Masse Drag Conveyor
Model 500×600 (20”×24”) and larger sizes have take ups mounted in this
direction.
Note: Paddles in Models above 400mm in width have notched paddles to reduce friction and noise. A
sweeper paddle(s) with NO notch is provided to ensure the conveyor properly cleans out. When
changing paddles it is important that you replace a sweeper paddle with another sweeper paddle. The
sweeper paddle is black in colour.
Note: In two deck and En Masse conveyors all 400mm (16”) and larger sprockets are split for easier
removal.
9
ASSEMBLY INSTRUCTIONS
Assembly of a MMS Drag Conveyors may vary between different models and lengths. Some of our
shorter drag conveyors are shipped fully assembled. Longer drag conveyors are usually shipped in
sections which must be assembled in a particular manner.
HEAD AND DRIVE

It is usual for all drag conveyor heads, including the drive, to be shipped fully assembled. The
“correctness” of the head section is critical to the operation of a drag conveyor, and it is therefore
important to carry out the following checks.
1) Thoroughly inspect the complete head and drive section for any damage or misalignment which may
have occurred during shipping or handling.
2) Check that the sprocket is on the centre line of the drag head. Check that sprocket “key” is in place
and that the set screws are tight.
3) If the drive has a guard, remove it and check the alignment and tightness of all the drive components.
4) Carefully turn the drive over by hand using the “V” belts to check if all moving parts turn freely and
do not rub on any stationary parts. For drives using sprocket and chain you must remove the
chain from the sprockets and then turn. Adjust if required.
5) Check, and adjust if required, the tension of the drive belts or chain. (Refer to Maintenance-Drive
section of this manual ).
6) Replace guard carefully and securely.
TAIL
Drag conveyor tail sections are usually shipped fully assembled. The tail section is critical to the
satisfactory operation of a drag conveyor and, therefore, the following checks should be carried out.
1. Thoroughly inspect the complete tail section for any damage or misalignment which may have
occurred during shipping or handling.
2. Check that the sprocket is on the centre line of the drag boot. Check that sprocket “key” is in place
and that the set screws are tight.
3. Model 2 drag conveyors are equipped with a “Push Box” chain tightening system. It is important that
the “Gap” of the telescoping system be equal all around when in operation.
10
CHAIN / FLIGHTING
The drag conveyor chain is supplied installed in the drag conveyor.
A) For drag conveyors supplied installed in one piece it is only necessary to adjust the tension of the drag
chain, and put the unit into service after following the proper startup procedures.
B) For drag conveyors that are shipped in (2) or more lengths the drag conveyor must be assembled as
indicated by the match marking. The drag conveyor chain is installed in the drag conveyors trough
sections and will require connection using the supplied connector links. The drag conveyor chain is then
properly tightened using the chain takeup system, and the unit is ready for service after following the
proper startup procedures.
C) For those times when chain is shipped separate from the trough sections it is important to install the chain
with the UHMW paddle towards the discharge end on the bottom of the conveyor section. The drawings
shown on this page show the paddles fitted to the chain and in the direction of product flow to the
discharge.
D) When connecting the chain, ensure the take-up unit is at the minimum position to give the maximum
amount of adjustment. DO NOT over tighten chain, as this will result in excessive wear and vibration.
E) When replacing notched paddles in Two Deck Drag Conveyors it is important that you replace the
sweeper paddle (black in colour) with another sweeper paddle. The sweeper paddle ensures the drag
conveyor provides proper cleanout. (See Pg.8 -10)
Welded Paddle Attachment UHMW Paddle
UHMW Paddle
Welded Paddle Attachment
LINERS Lock Nut Bolt

Trough liners can be provided for abrasive materials. These liners can be A/R plate, UHMW or other
abrasive resistant materials. Contact MMS for assistance in deciding the need for liners.
11
INSTALLATION INSTRUCTIONS
The information given in this manual is based on standard procedures used in the industry and MMS
Engineering assumes no liability for their interpretation and use.
Should there be some delay between when this equipment was received and its eventual installation, any separate
parts should be carefully stored so they can be easily located and identified when required. Keep packing lists for
this reason. We cannot be responsible for the loss of items that are listed and included on our packing list.
The best method of installation depends on the size of the conveyor and its location with respect to other structures
and equipment. During installation, common sense is the most important guide.
Installation of conveyors must be carried out by qualified and experienced personnel.
LIFTING AND MOVING

Extreme care must be taken to prevent damage when moving assembled conveyors or components. Spreader bars
with slings are the recommended support method for lifting. The unsupported span should be no longer than 4
metres (12’). Never lift a conveyor with only one support point. Unusually heavy items such as drives or gates
shall be considered when choosing support points because of load balance and their bending effect.
COMPLETELY ASSEMBLED DRAG CONVEYOR

When a drag conveyor is shipped fully assembled, it is ready for installation upon arrival. However, it is wise to
firstly cheek the entire conveyor for any damage or misalignment which may have occurred during shipping or
handling.
SITE ASSEMBLED DRAG CONVEYOR

If the shipment consists of more than one drag conveyor, it is suggested you separate all components according to
the shipping tags or item numbers, which are fastened to each part.Arrange each drag conveyor section in proper
sequence according to match-marks tagged as illustrated in Fig. 1. You will note the match-marking at the ends of
each section are the same markings as indicated on the conveyor arrangement drawing supplied for each conveyor.
When bolting the drag conveyor trough sections together, line up the inside bottom surfaces carefully to
eliminate any ledges or offsets. Failure to properly align trough sections may result in damaged flights,
excessive wear and noisy operation.
Check all sprockets and bearings to be certain set screws or locking assemblies are tight on the shafts. Check both
head and tail sprockets to see that they are centred in the trough. Every effort has been made in our factory to be
certain all bolts, set screws and sprockets etc. have been properly set and tightened at assembly. However, some
loosening may occur during shipping and handling.
Anti Plugging Door Inlet
A A B B
Chain Figure 1. Match Marking of Drag Conveyor
Self Cleaning Tail
Tightening
Head
12
INLETS
Drag Conveyor can be fitted with various types of inlets. A typical inlet can be one of the following:
Product Flow
A) “ L” iron double flanged frame that is welded to the lid section. This inlet can be installed on any
type of drag conveyors manufactured by MMS. The angle iron frame inlet does NOT prevent
product from coming in contact with the return paddles and therefore is not suitable for situations
that require gentle and/or clean handing of the product.
B) Divided flow inlets can be installed on any type of drag conveyors manufactured by MMS. Divided
flow inlets allow product to pass into the conveyor UNDER the return chain paddles. This system is
preferred to ensure gentle and/or clean handling of the product.
C) The Two Deck Drag uses the top section of the drag as the first point of material entry into the drag. The
material is then dragged towards the tail section until it reaches a discharge opening. The material passes from
the upper section into the lower section and then is transferred to the discharge end or to an intermediate
discharge. The lower section of the Two Deck Drag is deeper in profile than the upper section and this
prevents over feeding and possible plugging of the lower section.
13
D) Side Flow inlets are supplied on the Ultramax Drag Conveyor. The side flow inlet allows the product
to enter into the drag below the returning chain and paddle. (Pos. 2) With the product entering the drag
paddle under the returning chain this provides gentle handling and clean discharging of the product. IE:
No product touches the lower portion of drag conveyor chain.
Note: Pos. 1, 2 and 3 best suited for surge feeding from an under bin discharge.
When the internal flow control plate is raised to
the upper position this allows product to flood the
conveyor. Operating the drag conveyor in this
position allows the product to cover the paddle
Pos. 1
and the chain. The drag conveyor will deliver its
maximum capacity but will not provide Ultra
clean operation. Best suited for a single discharge
at the head section.
Maximum Capacity
(Product Over Chain)
When the internal flow control plate is lowered to its

lowest position this allows restricted flow into the
Pos. 2 drag conveyor. This position will not allow the
product to enter into the links of the drag chain. For
Ultra clean operation for most dry free flowing
materials this is the preferential operating position.
Ultra Clean
(Product Under Chain)
When the internal flow control plate is set at its 60o

position this allows restricted flow into the drag
Pos. 3 conveyor. This position will not allow the product to
enter into the links of the drag chain. The 60o
position is for materials that are extremely “fluid”.
Ultra Clean (60o)

(Product Under Chain)
Bulky material such as meals that are transferred via
spouting to the inlet can choke inlets with the internal
control flap. IG: Spouting from elevator discharges. The
Pos. 4 “inflow” side inlet provides a larger opening to allow the
material unimpeded access to the drag paddles and trough.
This inlet cannot offer Ultra clean operation (product
under chain). The inlet does provide maximum capacity
with superior cleanout using the drop door discharge.
“In Flow” Side Inlet 14
CONVEYOR FILL (Side Flow)
When spouting a Side Flow inlet for “inflow” conditions such as a spout from an elevator to the inlet
the preferred method is shown in Fig. 2. The spout is to be installed into the inlet at or about the same
angle of the side inlet (A). Spouting is also to be installed 90o (or) as close as possible to the length of
the conveyor (B). (B)
(A)
Figure 2.
“Inflow” spouting to the inlet as shown in Fig. 3 can result in a blockage at the inlet, when handling
bulky products such as meals.
Figure 3.
CONVEYOR FILL (Divided Flow)

Full size opening “Inflow” spouting is to be installed as shown in Fig. 4. For spouting that is smaller
than the inlet then install as shown in Fig. 5.
200mm r a i s e d c a p
Figure 4. Figure 5.
“Inflow” spouting or surge spouting installed incorrectly as shown in Fig. 6 can result in improper filling
that will affect capacity.
15
Figure 6.
INTERMEDIATE DISCHARGE SLIDES/DOORS
All drag conveyors are supplied with a head section which is the end discharge of the conveyor.
Intermediate discharges can be supplied for all “U”, “□”, and bone style trough conveyors. A typical
discharge can be one of the following:
B) Curved Slide (Standard “U” trough)

A) Flat Plate Channel Iron (En Masse) (Two Deck).
C) Ultramax Drop Door D) Bone Style Drop Door
NOTE (TO AVOID PLUGGING):

It is important that the opening and closing of slides / drop doors on a drag conveyor with
multi-outlets be programmed to ensure the proper sequencing.
It is important that the conveyor trough be completely emptied, and the appropriate gates closed and
opened ready for the next cycling.
All equipment upstream of the drag conveyor requires programming to allow for proper cleanout of
the drag BEFORE the closing of the drop door.
It is important that bin high level switches and other limit switches be positioned to prevent plugging
of the conveyor. The bin high level switch must ensure that when a signal is given that there is ample
room in the bin to empty the conveyor, and all upstream equipment feeding the conveyor.
16
Inspection Port
Lid Release Section
Product Flow
(Open) (Closed)
Figure 7. Ultramax Drop Door
Self Cleaning Paddle Rails
Door Adjustment Linkeage (Note 1)
Note1: If the door does not seat properly when closed or sticks when opening then adjustment to the
Door Adjustment Linkage should correct the problem. Improper air pressure to the air cylinder can also
result in poor door operation.
Note: The required air pressure is 6 Bars (87PSI), air volume is 750 L/Min. (27Cu.Ft./Min.) for
50mm Dia. and 850 L/Min. (30Cu.Ft./Min.) for 63mm Dia. cylinder.
17
TAKE-UP CHAIN ADJUSTMENT SCREW
All drag conveyors are fitted with (2) take-up chain adjustment screws (Fig.8). It is important than when
tightening the drag conveyor chain and paddle system that these take-ups be adjusted equally and evenly.
To ensure that the shaft is in alignment prior to the locking of the adjustment screw a measuring tape is
to be used to verify its position (Fig. 9).
Internal View of “ACME” Thread

Lock Nut
Telescoping Section
Adjustment Nut
Figure. 8
Measure
Here
Improper Alignment Proper Alignment
Figure. 9
WARNING! : Some Drag conveyors are fitted with Pillow Block bearings and these bearings come
with external seals. DAMAGE TO THESE SEALS CAN OCCUR IF PROPER ATTENTION IS NOT
GIVEN TO THE EQUAL AND EVEN TIGHTENING OF THE TAKE-UPS.
WARNING! : Do not remove shims under the bearing housings. These shims ensure the shaft is in
proper alignment through the bearings. When replacing bearings ensure shims are properly re-installed
under the bearing housing.
18
CONVEYOR CHAIN ADJUSTMENT
Depending on the application/installation allowance the drag conveyor will be fitted with either a head chain
tightening system (Model 1) (Fig. 10). or a tail chain tightening system (Model 2) (Fig. 11).
To use the chain tightening system you must first release the Lock Nuts on the ends of the chain Take Up
units and on the top of the “Push Box” (Model 2 only). Using a suitable sized wrench / socket the Take Up
Adjustment screw can then be used to tighten / loosen the chain.
Safety Stop
Limit Switch Wheel Position Anti Plugging Door
Limit Switch Bracket
Lock Nut
Take Up
Adjustment Screw
Chain Takeup Unit
Figure. 10 Head (MODEL 1)

Note: The head section anti-plugging door is fitted with a Limit Switch Bracket and a Safety Stop. The
Safety Stop is at a length suitable to allow the opening of the door, if at any time the drag conveyor is
about to plug. The amount of door opening allows enough movement to trigger the Limit Switch. The nut
on the end of the Safety Stop restricts the amount of door opening to protect personnel. The Limit Switch
may or may not be supplied with the conveyor. In order to protect the conveyor from damage due to a
plugged condition a Limit Switch device must be installed.
Tail (MODEL 2)
NOTE: ①.When tightening the chain it is important to maintain sprocket alignment by alternating between the adjusting nuts on the
take-up unit. Make sure the sprocket is parallel to casing sides and the chain tracks centrally on the sprocket when tightening the take-up at
final position.②.Do not overtighten the chain as this will create excessive stresses that may damage the equipment and shorten the
chain life.③.After adjustment to the chain ensure that the Lock Nuts on the Take Up units are tightened snugly.
19
Ultramax Drag Conveyor Plug Conditions
In order to protect drag conveyors from damage in plug situations the head section is fitted with an
anti-plugging door. This door is to be connected to a lever style limit switch (provided by others). See
page 19 and 20 of this manual.
NOTE:
The Ultramax Drag Conveyor will discharge 100% of dry free flowing material transferred to intermediate
discharges and therefore prevent carryover. There are however instances where sticky material will cling to
the paddle surface, and this small amount can be carried over the discharge hole. To allow for the most
sanitary conditions we recommend the head section discharge to be fitted with on overflow / carry over
spout. Do not use the head discharge to fill a bin. When the drag is running and delivering material to
the intermediate gates any stick on material that eventually falls off the paddle en-route to the head end
will be rejected (Fig. 12) out of the system. In the event of an overflow condition the head discharge will
prevent damage to the drag conveyor chain and paddles. The discharged material is then to be spouted
from the valve to a receptor such as a tote bag for reclaim purposes.
OVERFLOW/CARRYOVER
Figure. 12
WARNING:
The operator should be aware that in the event of a plug situation at one the multi-discharges the
material will be transferred to the head discharge section and be discarded. The material will be
discarded to the receptor or tote, and in effect the spout will perform as an anti-plugging device, and
prevent damage to the conveyor.
20
LEVELLING
It is very important to have the conveyor aligned. When the chain starts moving it is just like
a gyroscope it will align itself whether the conveyor is straight or not and that is why
paddles may sometimes climb on the side of the conveyor. There are a number of devices for
aligning a conveyor. The most common are the level, the stringline and the transit.
Whichever method is used, it will be necessary to check the “alignment” in two planes, 90
degrees apart.
For conveyor assemblies purchased as parts or merchandise, assemble as follows: Place conveyor troughs
in proper sequence with tail, inlet and head in proper location. Connect the trough flanges loosely. Do not
tighten bolts. Align the troughs using string line/level then tighten flange bolts. The drag chain is then
pulled into the trough along the bottom and around the head and tail sprockets for connection.
String Line
Side View Alignment Procedure

Head (Using String) Inlet Tail
String Line
Top View Alignment Procedure

(Using String)
Level
(Using Level)
21
OPERATION INSTRUCTIONS
START-UP FOR THE FIRST TIME

Before putting the drag conveyor into operation, it must be checked for correct working. Special
care must be taken to ensure clearance of flights particularly around the tail sprocket in the
contoured tail section.
1. All foreign material must be removed from the drag conveyor before it is started.
2. Remove drive belts / sprockets and start motor to determine proper operational
direction of the equipment. (Fig. 13) Damage to equipment and injury to personnel is
possible if equipment is started in the wrong direction. Correct motor direction if
needed. For drag conveyors provided with direct drives this procedure requires extra
caution as per item 5.
3. Before operation, close all clean-out slides and inspection panels and ensure all drive
guards are in place.
4. Start the conveyor motor and listen carefully for any abnormal noises or operations, in
the drive and the drag conveyor.
5. Never attempt to remove covers or inspection windows or put hands into the machine
while it is in operation.
6. Measure and record the no load motor current.
Figure 13.
ATTENTION
Note: All new installations using one or several pieces of equipment should be “flushed clean” with corn or some
other abrasive type products. This flushing cleans out unwanted debris that may be lodged in the equipment. Flushing
will also shine the steel body of the equipment to ensure less friction and improved product flow.
Note: When a conveyor is new or after it remains idle for a season it should go through a “break–in” period to
smooth and polish the casing interior. This allows the product to slide inside the conveyor with a minimum of friction
resistance and thus obtain maximum conveyor capacity. To “break –in” a conveyor it must be run at partial
capacity until a shine appears on the inside casing. Running a conveyor at full capacity prior to “break-in” will
almost certainly result in the conveyor choking and possible equipment damage. Observe for unusual noises,
overheating of bearing or drive misalignment. Should any of these occur, re-check the installation instructions and
take the necessary corrective steps. Chain tightness should be checked every 24 hours of operation until the initial
stretch has been eliminated.
22
When operating the conveyor, the following should be carried out in order to avoid an unsafe or
hazardous condition.
1. Conveyors should not be operated unless they are completely enclosed and power
transmission guards are in place. If the conveyor is to be opened for inspection,
cleaning or observation, the motor driving the conveyor should be locked out
electrically so that it cannot be restarted by anyone unless all lids are closed and
all other guards are in place.
2. Do not use a rod or stick to poke the material into the conveyor.
3. Do not walk on top of the conveyor and do not place hands or feet in any of the
conveyor openings.
4. Keep areas around the conveyor and the drive unit free and clear at all times.
5. Do not overload conveyor. Do not exceed conveyor speed, capacity, material

density, or rate of flow for which the conveyor and drive were designed.
6. Shut off drag conveyors when they are not handling product. Operating drag
conveyors with no product creates unnecessary noise and wear and tear on
paddles and trough.
7. If the conveyor is to be inoperative for a prolonged period of time, operate

conveyor until cleared of all material. This is particularly important when the
material conveyed tends to harden or become more viscous, or sticky if allowed to
stand for a period of time.
8. ULRAMAX CONVEYOR DROP DOOR DISCHARGE

Do not close drop door when product is discharging. STOP product flow then
close the door. This will ensure the door is seated firmly in its seal, and provide
a smooth bottom for superior cleanout of the drag conveyor. Closing the door
while product is discharging will damage the door.
23
MAINTENANCE INSTRUCTIONS
THE MOTOR ISOLATION SWITCH MUST BE OFF BEFORE CARRYING OUT
MAINTENANCE WORK OF ANY KIND
It is good practice to inspect drag conveyors monthly for excessively worn or damaged
components. Pay particular attention to the intake and discharge points, transmission parts,
bearing lubrication and the conveyor chain system. Ensure that all safety guards and lids
are in place. Never operate a drag conveyor with a safety guard off or a lid open.
An inspection schedule should be established in order to ensure that the equipment is in good operating
condition at all times. Here are some of the things which should be inspected and maintained regularly.
1. Inspect chain and paddles for loose bolts and damaged paddles (replace missing and damaged
paddles). Check general chain condition.
2. Paddles in Two Deck Drag Conveyor above 400mm in width have notched paddles to reduce
friction and noise. A sweeper paddle(s) with NO notch is provided to ensure the conveyor
properly cleans out. When changing paddles it is important that you replace a sweeper paddle
with another sweeper paddle. The sweeper paddle is black in colour.
3. Check chain tension. Remove the necessary links if the chain take-up is at its maximum.
4. Check chain return carrier tracks for excess wear.
5. Inspect the transmission v-belts or chain for tension and condition.
6. Check gearboxes regularly for sufficient oil and signs of leakage. Keep breathers CLEAN.
7. Check bearings for sufficient lubrication and evidence of overheating. Do not overgrease!
8. Check all sheave / sprocket and drive attaching parts for security.
9. Check all hardware and tighten as required.
24
LUBRICATION
The ball bearings of flange bearings on each end of the shaft should be greased at least every 3 months.
Conveyors supplied with SNL Pillow Blocks require that the grease be changed annually. Oil level in
transmission gearboxes should be checked monthly and renewed annually. Never overfill a gearbox with
oil. Fill gearbox to lower fill plug as noted in the gearbox manual. The transmission chain requires light
greasing monthly. The conveyor drag chain does not require any lubrication. Do not over grease
bearings as this can damage the bearing seals.
GEARBOX INFORMATION
The gearbox information supplied with equipment has been shown in specification sheet. We have also
included a copy of the gearbox operating instructions. It is the responsibility of the owner to ensure that
the proper operating procedures governing the use / maintenance of the gearbox be applied. For more
detailed information on the gearbox please review the manual at the back of this binder.
CONVEYOR CHAIN AND SPROCKET LIFE

Chain and sprocket life is relative to drag conveyor usage. It is important to inspect these components
frequently and replace if needed. This could save costly equipment breakdown during an important
phase of operation. The following points will indicate the condition of chain and sprockets.
Replace Drag Conveyor Chain When:

1. Holes or crevices appear on the chain bushing or roller surfaces.
2. Chain pitch elongation is 2% of chain pitch. (4 inch pitch = 2.03 mm)
3. Chain link plates wear at joint. The strength of the chain is reduces critically when the amount of
wear exceeds 1/3 of original plate thickness.
Replace sprocket when tooth wear exceeds 6 mm (1/4”) in depth, making original PCD of the sprocket
12 mm (1/2”) smaller in diameter.
Extended Shutdown / Storage

If the conveyors are to have an extended shutdown or storage (beyond one month) the following should
be performed:
1) Insure all foreign material is removed from the conveyor and surface coatings are in good order.
2) All bearings and drives are lubricated and protected per manufacturer’s instructions.
3) The conveyor is protected from weather, moisture and extreme temperatures. Do not use plastic or
other coverings which promote condensation under the covering.
4) All exposed metal surfaces are coated with a rust preventative oil that is applied per instructions.
1) Prior to startup, installation and operation instructions contained in this manual must be performed.
25
Problem / Cause Remedy Chart
PROBLEM CAUSE REMEDY
PREMATURE TROUGH A) Gauge too light A) Increase thickness. Consult MMS
FAILURE recommendation.
B) Worn flights B) Replace flights
C) Excessive chain speed C) Check speed
ACCELERATED FLIGHT WEAR A) Excessive heat A) Change flight material. UHMW
B) Speed too high
limited to 82℃/175ºF
B) Slow drag down. Consult MMS

engineering section to determine
proper speed.
CHAIN BREAKAGE A) Worn chain A) Change chain if worn
B) Take-up loose B) Adjust take-up
DRIVE SHAFT BREAKAGE A) Excessive torque A) Recalculate drive requirements
B) Obstruction in conveyor B) Check sprocket alignment
C) Chain Take up too tight C) Loosen Take up
MOTOR/HEATERS OVERLOAD A) Amp demand excessive A) 1. Recheck horsepower for motor
calculations
2. Check material characteristics
3. Check capacity. Assure
regulated feed.
INLET BEARING FAILURE A) Material getting into bearing A) Add or upgrade seal to keep
material out of bearing. Change to
outboard bearing.
B)Insufficient lubrication B) Lubricate properly
DISCHARGE BEARING A) Material getting into bearing A) 1. Add or upgrade seal.
FAILURE 2. Change to outboard bearing.
26
MAINTENANCE SCHEDULE
Drag Conveyor
Daily Weekly Monthly 3 mths 6 mths 12 mths
1. Visually check motor
2. Grease motor bearings
3. Check gearbox oil
4. Change gearbox oil
5. Visually check gearbox seals
6. Check gearbox mounting
7. Visually check drive pulleys/sprockets
8. Check drive pulleys/sprockets mounting
9. Visually check drive belts/chain
10. Check drive belt/chain tension
11. Visually check head and tail bearings
12. Grease head and boot bearings (Flange)
13. Grease head and tail bearings (SNL Pillow Block)
14. Check head and tail sprockets for alignment
15. Check drag chain tension
16. Check paddles and mounting
17. Visually check liners (optional supply)
18. Visually check drag casing
Ultramax Drop Door

1. Inspect locking mechanism for wear. Ensure snap
√
ring is firmly in place.

2. Grease door hinge.
√
3. Inspect airlines, cylinder and solenoids.

√
4. Inspect air cylinder mounts.

√
Comments
The customer shall select the frequency of services to the equipment. Consideration is to be given to the original
manufacturer (Gearboxes and Bearings) suggested routine and the customers demands on the equipment.
27
Instruction Manual for Dodge Imperial & ISAF Bearing
These instructions must be read thoroughly before installation or operation.
WARNING: To ensure the drive is not unexpectedly started, mounting bearing with shaft sizes 3-15/16” and larger, the
turn off and lock-out or tag power source before proceeding. following TEST must be performed. As a test to insure you
Failure to observe these precautions could result in bodily have reached the “ZERO Reference Point” tap on the O. D.
injury. of the nut with a hammer and attempt to rotate the nut using
both hands. If the nut will not rotate then you have reached
Inspection the “ZERO Reference Point” and you should proceed to step
5. If you can rotate the nut, using both hands, then you have
Inspect shaft to ensure it is smooth, straight, clean, and not reached the true “ZERO Reference Point”, and should
within commercial tolerances. repeat step 4A until “ZERO Reference Point” is obtained.
When the “ZERO Reference Point” is reached, the bearing
will not be able to move by hand axially on the shaft.
Mounting
Scribe Line
Install the Non-Expansion unit first.
Locknut
Lock Plate
Adapter Sleeve
Figure 2
5. Scribe a line through the locknut face and adapter race.
6. Using a Spanner or Drift & Hammer, rotate locknut clockwise
by the number of turns shown in Table 1.
Figure 1
1. Remove lock plate located on the face of the locknut.

2. Turn locknut counter clockwise until bearing will freely slide
onto the shaft.
3. Slide bearing to the desired position on the shaft. Dismount Mount
NOTE: All Weight Must Be Removed from the Bearing

When Obtaining The ZERO Reference Point”.
4. The “ZERO Reference Point” is defined as the point when

the clearance between the adapter sleeve, shaft and bearing
bore has been removed.
To reach the “ZERO Reference Point” rotate locknut Figure 3

clockwise, using both hands, as tight as possible. When
Table 1 - Locknut Rotation from “Zero Reference Point”
WARNING: Because of the possible danger to persons(s) or Shaft Size (inches) Locknut Rotation
property from accidents which may result from the improper 1-1/8 - 1 7/16 3/4 to 7/8 turn
use of products, it is important that correct procedures be
* 1-1/2 3/4 to 7/8 turn
followed. Products must be used in accordance with the
engineering information specified in the catalog. Proper ** 1-1/2 7/8 to 1 turn
installation, maintenance and operation procedures must 1-5/8 - 2 7/8 to 1 turn
be observed. The instructions in the instruction manuals
must be followed. Inspections should be made as necessary 2-3/16 - 3 1 to 1-1/4 turns
to assure safe operation under prevailing conditions. Proper 3-3/16 - 4 1-1/4 to 1-1/2 turns
guards and other suitable safety devices or procedures as 4-7/16 - 4 1/2 1-1/8 to 1-3/8 turns
may be desirable or as may be specified in safety codes
4-15/16 - 5 1/2 1-3/8 to 1-5/8 turns
should be provided, and are neither provided by Baldor
Electric Company nor are the responsibility of Baldor 5-15/16 - 6 1 to 1-1/4 turns
Electric Company. This unit and its associated equipment 6-7/16 - 7 1-1/8 to 1-3/8 turns
must be installed, adjusted and maintained by qualified * IMPERIAL IP & ISAF
personnel who are familiar with the construction and ** IMPERIAL IP With Type E Dimensioned Housing
operation of all equipment in the system and the potential
hazards involved. When risk to persons or property may be
involved, a holding device must be an integral part of the
driven equipment beyond the speed reducer output shaft.
1
7. Slide lock plate over shaft and align tang of lock plate with Field Conversion of a Non-Expansion
slot in adapter sleeve.
8. TIGHTEN NOT LOOSEN locknut until lock plate slots overlap
Bearing into an Expansion Bearing
the two threaded holes on the locknut face.
Imperial IP
9. Insert and tighten button head screws to locknut face.
10. Bolt down pillow block or flange unit to the structure.
1. Move snap ring opposite collar side, to the outmost snap
ring groove.
Install the Expansion Unit 2. Remove Non-Expansion nameplate and re-label as an
Expansion bearing.
ISAF
onto the shaft.
a. If Locknut Facing Outboard: Align housing mounting
1. Remove bearing cap.
holes with substructure mounting holes and snug
2. Remove stabilizing ring.
bolts. Push insert as far as possible in the direction of
3. Reassemble cap on base and torque cap bolts to values in
the fixed bearing.
Table 2.
b. If Locknut Facing Non-Expansion Bearing: Align
housing mounting holes with substructure mounting
holes and snug bolts. Position Expansion bearing Table 2 - Cap Bolt Torque for ISAF Grade 5 Bolts
insert in center of housing (NOTE: This is necessary 2 Bolt Base 4 Bolt Base
ISAF
because in the process of mounting, the bearing is Shaft Size (inches) Torque Torque
Bolt Size Bolt Size
being drawn toward the locknut.) Ft-Lbs. Ft-Lbs.
1-7/16 - 1-11/16 3/8 - 16 24 - 30
Note: All Weight Must be Removed from the Bearing 1-15/16 - 2-3/16 7/16 - 14 40 - 50
when Obtaining the “ZERO Reference Point”.
2-7/16 - 2-1/2 1/2 - 13 60 - 75 1/2 - 13 60 - 75
3. Follow steps 4 through 10 found under mounting of the Non- 2-11/16 - 3 5/8 - 11 120 - 150 5/8 - 11 120 - 150
Expansion bearing. 3-3/16 - 3-1/2 3/4 - 10 208 - 260 3/4 - 10 208 - 260
3-11/16 - 4 3/4 - 10 208 - 260
Dismounting
4-7/16 - 4-1/2 7/8 - 9 344 - 430
1. Remove weight off bearing via slings or jacks. 4-15/16 - 7 1-8 512 - 640
2. Remove mounting bolts from bearing.
3. Remove button head screws and lock plate from locknut. Grease Lubrication
4. (Figure 3) Rotate locknut counter clockwise until bearing
freely slides from the shaft. DODGE IP and ISAF bearings are pre-packed with NLGI #2
Lithium Complex grease. For re-lubrication select a grease that
is compatible with a #2 Lithium Complex grease. Re-lubricate in
accordance with Table 3.
Table 3 - Re-Lubrication Intervals (Months) Based on 12 hours per day, 150° F M

Shaft Size RPM
(inches) 250 500 750 1000 1250 1500 2000 2500 >3000
1-1/8 to 2 4 3 2 2 1 0.5 0.25 0.25 0.25
2-3/16 to 2-1/4 3.5 2.5 1.5 1 0.5 0.5 0.25 0.25 0.25
2-3/8 to 3 3 2 1.5 1 0.5 0.25 0.25 0.25 0.25
3-3/16 to 3-1/2 2.5 1.5 1 0.5 0.25 0.25 0.25 0.25 -
3-11/16 to 4-1/2 2 1.5 1 0.5 0.25 0.25 0.25 - -
4-15/16 to 5-1/2 1.5 1 0.5 0.25 0.25 0.25 - - -
5-15/16 to 6 1 0.5 0.5 0.25 0.25 0.25 - - -
6-7/16 to 7 1 0.5 0.25 0.25 0.25 - - - -
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company All Rights Reserved. Printed in USA.
MN3009 (Replaces 499331) *3009-0812* 08/12 TCP 25,000
DRAG CONVEYOR SPECIFICATION SHEET
Customer: GREENFIELD GLOBAL TIVERTON Date: June 2018

Project: NEW RECEIVING EXPANSION
Date
Job # 370724-2 Req'd
RAL7035
Re: PIT RECEIVING CV-2101 Colour: Grey
QTY.
Name of Conveyor: RECEIVING CONVEYOR
Capacity: 120 MTPH
Conveyor Model: 24610 DOUBLE DECK
Slider / Roller
Return: Divider plate
Qty. of Rollers:
Constructed From: CARBON STEEL
Overall Length: 47ft - inclined - 23'8" lift
Length C.C.: 44'-6"
Reducer Location at Disch.: LEFT
Reducer: TA5215H25 X 2 15/16"
Reducer Sheave / Sprocket: 3B9.4-SK
Reducer Bushing: SK X 1 5/8
Motor: 20 HP 3/60/575/1800 TEXP
Motor Mount: TA-5
Motor Sheave / Sprocket: 3B6.2-SD
Motor Bushing: SD X 1 3/8
Drive Belt / Chain: B90 3
RPM: 46
Chain Speed: 100 FPM
Motor Guard: STD SOLID
Gauge of Trough: 1/4" AR400 BOLT ON BOTTOMS & SIDES
Type of Lid:
Head Section: 24610
# of Additional Disch.:
# of Side Flow
Inlets:
# of Standard Inlets: Divided flow inlet x 30" long 1
Take-up Location: HEAD
Head 3 7/16" X 2
Shaft: 15/16" 1
Head Sprocket: 81XC10F-3G- 3 7/16" SPLIT SOLID 1
DODGE P4B520-ISAF-307 - Trident triple
Head Bearings: seals 2
Tail STD SELF
Section: CLEAN
Tail Shaft: 2 7/16"
81XC10F-3G-SPLIT
Tail Sprocket: SOLID
DODGE P4B515-ISAF-207 - Trident triple
Tail Bearings: seals 2
Chain &
Attachments: 81XHD 95
Paddles: 3/4" x 6" x 24" UHMW
Qty. of Pad. & Back Plates: 110
Spacing for Paddles &
Backing Plates: 10 1/2" OC
PlugSwitch: LSXM4N 1
Zero Speed Switch: P8004V10C SSR 24-240VAC/DC 1
General Notes:
VALVES
SAFETY

INSTRUCTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS 1
TO THE OWNER 3
LIMITED WARRANTY 3
MODIFICATIONS 3
SIGN-OFF SHEET 6
DRIVE / CYLINDER 7
COMPLETELY ASSEMBLED BASKET VALVE 9
INLET 9
DISCHARGES 9
LEVELLING 10
BASKET LIFE 13
EXTENDED SHUTDOWN 13
REMOVE / INSTALL BASKET 14
DATA LIST 16
GEARBOX
DRAWINGS
1
SAFETY ALERT SYMBOL

CONCERNING YOUR PERSONAL SAFETY. WATCH FOR THIS SYMBOL AS IT POINTS
OUT IMPORTANT SAFETY PRECAUTIONS. IT MEANS “ATTENTION BECOME ALERT!
YOUR PERSONAL SAFETY IS INVOLVED!” READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
WARNING
Anyone who will operate or work around this equipment shall

first read this manual!
2
TO THE OWNER
Your new MMS Basket Valve has been designed as a quality product to give years of dependable
service. The care of this equipment will greatly affect the satisfaction and service you will obtain
from it. Use this manual as a guide and observe the instructions and suggestions we have
recommended. For additional information, please contact us.

When receiving merchandise, it is important to check both the number of parts and their description
with the packing list. All claims for freight damage or shortage must be made by the consignee
within 10 days from date of delivery. In the event of freight damage, the consignee should accept
the shipment after noting the damage on the delivery docket, reorder replacement part/s and file
claim to cover loss.
LIMITED WARRANTY
All MMS products are warranted to the original consumer purchaser to be free from defects in
material and workmanship and to do the work for which intended under normal use and service,
ordinary wear and tear excepted, for a period of twelve (12) months from date of shipping for local
customers and thirteen (13) months for export customers.
NOTE: To clarify the terms normal use and service and ordinary wear and tear we offer the
following explanation: The wear parts of equipment that are exposed to abrasive materials
such as whole and cracked soy beans may not qualify for warranty. It is not our intention to
bypass our warranty responsibility as a supplier of your equipment purchase. Our intent with
this statement is only to draw your attention to the fact that under certain circumstances and
conditions some parts will require more frequent repair or replacement. In the event that there
is premature wear of a part both parties will discuss a fair solution.
All products must be assembled/installed to instructions provided and all safety shields and guards
must be installed prior to startup. We make no other express warranty, nor is anyone authorized to
make any on our behalf. MMS will repair or replace, at its option and free of charge, any part which
proves defective in material or workmanship during the warranty period, provided the part is
returned at our request to our factory for our examination, transportation charges prepaid.
Any damage to this product as a result of misuse, abuse, neglect, accident, improper installation,
alterations or repairs, (not our own) or any other use contrary to our instructions will void the
warranty. This warranty is limited to defective parts repair and/or replacement only. Labor
charges and/or damage incurred in installation, repair or replacement are not covered by this
warranty as well as incidental and consequential damages connected therewith are excluded.
MODIFICATIONS
It is the policy of MMS to improve its products whenever possible and practical to do so. We
reserve the right to make changes, improvements and modifications on any equipment sold
previously.
3
SAFETY INFORMATION

operator and others who come in contact with the equipment as our prime concern. The manual
presents some of the day to day work problems encountered by the operator and other personnel. We
wrote this manual to help you understand safe operating procedures for Basket Valves. We want you
as our partner in safety.
valve, in such a manner as to comply with Occupational Safety and Health Acts and with all
National and Local laws and ordinances.

1. Maintain a safety training and safety equipment operation/maintenance program for all
employees.
2. Basket Valves shall not be operated unless the valve access ports are in place and closed. If the
valve ports are to be opened for inspection cleaning or observation the motor or cylinder that
activates the valve is to be LOCKED OUT electrically / pneumatically in such manner that it
cannot be operated by anyone however remote from the area.
inspection, cleaning or maintenance of the equipment to check that the equipment cannot be
started.
4. SAFETY DEVICES AND CONTROLS must be purchased and provided by the
purchaser/owner as required by applicable laws, standards and good practices.
5. Do not attempt any maintenance or repairs of the valve until power has been LOCKED OUT to
the motor or cylinder.
7. Frequent inspections of these controls and devices to ensure proper working order and correct
positioning must be performed.
9. Do not walk on valve.
10. Do not poke or prod material into the valve with a bar or stick.
11. Do not place hands, feet or any part of the body or clothing in the valve or openings.
12. Do not overload valve or attempt to use it for other than its intended use.
13. Always regulate the feeding of material into the valve at a uniform and continuous rate.
14. Do not attempt to clear a jammed valve until power has been LOCKED OUT.
15. Do not attempt field modification of the valve or components.
16. Valve inlet and discharge openings are designed to connect to other equipment or machinery so
that the flow of material into and out of the Basket Valve is completely enclosed.
4
17. Always operate the valve in accordance with these instructions and those contained on the
MMS insists that disconnecting and locking out the power to the motor or cylinder driving the
valve provides the only real protection against injury. Secondary safety devices are available;
however, the decision as to their need and the type required must be made by the
owner-assembler as we have no information regarding plant wiring, plant environment, the
interlocking of the valve with other equipment, and the extent of plant automation.
Other devices should not be used as a substitute for locking out the power prior to removing
guards or covers. We caution that use of the secondary devices may cause employees to develop
a false sense of security and fail to lock out power before removing covers or guards. This could
result in a serious injury should the secondary device fail or malfunction.
There are many kinds of electrical devices for interlocking of equipment systems such that if the
valve in a system or process is stopped other equipment feeding it, or following it can also be
necessary items to make the valve installation comply with the law and accepted standards.
equipment.
Operation of this valve shall be limited to competent and experienced persons. In addition, anyone
who will operate or work with this equipment must use good common sense. In order to be qualified,
he/she must also know and meet all other relevant requirements such as:
manage or operate machinery should receive appropriate training and
instruction for health and safety. Do not assume that people already know or
can informally learn about machinery safety.
4. A person who has not read and understood all operating and safety
instruction is not qualified to operate this equipment.
5
SIGN-OFF SHEET
Workplace Health and Safety requires each owner and/or employer to inform
every person working with or near this equipment as to operating procedures
and safety precautions. The sign-off sheet below is provided as a convenient
means by which to record when such information was conveyed.
6
DRIVE / CYLINDER
It is usual for all valves, including the activator (actuator or cylinder), to be shipped fully assembled.
1) Thoroughly inspect the drive section for any damage or misalignment which may have occurred
during shipping or handling.
2) If the activator has a guard, remove it and check the alignment and tightness of all
components.
3) Check if basket turns freely and does not rub on any stationary parts. Disconnect actuator or
cylinder to check. For drives using sprocket and chain you must remove the chain from the
sprockets and then turn. Adjust if required.
7
BASKET VALVE
Inspection Port
Cylinder Mount
Port Fastener
Standard 0o
FRONT VIEW Double Flanges
(Inlet and Outlets)
50o One Side 50o Both Sides
FRONT VIEW FRONT VIEW
Inspection Port
Port Fasteners
Cylinder Mount
SIDE VIEW
8
Should there be some delay between when this equipment was received and its eventual installation,
any separate parts should be carefully stored so they can be easily located and identified when
required. Keep packing lists for this reason. We cannot be responsible for the loss of items that are
listed and included on our packing list.
The best method of installation depends on the size of the valve and its location with respect to other
structures and equipment. During installation, common sense is the most important guide.
Installation of Basket Valves must be carried out by qualified and experienced personnel.
COMPLETELY ASSEMBLED BASKET VALVE

When a Basket Valve is shipped fully assembled, it is ready for installation upon arrival. However, it
is wise to firstly cheek the entire valve for any damage which may have occurred during shipping or
handling.
INLET
The inlet is provided on one end of the Basket Valve and is positioned to ensure that the incoming
product is delivered to the centreline of the Basket Valve.
DISCHARGES
There are two discharges on the Basket Valve. The position of the basket determines the product
flow. Be sure to check this position before moving product through the valve.
9
LEVELLING
It is very important to have the valve mounted level. It is necessary to check the
“alignment” of the valve body in two planes, 90 degrees apart using a level.
Level Level
10
The information given in this manual is based on standard procedures used in the industry and
MMS Engineering assumes no liability for their interpretation and use.

Before putting the Basket Valve into operation, it must be checked for correct working.
1. All foreign material must be removed from the Basket Valve before it is started.
2. Remove cylinder or actuator and cycle basket to ensure free movement.
3. Before operation, close both inspection ports and ensure they are locked.
4. On start up listen carefully for any abnormal noises or operations, in the activator
and the valve.
5. Never attempt to remove covers or put hands into the valve while it is in operation.
Figure 1.
ATTENTION
Note: All new installations using one or several pieces of equipment should be “flushed clean” with
corn or some other abrasive type products. This flushing cleans out unwanted debris that may be
lodged in the equipment. Flushing will also shine the steel discharge and inlet of the equipment to
ensure less friction and improved product flow.
Note: When a Basket Valve is new or after it remains idle for a season it should go through a
“break–in” period to smooth and polish the casing interior. This allows the product to slide inside
the valve discharge with a minimum of friction resistance and thus obtain maximum capacity. To
“break –in” a valve it must be run at partial capacity until a shine appears on the inside casing.
Running a valve at full capacity prior it “break-in” will almost certainly result in the valve
choking and possible equipment damage. Observe for unusual noises, actuator or cylinder
misalignment. Should any of these occur, re-check the installation instructions and take the
necessary corrective steps.
11
When operating the Basket Valve, the following should be carried out in order to avoid an unsafe or
1. Basket Valve should not be operated unless they are completely enclosed and
guards are in place. If the valve is to be opened for inspection, cleaning or
observation, the actuator / cylinder should be locked out electrically so that it
cannot be restarted by anyone unless all lids are closed and all other guards
are in place.
2. Do not use a rod or stick to poke the material into the valve.
3. Do not walk on top of the valve and do not place hands or feet in any of the
valve openings.
4. Keep areas around the valve and the actuator / cylinder unit free and clear at
all times.
5. Do not overload valve. Do not exceed the material density or rate of flow
for which the valve was designed.
6. If the valve is to be inoperative for a prolonged period of time, operate the

valve until cleared of all material. This is particularly important when the
material conveyed tends to harden or become more viscous, or sticky if
allowed to stand for a period of time.
12
THE ELECTRICAL ISOLATION SWITCH MUST BE OFF BEFORE
CARRYING OUT MAINTENANCE WORK OF ANY KIND
It is good practice to inspect Basket Valves semi-annually for excessively worn or

damaged components. Pay particular attention to the internal basket, actuator or
cylinder. Ensure that all safety guards and lids are in place. Never operate a Basket
Valve with the inspection open.
An inspection schedule should be established in order to ensure that the equipment is in good
operating condition at all times. Here are some of the things which should be inspected and
maintained regularly.
1. Inspect the bolt system that holds the internal basket to the valve housing. Tighten and replace
bolts as necessary.
2. Check the internal basket for wear and replace as necessary.
3. Inspect the cylinder / actuator or chain for tension and condition.

BASKET LIFE
Replace the Basket Valve when it has worn to the point that the bottom plate has worn 50% of its
original thickness.
Extended Shutdown / Storage

If the Basket Valve is to have an extended shutdown or storage (beyond one month) the following
should be performed:
1) Insure all foreign material is removed from the valve and surface coatings are in good order.
3) The valve is protected from weather, moisture and extreme temperatures. Do not use plastic or
5) Prior to startup, installation and operation instructions contained in this manual must be
performed.
13
Procedure for Removal / Replacement of Internal Basket
STEP 1: Disconnect Cylinder
STEP 2: Remove Bolts

(Both Sides of Valve)
FRONT VIEW SIDE VIEW
STEP 3:
Remove the Shaft
STEP 4: Open Door

and Remove Basket
To Replace Basket Reverse the Step 3 to 1
14
Basket Valve

1. Visually check cylinder seals (when applicable)
2. Visually check electric actuator (when applicable)
3. Check basket for wear
4. Visually check valve housing
5. Check position of sensor is correct
6. Check for air leaks (when applicable)
Comments
The customer shall select the frequency of services to the equipment. Consideration is to be given to the original
manufacture (Gearboxes and Bearings) suggested routine and the customers demands on the equipment.
15
SLIDE AND VALVE SPECIFICATION
Date
Job # 370724-4 Req'd
Re: TWO-WAY VALVE - DV-2102 Colour RAL7035 Grey
QTY.
Name of Valve/Slide: RECEIVING SCALPER DIVERT 1
Item #:
12" BYPASS DIVERT
Size & Type: VALVE 0-0
STD - Urethane lined
Inlet Type: basket
Discharge Type #1:
Discharge Type #2:
Access Door Hinge:

Access Door Latch: 2
Manual Control
Control Lever Type: Control Bar with TE87 Spring
Control Lever Side/Dir:
Control Weights: Cable weight Handles 1 1/2"x 6"
Control Cable:
Control Cable Pulleys:
Electric Control
Cylinder:
Cylinder:
Rear Mount:
Front Mount:
Rod Clevis & Pin:
Cylinder Fittings:
D.C. Valve:
Din Plug:
P-Port Fitting:
A & B Port Fitting:
Exhaust Port Fitting (2 of):
Location:
Indicator Switch:
SLIDE AND VALVE SPECIFICATION
Date
Job # 370724-14 Req'd
Re: TWO-WAY VALVE - DV-2101 Colour: RAL7035 Grey
QTY.
Name of Valve/Slide: ELEVATOR DIVERT TO BINS 1
Item #:
12" BYPASS DIVERT VALVE
Size & Type: 50-50
Inlet Type: STD - Urethane lined basket
Discharge Type #1:
Discharge Type #2:
Access Door Hinge:
Access Door Latch: 2
Manual Control
Control Lever Type:
Control Lever Side/Dir:
Control Weights:
Control Cable:
Control Cable
Pulleys:
Electric Control
Actuator NORD GEAR SK0204-56C 20RPM M2B 1
Motor 1/3HP 1725RPN EPNV MOTOR 56C 575V/3/60 1
Driver Sprocket ANSI #35 11T SPROCKET X 3/4" DIA - 35BS11 1
Driven Sprocket ANSI #35 60T SPROCKET X 1" DIA - 35BS60 1
D.C. Valve:
Din Plug:
P-Port Fitting:
A & B Port Fitting:
Exhaust Port Fitting (2
of):
Location:
Indicator Switch: Honeywell LSXM4N Limit switch
DPDT (2NO/2NC) Center neutral
General Notes:
ROTARY SCALPER
SAFETY
INSTRUCTIONS
TABLE OF CONTENTS

TO THE OWNER 2
LIMITED WARRANTY 2
MODIFICATIONS 2
SAFETY EQUIPMENT 2
DRIVE/BRUSH 6
SCREEN / BRUSH ADJUSTMENT 6
LIFTING AND MOVING 7
COMPLETELY ASSEMBLED ROTARY SCALPER 7
INLET 7
DISCHARGES 7
LEVELLING 7
ROLLER CHAIN DRIVES 10
INSTALLATION 10
CONDITION OF COMPONENTS 10
DRIVE ALIGNMENT 10
INSTALLING THE CHAIN 10
CHAIN TENSION 11
LUBRICANTS 12
GEAR UNIT STRUCTURE 15
GEAR UNIT START UP 16
WEAR PART DEFINITIONS 17
RECOMMENDED SPARE PARTS 18
SCALPER REAL ASSEMBLY DRAWINGS 19
SPECIFICATION SHEETS AND DRAWINGS
1
SAFETY ALERT SYMBOL

IMPORTANT SAFETY PRECAUTIONS. IT MEANS “ATTENTION BECOME ALERT!
YOUR PERSONAL SAFETY IS INVOLVED!” READ THE MESSAGE THAT FOLLOWS AND
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
WARNING
Anyone who will operate or work around this equipment shall

first read this manual!
1
TO THE OWNER
Your new MMS Rotary Scalper has been designed as a quality product to give years of dependable service.

When receiving merchandise, it is important to check both the number of parts and their description with the
packing list. All claims for freight damage or shortage must be made by the consignee within 10 days
from date of delivery. In the event of freight damage, the consignee should accept the shipment after noting
the damage on the delivery docket, reorder replacement part/s and file claim to cover loss.
LIMITED WARRANTY
workmanship and to do the work for which intended under normal use and service, ordinary wear and tear
excepted, for a period of twelve (12) months from date of shipping for local customers and thirteen (13)
months for export customers.
NOTE: To clarify the terms normal use and service and ordinary wear and tear we offer the following
explanation: The wear parts of equipment that are exposed to abrasive materials such as whole and
cracked soy beans may not qualify for warranty. It is not our intention to bypass our warranty
responsibility as a supplier of your equipment purchase. Our intent with this statement is only to draw
your attention to the fact that under certain circumstances and conditions some parts will require
more frequent repair or replacement. In the event that there is premature wear of a part both parties
will discuss a fair solution.
All products must be assembled/installed to instructions provided and all safety shields and guards must be
installed prior to startup. We make no other express warranty, nor is anyone authorized to make any on our
behalf. MMS will repair or replace, at its option and free of charge, any part which proves defective in
material or workmanship during the warranty period, provided the part is returned at our request to our
factory for our examination, transportation charges prepaid. Any damage to this product as a result of
misuse, abuse, neglect, accident, improper installation, alterations or repairs, (not our own) or any other use
contrary to our instructions will void the warranty. This warranty is limited to defective parts repair
and/or replacement only. Labor charges and/or damage incurred in installation, repair or replacement
are not covered by this warranty as well as incidental and consequential damages connected therewith
are excluded.
MODIFICATIONS
It is the policy of MMS to improve its products whenever possible and practical to do so. We reserve the
right to make changes, improvements and modifications on any equipment sold previously.
SAFETY EQUIPMENT
Please, remember that safety equipment provides important protection for persons working near a machine
that is in operation. Be sure ALL safety shields and protection devices are installed and properly maintained.
2
SAFETY INFORMATION

wrote this manual to help you understand safe operating procedures for Rotary Scalpers. We want you
scalper, components and scalper assemblies in such a manner as to comply with Occupational Safety
and Health Acts and with all National and Local laws and ordinances.

2. Rotary Scalpers shall not be operated unless the scalper housing completely encloses the scalper
moving elements and power transmission guards are in place. If the scalper is to be opened for
inspection cleaning or observation the motor driving the scalper is to be LOCKED OUT electrically
in such manner that it cannot be restarted by anyone however remote from the area unless the
scalper housing has been closed and all other guards are in place.
4. If the scalper must have an open housing as a condition of its use and application, the entire scalper is
then to be guarded by a railing or fence, in accordance with National and local laws.
constructed in such a way that the scalper opening is covered by a grating. If the nature of the
material is such that a grating cannot be used, then the exposed section of the scalper is to be
elements is less than 100 mm (4〞), the grating opening must not exceed 12mm (1/2〞)×50mm (2
〞). In all cases the openings shall be restrictive to keep any part of the body or clothing from
coming in contract with moving parts of the equipment. SOLID COVERS should be used at all
other points and must be designed and installed so that personnel will not be exposed to accidental
contact with any moving parts of the equipment.
3
9. Do not attempt any maintenance or repairs of the scalper until power has been LOCKED OUT.
working order and correct positioning must be performed.
13. Do not walk on scalper covers, gratings or guards.
14. Do not poke or prod material into the scalper with a bar or stick.
15. Do not place hands, feet or any part of the body or clothing in the scalper or openings.
16. Do not overload scalper or attempt to use it for other than its intended use.
17. Always regulate the feeding of material into the unit at a uniform and continuous rate.
18. Do not attempt to clear a jammed scalper until power has been LOCKED OUT.
19. Do not attempt field modification of the scalper or components.
20. Rotary Scalper inlet and discharge openings are designed to connect to other equipment or
machinery so that the flow of material into and out of the Rotary Scalper is completely enclosed.
21. Before power is connected to the drive, a pre-start up check shall be performed to ensure the
22. Rotary Scalpers are not normally manufactured or designed to handle materials that are hazardous
to personnel. These materials which are hazardous include those that are explosive, flammable,
toxic or otherwise dangerous to personnel. Scalpers may be designed to handle these materials.
Scalpers are not manufactured or designed to comply with National and Local codes for unfired
pressure vessels. If hazardous materials are to be conveyed or if the scalper is to be subjected to
internal or external pressure, then consult MMS prior to any modifications.
23. Always operate the scalper in accordance with these instructions and those contained on the caution
labels affixed to the equipment.
decision as to their need and the type required must be made by the owner-assembler as we have
no information regarding plant wiring, plant environment, the interlocking of the Rotary Scalper
with other equipment, and the extent of plant automation.
guards or covers. We caution that use of the secondary devices may cause employees to develop a
false sense of security and fail to lock out power before removing covers or guards. This could
There are many kinds of electrical devices for interlocking of equipment systems such that if the Rotary
Scalper in a system or process is stopped other equipment feeding it, or following it can also be
4
necessary items to make the Rotary Scalper installation comply with the law and accepted standards.
Explosion venting may be required depending on location, and / or product
being transferred through this equipment. To operate without proper explosion
venting may result in fire or explosion. Check local industrial codes and policies.
equipment.
Operation of this Rotary Scalper shall be limited to competent and experienced persons. In addition,
instruction for health and safety. Do not assume that people already know or
can informally learn about machinery safety.
4. A person who has not read and understood all operating and safety instruction
is not qualified to operate this equipment.
5
DRIVE / BRUSH
It is usual for all Rotary Scalpers, including the drive, to be shipped fully assembled.
1) Thoroughly inspect the drive section for any damage or misalignment which may have occurred
during shipping or handling.
2) Check that the screw cleaning brush adjustment lever is functioning.
3) If the drive has a guard, remove it and check the alignment and tightness of all the drive
components.
4) Carefully turn the drive over by hand using the “V” belts to check if all moving parts turn freely
and do not rub on any stationary parts. For drives using sprocket and chain you must remove
the chain from the sprockets and then turn. Adjust if required.
section of this manual).
SCREEN / BRUSH / ADJUSTMENT

The Rotary Scalper is supplied with an internal screen mounted to a circular frame.
A brush system is supplied and is used to clean the screen as the screen rotates. The brush is mounted on
a shaft and this shaft has adjustment to allow the brush to stay in contact with the screen. The brush will
wear with use and must be replaced as necessary.
Brush
Wire Screen Reel
Brush Adjustment
6
any separate parts should be carefully stored so they can be easily located and identified when required.
Keep packing lists for this reason. We cannot be responsible for the loss of items that are listed and
included on our packing list.
The best method of installation depends on the size of the scalper and its location with respect to other
Installation of Rotary Scalpers must be carried out by qualified and experienced personnel.
LIFTING AND MOVING

Extreme care must be taken to prevent damage when moving assembled Rotary Scalpers or components.
Never lift a scalper with only one support point.
COMPLETELY ASSEMBLED ROTARY SCALPER

When a Rotary Scalper is shipped fully assembled, it is ready for installation upon arrival. However, it
is wise to firstly cheek the entire scalper for any damage which may have occurred during shipping or
handling.
INLET
The inlet is provided on one end of the Rotary Scalper and is positioned to ensure that the incoming
product is delivered to the centreline of the Rotary Scalper turning reel.
DISCHARGES
There are two discharges on the Rotary Scalper. The discharge for foreign material (oversize only) is
located at the end of the scalper. The centreline discharge is for the “scalped” clean product.
LEVELLING
It is very important to have the Rotary Scalper mounted level. The screen on the inside
of the scalper frame is mounted on a set angle to provide proper cleaning at a specified
capacity rate. It is necessary to check the “alignment” of the scalper body in two planes,
90 degrees apart using a level.
7

Before putting the Rotary Scalper into operation, it must be checked for correct working. Special care
must be taken to ensure the screen cleaning brush is set properly against the rotating screen surface.
1. All foreign material must be removed from the Rotary Scalper before it is started.
direction of the equipment. (Fig. 1) Damage to equipment and injury to personnel is
possible if equipment is started in the wrong direction. Correct motor direction if
needed. For Rotary Scalpers provided with direct drives this procedure requires extra
caution as per item 5.
3. Before operation, close all clean-out slides and inspection panels and ensure all drive
guards are in place.
4. Start the scalper motor and listen carefully for any abnormal noises or operations, in
the drive and the Rotary Scalper.
5. Never attempt to remove covers or inspection windows or put hands into the
machine while it is in operation.
Figure 1.
ATTENTION
Note: All new installations using one or several pieces of equipment should be “flushed clean” with
corn or some other abrasive type products. This flushing cleans out unwanted debris that may be
lodged in the equipment. Flushing will also shine the steel discharge and inlet of the equipment to
ensure less friction and improved product flow.
8
Note: When a Rotary Scalper is new or after it remains idle for a season it should go through a
“break–in” period to smooth and polish the casing interior. This allows the product to slide inside the
scalper discharge hopper with a minimum of friction resistance and thus obtain maximum capacity. To
“break –in” a scalper it must be run at partial capacity until a shine appears on the inside casing.
Running a scalper at full capacity prior it “break-in” will almost certainly result in the scalper
choking and possible equipment damage. Observe for unusual noises, overheating of bearing or
drive misalignment. Should any of these occur, re-check the installation instructions and take the
necessary corrective steps.
Note: When a Rotary Scalper is new or after it remains idle for a season it should be opened and the
screen checked to ensure it is intact and not plugged with debris.
When operating the Rotary Scalper, the following should be carried out in order to avoid an unsafe or
1. Rotary Scalper should not be operated unless they are completely enclosed and
power transmission guards are in place. If the scalper is to be opened for
inspection, cleaning or observation, the motor driving the scalper should be
locked out electrically so that it cannot be restarted by anyone unless all lids are
closed and all other guards are in place.
2. Do not use a rod or stick to poke the material into the Rotary Scalper.
3. Do not walk on top of the scalper and do not place hands or feet in any of the
scalper openings.
4. Keep areas around the scalper and the drive unit free and clear at all times.
5. Do not overload scalper. Do not exceed scalper speed, capacity, material

density, or rate of flow for which the scalper and drive were designed.
6. Shut off Rotary Scalpers when they are not handling product. Operating Rotary
Scalpers with no product creates unnecessary noise and wear and tear.
7. If the scalper is to be inoperative for a prolonged period of time, operate the

scalper until cleared of all material. This is particularly important when the
material cleaned tends to harden or become more viscous, or sticky if allowed to
stand for a period of time.
9
Roller Chain Drives
Installation
To obtain maximum service-life and efficiency from a chain drive, it is necessary that certain
precautions in installation be taken. Chain drive installation is relatively simple and good results may
be obtained when the following conditions are met:
1. The roller chain, sprockets, and other components are in good condition.
2. The sprockets are properly aligned.
3. Provision is made for adequate lubrication.
4. The chain is correctly tensioned.
Condition of Components
Shafting, bearings, and foundations should be supported rigidly to maintain the initial alignment.
Roller chain should be free of grit and dirt. Wash chain in kerosene when required. Relubricate!
Drive Alignment
Misalignment results in uneven loading across the width of the chain and may cause roller linkplate and
sprocket tooth wear. Drive alignment involves two things: parallel shaft alignment and axial sprocket
alignment.
1. Shafts should be parallel and level. This condition may be readily checked by the use of a
feeler bar, and a machinist's level. It there is axial movement of the shaft (as in the case of an
electric motor), lock the shaft in the normal running position before aligning the sprockets.
2. Sprocket axial alignment can be checked with a straight edge which will extend across the
finished sides of the two sprockets. Normally, it is good practice to align the sprockets as close
to the shaft bearing as possible. For long center distances, use a taut cord, or wire long enough
to extend beyond each of the sprockets.
Installing the Chain
Recheck all preceding adjustments for alignment and make certain all setscrews, bolts and nuts are
tight. Fit chain around both sprockets and bring the free ends together on one sprocket for connection,
The sprocket teeth will locate the chain end links. Install the connecting link, and connecting link
coverplate, and the spring clip or coffer pins. On larger pitch chains or heavy multiple strand, it may
be necessary to lock the sprockets for this operation. When press fit coverplates are used, be careful
not to drive the plate on so far as to grip the roller links. Stiff joints can result if this is done. On drives
with long spans, it may be necessary to support the chain with a plank or bar as the connection is
made.
10
Chain Tension
Check chain tension to be certain the slack span has 4-6% mid-span movement in horizontal drives
and 2-3% in vertical drives.
Recommended Possible Mid-span Movement AC
Tangent Length Between Sprockets

Drive Center-Line 125mm 250mm 375mm 500mm 750mm 1000mm 1500mm 2000mm 2500mm
Horizontal to 45 degrees 6mm 12mm 20mm 25mm 40mm 50mm 75mm 100mm 125mm
Vertical to 45 degrees 3mm 6mm 10mm 12mm 20mm 25mm 40mm 50mm 65mm
AC = Total Possible Mid-Span Movement
Depth of Free Sag = 20mm AB, approximately.
For more detailed information see: WWW.maintenanceresources.com
11
12
13
14
15
16
Wear Part Definitions
MMS considers any part in direct contact with the flow of the
product to be wear part and is under a limited warranty. If a part in
these conditions wear out before the 12 month period is up it will
need to be review to determine if it is a defect or product wear.
It is difficult to predict the life expectancy of any part in the direct

product flow, as there are many variables that effect wear of any
part. The major contributor to wear is the abrasiveness of the
product received and how much dirt (fine grit) is in with it. Another
factor is impact of the product on the surface on any material; so
this is why the inlets are generally lined with wear plates to slow
down the product reducing down stream wear, helping to increase
wear life.
In high usage (24/7) and wear applications MMS has manufactured a

new HD Rotor option to increase the life of the cage. MMS has also
added a replaceable product deflector plate that helps to keep
product and product impact away from the main rotor shaft. Even
with these improvements as mentioned above life of these parts
varies with product types and usage of the scalper.
In summary all parts in direct product contact such as inlet spout -

product deflector - rotor – hopper screens – product slow down in
cage and wear liners, should be part of your maintenance program,
monitored on a regular basis and replaced as required.
Please review drawing indicating new replaceable products deflector

and typical high wear points for the scalper for regular monitoring.
Model 3696 Grain Scalper Parts
RECOMMENDED SPARE PARTS
Description Part #
Sew-Eurodrive R87DT90L4 21RPM 2HP 460V 3696-01
80SF42 Driven Sprocket 3696-02
80SF20 Drive Sprocket 3696-03
SF x 2 7/16" Driven Bushing 3696-04
SF x 2 1/8" Drive Bushing 3696-05
5/8" x 5/8" x .25" Wire Dia. Screens (Full Set Req'd for Rotor 3696-06
6" Dia. Brush x 48" Long .22 Nylon (2 Per Scalper) 3696-07
SKF 2 7/16 TF Drive Bearing 3696-08
SKF FY 2 7/16 TF Tail Bearing 3696-09
SKF FYTB 3/4 TF Brush Bearing (4 per Scalper) 3696-10
Inlet Divert Plate & Pipe Guards 3696-11
Rotor Cage (less Screens) 3696-12
Dirve Shaft 2 7/16" 3696-13
End Shaft 2 7/16" 3696-14
Roller Chain #80 x 10' 3696-15
19
20
Shell Omala S2 G 220
Version 1.1
Effective Date 12-09-2011
Material Safety Data Sheet According to the Controlled Product Regulations
1. MATERIAL AND COMPANY IDENTIFICATION
Material Name : Shell Omala S2 G 220

Uses : Gear lubricant.
Product Code : 001D7837
Manufacturer/Supplier : Shell Canada Products

400 - 4th Avenue S.W
Calgary AB T2P 0J4
Canada
Telephone : (+1) 8006611600
Fax : (+1) 4033848345
Emergency Telephone Number

: CHEMTREC (24 hr): (+1) 800-424-9300
CANUTEC (24 hr): (+1) 613-996-6666
2. COMPOSITION/INFORMATION ON INGREDIENTS
Mixture Description: : Highly refined mineral oils and additives.
The highly refined mineral oil contains <3% (w/w) DMSO-extract, according to IP346.
Refer to Chapter 8 for Occupational Exposure Guidelines.
3. HAZARDS IDENTIFICATION
WHMIS Class/Description : THIS PRODUCT IS NOT A WHMIS CONTROLLED

SUBSTANCE.
Routes of Exposure : Skin and eye contact are the primary routes of exposure
although exposure may occur following accidental ingestion.
Health Hazards : Not expected to be a health hazard when used under normal
conditions. Prolonged or repeated skin contact without proper
cleaning can clog the pores of the skin resulting in disorders
such as oil acne/folliculitis. Used oil may contain harmful
impurities.
Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formation
of black pustules and spots on the skin of exposed areas.
Ingestion may result in nausea, vomiting and/or diarrhoea.
Safety Hazards : Not classified as flammable but will burn.
Environmental Hazards : Not classified as dangerous for the environment.
4. FIRST AID MEASURES
General Information : Not expected to be a health hazard when used under normal
conditions.
1/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
Inhalation : No treatment necessary under normal conditions of use. If

symptoms persist, obtain medical advice.
Skin Contact : Remove contaminated clothing. Flush exposed area with water
and follow by washing with soap if available. If persistent
irritation occurs, obtain medical attention.
Eye Contact : Flush eye with copious quantities of water. If persistent
irritation occurs, obtain medical attention.
Ingestion : In general no treatment is necessary unless large quantities
are swallowed, however, get medical advice.
Advice to Physician : Treat symptomatically.
5. FIRE FIGHTING MEASURES
Clear fire area of all non-emergency personnel.
Flash point : Typical 240 °C / 464 °F (COC)

Upper / lower : Typical 1 - 10 %(V)(based on mineral oil)
Flammability or
Explosion limits
Auto ignition temperature : > 320 °C / 608 °F
Hazardous Combustion : Hazardous combustion products may include: A complex
Products and Specific mixture of airborne solid and liquid particulates and gases
Hazards (smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.
Suitable Extinguishing : Foam, water spray or fog. Dry chemical powder, carbon
Media dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing : Do not use water in a jet.
Media
Protective Equipment for : Proper protective equipment including breathing apparatus
Firefighters must be worn when approaching a fire in a confined space.
6. ACCIDENTAL RELEASE MEASURES
Protective Measures : Avoid contact with skin and eyes. Use appropriate containment
to avoid environmental contamination. Prevent from spreading
or entering drains, ditches or rivers by using sand, earth, or
other appropriate barriers.
Clean Up Methods : Slippery when spilt. Avoid accidents, clean up immediately.
Prevent from spreading by making a barrier with sand, earth or
other containment material. Reclaim liquid directly or in an
absorbent. Soak up residue with an absorbent such as clay,
sand or other suitable material and dispose of properly.
Additional Advice : Local authorities should be advised if significant spillages
cannot be contained.
7. HANDLING AND STORAGE
General Precautions : Use local exhaust ventilation if there is risk of inhalation of

vapours, mists or aerosols. Properly dispose of any
contaminated rags or cleaning materials in order to prevent
fires. Use the information in this data sheet as input to a risk
2/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
assessment of local circumstances to help determine

appropriate controls for safe handling, storage and disposal of
this material.
Handling : Avoid prolonged or repeated contact with skin. Avoid inhaling
vapour and/or mists. When handling product in drums, safety
footwear should be worn and proper handling equipment
should be used.
Storage : Keep container tightly closed and in a cool, well-ventilated
place. Use properly labelled and closeable containers. Store at
ambient temperature.
Recommended Materials : For containers or container linings, use mild steel or high
density polyethylene.
Unsuitable Materials : PVC.
Additional Information : Polyethylene containers should not be exposed to high
temperatures because of possible risk of distortion.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
If the American Conference of Governmental Industrial Hygienists (ACGIH) value is provided on

this document, it is provided for information only.
Occupational Exposure Limits
Material Source Type ppm mg/m3 Notation

Oil mist, mineral ACGIH TWA(Inhala 5 mg/m3
ble fraction.)
Consult local authorities for acceptable exposure limits within their jurisdiction.
Exposure Controls : The level of protection and types of controls necessary will vary
depending upon potential exposure conditions. Select controls
based on a risk assessment of local circumstances.
Appropriate measures include: Adequate ventilation to control
airborne concentrations. Where material is heated, sprayed or
mist formed, there is greater potential for airborne
concentrations to be generated.
Personal Protective : Personal protective equipment (PPE) should meet
Equipment recommended national standards. Check with PPE suppliers.
Respiratory Protection : No respiratory protection is ordinarily required under normal
conditions of use. In accordance with good industrial hygiene
practices, precautions should be taken to avoid breathing of
material. If engineering controls do not maintain airborne
concentrations to a level which is adequate to protect worker
health, select respiratory protection equipment suitable for the
specific conditions of use and meeting relevant legislation.
Check with respiratory protective equipment suppliers. Where
air-filtering respirators are suitable, select an appropriate
3/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
combination of mask and filter. Select a filter suitable for

combined particulate/organic gases and vapours [boiling point
>65°C(149 °F)].
Hand Protection : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection: PVC, neoprene or nitrile rubber
gloves. Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, glove thickness, dexterity. Always
seek advice from glove suppliers. Contaminated gloves should
be replaced. Personal hygiene is a key element of effective
hand care. Gloves must only be worn on clean hands. After
using gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended.
Eye Protection : Wear safety glasses or full face shield if splashes are likely to
occur.
Protective Clothing : Skin protection not ordinarily required beyond standard issue
work clothes.
Monitoring Methods : Monitoring of the concentration of substances in the breathing
zone of workers or in the general workplace may be required to
confirm compliance with an OEL and adequacy of exposure
controls. For some substances biological monitoring may also
be appropriate.
Environmental Exposure : Minimise release to the environment. An environmental
Controls assessment must be made to ensure compliance with local
environmental legislation.
9. PHYSICAL AND CHEMICAL PROPERTIES
Appearance : Brown. Liquid at room temperature.

Odour : Slight hydrocarbon.
Odour threshold : Data not available
pH : Not applicable.
Initial Boiling Point and : > 280 °C / 536 °F estimated value(s)
Boiling Range
Pour point : Typical -18 °C / 0 °F
Vapour pressure : < 0.5 Pa at 20 °C / 68 °F (estimated value(s))

Specific gravity :
Density : Typical 899 kg/m3 at 15 °C / 59 °F
Water solubility : Negligible.
n-octanol/water partition : > 6 (based on information on similar products)
coefficient (log Pow)
Kinematic viscosity : Typical 220 mm2/s at 40 °C / 104 °F
Vapour density (air=1) : > 1 (estimated value(s))
Evaporation rate (nBuAc=1) : Data not available
10. STABILITY AND REACTIVITY
Stability : Stable.
4/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
Conditions to Avoid : Extremes of temperature and direct sunlight.

Materials to Avoid : Strong oxidising agents.
Hazardous : Hazardous decomposition products are not expected to form
Decomposition Products during normal storage.
Hazardous : No
Polymerisation
Sensitivity to Mechanical : No
Impact
Sensitivity to Static : No
Discharge
11. TOXICOLOGICAL INFORMATION
Basis for Assessment : Information given is based on data on the components and the
toxicology of similar products.
Routes of Exposure : Skin and eye contact are the primary routes of exposure
although exposure may occur following accidental ingestion.
Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat.
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit.
Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal
conditions of use.
Skin Irritation : Expected to be slightly irritating.
Eye Irritation : Expected to be slightly irritating.
Respiratory Irritation : Inhalation of vapours or mists may cause irritation.
Sensitisation : Not expected to be a skin sensitiser.
Repeated Dose Toxicity : Not expected to be a hazard.
Mutagenicity : Not considered a mutagenic hazard.
Carcinogenicity : Product contains mineral oils of types shown to be non-
carcinogenic in animal skin-painting studies. Highly refined
mineral oils are not classified as carcinogenic by the
International Agency for Research on Cancer (IARC). Other
components are not known to be associated with carcinogenic
effects.
Reproductive and : Not expected to be a hazard.

Developmental Toxicity
Additional Information : Used oils may contain harmful impurities that have
accumulated during use. The concentration of such impurities
will depend on use and they may present risks to health and
the environment on disposal.
ALL used oil should be handled with caution and skin contact
avoided as far as possible.
12. ECOLOGICAL INFORMATION
Ecotoxicological data have not been determined specifically for this product. Information given is
based on a knowledge of the components and the ecotoxicology of similar products.
Acute Toxicity : Poorly soluble mixture.May cause physical fouling of aquatic
organisms.Expected to be practically non toxic:LL/EL/IL50 >
100 mg/l(to aquatic organisms)(LL/EL50 expressed as the
5/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
nominal amount of product required to prepare aqueous test

extract).Mineral oil is not expected to cause any chronic effects
to aquatic organisms at concentrations less than 1 mg/l.
Mobility : Liquid under most environmental conditions. Floats on water. If

it enters soil, it will adsorb to soil particles and will not be
mobile.
Persistence/degradability : Expected to be not readily biodegradable. Major constituents
are expected to be inherently biodegradable, but the product
contains components that may persist in the environment.
Bioaccumulation : Contains components with the potential to bioaccumulate.
Other Adverse Effects : Product is a mixture of non-volatile components, which are not
expected to be released to air in any significant quantities. Not
expected to have ozone depletion potential, photochemical
ozone creation potential or global warming potential.
13. DISPOSAL CONSIDERATIONS
Material Disposal : Recover or recycle if possible. It is the responsibility of the

waste generator to determine the toxicity and physical
properties of the material generated to determine the proper
waste classification and disposal methods in compliance with
applicable regulations. Do not dispose into the environment, in
drains or in water courses.
Container Disposal : Dispose in accordance with prevailing regulations, preferably to
a recognised collector or contractor. The competence of the
collector or contractor should be established beforehand.
Local Legislation : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.
14. TRANSPORT INFORMATION
Canadian Road and Rail Shipping Classification
This product is not regulated under the Canadian Transportation of Dangerous Goods
Regulations for transport by road and rail.
15. REGULATORY INFORMATION
The regulatory information is not intended to be comprehensive. Other regulations may apply
to this material.
This product has been classified in accordance with the hazard criteria of the Controlled
Products Regulations (CPR) and the MSDS contains all the information required by the CPR.
WHMIS Class/Description : THIS PRODUCT IS NOT A WHMIS CONTROLLED

SUBSTANCE.
6/7
Print Date 12-29-2011 000000019496
MSDS_CA
Version 1.1
Inventory Status
EINECS : All components

listed or polymer
exempt.
TSCA : All components
listed.
DSL : All components
listed.
16. OTHER INFORMATION
MSDS Version Number : 1.1
MSDS Effective Date : 12-09-2011
MSDS Revisions : A vertical bar (|) in the left margin indicates an amendment
from the previous version.
MSDS Regulation : The content and format of this (M)SDS is in accordance with
the Controlled Product Regulations.
MSDS Prepared By : Shell Product Stewardship; 1-800-661-1600
MSDS Distribution : The information in this document should be made available to
all who may handle the product.
Disclaimer : The information contained herein is based on our current

knowledge of the underlying data and is intended to describe
the product for the purpose of health, safety and environmental
requirements only. No warranty or guarantee is expressed or
implied regarding the accuracy of these data or the results to
be obtained from the use of the product.
7/7
Print Date 12-29-2011 000000019496
MSDS_CA
Instruction Manual for Dodge Imperial & ISAF Bearing
These instructions must be read thoroughly before installation or operation.
WARNING: To ensure the drive is not unexpectedly started, mounting bearing with shaft sizes 3-15/16” and larger, the
turn off and lock-out or tag power source before proceeding. following TEST must be performed. As a test to insure you
Failure to observe these precautions could result in bodily have reached the “ZERO Reference Point” tap on the O. D.
injury. of the nut with a hammer and attempt to rotate the nut using
both hands. If the nut will not rotate then you have reached
Inspection the “ZERO Reference Point” and you should proceed to step
5. If you can rotate the nut, using both hands, then you have
Inspect shaft to ensure it is smooth, straight, clean, and not reached the true “ZERO Reference Point”, and should
within commercial tolerances. repeat step 4A until “ZERO Reference Point” is obtained.
When the “ZERO Reference Point” is reached, the bearing
will not be able to move by hand axially on the shaft.
Mounting
Scribe Line
Install the Non-Expansion unit first.
Locknut
Lock Plate
Adapter Sleeve
Figure 2
5. Scribe a line through the locknut face and adapter race.
6. Using a Spanner or Drift & Hammer, rotate locknut clockwise
by the number of turns shown in Table 1.
Figure 1

onto the shaft.
3. Slide bearing to the desired position on the shaft. Dismount Mount
NOTE: All Weight Must Be Removed from the Bearing

When Obtaining The ZERO Reference Point”.
4. The “ZERO Reference Point” is defined as the point when

the clearance between the adapter sleeve, shaft and bearing
bore has been removed.
To reach the “ZERO Reference Point” rotate locknut Figure 3

clockwise, using both hands, as tight as possible. When
Table 1 - Locknut Rotation from “Zero Reference Point”
WARNING: Because of the possible danger to persons(s) or Shaft Size (inches) Locknut Rotation
property from accidents which may result from the improper 1-1/8 - 1 7/16 3/4 to 7/8 turn
use of products, it is important that correct procedures be
* 1-1/2 3/4 to 7/8 turn
followed. Products must be used in accordance with the
engineering information specified in the catalog. Proper ** 1-1/2 7/8 to 1 turn
installation, maintenance and operation procedures must 1-5/8 - 2 7/8 to 1 turn
be observed. The instructions in the instruction manuals
must be followed. Inspections should be made as necessary 2-3/16 - 3 1 to 1-1/4 turns
to assure safe operation under prevailing conditions. Proper 3-3/16 - 4 1-1/4 to 1-1/2 turns
guards and other suitable safety devices or procedures as 4-7/16 - 4 1/2 1-1/8 to 1-3/8 turns
may be desirable or as may be specified in safety codes
4-15/16 - 5 1/2 1-3/8 to 1-5/8 turns
should be provided, and are neither provided by Baldor
Electric Company nor are the responsibility of Baldor 5-15/16 - 6 1 to 1-1/4 turns
Electric Company. This unit and its associated equipment 6-7/16 - 7 1-1/8 to 1-3/8 turns
must be installed, adjusted and maintained by qualified * IMPERIAL IP & ISAF
personnel who are familiar with the construction and ** IMPERIAL IP With Type E Dimensioned Housing
operation of all equipment in the system and the potential
hazards involved. When risk to persons or property may be
involved, a holding device must be an integral part of the
driven equipment beyond the speed reducer output shaft.
1
7. Slide lock plate over shaft and align tang of lock plate with Field Conversion of a Non-Expansion
slot in adapter sleeve.
8. TIGHTEN NOT LOOSEN locknut until lock plate slots overlap
Bearing into an Expansion Bearing
the two threaded holes on the locknut face.
Imperial IP
9. Insert and tighten button head screws to locknut face.
10. Bolt down pillow block or flange unit to the structure.
1. Move snap ring opposite collar side, to the outmost snap
ring groove.
Install the Expansion Unit 2. Remove Non-Expansion nameplate and re-label as an
Expansion bearing.
ISAF
onto the shaft.
a. If Locknut Facing Outboard: Align housing mounting
1. Remove bearing cap.
holes with substructure mounting holes and snug
2. Remove stabilizing ring.
bolts. Push insert as far as possible in the direction of
3. Reassemble cap on base and torque cap bolts to values in
the fixed bearing.
Table 2.
b. If Locknut Facing Non-Expansion Bearing: Align
housing mounting holes with substructure mounting
holes and snug bolts. Position Expansion bearing Table 2 - Cap Bolt Torque for ISAF Grade 5 Bolts
insert in center of housing (NOTE: This is necessary 2 Bolt Base 4 Bolt Base
ISAF
because in the process of mounting, the bearing is Shaft Size (inches) Torque Torque
Bolt Size Bolt Size
being drawn toward the locknut.) Ft-Lbs. Ft-Lbs.
1-7/16 - 1-11/16 3/8 - 16 24 - 30
Note: All Weight Must be Removed from the Bearing 1-15/16 - 2-3/16 7/16 - 14 40 - 50
when Obtaining the “ZERO Reference Point”.
2-7/16 - 2-1/2 1/2 - 13 60 - 75 1/2 - 13 60 - 75
3. Follow steps 4 through 10 found under mounting of the Non- 2-11/16 - 3 5/8 - 11 120 - 150 5/8 - 11 120 - 150
Expansion bearing. 3-3/16 - 3-1/2 3/4 - 10 208 - 260 3/4 - 10 208 - 260
3-11/16 - 4 3/4 - 10 208 - 260
Dismounting
4-7/16 - 4-1/2 7/8 - 9 344 - 430
1. Remove weight off bearing via slings or jacks. 4-15/16 - 7 1-8 512 - 640
2. Remove mounting bolts from bearing.
3. Remove button head screws and lock plate from locknut. Grease Lubrication
4. (Figure 3) Rotate locknut counter clockwise until bearing
freely slides from the shaft. DODGE IP and ISAF bearings are pre-packed with NLGI #2
Lithium Complex grease. For re-lubrication select a grease that
is compatible with a #2 Lithium Complex grease. Re-lubricate in
accordance with Table 3.
Table 3 - Re-Lubrication Intervals (Months) Based on 12 hours per day, 150° F M

Shaft Size RPM
(inches) 250 500 750 1000 1250 1500 2000 2500 >3000
1-1/8 to 2 4 3 2 2 1 0.5 0.25 0.25 0.25
2-3/16 to 2-1/4 3.5 2.5 1.5 1 0.5 0.5 0.25 0.25 0.25
2-3/8 to 3 3 2 1.5 1 0.5 0.25 0.25 0.25 0.25
3-3/16 to 3-1/2 2.5 1.5 1 0.5 0.25 0.25 0.25 0.25 -
3-11/16 to 4-1/2 2 1.5 1 0.5 0.25 0.25 0.25 - -
4-15/16 to 5-1/2 1.5 1 0.5 0.25 0.25 0.25 - - -
5-15/16 to 6 1 0.5 0.5 0.25 0.25 0.25 - - -
6-7/16 to 7 1 0.5 0.25 0.25 0.25 - - - -
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company All Rights Reserved. Printed in USA.
MN3009 (Replaces 499331) *3009-0812* 08/12 TCP 25,000
ROTARY SCALPER SPECIFICATION SHEET

Date
Job # 370724-5 Req'd
HOT DIP
Re: 150 MTPH SCALPER - ME-2101 Colour: GALVANIZED
QTY.
MODEL 3696 1
WEIGHT
ROTOR DIAMETER 36" DIA
ROTOR LENGTH 96"
SCREEN SIZE 5/8 X 5/8 X .250 WIRE DIA.
6" DIA X 3/4 BORE X 48" LONG .22 BL
BRUSH SIZE NYLON 2
BRUSH SHAFT 3/4" DIA 1
BRUSH SHAFT
BEARINGS NTN UCFL204-012D1 3/4" 2
END BEARINGS DODGE P4B515-ISAF-207R 2
SHAFT SIZE 2 7/16"
RPM 10
MOTOR HP 2 HP TEXP 145TC 3/60/575/1800
SCALPER
SPROCKET 80SF42
SCALPER
BUSHING SF X 2 7/16
GEAR BOX SEW-EURODRIVE R87 AM145 21 RPM M6
GEAR BOX SPROCKET 80SF20
GEAR BOX BUSHING SF X 2 1/8
CHAIN #80 ROLLER
MOTOR GUARD STD
ZERO SPEED SENSOR WG1-4B-4 WHIRLIGIG
P8004V10C SSR 24-240V AC/DC
GENERAL NOTES AJUSTABLE FLOW CONTROL CONE

URETHANE & DISCHARGE HOPPER INLET
LINER
BUCKET ELEVATOR
SAFETY

INSTRUCTIONS
TABLE OF CONTENTS
TABLE OF CONTENTS 1
TO THE OWNER 3
RECEIVING MERCHANDSE & FILING CLAIMS 3
LIMITED WARRANTY 3
MODIFICATIONS 3
SAFETY EQUIPMENT 3
SIGN-OFF SHEET 7
BUCKET ELEVATOR MODELS 8
HEAD AND DRIVE 9
HEAD PULLEY RUBBER LAGGING 9
LESTOCK CASING 10
BOOT 10
BELA/CHAIN AND BUCKETS 11
LINERS 11
SITE ASSEMBLED ELEVATOR 13
PLUMBING AND ALIGNMENT 16
BELT INSTALLATION 16
BELT CONNECTION 19
BELT ADJUSTMENT 20
ELEVATOR DUST CONTROL 21
LUBRICATION 24
GEARBOX INFROMATION 24
DRIVE CHAIN AND “V” BELT MAINTENANCE 25
HEAD PULLEY RUBBER LAGGING 25
EXTENDED SHUTDOWN / STORAGE 25
PROBLEM / CAUSE 29
ELEVATOR SPECIFICATION SHEETS
DRAWINGS
1
SAFETY ALERT SYMBOL

IMPORTANT SAFETY PRECAUTIONS. IT MEANS “ATTENTION BECOME ALERT! YOUR
PERSONAL SAFETY IS INVOLVED!” READ THE MESSAGE THAT FOLLOWS AND BE
ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
WARNING
Anyone who will operate or work around this equipment shall first
read this manual!
2
TO THE OWNER
Your new MMS Bucket Elevator has been designed as a quality product to give years of dependable service.

When receiving merchandise, it is important to check both the number of parts and their description with the
packing list. All claims for freight damage or shortage must be made by the consignee within 10 days from date
of delivery. In the event of freight damage, the consignee should accept the shipment after noting the damage on
the delivery docket, reorder replacement part/s and file claim to cover loss.
LIMITED WARRANTY
workmanship and to do the work for which intended under normal use and service, ordinary wear and tear
excepted, for a period of twelve (12) months from date of shipping for local customers and thirteen (13) months
for export customers.
NOTE: To clarify the terms normal use and service and ordinary wear and tear we offer the following
explanation: The wear parts of equipment that are exposed to abrasive materials such as whole and
cracked soy beans may not qualify for warranty. It is not our intention to bypass our warranty
responsibility as a supplier of your equipment purchase. Our intent with this statement is only to draw
your attention to the fact that under certain circumstances and conditions some parts will require more
frequent repair or replacement. In the event that there is premature wear of a part both parties will
discuss a fair solution.
All products must be assembled/installed to instructions provided and all safety shields and guards must be
installed prior to startup. We make no other express warranty, nor is anyone authorized to make any on our
behalf. MMS will repair or replace, at its option and free of charge, any part which proves defective in material
or workmanship during the warranty period, provided the part is returned at our request to our factory for
our examination, transportation charges prepaid. Any damage to this product as a result of misuse, abuse,
neglect, accident, improper installation, alterations or repairs, (not our own) or any other use contrary to our
instructions will void the warranty. This warranty is limited to defective parts repair and/or replacement
only. Labor charges and/or damage incurred in installation, repair or replacement are not covered by this
warranty as well as incidental and consequential damages connected therewith are excluded.
MODIFICATIONS
It is the policy of MMS to improve its products whenever possible and practical to do so. We reserve the right to
make changes, improvements and modifications on any equipment sold previously.
SAFETY EQUIPMENT
Please, remember that safety equipment provides important protection for persons working near a machine
that is in operation. Be sure ALL safety shields and protection devices are installed and properly maintained.
3
SAFETY INFORMATION

wrote this manual to help you understand safe operating procedures for bucket elevators. We want you
elevator in such a manner as to comply with Occupational Safety and Health Acts and with all National
and Local laws and ordinances.

2. Bucket elevators shall not be operated unless the elevator housing completely encloses the elevator
moving elements and power transmission guards are in place. If the elevator is to be opened for
inspection, cleaning or observation, the motor driving the elevator is to be LOCKED OUT
electrically in such a manner that it cannot be restarted by anyone however remote from the area
unless the elevator housing has been closed and all other guards are in place.
4. If the elevator must have an open housing as a condition of its use and application, the entire
elevator is then to be guarded by a railing or fence, in accordance with National and Local Safety
Standards.
constructed in such a way that the conveyor opening is covered by a grating. If the nature of the
material is such that a grating cannot be used, then the exposed section of the elevator is to be
elements is less than 100mm (4”), the grating opening must not exceed 12mm(1/2”)×50mm(2”). In
all cases the openings shall be restrictive to keep any part of the body or clothing from coming in
contact with moving parts of the equipment. SOLID COVERS should be used at all points and
must be designed and installed so that personnel will not be exposed to accidental contact with any
moving parts of the equipment.
9. Do not attempt any maintenance or repairs of the elevator until power has been LOCKED OUT.
4
working order and correct positioning.
13. Do not walk on elevator covers, gratings or guards.
14. Do not poke or prod material into the elevator with a bar or stick.
15. Do not place hands, feet or any part of the body or clothing in the elevator openings.
16. Do not overload the elevator or attempt to use it for other than its intended use.
17. Always regulate the feeding of material into the elevator at a uniform and continuous rate.
18. Do not attempt to clear a jammed elevator until power has been LOCKED OUT.
19. Do not attempt field modifications of the elevator.
20. Bucket elevator inlet and discharge openings are designed to connect to other equipment or
machinery so that the flow of material into and out of the bucket elevator is completely enclosed.
21. Before power is connected to the drive a pre-start up check shall be performed to ensure the
22. Removal of backstop may cause unexpected rollback of the elevator belt and cups. Remove or
block all external loads before servicing unit. Failure to observe these precautions could result in
bodily injury.
23. If the material conveyed is in excess of 82oC/175oF or if a change in the original intended use of the
equipment is considered, the factory shall be consulted before modifications are made.
24. Bucket elevators are not manufactured or designed to handle materials that are hazardous to
personnel unless specially designed. These materials which are hazardous include those that are
explosive, flammable, toxic or otherwise dangerous to personnel. Elevators may be designed to
handle these materials. Elevators are not manufactured or designed to comply with National and
Local codes for unfired pressure vessels. If hazardous materials are to be conveyed or if the elevator
is to be subjected to internal or external pressure, MMS should be consulted prior to any
modifications.
25. Always operate the bucket elevator in accordance with these instructions and those contained on the
decision as to their need and the type required must be made by the owner-assembler as we have
no information regarding plant wiring, plant environment, the interlocking of the bucket
elevator with other equipment, and the extent of plant automation.
guards or covers. We caution that use of the secondary devices may cause employees to develop a
false sense of security and fail to lock out power before removing covers or guards. This could
5
There are many kinds of electrical devices for interlocking of equipment systems such that if the bucket
elevator in a system or process is stopped other equipment feeding it, or following it can also be
necessary items to make the bucket elevator installation comply with the law and accepted standards.
Explosion venting may be required depending on location, and / or product being
transferred through this equipment. To operate without proper explosion venting
may result in fire or explosion. Check local industrial codes and policies.
equipment.
Operation of this bucket elevator shall be limited to competent and experienced persons. In addition,
instruction for health and safety. Do not assume that people already know or can
informally learn about machinery safety.
4. A person who has not read and understood all operating and safety instruction is not
qualified to operate this equipment.
6
SIGN-OFF SHEET
Workplace Health and Safety requires each owner and/or employer to inform
every person working with or near this equipment as to operating procedures and
safety precautions. The sign-off sheet below is provided as a convenient means by
which to record when such information was conveyed.
7
Centrifugal and Continuous Discharge Elevators
②
③
④ ④a
⑩
⑨
⑥ ⑧
⑦
Centrifugal Elevator Continuous Discharge Elevator

○1 .Head section with hinged bonnets.
2 .Inspection port.
○
3 .Adjustable cup wiper.
○
4 .Double Legstock casings.
○ ○4 a. One Piece casings
○.Access door for belt and cups.

5
6 .Standard Boot section.
○
7 .Self-Cleaning Boot section.
○
8 .Screw Type Belt tightening system.
○
9 .Gravity Type Belt tightening system.
○
10 .Gravity Weight Box.
○
NOTE:
It is the installer’s responsibility to provide a suitable foundation and mounting bolts to
install the elevator.
8
Assembly of a MMS Bucket Elevator may vary between different models and discharge heights.
Elevators are usually shipped in sections which must be assembled in a particular manner. The
Assembly Instructions in this manual offer information as to how to assemble a variety of possible
elevator arrangements.
HEAD AND DRIVE

It is usual for all elevator heads, including the drive, to be shipped fully assembled. The “correctness”
of the head section is critical to the operation of a bucket elevator, and it is therefore important to carry
out the following checks.
1) Thoroughly inspect the complete head and drive section for any damage or misalignment which
may have occurred during shipping or handing.
2) If the drive has a guard, remove it and check the alignment and tightness of all the drive components.
3) Carefully turn the drive over by hand using the “V” belt to check if all turn parts move freely and
do not rub on any stationary parts. For drives using sprocket and chain you must remove the chain
from the sprockets and then turn. Adjust if required.
section of this manual)
6) After installation of the belt and cups check to ensure the adjustable cup wiper is within 20mm of
the cup leading edge.
Hinged Access
Inspection Ports
Adjustable Cup Wiper
HEAD PULLEY RUBBER LAGGING

Elevator head pulleys are fitted with “Holtz” slide in / out replaceable rubber lagging. The rubber
lagging provides grip to the elevator belting and prevents slippage of the belt.
It is important that the lagging be replaced when worn to 50% (6mm) of its original thickness. Belt
slippage can cause damage to the belt and create a potential fire hazard.
9
LEGSTOCK
These sections may be supplied with or without the need to use an “X” Brace. One set of access doors
provided per elevator. These doors are supplied bolted in position. Doors are to be removed for the
installation of the belt and cups.
Access Doors
Figure 1. Figure 2.
BOOT With “X” Brace No “X” Brace

Elevator boots are shipped fully assembled. The boot section is also critical to the satisfactory operation
of a bucket elevator and, therefore, the following checks should be carried out.
1) Thoroughly inspect the complete boot section for any damage or misalignment which may have
occurred during shipping or handling.
2) Carefully turn the boot pulley over by hand to ensure that it is free and relatively easy to turn.
3) Raise the boot pulley to the highest position using the take-up units prior to installing the belt. For
gravity boot tensioning devices you must raise the pulley with a cable tackle or other lifting
apparatus prior to installing the belt.
4) Check that all the cleanout slide plates operate freely.
Weight Box
Belt Tracking Screw
Belt Tightening Belt Tightening System

Adjustment Slot
Clean out Slide Plate
Clean out Slide Plate
Standard Boot - Gravity Takeup System Self Cleaning Boot - Screw Takeup System
10
BELT/CHAIN AND BUCKETS
Bucket elevator belts (Fig. 3) are shipped prepunched. A chain type elevator will be supplied with the correct
bucket attachments suitably spaced. Whether the buckets are fitted to the belt or chain before the elevator is
installed will depend on site preference. Note: When installing cups on a belt that is already in the elevator,
you must install (2) cups skip (10) spaces and then repeat. Using this process will ensure the belt does not get
too heavy on one side and therefore difficult to turn and hold in place. Tighten bucket bolts carefully and
consistently. Because of the “softness” of various belting materials, the assembler has to rely on common
sense to determine when a bucket bolt is tight enough. (Fig. 4)
There is a correct side of the belt to attach the buckets

Thicker cover
Thinner cover
Buckets this side
Pulley this side
Figure 3. End Section of Belting
ATTACHING BUCKETS TO ELEVATOR BELT

PROPER IMPROPER SPACER WASHER
(OPTIONAL)
Belt
Bucket
Flat Washer
With Plastic Buckets
Figure 4.
LINERS
Elevator head discharge sections and boot inlets can be supplied with abrasive resistant liners. Contact
MMS for assistance in deciding the need for liners.
11
CUP INSTALLATION PROCEDURES
Belt Belt
Domed washer
Small washer “Mudguard” washer
Bolt Nyloc nut Nyloc nut
Bolt
PRESSED METAL BUCKETS POLYETHYLENE, NYLON

& CAST BUCKETS
Belt Chain
Spacer
“Mudguard” washer “Mudguard” washer
Bolt Nyloc Nut Nyloc nut
Bolt
Attachment
POLYETHYLENE BUCKET CHAIN APPLICATION

& SPACER
Cup Mounting Details
12
The information give in this manual is based on standard procedures used in the industry and MMS
any separate parts should be carefully stored so they can be easily located and identified when required.
Keep packing lists for this reason. We cannot be responsible for the loss of items that are listed and
included on our packing list.
The best method of installation depends on the size of the elevator and its location with respect to other
Installation of elevators must be carried out by qualified and experienced personnel.
SITE ASSEMBLED ELEVATOR

If this shipment consists of more than one elevator, it is suggested that all components be separated into
their individual elevator item numbers.
NOTE: Dependent on elevator size and height the lower sections of legstock may be heavier
material than the upper sections. These heavier legstock sections will be properly marked for
installation location. It is the responsibility of the installer to ensure their proper position during
the assembly of the elevators.
Elevators can be supplied with legstock in single sections (Fig. 5) or double sections (Fig. 6). If your
elevator is supplied with single sections you must ensure a tie“X”brace that is provided with elevator
is inserted at each connecting joint in the legstock. If your elevator legstock is supplied as double
casing then no “ X ” brace is required.
Elevators supplied with legstock sections that house both the up and down travel of the belt and cups are
called “one piece” sections. These legstock sections can be installed similar to those shown in (Fig. 7).
One section of the elevator casing comes with access doors. These doors are used when installing the
belt and cups and for future maintenance. The elevator power must be “locked off” when these doors
are open. (Fig.5) and (Fig. 7)
Access Access
Door Door
Figure 5 Figure 6 Figure 7

“X” Braced Legstock Double Legstock Section One Piece Section
13
SITE ASSEMBLED ELEVATORS
The assembly location for the elevator should be chosen to be as close as practical to where it is going to
stand. This should make it easier for the crane when lifting the elevator into position. It is a good idea to
meet in advance with your crane operator, as he may have installed elevators before and he may be able to
give you helpful hints which might save hours of crane hire.
The following suggestions illustrate three of the most usual methods of standing an elevator. Check each
method carefully, talk it over with the crane operator and decide on the one most suited of the circumstances.
Carefully align flanges of legstock casing before tightening bolts. Failure to do so may
result in flange misalignment which could cause belt and/or bucket damage. When
bolting the leg sections together, firstly apply a sealant to the flanges to assure
weather and dust tight connections. Each and every intermediate section must be level
and plumb. It is common to find minor deviations in these types of fabricated assemblies.
Most often they can be corrected by rotating 180° or turning end for end. If this does not
solve an out of level or out of plumb condition it will be necessary to use metal shims and
caulk the resulting gap. When a gap occurs in a corner of the casing, metal shims should
be used and should extend a minimum of 150mm (6”) in both directions. Ensure that
shims do not project inside the casing. Each intermediate section must be plumbed to less
than 3mm (1/8 ”) deviation before proceeding to the next section.
Sling elevator by lifting lugs provided on the head.
Take care when lifting an elevator with a distributor valve mounted to the elevator head
discharge. The elevator becomes “top heavy” and will want to roll over. We recommend a
temporary stabilizer fastened at the bottom end of the section being hoisted to prevent roll
over.
The center of balance of an elevator may also change as it is being raised.
Method 1 Involves assembling the elevator completely on the ground and then lifting it up into position.
This method is not recommended for elevators longer than about 20 meters. If the elevator is to be
supported by guy wires, they should be fitted to the elevator before it is lifted.
METHOD 1
14
Method 2 Involves assembling the elevator in (2) or more sections.
Install the boot and fasten firmly into place ready to receive the first section(s) of legstock. Dependent on
accessibility the next section(s) of legstock can be installed one at a time or in a series of previously bolted
sections. The elevator must be supported at appropriate levels to a rigid structure or guy wired as the
elevator legstock sections are erected. Once the legstock lower sections are firmly in place the upper
section which consists of the head and an acceptable number of legstock sections can be raised and set in
place atop the lower sections of legstock.
NOTE: A qualified elevator installer will determine the appropriate levels to provide bracing in
accordance with the elevator height and available support.
NOTE: An acceptable number of legstock sections to be raised with the head section must be
determined by a qualified elevator installer. The crane operator must be included in this decision to
ensure the safe operating conditions of the crane.
METHOD 2.
Method 3 is used for an elevator when fitted in a support tower. The elevator and associated parts are fitted
into the tower prior to lifting into position.
NOTE: The details for a safe installation of on elevator as described in Method 2 apply to this type of
installation.
METHOD 3.
15
PLUMBING AND ALIGNMENT
A) It is very important to have the elevator plumb. When the belt starts
moving it is just like a gyroscope – it will plumb itself whether the elevator is
plumb or not. That is why a belt may sometimes rub on the side of the elevator.
B) There are a number of devices for plumbing an elevator. The most common are
the level and transit. Whichever method is used, it will be necessary to check
the “plumbness” in two planes, 90 degrees apart.
NOTE: Drop a plumb line from the head pulley to boot pulley, to assure the
alignment is correct.
C) Relevant to the height and accessibility of the elevator, it is recommended that
the plumbing of the elevator be carried out at various stages of the installation.
Consideration should be given to the fixing in place of the elevator until the
elevator is completely installed because alterations to the finish plumb
alignment may be required. Once the elevator is given the proper alignment it
can be permanently fixed in position. Careful planning in the plumbing and
alignment of the elevator will ensure quiet trouble free operation.
D) Casings must be braced or anchored to a rigid structure every 12m (40’),
and not more than 1.5 m (5’), below the head section (Fig.9). If a rigid
structure is not available, guy wires may be used as shown in (Fig.10).
BELT INSTALLATION
The method used to fit the belt and buckets depends on each individual situation. It is “easier” to fit the
buckets onto the belt before it is pulled into the elevator. However, it may not be practical or safe to do
it in that manner. The most common way is to pull the belt in first then install the buckets (Fig. 8)
illustrates this method.
* Feed Cable into elevator against running direction.
* Attach cable to belt and draw into legstock.
* Bring belt ends together and pull together with

come-a-long.
Belt Cable * Join belt using the belt overlap method or

mechanical splice.
* Adjust tension of belt, using boot pulley takeup

system.
Cable Figure 8.
16
SELF SUPPORTING ELEVATOR
FLOOR BRACING PROCEDURE
FLOOR
DECKING
FLOOR
FRAME
TYPICAL ROOF
BRACING [ OPTIONAL ]
CASING
BRACE
TYPICAL FLOOR
BRACING
NOTE:
WELD BRACING TO ELEVATOR CASING BEFORE
THE INSTALLATION OF THE BELT AND CUPS
Figure 9.
17
SELF SUPPORTING ELEVATOR
GUY WIRE PROCEDURE
NOTE:
CROSSED GUY WIRES CAN BE USED
TO CORRECT ANY MINOR TWISTING PLAN VIEW
IN THE ELEVATOR TRUNKING.
GUY WIRE CABLE

8mm [ 5/16" ]
SIDE VIEW
UP TO 20M WITH ONE SET OF GUY WIRES

UP TO 40M WITH TWO SETS OF GUY WIRES
NOTE: INSTALLATION OF CABLE TO BE 45 DEGREES WHEN POSSIBLE
Figure 10.
18
BELT CONNECTION
A) The elevator belt can be connected using the belt overlap system. (Fig. 11) (See Next Page)
---The belt provided is supplied with adequate length to allow for on overlap of the belt for 3 to 6
cups dependent on the size of the elevator.
---Please follow these recommendations:
Model 7520 (3) cups up to 25m (80’) and (4) cups in excess of 25m.
Model 11624 (4) cups up to 25m(80’) and (5) cups in excess of 25m.
Model 14736 (5) cups up to 25m (80’) and (6) cups in excess of 25m.
NOTE: It is recommended, especially in cold environments, that the belt be draped over the head
pulley and allowed to hang for at least 24 hours. This will relieve stresses resulting from being
rolled up and tend to achieve initial stretch common to belting.
1) Ensure the belt adjustment take up units on the boot are raised to their uppermost position.
2) Accurately square one end of the belt.
3) With a cable tackle or similar tensioner pull the ends of the belt together and overlap.
4) When overlapping ensure that the belt is positioned to ride softly, over the head pulley.
( Fig.11)
Recommended that you retighten the belt after 24hrs prior to doing the final connection to
remove stretch and then do splice connection.
5) Tighten belt and align cup belt holes and then install cups to splice the belt. (Fig. 12)
6) Remove belt tensioning device.
Note: If may be necessary to drill new holes in one of the overlapping belts to maximize the
tensioning of the belt.
B) Mechanical belt joining systems such as “Gripwell” and Maxi-splice” can be supplied. (Fig. 13)
The system supplied will depend on the elevator capacity, belt and loading. Whatever mechanical
belt joining system is used, the method of joining a belt is basically the same, and the following
procedures are recommended.
Note: It is recommended, especially in cold environments, that the belt be draped over the head
pulley and allowed to hang for at least 24 hours. This will relieve stresses resulting from being
rolled up and tend to achieve initial stretch common to belting.
1) Ensure belt adjustment is slackened off as much as possible.
2) Accurately square one end of belt.
3) Space out joiners across the end of the belt and mark hole positions across the belt and 80mm
in from the end of the belt. Drill slightly undersized holes.
4) With a cable tackle or other tensioner, pull the ends of belt together, overlapping the ends.
19
Recommended that you retighten the belt after 24hrs prior to doing the final connection to
remove stretch and then do splice connection.
5) Accurately position and align “long” end of belt over the squared and drilled end. Mark hole
positions in “long” and through the existing holes on the “short” end. Drill holes.
6) Tension belt to cause “slackness” in the ends of the belt, so fasteners can be fitted. Tighten
fasteners evenly. Remove belt tensioning device.
Hex Head Bolt

End Plate
Level Hoist Belt
Center Plate
Direction of Travel Special Locknut
Figure 11. Belt Overlap Figure 12. Figure 13. Mechanical Belt Splice
BELT ADJUSTMENT
Tighten the elevator belt by adjusting the boot pulley take-up threads to move the pulley down. Change
from side to side until the belt becomes reasonably tight. You can check for tightness, through the leg
inspection door, by pulling the belt towards you. The belt will “feel” tight when it wants to “spring
back” as you try to pull it towards you.
Be sure the motor isolation switch is locked off and tagged before this check is done.
Do not over tighten the belt with the takeup units as it may stretch excessively when
in use.
20
Elevator Dust Control
Elevators both standard and self cleaning models are fabricated products that have been manufactured,
and assembled with tolerances as close as this type of manufacturing permits.
A). The head section are welded where practical and the bolted section of the main body is bolted
and silicone sealed. The top section referred to as the bonnet has a male and female connection
where the two halves meet. This flange is then covered with a wire reinforced weather strip to
prevent the ingress of foul weather conditions and the egress of product.
B). The legstock casing is solid welded both on the trunk, and at the end flanges to prevent ingress of
foul weather conditions, and egress of product. During assembly the end flanges are silicone
sealed, and then connected with adequate bolts to prevent leakage.
C). The boot sections are welded where practical, and bolted sections are silicone sealed. To assist in
sealing the elevator boots from the leakage of product in the standard boots we have installed
UHMW seals around the boot shafts, and a belting strip mounted on the inside of the boot above
the end cleanout doors. The self cleaning models are fitted with a gasket where the telescoping
section of the self cleaning boot and the fixed section contact. That seal combined with UHMW
shaft seals, and a double plate seal provided on the bottom clean out door are adequate to prevent
leaks under most conditions.
The elevator boot is not a pressure vessel and this is noted in the manual on page 5 item #23. Since it
is not a pressure vessel the boot cannot achieve the type of seal that would be attributed to that of a
pressure vessel. Excessive air pressure in a boot in combination with the product will create a dusty
environment both inside and outside the boot.
Excessive dust and air conditions in the boot, in the elevator trunk, and head discharge section also
present an opportunity for an explosion under certain conditions. Excessive air particularly in the boot
section will expel dust through the gaskets and shaft seals. It is the responsibility of the owner and or
installer to provide relief for the air and dust in an elevator. This air relief is generally introduced at the
boot, in the legstock casing, at the head section or in all three locations. The amount and type of
equipment used to provide the air and dust relief is relevant to the wishes of the customer, and/or the
safety standard requirements of the company or the local authorities.
21

Before putting the bucket elevator into operation, it must be checked for correct working. Special care
must be taken to see that the belt and buckets are free to move. The belt assembly should not touch the
housing.
1. All foreign material must be removed from the bucket elevator before it is
started.
direction of the equipment. (Fig. 14) Damage to equipment and injury to
personnel is possible if equipment is started in the wrong direction. Correct motor
direction as needed. For bucket elevators with direct drives this procedure
requires extra caution as per items 3 and 4.
Figure 14.
Note: All new installations using one or several pieces of equipment should be
“flushed clean” with corn or some other abrasive type products. This flushing cleans
out unwanted debris that may be lodged in the equipment. Flushing will also shine
the steel body of the equipment to ensure less friction and improved product flow.
3. Never attempt to remove covers or inspection windows to put hands into the
machine while it is in operation.
4. Before operation, close all clean-out slides and inspection panels and ensure all
drive guards are in place.
5. Start the elevator motor and listen carefully for any abnormal noise or operations.
6. Initial start up of elevator should commence with several short jogs gradually
lengthening in duration without material.
22
7. Check the belt is tracking correctly at both the head and boot. If the belt needs
tracking at the head pulley, adjust it before “fine tuning” the boot pulley tracking.
To track the HEAD pulley, jack the bearing/s as required and shim to hold in
place. RAISE the bearing on the side the belt is running towards. Next, track belt
around the BOOT pulley. This is done by LOWERING the bearing on the side
the belt is running. The belt should run in the middle of the head and tail pulleys.
8. For elevators using gravity takeups add weight (concrete or steel stampings) to
weight box as required for smooth operation. Weight must be uniformly
distributed in the weight box and sufficient to remove slack from the belt. The
takeup units located to each side of the weight box are to assist in tracking the
elevator belt. There are also screw takeups one on each side of the boot to adjust
the boot shaft and pulley for tracking of the elevator belt.
9. Track belt by making small adjustments and then observe results.
11. Gradually begin feeding material to the elevator. Increase feed rate slowly until
reaching design capacity. Empty elevator. LOCK OUT ALL POWER. Check for
loose fasteners. Check alignment of the elevator belt.
12. Elevator boots come with a boot inlet chute. This chute is designed to properly
direct the flow product into the elevator cup. (Fig. 15) Any other inlets for
product that are installed on the elevator must be designed to ensure that it is fed
evenly and central to avoid forcing the belt to one side. Improper filling of the
cups can make it difficult to track the belt and will affect capacity. (Fig. 16)
13. During normal operations, avoid starting and stopping any elevator when loaded
with material. Elevator should be checked for loose fasteners and alignment
at least once a month.
Figure 15. Figure 16.

Proper Filling Improper Filling
23
THE MOTOR ISOLATION SWITCH MUST BE OFF BEFORE CARRYING OUT
MAINTENANCE WORK OF ANY KIND
It is good practice to inspect bucket elevators monthly for excessively worn or damaged
components. Pay particular attention to the transmission parts, bearing lubrication and
the elevator belt and cups. Ensure that all safety guards and lids are in place. Never
operate a bucket elevator with a safety guard off or a lid open.
An inspection schedule should be established in order to ensure that the equipment is in good operating
condition at all times. Here are some of the things which should be inspected and maintained regularly.
1. Inspect belt and cups for loose bolts, damaged cups (replace damaged and missing cups). Check
general belt condition and belt splice.
2. Check belt tension. At some point when the take up system has no further ability to tension the belt
it will be necessary to disconnect the belt at the splice and re-tension using a come-a-long or other
tensioner device.
3. Check cup wiper in the head discharge to ensure it is within 20mm of the leading edge of the cup.
4. Inspect the transmission v-belts or chain for tension and condition.
5. Check gearboxes regularly for sufficient oil and signs of leakage. Keep breathers CLEAN.
7. Check all sheave / sprocket and drive attaching parts for security.
LUBRICATION
The ball bearings of flange bearings on each end of the shaft should be greased at least every 3 months.
Bucket elevators supplied with SNL Pillow Blocks require that the grease be changed annually. Oil
level in transmission gearboxes should be checked monthly and renewed annually. Never overfill a
gearbox with oil. Fill gearbox to lower fill plug as noted in the gearbox manual. The transmission chain requires
light greasing monthly. Do not over grease bearings as this can damage the bearing seals.
GEARBOX INFORMATION
The gearbox information supplied with equipment has been shown in the specification sheet. We
have also included a copy of the gearbox operating instructions. It is the responsibility of the owner to
ensure that the proper operating procedures governing the use / maintenance of the gearbox be
applied. For more detailed information on the gearbox please review the manual at the back of this
binder.
24
DRIVE CHAIN AND “V” BELT MAINTENANCE
The supplied equipment is fitted with either a direct drive, chain drive or “V” belt drive.
HEAD PULLEY RUBBER LAGGING

The rubber lagging on the head pulley will wear with use. It is important to inspect this lagging
frequently and replace when worn to 50% (6mm) of its original thickness.
EXTENDED SHUTDOWN / STORAGE

If the bucket elevator is to have an extended shutdown or storage (beyond one month) the following
should be performed:
1) Ensure all foreign material is removed from the elevator and surface coatings are in good order.
3) Elevator belt is rotated every two weeks.
4) The elevator is protected from weather, moisture, and extreme temperatures. Do not use plastic or
6) Prior to start-up, inspection and service instructions contained in this manual must be performed.
25
Installation of Taper-Bore Style Roller Bearings
Before mounting spherical taper-bore roller bearings on taper-shaft fits or adapters, the internal
clearance should be checked and recorded. The measurement is made on one sided of the bearing only,
recommended practice is to rest the bearing upright on a table insert the feeler gauge between the top
roller and the inside of the outer ring.
Mounting Procedure
1. Check internal clearance between the rollers and the outer race on the open side. Feeder gauge must
be inserted far enough to contact entire roller surface.
2. Lightly oil surface of bearing bore and install on taper shaft or taper adapter sleeve without lock
washer.
3. Check internal clearance as nut tightened. Nut must be tightened until internal clearance is reduced
the amount shown in the table below.
4. Remove nut, install lock washer, and retighten nut. Secure lock washer.
Shaft Diameter Clearance Reduction

5 1
1 /8 to 3 /2 .001 to .002
1 1
3 /2 to 6 /2 .002 to .0035
1 1
6 /2 to 10 /4 .0035 to .0055
Shaft Diameter Clearance Reduction

40mm to 90mm 0.0254 to 0.0508
90mm to 165mm 0.0508 to 0.0889
165mm to 260mm 0.0889 to 0.1397
The above values are for most common applications. For special cases, such as high temperature
equipment, bearings on hollow specifications and instructions for special applications.
Fixed and Floating Bearings

Temperature variations will expand and contract the components of any machine. Because of this, it is
essential that such parts be permitted to expand and contract without restriction. For that reason, only
one bearing on any one shaft should be fixed axially in the housing (called a fixed or held bearing) to
prevent axial or endwise motion. All other bearings on that same shaft should have adequate axial
clearance in the housing (referred to as floating or free bearings).
26
Mounting SNL Housings with Double-lip Seals
Before starting installation work, the following instructions should be carefully
read:
1. Ensure that the environment is clean.
2. Check the dimensional and form accuracy of the shaft sealing.
3. Check that the surface roughness of the support surface R2</=12.5 um. The
flatness (planicity) tolerance should be to IT7. For moderate demands IT8 may
be satisfactory.
4. Position the housing on the support surface. Fit the attachment bolts but do not
tighten them.
NB. When relubrication is required, the housing must be positioned with the grease
nipple at the opposite side of the lock nut.
5. Insert one seal half in each of the grooves in the housing base. Fill the space
between the two sealing lips with grease. If the housing is to be used at the end
of a shaft, insert an end cover at one side instead of the seal half.
6. Mount the bearing on the shaft-either directly on a stepped shaft or using an
adapter sleeve. Completely fill the bearing with grease. The remainder of the
recommended grease quantity should be put in the housing base at the sides
(Table 1).
7. Lay the shaft with bearing in the housing base.
8. Put one locating ring (when needed) at each side of the bearing.
9. Carefully align the housing base. Vertical markings at the middle of the side
faces and ends of the housing base can facilitate this. Then lightly tighten the
attachment bolts.
10. The remaining seal halves should be inserted in the seal grooves in the housing
cap and the space between the sealing lips filled with grease.
11. The housing cap should be placed over the base and the cap bolts (to join cap
and base) tightened to the torque specified to Table 2. The cap and base of one
housing are not interchangeable with those of other housings. The cap and base
should be checked to see that they bear the same identification.
12. Fully tighten the attachment bolts in the housing base. Recommended tightening
torques are given in Table 3.
27
LUBRICATION and BOLT TORQUE
Table 1 Table 2 Table 3
Housing Grease Cap bolts 8.8 Attachment bolts 8.8
SNH/SNL Intial Fill Tightening torque Tightening torque
Grams Nm Nm
505,205 25 M10×40 50 M12 90
506-605,206-305 40 M10×40 50 M12 90
507-606,207 50 M10×50 50 M12 90
508-607,208-307 60 M10×50 50 M12 90
509,209 65 M10×50 50 M12 90
510-608,210 75 M10×55 50 M12 90
511-609,211 100 M12×60 80 M16 220
512-610,212 150 M12×60 80 M16 220
513-611,213 180 M12×65 80 M16 220
515-612,215 230 M12×65 80 M16 220
516-613,216 280 M12×70 80 M20 430
517,217 330 M12×80 80 M20 430
518-615,218 430 M16×90 150 M20 430
519-616 480 M16×90 150 M20 430
520-617 630 M20×100 200 M24 750
522-619 850 M20×100 200 M24 750
524-620 1000 M20×110 200 M24 750
526 1100 M24×130 350 M24 750
528 1400 M24×130 350 M30 1400
530 1700 M24×130 350 M30 1400
532 2000 M24×130 350 M30 1400
Important general data:

Shaft Direct mounting Depends on the application
Sleeve mounting h9/IT5-h10/IT7
Supporting Flatness IT7-IT8
Surface roughness Ra</=12.5 μm
Painting system SNL Alkyd RAL9005 Pigment black
SNL Alkyd RAL 5007 Pigment blue
Thickness 30-80 μm
Label with special designation
Label can be painted over, designation will be visible after removal of protection cover.
Mounting of bearing reference
SKF Bearing Maintenance Handbook (publication 4100E) or SKF General Catalogue (Publication 4000E)
28
Problem / Cause
PROBLEM POSSIBLE CAUSE
Elevator Vibrates
1. Foreign matter in boot
2. Excessively tight chain/belt
3. Excessively loose chain/belt
4. Loose or broken buckets
5. Buckets hitting cup wiper
6. Misaligned elevator head and boot shaft
7. Elevator is not adequately braced.
8. Chain/belt hitting inside of casing when casing is not plumb
Elevator Will Not Start 1. Electrical problem

2. Broken V-Belts or drive chains
3. Boot excessively plugged with material
4. Obstruction in boot
5. Excessively tight chain/belt
6. Backstop incorrectly installed
7. Reducer failure
Pillow Blocks Get Hot 1. Over lubrication

2. Under lubrication
3. Excessive chain/belt tension
4. Misalignment of head shaft pillow blocks
5. Misalignment between head and boot shaft
Elevator Not Discharging Properly 1. Speed incorrect - Consult MMS

2. Air cushion - Vent the compartment being filled
3. Light fluffy materials - reduce speed up to 15%
4. Certain materials may require perforated buckets
5. Some materials may be affected by static electricity
29
Bucket Elevator
1. Visually check motor
2. Grease motor bearings
3. Check gearbox oil
4. Change gearbox oil
5. Visually check gearbox seals
6. Check gearbox mounting
7. Visually check drive pulleys/sprockets
8. Check drive pulleys/sprockets mounting
9. Visually check drive belts/chain
10. Check drive belt/chain tension
11. Check backstop mounting
12. Visually check head and boot bearings
13. Grease Boot Bearings (flange)
14. Grease Boot Bearing (SNL)
15. Grease head bearings (SNL)
16. Check/adjust discharge cup wiper
17. Check head pulley lagging
18. Visually check elevator belting / chain
19. Check belt joiners / splice
20. Check belt tracking head and boot
21. Check belt tension
22. Check buckets and mounting
23. Check bucket bolts
24. Visually check elevator casing
Comments
The customer shall select the frequency of services to the equipment. Consideration is to be given to the
original manufacturer (Gearboxes and Bearings) suggested routine and the customers demands equipment.
30
BS Series Cam Clutches
Model BS85F-BS465F Grease Lubricated
Thank you for choosing Tsubaki E&M products.

Before installing or working on the product, check label for correct size and make sure you
have the complete set of parts. If any parts are missing, contact your distributor immediately.
This manual should be considered an essential part of the unit and remain with the unit when
redistributed.
SAFETY
・ Your Cam Clutch is a high quality, sophisticated unit which should be handled by experienced engineers
only.
・ For safety purposes, make sure this manual is easily accessible by the user at all times.
Safety precautions in this manual are classified into two categories: “WARNING” and “CAUTION”.
These are defined as follows:
Death or serious injury may result from misusing the product without
WARNING
following the instructions.
Minor or moderate injury, as well as damage to the product may result
CAUTION from misusing the product without following the instructions.
Notice that although categorized under “CAUTION”, subjects discussed may lead to serious results depending on the situation.
WARNING
・ Make sure turning forces are not applied to Cam Clutch or turning shaft of the equipment when
conducting inspection or maintenance.
・ Pay special attention to the back stopping application to prevent accidents.
・ Frequent starting and stopping will apply excessive force on the mounting. Verify mounting strength.
・ Inaccurate installation and mounting, various load conditions, wear and tear of parts, and life
expectancy can all affect the performance of a Cam Clutch. Inspect and maintain periodically and
install a safety devise on your equipment.
・ Comply with Ordinance on Labor Safety and Hygiene 2-1-1 general standards.
CAUTION
・ To ensure safety and optimal performance, carefully read this instruction manual in its entirety.
・ Confirm rotational direction prior to installing.
1
CONSTRUCTIONS
BS-F
Parts name
① Inner race ④ Thrust bearing ⑦ Torque arm ⑩ Labyrinth ring ⑬ Cotter pin
② Outer race ⑤ Side plate ⑧ Pin ⑪ Socket plug
③ Cam cage ⑥ Labyrinth plate ⑨ Oil seal ⑫ Air breather
2
INSTALLATION
Clutch-Shaft
NO!
YES!
Do not use a tapered key!
Only a parallel key is recommended.
Fix BS Cam Clutch to a shaft with an

end plate or a shaft collars.
When mounting BS Cam Clutch,

apply pressure only to inner race end.
Do not hit clutch side plate, labyrinth
Check direction of shaft plate or bolts.
rotation and clutch
inner race rotation
1. Before installation, check if the direction of shaft rotation is the same as the inner race of BS cam clutch, which is
shown by an arrow mark on the inner race end.
2. Securely install the torque arm to the BS Cam Clutch using furnished torque arm pins and cotter pins. Refer to
'Page 4: Installation of Torque Arm'.
3. Recommended fit of bore to shaft is H8 (Clutch Bore) to h8 (Shaft) or H7 to h7 (Refer to Table below).
Interference fit and shrink fit are prohibited for clutch fixing.
4. When mounting the BS cam clutch, apply pressure only to a clutch inner race. When tapping the inner race,
use a soft hammer in order to avoid damage on the clutch inner race end. Do not hit the clutch side plate,
labyrinth plate or bolts with hammer.
5. Only a parallel key is recommended for clutch fixing. Do not use a tapered key. And there must be clearance
between clutch keyway and key top. The key should be in accordance with ISO R773 (DIN 6885.1) or ANSI B17,
1-1967 (R 1998).
6. Shaft is best machined with ‘lead in’ of -0.1mm x 15% of the backstop width to facilitate the backstop being
mounted with the keyway protruding into the ‘lead in’ for easy alignment.
7. Check key will slide through the backstop keyway and corner radius is clear for fitment.
8. In order to suppress the temperature rise of BS backstops and to extend the lubricant life, installation of a
protective cover against direct sunlight is recommended.
Clearance
Inner Race
Loose on top of key
Tight fit on both-sides of key
Shaft
Key
Nominal Bore Dia. (mm) Tolerance for Shaft (mm) Tolerance for Clutch Bore (mm)
h7 h8 H7 H8
Above 30 up to 50 0 ~ -0.025 0 ~ -0.039 +0.025 ~ 0 +0.039 ~ 0
50 ~ 80 0 ~ -0.030 0 ~ -0.046 +0.030 ~ 0 +0.046 ~ 0
80 ~ 120 0 ~ -0.035 0 ~ -0.054 +0.035 ~ 0 +0.054 ~ 0
120 ~ 180 0 ~ -0.040 0 ~ -0.063 +0.040 ~ 0 +0.063 ~ 0
180 ~ 250 0 ~ -0.046 0 ~ -0.072 +0.046 ~ 0 +0.072 ~ 0
250 ~ 315 0 ~ -0.052 0 ~ -0.081 +0.052 ~ 0 +0.081 ~ 0
315 ~ 400 0 ~ -0.057 0 ~ -0.089 +0.057 ~ 0 +0.089 ~ 0
400 ~ 500 0 ~ -0.063 0 ~ -0.097 +0.063 ~ 0 +0.097 ~ 0
3
INSTALLATION
Torque Arm
Torque Arm Fixing
The end of torque arm shall be restrained to prevent rotation by a set of angle iron. (See illustration below).
But the torque arm shall be free axially and radially in order to prevent the clutch from any load induced
by misalignment and distortion.
Restraining brackets of torque arm shall be bolted rather than welded to the conveyor frame in order to
install the torque arm correctly, and allow 2-5mm clearance between torque arm and restraining bracket.
Torque Arm end

must be free
axially.
Total clearance should be

between 2 to 5 mm.
4
LUBRICATION
Maintenance &
Check Items for Installation
Make sure the cam clutch is installed under an environment which the ambient temperature is within the range of
-40ºC to 65 ºC.
Check if the clutch is lubricated properly and/or installed correctly by monitoring the cam clutch running
temperature, normally it would not exceed 100ºC.
Note: BS-F operating temperatures may surge at maximum overrunning speed. An adequate cooling device is
required if BS-F operating temperatures exceed 100°C due to the heat emission of the driven equipment.
Noise Check
During operation if noise is heard by a noise-accentuator stick as continuous rumbling sound, this is normal
and of no concern. If an abnormal variation in sound is heard the following points could be the cause:-
(a) Installation problem with torque arm.
(b) Extreme wear caused by poor lubrication.
(c) Dust or metal pieces contaminating the grease.
(d) Damage to inner race by extreme pressure at key fixing.
(e) Internal dislodged by PRESSING AGAINST outer race
Grease lubrication
Grease is packed in the clutch before shipment but requires periodic maintenance as specified below.
Maintenance
• Periodic change of grease is necessary after 7,500 to 10,000 hours of operation. The actual
operation time between changes should be decided after considering the operating conditions.
Inject new grease after draining and cleaning inside of the BS Cam Clutch. The detailed procedure
is described on the next page. When the grease is to be changed, be sure to drain and clean the
inside of the BS Cam Clutch beforehand.
• Grease sampling should be taken @ regular 12 month intervals depending on environmental &
contamination conditions. Additional grease replacement might be needed during sampling if
excessive liquid is removed, replace at least 50% more by volume than lost. Removal of breather will
provide access to fill the CORRECT grease type.
• Approximate Amount of Grease Required

Size BS85F BS95F BS115F BS140F BS165F BS200F
g 65 75 105 150 160 190
Size BS225F BS250F BS270F BS300F BS360F BS425F BS465F

kg 1.3 1.4 1.6 1.8 1.9 3.5 4.4
• Recommended Grease for ambient temperature range -40˚C ~ +65˚C

Grease supplier Product name
Exxon Mobil Beacon 325
Note: Beacon 325 is NOT able to be mixed with other greases.

Do not use grease that contains EP additives.
• . Air Breather Positions

45 degree or less from 12:00 O'clock
5
Cleaning
• Wipe off dust around plugs.
• Remove two plugs one on the top, another on the bottom of the clutch.
• Rotate the shaft and pour cleaning oil (Kerosene) into the top plug in order to drain mixture of old
grease and poured cleaning oil through the bottom plug.
• Quantity of cleaning oil necessary is : one charge about I litre for BS85F to BS225F
one charge about 3 litres for BS250F to BS360F
one charge about 6 litres for BS425F to BS465F
Important : After draining of the mixture of oil and old grease, stop the shaft rotation, otherwise
damage could result.
• Attach the bottom plug and remove the side (level) plug. Pour cleaning oil again until the oil flows
out from the side (level) plug.
Necessary quantity of cleaning oil as per chart.
Size BS85F BS95F BS115F BS140F BS165F BS200F

Litres 0.1 0.1 0.2 0.3 0.3 0.4
Size BS225F BS250F BS270F BS300F BS360F BS425F BS465F

Litres 1.3 2.9 3.3 4.2 4.8 5.6 7.0
• Attach the side plug and rotate the shaft for 10 minutes (this is to drain old, remaining grease inside).
Stop the rotation of the shaft and drain the contents.
• Repeat this procedure more than two times until all grease is completely removed.
Note: During shaft rotating, be sure to keep pouring oil. Before stopping oil supply, stop rotation of
the shaft. If the clutch is rotated without lubricant, it may cause dry contact in the clutch.
Grease Injection
• Remove two plugs – one on top, another on bottom. Attach a grease nipple (thread size PT ¼) on
the top hole of the clutch.
• Inject grease by a grease gun until the grease comes out from the bottom plug hole.
Approximate amount of grease to be used is shown on previous page.
During this procedure the shaft shall be stationary, until recommended quantity is injected.
Remove the grease nipple and replace the original top and bottom plugs. Tighten all plugs of the
clutch.
• After completion of grease change, rotate the shaft for 2 hours for test run in order to get good
lubricating condition, during this test run do not apply hold back torque on the clutch.
6
Tsubaki E&M Co.: hereinafter referred to as “Seller”
Customer: hereinafter referred to as “Buyer”
Goods sold or supplied by Seller to Buyer: hereinafter referred to as “Goods”
1. Warranty period without charge
18 months effective the date of shipment or 12 months effective the first use of Goods, including installation of Goods
to Buyer’s equipment or machines - whichever comes first.
2. Warranty coverage
Should any damage or problem with the Goods arise within the warranty period, given that the Goods were
operated and maintained under instructions provided in the manual, Seller would repair and replace at no charge
once the Goods are returned to Seller. The following are excluded from the warranty.
1) Any costs related to removing Goods from the Buyer’s equipment or machines to repair or replace parts.
2) Costs to transport Buyer’s equipment or machines to the Buyer’s repair shop.
3) Costs to reimburse any profit loss due to any repair or damage and consequential losses caused by the Buyer.
3. Warranty with charge
Seller will charge any investigation and repair of Goods caused by:
1) Improper installation by failing to follow the instruction manual.
2 )Insufficient maintenance or improper operation by the Buyer.
3) Incorrect installation of Goods to other equipment or machines.
4) Any modifications or alterations of Goods by the Buyer.
5) Any repair by engineers other than the Seller or those designated by the Seller.
6) Operation in an inappropriate environment not specified in the manual.
7) Force Majeure or forces beyond the Seller’s control such as natural disasters and injustice done by a third party.
8) Secondary damage or problem incurred by the Buyer’s equipment or machines.
9) Defected parts supplied, or specified by the Buyer.
10) Incorrect wiring or parameter setting by the Buyer.
11) The end of life cycle of the Goods under normal usage.
12) Loss or damage not liable to the Seller.
4. Dispatch Service
Service to dispatch a Seller’s engineer to investigate, adjust or trial test Seller’s Goods is at the Buyer’s expense.
5. Disclaimer
1) In our constant efforts to improve, Tsubaki E&M may change the contents of this document without notice.
2) Considerable effort has been made to ensure that the contents of this document are free from errors. However,
Tsubaki E&M makes no warranties with respect to the accuracy of information described herein. In the mean time,
we would appreciate comments or reports on any inaccuracies or omissions found in this document to help us
make timely amendments as necessary. Your cooperation is greatly appreciated.
1-1, Kohtari-Kuresumi, Nagaokakyo

TSUBAKI E&M CO.
Kyoto 617- 0833, Japan
Phone : +81-75-957-3131
Facsimile: +81-75-957-3122
Internet : http://tsubakimoto.com/tem/
Global Associated Partners:
U.S. Tsubaki Power Transmission, LLC Tsubakimoto Singapore Pte. Ltd. Tsubakimoto Europe B.V.
http://www.ustsubaki.com/ http://tsubaki.sg/ http://tsubaki.eu/
Tsubaki of Canada Limited Taiwan Tsubakimoto Co. Tsubakimoto U.K. Ltd.

http://tsubaki.ca/ http://tsubakimoto.com.tw/ http://tsubaki.eu/
Tsubaki Australia Pty. Limited Tsubakimoto Chain (Shanghai) Co., Ltd.

http://tsubaki.com.au/ http://tsubaki.cn/
Bulletin No. CC04N-00E
7
BS Series, BS-HS Series, BS-R series Cam Clutch
Installation and Maintenance Instruction
BS30, BS50, BS65, BS75, BS85, BS95, BS110, BS135, BS160, BS200
BS220, BS250, BS270, BS300, BS350, BS425, BS450
BS160HS, BS200HS, BS220HS, BS250HS, BS270HS, BS300HS, BS350HS, BS425HS, BS450HS
BS65R, BS75R, BS85R, BS95R, BS110R, BS135R, BS160R, BS200R

BS220R, BS250R, BS270R, BS300R, BS350R, BS425R, BS450R
Thank you for choosing Tsubaki E&M products.

Before installing or working on the product, check label for correct size and make sure you have the
complete set of parts. If any parts are missing, contact your distributor immediately.
This manual should be considered an essential part of the unit and remain with the unit when
redistributed.
SAFETY
 Your Cam Clutch is a high quality, sophisticated unit which should be handled by experienced engineers only.
 For safety purposes, make sure this manual is easily accessible by the user at all times.
 To ensure safety and optimal performance, carefully read this instruction manual in its entirety.
Death or serious injury may result from misuse, improper installation and/or improper
WARNING maintenance of this product. Please refer to the detailed instructions provided in this
manual for installation and maintenance specifications.
WARNING
USE CARE TO PREVENT INJURY
COMPLY WITH THE FOLLOWING TO
AVOID SERIOUS PERSONAL INJURY:
1. Guards must be provided on all chain and sprocket installations in

accordance with provisions of ANSI/ASME B15.1 - 2000
“Safety Standards for Mechanical Power Transmission Apparatus,” and
ANSI/ASME B20.1 - 2012 “Safety Standards for Conveyors and Related
Equipment,” or other applicable safety standards. When revisions of
these standards are published, the updated edition shall apply.
2. Always lock out the power switch before installing, removing, lubricating
or servicing a system which uses PTUC product.
3. When connecting or disconnecting PTUC products, eye protection is required.

Wear safety glasses, protective clothing, gloves and safety shoes.
4. Improper installation or mounting, as well as operating conditions and maintenance,

can affect the performance of a cam clutch. The cam clutch should be inspected regularly.
“PTUC is used by U.S. Tsubaki to designate “Power Transmission Unit Components.”

PTUC products include Cam Clutch DISCO, POWER-LOCKⓇ, Shock Relay, Gearmotor,
TM
HF Drive, Shock Damper, Power cylinder , Couplings, SCR variable speed motor and
other like products manufactured by/for Tsubaki.
Constructions
BS160 to BS200
BS85 to BS135
BS65 to BS75
BS30 toBS50
① Inner race ⑤ Spring ① Inner race ⑥ Plate

① Inner race ⑤ Thrust metal
② Outer race ⑥ Plate ② Outer race ⑦ Thrust metal
② Outer race ⑥ Snap ring ① Inner race ⑥ Oil seal
③ Cam ⑦ Snap ring ③ Cam ⑧ Snap ring
③ Cam cage ⑦ Oil Seal ② Outer race ⑦ Grease fitting
④ Roller ⑧ Oil seal ④ Roller ⑨ Oil seal
④ Plate ③ Cam cage ⑧ O-ring
⑤ Spring
④ Seal supporter ⑨ Snap ring
⑤ Thrust metal
BS250 to BS450
BS300HS to BS450HS*
BS160HS to BS270 HS
① Inner race ⑥ Oil seal

① Inner race ⑥ Oil seal ② Outer race ⑦ Grease fitting ① Inner race ⑥ Thrust Bearing
② Outer race ⑦ Grease fitting ③ Cam cage ⑧ O-ring ② Outer race ⑦ Oil seal
③ Cam cage ⑧ O-ring ④ Seal supporter ⑨ Snap ring ③ Cam cage ⑧ Grease fitting
④ Seal supporter ⑨ Snap ring ⑤ Bearing ④ Roller cage ⑨ O-ring
⑤Thrust metal ⑤ Seal Supporter
*This drawing shows the construction of BS425HS and BS450HS which has 2 lines Cam cages.
There is the single line of Cam cage in BS300HS and BS350HS.
2
Installation and Usage
1. Recommended shaft tolerance is shown below.
Clutch Bore Shaft Fit Guide

0 to 1.20 inches dia. Line fit to .0008 inches loose
0 to 30mm dia. (0.020mm)
1.20 to 2.00 inches dia. Line fit to .0010 inches loose
30mm to 50mm dia. (0.025mm)
50mm to 80mm dia. (0.030mm)
80mm to 120mm dia. (0.036mm)
120mm to 180mm dia. (0.041mm)
180mm to 250mm dia. (0.046mm)
250mm to 315mm dia. (0.051mm)
315mm to 400mm dia. (0.058mm)
400mm to 450mm dia. (0.064mm)
2. Before installation, verify that the direction of inner race rotation (shown by the arrow on the end face of inner race) is
same as the shaft rotating direction of conveyor
3. Securely install the torque arm to Cam Clutch using bolts with a strength class of 10.9 grade or higher. Make sure the
surface of torque arm that contacts the end face of outer race is flat and free of dust in order to get enough frictional
force.
4. Apply pressure only on the end face of inner race when installing the BS Cam Clutch onto the shaft. Do not hit the inner
race directly with a hammer or apply pressure on the outer race, oil seal, or grease fitting.
5. Always use a parallel key for installation onto the shaft and then fix the BS Cam Clutch to the shaft with the end plate.
Never use a tapered key, otherwise the BS Cam Clutch will be damaged. The key should be in accordance with ANSI
B17, 1-1967 (R 1998).
6. When installing models BS160HS or BS160 and above (grease lubrication types), place one the four socket plugs
underneath the Cam Clutch. This will allow for easy drainage of the grease during maintenance.
7. The end tip of torque arm will swing to some extent while the conveyor is operating. Support the torque arm end tip only in
the direction of rotation, but be sure to allow it a certain amount of free movement axially. (Refer to installation diagram).
The Cam Clutch sustains damage if the torque arm end tip is fixed securely.
8. A single torque arm is sufficient for models BS30 to BS200, BS160HS and BS200HS. One torque arm on each side is
required for models BS220HS to BS450HS and BS220 to BS450. It is recommended to use the standardized torque arm
and safety cover for the BS Cam Clutch.
 BS-R Series Installation Procedures

Pre-Installation
1. The oil reservoir and the end plate are fixed to the BS Cam Clutch temporarily when packed to prevent dust from
entering during transportation. Carefully remove them from the clutch and prevent the dust from penetrating into
the clutch.
2. For models BS160R to BS450R, apply grease in the space between the dust cover and the seal supporter.
(The grease prevents the dust from entering.)
3. Attach the dust cover to the clutch.
3
4. Check whether the rotational direction of the conveyor shaft corresponds to that of the BS Cam Clutch viewed from
the oil reservoir (the overrunning direction is shown as an arrow on the end face of the inner race.
5. Securely install the torque arm to the BS Cam Clutch using bolts with a strength class of 10.9 grade or higher.
Make sure the surface of the torque arm which contacts the end face of the outer race is flat and free of dust, to
ensure enough friction force is achieved.
Installation
1. Pre-insert the V-ring (except models from BS65R to BS135R) into the conveyor shaft in the correct direction.
2. Securely install the BS Cam Clutch onto the shaft. Apply pressure only on the end face of the inner race when
inserting the BS Cam Clutch onto the shaft. Do not hit the inner race directly with a hammer or apply pressure on
the outer race.
3. Apply the sealant supplied, to the end face of the inner race and packing, and fix the BS Cam Clutch unit to the
conveyor shaft with the end plate. At same time, use the seal washer on each bolt to prevent oil leakage.
4. After cleaning the inside of the oil reservoir, apply the sealant on the mating face of the oil reservoir. Place the oil
Level gauge vertically (red line is bottom, and blue is top), for model BS65R to BS200R; install the oil
reservoir to the end face of the outer race with the bolts, while for models from BS220R and above; install the oil
reservoir to the seal supporter using the bolts.
Carefully prevent dust from penetrating the Cam Clutch or oil reservoir.
5. Press the pre-inserted V-ring entirely so that the face of the dust cover contacts closely.
 Lubrication and Maintenance*
Oil lubricated Cam Clutches do not ship pre-lubricated. Inject the appropriate oil before use.
* Actual maintenance may vary depending on usage and operating conditions.
4
・ Recommended Grease for BS30 to BS350, BS160HS to BS450HS
Brand BS Series Cam Clutch BS-HS Series
Alvania Grease S1, Sunlight Grease 1
Shell -----
Aeroshell No.7, Aeroshell No.22
Fiske Bros. Lubriplate Low-Temp, Aero Lubriplate -----
Kyodo Yushi Multemp PS No.1 Emalube M
Petro-Canada PRECISION Synthetic PRECISION Synthetic
Notes: 1. Do not use grease that contains EP additives.
2. The ambient operating temperature range of the grease listed above is +20F (-5C) and +104F (+40C).
Please consult Tsubaki if operating outside of this range.
・ Drain the grease and clean the inside of BS and BS-HS Series Cam Clutch (Except BS425&450)
Discharge the grease
1. Wipe off the dust around the plug area on the outer race.
2. Remove the upper plug and loosen both side plugs.
3. Pour the proper amount of cleaning oil into the Cam Clutch with the weak pressure by using equipment like the
“TSUBAKI maintenance kit”. The quantity of cleaning oil for each model is shown in the table below.
Amount of cleaning oil for BS Series Cam Clutch
Size BS160 BS200 BS220 BS250 BS270 BS300 BS335 BS350

OZ (Liters) 33.3 (1.0) 33.3 (1.0) 33.3 (1.0) 100 (3.0) 100 (3.0) 100 (3.0) 100 (3.0) 100 (3.0)
Amount of cleaning oil for BS-HS Series Cam Clutch
Size BS160HS BS200HS BS220HS BS250HS BS270HS BS300HS BS350HS BS425HS BS450HS
OZ (Liters) 33.3 (1.0) 33.3 (1.0) 33.3 (1.0) 100 (3.0) 100 (3.0) 100 (3.0) 100 (3.0) 200 (6.0) 200 (6.0)
4. Fix the upper plug and tighten the side plugs and then keep operation the conveyor for two or three hours.
Re-clean
1. Remove the bottom plug, loosen the top plug and take oil out
2. Pour the cleaning oil with weak pressure from upper hole.
3. Cleaning process is complete when the oil discharge is transparency.
Re-charge the new grease

1. Attach the grease nipple to upper tap hole and loosen the one of side plug.
2. Charge the new grease with the grease gun. The amount of grease for each model is shown at next page.
3. Tighten the side plug and replace grease nipple with a plug.
Amount of grease for BS Series

Size BS160 BS200 BS220 BS250 BS270 BS300 BS335 BS350
Lbs (kg) 0.26 (0.12) 0.31 (0.14) 1.76 (0.8) 2.43 (1.1) 2.65 (1.2) 2.87 (1.3) 3.09 (1.4) 3.31 (1.5)
Amount of grease for BS-HS Series

Size BS160HS BS200HS BS220HS BS250HS BS270HS BS300HS BS350HS BS425HS BS450HS
Lbs (kg) 0.51 (0.23) 0.68 (0.31) 2.87 (1.3) 3.75 (1.7) 4.41 (2.0) 7.94 (3.6) 9.04 (4.1) 15.2 (6.9) 15.9 (7.2)
・ Recommended oil for BS425, BS450, BS65R to BS450R

Ambient temperature in Backstopping Applications
+14 ℉ to +86 ℉ (-10 ℃ to +30 ℃ ) +86 ℉ to +122 ℉ (+30 ℃ to +50 ℃ )
Any Automatic Transmission Fluid (ATF) Exxon Mobil Delvac 1330,
Shell Turbo Oil T32, Turbo Oil 68, Rimulla D oil 10W Essolube XT1 10W-30
Exxon Mobil DTE Oil Light, Multipurpose ATF, Delvac Hydraulic 10W, ATF220 Shell Rimulla D Oil 20W/20,
Teresso 32, Teresstic Oil 68, DTE Heavy Medium Rimura D Oil 30
Texaco Regal Oil R&O 68, Chevron GST Oil 68 White Parrot Super S-3-20W-20, 30
BP Rnergol THB32, Gulf Harmony 32
Notes: Do not use oil that contains EP Additives.
5
TSUBAKI E&M CO. 1-1, Kohtari-Kuresumi, Nagaokakyo Kyoto 617- 0833, Japan
Phone : +81-75-957-3131
Facsimile: +81-75-957-3122
Internet : http://tsubakimoto.com/tem/
Global Associated Partners:
U.S. Tsubaki Power Transmission, LLC Tsubakimoto Singapore Pte. Ltd. Tsubakimoto Europe B.V.
http://www.ustsubaki.com/ http://tsubaki.sg/ http://tsubaki.eu/
Tsubaki of Canada Limited Taiwan Tsubakimoto Co. Tsubakimoto U.K. Ltd.

http://tsubaki.ca/ http://tsubakimoto.com.tw/ http://tsubaki.eu/
Tsubaki Australia Pty. Limited Tsubakimoto Chain (Shanghai) Co., Ltd.

http://tsubaki.com.au/ http://tsubaki.cn/
２０１４／０７／１６ＢｕｌｌｅｔｉｎＮｏ．ＣＣ０1HY－００Ｅ
6
ELEVATOR SPECIFICATION SHEET

Date
Job # 370724-12 Req'd
RAL7035
Re: RECEIVING ELEVATOR - BE-2101 Colour: Grey
QTY.
Model: 14836 1
Capacity: 150 MTPH
Discharge Height: 100' 2"
Location of Reducer
Looking at Discharge: RIGHT
Motor: 25 HP TEXP 284TC 3/60/575/1800 1
Gear Box: DODGE TA6307H25 1
Gear Box Bushing: TA6307TB X 3 7/16" 1
Back Stop: TSUBAKI BS95F- 3 7/16" 1
Motor Sheave: 3B7.0-SK 1
Motor Sheave Bushing: SK x 1 7/8" 1
Gear Box Sheave: 3B11.0-SK 1
Gear Box Sheave
Bushing: SK x 2 3/16" 1
Drive Belts: B114 3
RPM: 45 RPM
Belt Speed: 423 FPM
Motor Guard: STD SOLID ALUMIUIM 1
Head Section: STD
Head Pulley & Bushing: 36" DIA X 16" W/ HOLTZ SLIDE LAG 1
Head Shaft: 3 7/16" 1
Dodge P4B515-ISAF-307 TRIDENT TRIPLE
Head Bearing: SEAL 2
Service Platform:
Discharge Trans.:
Leg Casing: 10 GA
Hinged Brixon model #2 latch 18"x18" &
Explosion Vents: 12"x30" 10
X-Braces: 4
Elev. Door Location:
Dog Leg:
Dog Leg Pulley:
Dog Leg Shaft:
Dog Leg Bearing:
Boot Section: STD SELF CLEAN
36" DIA X 16"
Boot Pulley & Bushing WING 1
Boot 2
Shaft: 7/16"
Dodge P4B515-ISAF-207 TRIDENT TRIPLE
Boot Bearing: SEAL 2
ERIEZ MAXIPOWER 14” WIDE 1 STEP
Boot Pocket Inlet: MAGNET 1
Location of Boot Door
Looking at Discharge:
Length of Belt & Type: 15" 3 PLY 330 1/16" X 1/16" GRAIN BELT 220
Elevator Buckets: 14 X 8 HD-MAX
Qty. of Buckets:
Bucket Spacing: 10" CENTERS 170
Elevator Bolts: 5/16 X 1 1/4 FANGED 1350
Ladder Length:
Number of EXPLOSION VENT
Landings: ACCESS 4
Zero Speed Switch: P8004V10C SSR 240VAC/DC 1
Touchswitch: TS2V4C 24 VDC C2 D1 4
Plug
Switch: Monitor Rotary indicator - Model KAX 1-8401-1 1
Bearing Temp Sensors: ADB20V3C/D3 NTC 3" PROBE 4
General Notes:
DUST COLLECTOR
BG-2101
&
FAN
BL-2101
FAN SELECTION Your Representative:
Adrian Buica P. Eng.
And Lawson Taylor Ltd.
PERFORMANCE
416 995-1964 Phone
905 627-9315 Fax
buica@lawson-taylor.ca
May 24, 2018
Job Name: LAWSON TAYLOR LTD.

Reference: Century Quote: 355826
Operating Requirements Fan Selection and Specifications

Volume, ACFM 4,500 Model HDAF-180
Static Pressure, in. wg 11.5 Fan RPM 3,530
Density, lb./ft.³ 0.075 Wheel Description HD Airfoil Wheel
Operating Temperature, °F 70 Wheel Width, % 65%
Wheel Diameter, in. 18.25
Inlet Diameter, in. 20.00
Outlet Velocity, ft./min. 2,729
Fan BHP 9.7 Suggested Motor HP: 10.0
AMCA Arrangement No. 4 Static Efficiency, % 81.9%
Motor Frequency, Hz 60 Cold Start BHP 9.7
Start-Up Temperature, °F 70 Construction Class Class IIP
CFSWin Version: 8.5.6690.15673 Database Version: 8.5.2

Cincinnati Fan Selector - © 2017 by Cincinnati Fan and Ventilator Co. All Rights Reserved
Your Representative:
FAN SOUND DATA
Adrian Buica P. Eng.
Lawson Taylor Ltd.
416 995-1964 Phone

905 627-9315 Fax
buica@lawson-taylor.ca
May 24, 2018
Job Name: LAWSON TAYLOR LTD.

Reference: Century Quote: 355826
Operating Requirements Fan Selection and Specifications
Volume, ACFM 4,500 Model HDAF-180

Static Pressure, in. wg 11.5 Fan RPM 3,530
Density, lb./ft.³ 0.075 Wheel Description HD Airfoil Wheel
Operating Temperature, °F 70 Wheel Width, % 65%
Wheel Diameter, in. 18.25
Inlet Diameter, in. 20.00
Outlet Velocity, ft./min. 2,729
Fan BHP 9.7
Static Efficiency, % 81.9%
AMCA Arrangement No. 4
Cold Start BHP 9.7
Motor Frequency, Hz 60
Construction Class Class IIP
Start-Up Temperature, °F 70
Fan Sound Data

Lp = Sound Pressure Level at a specific distance from the fan. Measured in decibels (dB) or A-weighted
decibels (dB(A)) re 0.0002 microbar.
Lw = Sound Power Level of the fan. Measured in decibels (dB) or A-weighted decibels (dB(A)) re 1E-12 watt.
dB = Decibel, ten times the logarithm (base 10) of the ratio of a value to a reference value.
dB(A) = A-Weighted decibel. A-weighting corrects the spectrum for human hearing response.
Sound Directivity Factor, Q : 2 - HemiSpherical radiation

Fan Inlet Ducting: Ducted
Fan Outlet Ducting: Ducted
Calculated Octave Band Sound Data (dB)

Quantity 63 Hz 125 Hz 250Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000Hz
Lw Total 89 99 106 104 101 97 95 93
Lw Inlet 86 96 103 101 98 94 92 90
Lw Outlet 86 96 103 101 98 94 92 90
Lp Total 61 70 77 75 72 68 66 64
Lp inlet 58 67 74 72 69 65 63 61
Lp outlet 58 67 74 72 69 65 63 61
Total A-weighted Sound Pressure Level, Lp dB(A) 77 at 5.0 feet from fan
Total A-weighted Sound Power Level, Lw dB(A) 106
Blade Passage Frequency, Hz 471 Casing noise. Add
• Sound Pressure values are calculated based upon assumed environmental conditions. Actual values may
15 dBA if open
vary for specific installations due to environmental factors (other noise sources, walls, duct design, etc.) outlet and no
• Noise from the driver is not included in these data. silencer
• Sound Pressure Level calculations assume free field propagation occuring outdoors.
• Duct End Corrections applied (AMCA 300-85 Appendix C).
CFSWin Version: 8.5.6690.15673 Database Version: 8.5.2

Cincinnati Fan Selector - © 2017 by Cincinnati Fan and Ventilator Co. All Rights Reserved
DUCT FLANGE
36
AIR
FLOW
11 9/16 20 3/8 TBA

INSIDE INSIDE FLANGE
FLANGE
SIL INLET TO MATCH FAN
MODEL: 112-016035 RECTANGULAR SILENCER CONSTRUCTION:

DESIGN: INDUSTRIAL GRADE -18 GA. G90 GALVANIZED CASING WITH INTERNAL BRACING AS REQUIRED
WEIGHT: 88 LBS. EACH -G90 GALVANIZED PERFORATED INTERNALS LINER.
QUANTITY: ONE (1) -ACOUSTIC MEDIA PACKED UNDER COMPRESSION.
-SILENCER INLET FLANGE DRILLED TO MATCH FAN DISCHARGE.
OCTAVE CENTER BAND (Hz) 63 125 250 500 1000 2000 4000 8000 -DUCT FLANGE TO MATCH EQUIPMENT.
SILENCER NET IL(dB) 2 3 6 9 16 18 12 6
FINISH:
SILENCED Lp: 77 dBA AT 5.0 FEET, AT POSITION B (TO THE SIDE) OF SILENCER,
UNDER " FREE FIELD " CONDITIONS.
PRESSURE DROP: 0.25" WG AT 4500 ACFM, 0.075 LBS/CU.FT. 70F.
TOLERANCES:
GENERAL SHEET, PLATE &
Lawson Taylor Ltd.
STRUCTURAL STEEL ±1/8". DUNDAS, ONTARIO, CANADA
FLANGE BOLT PATTERNS & CUSTOMER
CIRCLES ±1/16" (UNLESS Century Environmental
OTHERWISE SPECIFIED).
PROJECT
DIMENSIONS ARE IN INCHES TITLE

112-016035 VERTICAL OUTLET SILENCER
DWG SCALE: NTS
PO NO DWN APP DATE DWG REV
REV DESCRIPTION DATE DWN APP
SSP N/A 05-24-2018 P180524-002-01 0
E-98ADC:Bulletin E-98 DC5.0 7/8/09 8:44 AM Page 1
BULLETIN E-98ADC
Series DCT500ADC Timer Controller
Specifications – Installation & Operating Instructions
TIME OFF TIME ON
SEC mSEC
4-1/4
[107.95]
4-7/8
[123.83]
F1
1/16 6-1/4
[1.59] [158.75] 6-3/4
1/2 [171.45]
[12.70]
1-3/16
[30.16]
Introduction SPECIFICATIONS
The Series DCT500ADC Timer Controller is a timing system for pulse-jet type dust Output Channels: 4, 6, & 10 channels.
collectors or pneumatic conveying systems in either continuous or on-demand clean- Voltage Requirements: 10 to 35 VDC ( ).
ing applications. It is provided with either 4, 6, or 10 channels. The DCT500ADC was Power Consumption: 0.6 W.
designed for ease of installation in your dust collector system. For installations requir- Input Power: 106 W @ 35 VDC ( ) max.
ing fewer channels than available on the board, a shorting plug is provided to allow Load: 3A max per channel.
selection of the last used channel. Time-on and time-off settings are selected using Fuse: Type 3 AG, 3A @ 250 VAC (~).
two potentiometers. High-limit and low-limit control inputs are provided for use with Ambient Operation Temperature: -40 to 149°F (-40 to 65°C).
on-demand systems. When used in a continuous mode the high-limit input is Storage Temperature Limits: -40 to 176°F (-40 to 80°C).
jumpered. Humidity Conditions: 5 to 95% noncondensing.
On Time: 50 to 500 msec.
Installation On Time Accuracy: ±5% of setting.
Warning: Always replace the fuse with the proper type and rating. On Time Repeatability: ±1 msec.
The fuse is Type 3 AG fast acting 3 Amp @ 250V. DO NOT use slow- Off Time: 1 to 180 seconds.
blow type fuses. Failure to comply with this requirement will void man- Off Time Accuracy: 5% of setting.
ufacturer’s warranty. Pollution Degree: 2.
Altitude: 6560 ft (2000 m) max.
This equipment is intended to be powered using a recognized Class 2 Environment: Indoor use, must be installed in a weather-proof enclosure for out-
power supply. If powered from a DC bus a suitable transient protection side applications.
device meeting Installation Category II requirements must be used. Weight: 9 oz (255 g).
Protection provided by the equipment may be impaired if the equipment Agency Approvals: CE.
is used with accessories not provided or recommended by the manu-
facturer, or is used in a manner not specified by the manufacturer.
Connections
Power Requirements The power and solenoid connections are located at the lower edge of the board. The
The DCT500ADC Series controller is designed for operation with a DC power supply. terminal block is a “Euro” style connector system that clamps the wire within the con-
The supply voltage must be between 10 VDC and 35 VDC. Exceeding 35 VDC may nector body. The connector will accept wire sizes from 14 to 22 gages. These termi-
damage the unit. The solenoid outputs are driven from the power supply so the sole- nals should be torqued to 5 in. lb. The connectors are specified for single connection
noids must be rated for operation at the power supply voltage. The solenoids are but multiple wires may be connected to a single lug provided local codes allow this
connected as shown in the wiring diagram and must not be connected to any other and good workmanship practices are followed. When using stranded wire, make sure
external circuit. The solenoid common is the positive (+) lead and is internally con- that there are no “stray” strands. These may cause system failure or damage.
nected to the fused positive (+) supply. The individual outputs are switched to the Connect the (+) (-) power to (+) and (-). Connect the solenoids between the selected
negative (-) supply input through an open drain field effect transistor (FET). The out- output and the solenoid common. Solenoid common and (+) are internally connect-
puts are protected for inductive flyback transients of the solenoids. ed through fuse. Refer to Figure 2-1.
The wire should be stripped to no more than 0.25 in. A strip gauge is provided at the
Location lower right corner of the board. Longer than this may cause shorts. Switches con-
The system must be located in an enclosure that meets relevant safety standards and nected to the control inputs at the top of the board must be isolated normally open
electrical codes. There are no other special orientation requirements. Mount it using contacts connected only to the relevant terminal and to the common terminals.
the four mounting holes in the baseplate. The baseplate back is flush, so no special
spacers are needed to accommodate obstructions except for those imposed by the The following subparagraphs describe the external switch connections. Refer to fig-
location itself. ure 2-1 for switch connection illustration.
DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361,U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
E-98ADC:Bulletin E-98 DC5.0 7/8/09 8:44 AM Page 2
Time Off and Time On Setup

SHORT FOR
Time off defines the period of time between solenoid activations when no channels
CONTIUOUS
OPERATION
TIME OFF TIME ON are enabled. This value may be set between 1 second and 180 seconds with a res-
olution of 1 second. Time on defines the solenoid on time. The value may be set
between 50 msec and 500 msec with a resolution of 10 msec. If adjustments are
made while the system is in operation, the new setting will take effect in the follow-
ing solenoid cycle. Do not use excessive force to turn the potentiometers. This will
damage the unit. A factory installed option is available for a time on range of 0.05 to
10 seconds.
0.31 TYP [7.87]

4 PLACES
TB1
(-)
(+)
7.73 8.88
SOLENOIDS
[196.3] [225.6]
POWER
INPUT
FIGURE 2-1 Switch Connections
External Limit Switch Connection

4.00 4.00 TYP
The controller may be used with an external pressure limit switch or sensor to pro- [101.6]
vide demand-cleaning operation. A three pin terminal block provides connection for [101.6]
4.45
external high and low limit switches. A simple on-off system can be established with [113.0]
a single pressure switch connected to the high limit input. Better control can be
achieved with a high and low limit switch/gage such as the Dwyer Photohelic® pres- 5.74
sure gage. The switches must be isolated contacts between the high or low limit input [145.8]
and the common connection. The wiring from the switches must be two or three wires
with no other connections made to these. The common line must not be connected
to equipment ground or protective ground, since these may introduce electrical noise
and cause improper operation or possible damage to the control board. The opera-
tion of these inputs is summarized as follows:
Current Low Limit High Limit Next

Operation Switch Switch Operation
Weatherproof Enclosure Option
Hold Open Open Hold
Hold or Run X Closed Run
Hold Ø Open Hold
Hold Closed Ø Run
Run Closed ≠ Run Explanation of Symbols:
Hold Closed Ø Run Symbol Description
Run ≠ Open Hold
Ø – Transition from open to closed Caution: Risk of electric shock
≠ – Transition closed to open
X – Either open or closed
Operating Modes
Caution: Risk of danger, refer to user’s manual for further
Continuous Cycle Mode
information
The DCT500ADC has two operating modes available for different applications.
Starting with the most basic mode, it is capable of operating in a continuous cleaning
cycle. This can be initiated by placing a jumper between the high limit input and the
common connection. Two setup parameters control operation: time off, time on. Time
Direct current
on and time off specifically deal with the solenoid on time and the time interval
between the end of the on pulse and the start of the next.
Demand Mode
Demand mode operation can be configured using the high limit and low limit inputs.
~ Alternating current
A simple on-off system can be setup with a single pressure switch connected to the
high limit input. Better control can be achieved with a high and low limit switch set
such as is provided in the Dwyer Photohelic® pressure gage. In this on-demand Agency Approvals and Test Standards:
mode, time on and time off may be programmed to define the cleaning cycle. When CE: IEC 61000-4-2: 2001
the cycle is completed, the controller will continue the cycle until the last channel is IEC 61000-4-3: 2006
pulsed. The next cleaning cycle will always start on channel 1. A factory installed IEC 61000-4-4: 2004
option is available that will not clean to the end of a cycle, but rather stop where the IEC 61000-4-5: 2005
cleaning cycle ended. The next demand for cleaning will start where the last clean- IEC 61000-4-6: 2006
ing cycle left off. CENELEC EN 55022: 2007
FCC Part 15 CFR Title 47: 2007
System Setup ICES-003: 2004 Digital Apparatus (Industry Canada)
Last Channel Selection ANSI 63.4-2003
A jumper connector is provided to select the last channel used. Place the jumper on CENELEC EN 61326-1: 2006
the two pins corresponding to the last channel used in the installation. 2004/108/EC EMC Directive
©Copyright 2009 Dwyer Instruments, Inc Printed in U.S.A. 7/09 FR# 05-443180-10 Rev.1

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361,U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
Lit-By Fax: 888/891-4963
SERIES 2000-HA | HIGH ACCURACY MAGNEHELIC® DIFFERENTIAL PRESSURE GAGE
FEATURES/BENEFITS
•  Accurate within 1%
•  Mirrored scale overlay eliminates parallax error
•  Six point calibration certificate included
•  IP67 - Fully protects against dust and immersion
•  Optional corrosion resistant brushed 304 SS bezel
APPLICATIONS
•  Clean room positive pressure indication
•  Filter monitoring
•  Air velocity with Dwyer pitot tube
•  Blower vacuum monitoring
•  Fan pressure indication
•  Duct, room, or building pressures
Note: Shown with optional -SS bezel
DESCRIPTION
The SERIES 2000-HA High Accuracy Magnehelic® Gage is twice as accurate as the standard
Magnehelic® gage. The well-engineered High Accuracy Magnehelic® Gage offers a mirrored
overlay as standard in order to eliminate any parallax error when taking measurements. A six
point calibration certificate is included with each high accuracy model. The rugged IP67 casing
helps fully protect against dust and water ingress. The redesigned corrosion resistant brushed
304 stainless steel bezel option offers a clean tapered design, yet minimizes the possibility of
any dust accumulation on the edges.
6-Point Calibration
Certificate Included
SPECIFICATIONS
Air and non-combustible, compatible gases (natural gas option available). Note: May be used with hydrogen. Order a Buna-N diaphragm.
Service Pressures must be less than 35 psi.
Wetted Materials Consult factory.
Housing Die cast aluminum case and bezel with acrylic cover. Exterior finish is coated gray to withstand 168 hour salt spray corrosion test.
Accuracy ±1% FS (±1.5% on -0, -100PA, -125PA, -10MM and ±2% on -00, -60PA, -6MM ranges) throughout range at 70°F (21.1°C).
Pressure Limits -20 in Hg to 15 psig (-0.677 bar to 1.034 bar).
Overpressure Relief plug opens at approximately 25 psig (1.72 bar), standard gages only. See Overpressure Protection note on catalog page.
Temperature Limits 20 to 140°F (-6.67 to 60°C).
Size 4" (101.6 mm) diameter dial face.
Mounting Orientation Diaphragm in vertical position. Consult factory for other position orientations.
Process Connections 1/8" female NPT duplicate high and low pressure taps – one pair side and one pair back.
Weight 1 lb 2 oz (510 g).
Two 1/8" NPT plugs for duplicate pressure taps, two 1/8" pipe thread to rubber tubing adapters, and three flush mounting adapters with
Standard Accessories screws.
Agency Approvals Meets the technical requirements of EU Directive 2011/65/EU (RoHS II).
DWYER INSTRUMENTS, INC.

T: 219-879-8000 | F: 219-872-9057 | info@dwyermail.com
800-872-9141
dwyer-inst.com DS-2000-HA | 1/17
DIMENSIONS
HOW TO ORDER
Use the bold characters from the chart below to construct a product code
2001 -HA
SERIES/RANGE* OPTIONS*
in w.c./mm w.c. Pa kPa -HA - High accuracy scale
2000-00 - 0-0.25 in w.c. 2000-60NPA - 10-0-50 Pa 2000-1KPA - 0-1 kPa -SS - Brushed 304 stainless steel bezel
2000-00N - 0.5-0-0.2 in w.c. 2000-60PA - 0-60 Pa 2000-1.5KPA - 0-1.5 kPa
2000-0 - 0-0.5 in w.c. 2000-100PA - 0-100 Pa 2000-2KPA - 0-2 kPa
2001 - 0-1 in w.c. 2000-125PA - 0-125 Pa 2000-3KPA - 0-3 kPa
2002 - 0-2 in w.c. 2000-250PA - 0-250 Pa
2003 - 0-3 in w.c. 2000-300PA - 0-300 Pa
2004 - 0-4 in w.c. 2000-500PA - 0-500 Pa
2006 - 0-6 in w.c. 2300-60PA - 30-0-30 Pa
2010 - 0-10 in w.c. 2300-100PA - 50-0-50 Pa
2000-6MM - 0-6 mm w.c. 2300-120PA - 60-0-60 Pa
2000-50MM - 0-50 mm w.c.
2300-12MM - 6-0-6 mm w.c.
*Only our most popular models and options are listed. For additional available models, please visit:
https://www.dwyer-inst.com/Product/Pressure/DifferentialPressure/Gages/Series2000
Important Notice: Dwyer Instruments, Inc. reserves the right to make changes to or discontinue any product or service identified in this publication without notice. Dwyer advises its customers to obtain the latest
version of the relevant information to verify, before placing any orders, that the information being relied upon is current.

800-872-9141
dwyer-inst.com DS-2000-HA | 1/17
Bulletin E-57
Series 1950 Explosion-Proof Differential Pressure Switches

Specifications - Installation and Operating Instructions
Set Point Adjustment
Screw UL and CSA Listed, FM Approved For
CL. I GR. C, D - CL. II GR. E, F, G - CL. III
Series 1950 Switches

Operating ranges and deadbands
To order Operating Approximate
specify Range: Dead Band
Model Number Inches, W.C. At Min. Set Point At Max. Set Point
1/2˝ (12.7) 1950-02-2S 0.03 to 0.10 0.025 0.05
female NPT 1950-00-2F 0.07 to 0.15 0.04 0.05
Electrical 1950-0-2F 0.15 to 0.5 0.10 0.15
Conduit 1950-1-2F 0.4 to 1.6 0.15 0.20
Connection 1950-5-2F 1.4 to 5.5 0.3 0.4
1950-10-2F 3.0 to 11.0 0.4 0.5
1950-20-2F 4.0 to 20.0 0.4 0.6
Operating Approximate Dead Band
Model Number Range: PSI Min. Set Point Max. Set Point
1950P-2-2F 0.5 to 2.0 0.3 psi 0.3 psi
1950P-8-2F 1.5 to 8.0 1.0 psi 1.0 psi
1950P-15-2F 3.0 to 15.0 0.9 psi 0.9 psi
1950P-25-2F 4.0 to 25.0 0.7 psi 0.7 psi
Series 1950 Explosion-Proof Differential Pressure Switches com-
1950P-50-2F 15.0 to 50 1.0 psi 1.5 psi
bine the best features of the Series 1900 Pressure Switch with an inte-
gral explosion-proof and weather-proof housing. Each unit is UL & SPECIFICATIONS
CSA listed; FM approved for use in Class I, Groups C & D; Class II, Service: Air and non-combustible, compatible gases.
Groups E, F, & G; and Class III atmospheres (NEMA 7 & 9). They are Wetted Materials: Consult factory.
totally rain-tight for outdoor installations. Twelve models allow set- Temperature Limits: -40 to 140°F (-40 to 60°C); 0 to 140°F
points from .03 to 20 inches w.c. and from .5 to 50 psi (3.4 to 345 kPa). (-17.8 to 60°C) for 1950P-8, 15, 25, and 50. -30 to 130°F (-34.4 to
54.4°C) for 1950-02.
Easy access to the SPDT switch for electrical hook-up is provided by Pressure Limits:
removing the top plate of the three-part aluminum housing. Adjustment Continuous: 1950’s - 45˝ w.c. (0.11 bar);
to the set point of the switch can be made without disassembling the 1950P’s - 35 psi (2.41 bar); 1950P-50 only - 70 psi (4.83 bar).
housing. The unit is very compact, about half the weight and bulk of Surge: 1950’s - 10 psi (0.69 bar), 1950P’s - 50 psi (3.45 bar), 1950P-50
equivalent conventional explosion-proof switches. only - 90 psi (6.21 bar).
Enclosure Rating: IP54, NEMA 3, 7 and 9.
CAUTION Switch Type: Single-pole double-throw (SPDT).
For use only with air or compatible gases. Use of the Model 1950 Electrical Rating: 15 A @, 125, 250, 480 VAC, 60 Hz. Resistive 1/8
switch with explosive media connected to the Low pressure port HP @ 125 VAC, 1/4 HP @ 250 VAC, 60 Hz.
(including differential pressure applications in such media) is not rec- Electrical Connections: 3 screw type, common, normally open and
ommended. Switch contact arcing can cause an explosion inside the normally closed.
switch housing which, while contained, may render the switch inoper- Process Connections: 1/8˝ female NPT.
ative. If switch is being used to sense a single positive pressure rela- Mounting Orientation: Diaphragm in vertical position. Consult factory
tive to atmosphere, run a line from the low pressure port to a non-haz- for other position orientations.
ardous area free of combustible gases. This may increase response Set Point Adjustment: Screw type on top of housing.
time on -0 and -00 models. Weight: 3.25 Ib (1.5 kg); 1950-02 model, 4.4 lb (2 kg).
Agency Approvals: CE, UL, CSA, FM.
Note: The last number-letter combination in the model number identi-
fies the switch’s electrical rating (number) and diaphragm material (let-
ter). The 2F combination is standard as described in the physical data RESPONSE TIME: Because of restrictive effect of flame arrestors,
above. In case of special models, a number 1 rating is the same as 2; switch response time may be as much as 10-25 seconds where applied
a number 3 or 4 rating is 10A 125, 250, 480 VAC; 1/8 H.P. 125 VAC; 1/4 pressures are near set point.
H.P. 250 VAC; a number 5 or 6 rating is 1A 125 VAC. Letter B indicates
a Buna-N diaphragm; N = Neoprene; S = Silicone; and V = Viton®.

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46361, U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
17/64 [6.75] DIA MTG
HOLES (2) 3-1/2
[88.9]
RANGE ADJUSTMENT
SCREW
1950-02: 7-3/4˝ (196.9) dia. x 4-11/32˝
4-7/8 (110.3) depth. For complete dimensions
[123.8] request drawing 28-700175-00 from our
Customer Service Department
1/2 NPT(F)
ELEC. 5-7/16
CONDUIT [138.1]
CONNECTION
1/8 NPT(F) 3/8

HIGH PRESSURE 1-11/16 [9.53]
1/8 NPT(F) VENT DRAIN
PORT [42.9] PRESSURE 1-7/16
PLUG [36.5]
PORT
1950 Switch Outline Dimensions
INSTALLATION ADJUSTMENT: To Change the Set point

1. Select a location free from excess vibration and corrosive atmos- 1. Remove the plastic cap and turn the slotted Adjust-ment Screw at the
pheres where temperatures will be within the limits noted under top of the housing clockwise to raise the set point pressure and counter-
Specifications on reverse. Switch may be installed outdoors or in areas clockwise to lower the set point. After calibration, replace the plastic cap
where the hazard of explosion exists. See reverse for specific types of and re-check the set point.
hazardous service.
2. The recommended procedure for calibrating or checking calibration is
2. Mount standard switches with the diaphragm in a vertical plane and to use a “T” assembly with three rubber tubing leads, all as short as pos-
with switch lettering and nameplate in an upright position. Some switch- sible and the entire assembly offering minimum flow restriction. Run one
es are position sensitive and may not reset properly unless they are lead to the pressure switch, another to a manometer of known accuracy
mounted with the diaphragm vertical. and appropriate range, and apply pressure through the third tube. Make
final approach to the set point very slowly. Note that manometer and
3. Connect switch to source of pressure, vacuum or differential pressure. pressure switch will have different response times due to different inter-
Metal tubing with 1/4″ O.D. is recommended, but any tubing which will nal volumes, lengths of tubing, fluid drainage, etc. Be certain the switch
not restrict the air flow can be used. Connect to the two 1/8″ female NPT is checked in the position it will assume in use, i.e. with diaphragm in a
pressure ports as noted below: vertical plane and switch lettering and Dwyer nameplate in an upright
position.
A. Differential pressures - connect pipes or tubes from source
of greater pressure to high pressure port marked HIGH 3. For highly critical applications check the set point adjustment and if
PRESS, and from source of lower pressure to low pressure necessary, reset it as noted in step A.
port marked LOW PRESS.
MAINTENANCE
B. Pressure only (above atmospheric pressure) - connect The moving parts of these switches need no maintenance or lubrication.
tube from source of pressure to high pressure port. The low The only adjustment is that of the set point. Care should be taken to keep
pressure port is left open to atmosphere. the switch reasonably clean. Periodically the vent drain plug should be
rotated, then returned to its original position. This will dislodge deposits
C. Vacuum only (below atmospheric pressure) - connect tube which could accumulate in applications where there is excessive con-
from source of vacuum to low pressure port. The high densation within the switch. The Series 1950 Explosion-Proof Differential
pressure port is left open to atmosphere. Pressure Switch is not field serviceable and should be returned if repair
is needed (field repair should not be attempted and may void warranty).
4. To make electrical connections, remove the three hex head screws Be sure to include a brief description of the problem plus any relevant
from the cover and after loosening the fourth captive screw, swing the application notes. Contact customer service to receive a return goods
cover aside. Electrical connections to the standard single pole, double authorization number before shipping.
throw snap switch are provided by means of terminals marked “COM”
(common), “NO” (norm open), “NC” (norm closed). The normally open
contacts close and the normally closed contacts open when pressure
increases beyond the set point. Switch loads for standard models should
not exceed the maximum specified current rating of 15 amps resistive.
Switch capabilities decrease with an increase in ambient temperature,
load inductance, or cycling rate. Whenever an application involves one
or more of these factors, the user may find it desirable to limit the
switched current to 10 amps or less in the interest of prolonging switch
life.
©Copyright 2012 Dwyer Instruments, Inc. Printed in U.S.A. 1/12 FR# 26-440332-00 Rev. 13

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A. Fax: 219/872-9057 e-mail: info@dwyer-inst.com
®
SERIES 1950 | EXPLOSION-PROOF DIFFERENTIAL PRESSURE SWITCH
FEATURES/BENEFITS
• Explosion-proof and weatherproof housing provides device protection for
outdoor use or harsh environment operation
• External set point screw provides easy access without opening or
disassembling enclosure
• Easily accessible electrical connection simplifies the installation
APPLICATIONS
• HVAC applications
• Process applications
• All-weather applications
DESCRIPTION
The SERIES 1950 Explosion-proof Differential Pressure Switch combines the best features
of the popular Dwyer® Series 1900 Pressure Switch with an integral explosion-proof and
weatherproof housing, making it an exceptional value for either application. It is CE, UL
and CSA listed, FM approved for use in Class I, Div 1, Groups C and D, Class II Groups
E, F, and G and Class III hazardous atmospheres NEMA 7 & 9. Rain tight NEMA 3 (IP54),
weatherproof features include a drain plug and O-ring seal in cover. Electrical connections
are easily made by removing front cover. For convenience the set point adjustment screw
is located on the outside of the housing. Twelve models offer set points from .03 to 20 in
w.c. (0.0075 to 5 kPa) and from .5 to 60 psi (0.035 to 3.5 bar). The unit is very light and
compact - about half the weight and bulk of other explosion-proof or weatherproof switches
with separate enclosures.
SPECIFICATIONS
Service Air and non-combustible, compatible gases.
Wetted Materials Consult factory.
-40 to 140°F (-40 to 60°C); 0 to 140°F (-17.8 to 60°C) for 1950P-8, 15, 25, and 50. -30 to 130°F (-34.4 to 54.4°C)
Temperature Limits
for 1950-02.
1950’s - 45 in w.c. (0.11 bar); 1950P’s - 35 psi (2.41 bar); 1950P-50 only - 70 psi (4.83 bar). Surge: 1950’s - 10 psi
Pressure Limits (Continuous)
(0.69 bar), 1950P’s - 50 psi (3.45 bar), 1950P-50 only - 90 psi (6.21 bar).
Enclosure Rating NEMA 3 (IP54), NEMA 7 & 9.
Switch Type Single-pole double-throw (SPDT).
Electrical Rating 15 A @, 125, 250, 480 VAC, 60 Hz. Resistive 1/8 HP @ 125 VAC, 1/4 HP @ 250 VAC, 60 Hz.
Electrical Connections 3 screw type, common, normally open and normally closed.
Process Connections 1/8˝ female NPT.
Mounting Orientation Diaphragm in vertical position. Consult factory for other position orientations.
Set Point Adjustment Screw type on top of housing.
Weight 3.25 Ib (1.5 kg); 1950-02 model, 4.4 lb (2 kg).
Agency Approvals CE, CSA, FM, UL.

800-872-9141
dwyer-inst.com
®
DIMENSIONS WIRING DIAGRAM
1/8 FEMALE NPT 1-15/32 [37.30]

LOW PRESSURE CONNECTION 3/8 [9.53]
EXTERNAL
GROUND CAPTIVE SCREW 27/32 [21.43]
[2] Ø17/64 [6.75] MOUNTING
HOLES EQUALLY SPACED ON 27/32
A 4-7/8 [123.83] B.C. VENT DRAIN [21.43]
PLUG 1/8 FEMALE NPT HIGH
RANGE ADJUSTMENT SCREW PRESSURE CONNECTION
5-7/16 3/8 [9.53]
[138.13] 1-23/32 [43.64] 1/2 FEMALE NPT
3-1/2 [88.90] ELECTRICAL CONNECTION
HOW TO ORDER
Use the bold characters from the chart below to construct a product code.
XYZ -X -X X -X
SWITCH TYPE OPTIONS

1950 - Pressure Switch - Inches w.c. -AT - Aluminum Tag
1950P - Pressure Switch - PSID -PRESET - Preset
-ST - Stainless Steel Tag
RANGE
-02 - 0.03 - 0.10˝ w.c. DIAPHRAGM
-00 - 0.07 - 0.15˝ w.c. MATERIAL
-0 - 0.15 - 0.5˝ w.c. B - Buna-N
-1 - 0.4 - 1.6˝ w.c. F - Flurosilicone*
-5 - 1.5 - 5.5˝ w.c. N - Neoprene
-10 - 3.0 - 11.0˝ w.c. S - Silicone
MICRO SWITCH TYPE V - Fluroelastomer
-20 - 4.0 - 20.0˝ w.c.
-2 - 10G Mica Silver Contact*
-2 - 0.5 - 2.0 psid
-6 - 10G Phenolic Gold Contact
-8 - 1.5 - 8.0 psid
-M - 10C Phenolic Silver Contact
-15 - 3.0 - 15.0 psid
-25 - 4.0 - 25.0 psid
-50 - 15.0 - 50.0 psid
*The 2F is standard
Important Notice: Dwyer Instruments, Inc. reserves the right to make changes to or discontinue any product or service identified in this publication without notice. Dwyer advises its customers to obtain the
latest version of the relevant information to verify, before placing any orders, that the information being relied upon is current.

800-872-9141
dwyer-inst.com DS-1950 | 4/17
Pilot Valve Enclosures
for Hazardous Locations
Clean Air Systems

3-6VFD Combination Flame and Dust Certification
Ignition Proof Enclosures CSA/UL: NEC500 Div 1, NEC505 Zone 1
ATEX/IECEx: II Category 2G, II Category 2D
Goyen pilot valve enclosures for hazardous
locations are available in a combination of flame
proof and dust ignition proof assemblies, where
Restrictions
4, 5 and 6 pilot valves are available. The 3-6VFD This product's hazardous areas certifications are
can be supplied with combined international valid only for product that has not been modified
approvals: Canadian CSA/Underwriters since leaving the factory. Modifications made to
Laboratory UL and European ATEX/ the enclosure such as the fitment of additional
International IECEx. seals, the addition or removal of pilot valves and
coils, changes in markings, or physical
In addition, in Canada and Europe, Goyen offers modifications made to the enclosure itself will
enclosures that meet the requirements of both invalidate the product certifications. Only
flame proof and explosion proof designs activities described in 'Installation' and
simultaneously. This has the advantage of 'Maintenance' may be conducted without
simplifying assembly designs when using the affecting the certification of the product.
Goyen enclosures.
Construction Maintenance
Body: Diecast Aluminium AS313, LM24, 308 Annual maintenance of serviceable parts is
Ferrule: AISI 302 SS recommended. Serviceable items are the pilot
Armature: 430FR SS armature, armature spring, pilot valve body o-
Seals: Nitrile ring. The same model Goyen coil may also
Screws: AISI 302 SS replace damaged coils. All other items are non-
serviceable. Goyen recommend that
Operation appropriately qualified personnel conduct all
Recommended on time: 50 - 150ms maintenance activities. Certification of
On time range: 50 - 500ms maintenance staff and facilities may be required
under some certification schemes. Inappropriate
Recommended time between pulses: 1 minute or
service invalidates the product certifications.
more, if maximum on time is used.
Pilot Performance Product Warning Labels
Flow: 0.27 Kv/0.32 Cv
Maximum Working Pressure: 860 kPa/125 psi 3-6VFD Series
Minimum Working Pressure: 0 kPa/0 psi CSA/UL
Minimum Temperature: -40oC/-40oF CAUTION: open circuit before removing cover
Maximum Temperature: 82oC/-180oF ATTENTION: ouvrir le circuit avant d'enlever
Fluid Media: Air or inert gas le couvercle
WARNING: more than one live circuit.
Solenoid Performance
see diagram.
Voltage Inrush Hold Power AVERTISSEMENT: cet equipement renferme
Current mA Current mA plusieurs circuits sous tension. voir le schema
220/240 50/60 Hz 148/143 105/94 23.1 VA
100/120 50/60 Hz 234/255 180/152 19.8 VA ATEX/IECEx
24 VDC 873 873 20 W
24 VAC 1338 963 13 W Warning do not open whilst energised, do not
110 VDC 212 212 24 W open when explosive atmosphere is present. Use
cables rated at 135ºc when anti-condensation
heater is installed.
2 © Copyright by Tyco International Ltd. Pilot Valves for Haz 1/09

Goyen Controls Co Pty Ltd reserves the right to change product designs and specifications without notice.
Guide to Hazardous Areas Application Where there are no dust monitors in place on the
clean side of the dust collector, a broken bag
Within Dust Collectors
condition may exist for more than 10 hours before
rectification. Therefore the clean side is classed
Example zones around a dust collector
as Zone 1 (NEC505) or Zone 21 (Atex).
The following examples assume that the
particulate being collected is a combustible dust. Goyen supplies intrinsically safe and Atex 3G/D
dust monitors to raise an alarm in the case of a
Note that the responsibility for correctly assessing filter break. In this case the clean air plenum is
the hazardous zones around the dust collection classified as Zone 2 if the system will be rectified
equipment remains with the plant operator. within 10 hours.
In the event of a filter breakage, dust will enter The area surrounding the dust collector housing
the clean side of the dust collector. The migration may be classified as Zone 2. If there is adequate
of dust may be in sufficient concentration to ventilation around the dust collector the Zone 2
present a dust explosion risk. classification may be eliminated. The area around
the dust collection point is usually classified
as Zone 1.
Comparing area classification schemes

North America Europe (ATEX Scheme)
NEC 500 Divisions NEC 505 & CEC Zones Gas Zones Dust Zones Equipment Category* Group**
1 0 0 20 1 II
1 1 21 2 II
2 2 2 22 3 II
* Under the ATEX scheme equipment categories for use in gas environments are denoted by a 'G' suffix, and equipment categories for dust
environments are denoted by a 'D' suffix. Examples: Equipment category 2G is suitable for use in ATEX zone 1 areas. Equipment category
2D is suitable for use in ATEX zone 21 areas.
** Only Group II zones are shown. Group I zones are relevant to mining applications only.
Hazardous zone definitions

Division Zone Hazardous area characteristic
1 0 or 20 Hazardous condition is present continuously, for long periods, or frequently (more than 1000 hours per year)
1 or 21 Hazardous condition is likely to occur in normal operation occasionally (between 10 and 1000 hours per year)
2 2 or 22 Hazardous condition is unlikely to occur in normal operation, or infrequently and for short periods (less than
10 hours per year)
© Copyright 3
© Copyright byby Tyco
Tyco International
International Ltd. Ltd. Pilot Valves for BBD6Haz05/08
1/09
Goyen
Goyen Controls
Controls Co
Co Pty
Pty Ltd
Ltd reserves
reserves the right to
the right to change
change product
product designs
designs and
andspecifications
specificationswithout
withoutnotice.
notice.
3-6VFD Product Certifications
With heater kit fitted Without heater kit fitted
CSA
LR26709 LR26709
Class I, Group D Class II Groups E, F, G
Temp Code T2C Temp Code T4
UL
Listed 823N Listed 823N
3-6VFD Series Combination Class I, Group D Class I, Group D
Nema 7 Nema 9
Flame and Explosion Proof Pilot Class II Groups E, F, G Class II Groups E, F, G
Valve Enclosure Temp Code T3C Temp Code T3C
Diecast aluminium enclosure with explosion IECex
proof (Ex-e) and flame proof (Ex-d) protection Ex d IIB T3 Gb Ex d IIB T6 Gb
suitable for use in hazardous areas, available Ex tb IIIC T192ºC Db IP6X Ex tb IIIC T85ºC Db IP6X
optionally with anti-condensation heater. IECEx SIR 08.0045X IECEx SIR 08.0045X
ATEX
Suitable for II 2 G D II 2 G D
NEC500 Division 1, NEC505 Zone 1 and Ex d IIB T3 Gb Ex d IIB T6 Gb
ATEX/IECEx Zone 20 and 21 (II Cat 2G and 2D Ex tb IIIC T192ºC Db IP6X Ex tb IIIC T85ºC Db IP6X
equipment) hazardous environments, for piloting SIRA 02ATEX1408X SIRA 02ATEX1408X
Goyen diaphragm valves.
Spare parts
K0383 Single armature kit. Includes,
spring, armature, and o-ring.
G604718 DP Seal
How to Order
3-6VFD -
QT2 solenoid order code, drop the ‘K-’

Refer to Q Series Solenoid
Solenoid Type Product Specification
Approval Type C=CSA/UL, A=ATEX/IEC Ex
0=none, 5=24VDC,
Heater Type 6=100/120VAC 7=240VAC
Name Plate 1=Goyen, 0=none
0=NPT/NPT, 1=RP/M, 3=NPT/M, 4= RP/G

Thread Type (Pilot Thread/Enclosure Conduit Thread)
Number of Pilots Fitted 4, 5 or 6

CSA/UL Rated Enclosures
Part No. No. of Valves Thread Sizes Goyen Nameplate Heater Type Coil Voltage
3-6VFD4000C-330 4 1/8-3/4NPT No No 220/240VAC
3-6VFD4000C-331 4 1/8-3/4NPT No No 100/1 20V AC
3-6VFD4000C-336 4 1/8-3/4NPT No No 24VDC
3-6VFD5000C-330 5 1/8-3/4NPT No No 220/240VAC
3-6VFD5000C-331 5 1/8-3/4 NPT No No 100/120VAC
3-6VFD5000C-336 5 1/8-3/4NPT No No 24VDC
3-6VFD6000C-330 6 1/8-3/4NPT No No 220/240VAC
3-6VFD6000C-331 6 1/8-3/4NPT No No 100/1 20V AC
3-6VFD6000C-336 6 1/8-3/4NPT No No 24VDC
3-6VFD4007C-330 4 1/8-3/4NPT No 220/240VAC 220/240VAC
3-6VFD4006C-331 4 1/8-3/4NPT No 100/120VAC 100/1 20V AC
3-6VFD4005C-336 4 1/8-3/4NPT No 24VDC 24VDC
3-6VFD5007C-330 5 1/8-3/4NPT No 220/24QVAC 220/240VAC
3-6VFD5006C-331 5 1/8-3/4 NPT No 100/120VAC 100/120VAC
3-6VFD5005C-336 5 1/8-3/4 NPT No 24VDC 24VDC
3-6VFD6007C-330 6 1/8-3/4NPT No 220/240VAC 220/240VAC
3-6VFD6006C-331 6 1/8-3/4NPT No 100/120VAC 100/1 20V AC
3-6VFD6005C-336 6 1/8-3/4NPT No 24VDC 24VDC
ATEX/IECEx Rated Enclosures

Part No. No. of Valves Thread Sizes Goyen Nameplate Heater Type Coil Voltage
3-6VFD4110A-331 4 1/8RP-M25 Yes No 100/120VAC
3-6VFD4110A-332 4 1/8RP-M25 Yes No 24VAC
3-6VFD4110A-334 4 1/8RP-M25 Yes No 110VDC
3-6VFD6110A-331 6 1/8RP-M25 Yes No 100/1 20V AC
3-6VFD5115A-336 5 1/8RP-M25 Yes 24VDC 24VDC
3-6VFD5117A-330 5 1/8RP-M25 Yes 220/240VAC 220/240VAC
3-6VFD4100A-331 4 1/8RP-M25 No No 100/1 20V AC
3-6VFD4100A-336 4 1/8RP-M25 No No 24VDC
3-6VFD6117A-330 6 1/8RP-M25 Yes 220/240VAC 220/240VAC
3-6VFD6100A-330 6 1/8RP-M25 No No 220/240VAC
3-6VFD4100A-330 4 1/8RP-M25 No No 220/240VAC
3-6VFD5100A-331 5 1/8RP-M25 No No 100/1 20V AC
3-6VFD5100A-336 5 1/8RP-M25 No No 24VDC
3-6VFD5100A-330 5 1/8RP-M25 No No 220/240VAC
3-6VFD6100A-331 6 1/8RP-M25 No No 100/1 20V AC
3-6VFD6100A-336 6 1/8RP-M25 No No 24VDC
3-6VFD6116A-331 6 1/8RP-M25 Yes 100/1 20V AC 100/120VAC
3-6VFD6115A-336 6 1/8RP-M25 Yes 24VDC 24VDC
3-6VFD5017A-330 5 1/8RP-3/4 NPT Yes 220/240VAC 220/240VAC
© Copyright by Tyco International Ltd. Pilot Valves for Haz 1/09 5

3-6VFD
Dimensions and Weights [in mm and (inches)]
Weights
3-6VFD Series
Mass = 2.21 Kg + 0.08 Kg per fitted pilot
(4.87 lbs + 0.18 lbs per fitted pilot)

Installation Anti-Condensation Heater Elements
WARNING: Ensure that power is isolated from the According to model specification numbers, the is
system prior to installing or opening this product. enclosure type may be factory fitted with a heater
Where a heater kit is installed, ensure that the element to assist in the prevention of
heater has been de-energised for a minimum of condensation within the enclosure.
5 minutes prior to opening the enclosure. Ensure
that the enclosure is properly assembled with all Heater ratings
flange screws fully tightened (minimum 10Nm (7.4 Voltage Watts
ft.lbs)) prior to applying power in a hazardous area. 24VDC 48
110/120VAC 100
Mounting 220/240VAC 100
Enclosures should be mounted in a horizontal
Note that heater voltage matches solenoid voltages.
position, where the pilot valves and solenoid
assemblies are in the preferred vertical orientation. Heater Installation
Threads
Pilot valve inlet and exhaust outlets are offered in
both 1/8" BSPP (Rp) and NPT. The enclosure
base has one conduit entry with either M25 or
3/4" NPT thread.
Electrical connections
Refer to diagram below. The included Goyen QT2
solenoids are provided with screw/spade
terminals. These solenoids are neutrally linked at
the factory for customer convenience.
Pneumatic connections
These pilot valves are connected to the dust
collector reverse pulse jet valves using metric
4mm tubing (ID 0.157") or imperial ¼" tubing (ID
0.162") and maximum length of 1.5m (4.9 ft).
(1) Heater retaining clip

(2) Heater element
(3) Wiring terminal block
(4) Thermostat element
Heater terminal block connections
© Copyright by Tyco International Ltd. Pilot Valves for Haz 1/09 7

Australia
Head Office Queensland South Australia
Goyen Controls Co Pty Ltd Telephone: 1800 805 372 Telephone: 1800 805 372
268 Milperra Road Facsimile: 1300 658 799 Facsimile: 1300 658 799
Milperra, NSW 2214
Victoria Western Australia
Telephone: 1800 805 372 Telephone: 1800 805 372 Telephone: 1800 805 372
Facsimile: 1300 658 799 Facsimile: 1300 658 799 Facsimile: 1300 658 799
Asia USA
Goyen Controls Co Pty Ltd Goyen Controls Co Pty Ltd Goyen Valve Corporation
Shanghai Representative Office 73-M Jalan Mega Mendung 1195 Airport Road
1209 Greenland Business Centre Kompleks Bandar OUG Lakewood
1258 Yu Yuan Road 58200 Kuala Lumpur MALAYSIA New Jersey 08701
Shanghai PC200050 USA
CHINA Telephone: 60 37 987 6839
Facsimile: 60 37 987 7839
Telephone: 86 21 5239 8810 Greenspan Office: Singapore Telephone: 1 732 364 7800
Facsimile: 86 21 5239 8812 Tel/Facsimile: 65 6457 4549 Facsimile: 1 732 364 1356
Europe
Goyen Controls Co UK Ltd Tyco Umwelttechnik GmbH Mecair S.r.l.
Unit 3B Beechwood Im Petersfeld 6 Via per Cinisello 97
Chineham Business Park D-65624 Altendiez 20054 Nova Milanese
Basingstoke, Hampshire, RG24 8WA GERMANY Milano,
UNITED KINGDOM ITALY
Telephone: 44 1256 817 800 Telephone: 49 6432 1001/1002 Telephone: 39 362 375 118
Facsimile: 44 1256 843 164 Facsimile: 49 6432 63810 Facsimile: 39 362 375 124
Pilot Valves for Haz Rev7 1/09
www.cleanairsystems.com
FILTER SPECIFICATION SHEET

Date
Job # 370724-20 Req'd
Re: DUST COLLECTOR - BG-2101 Colour: Galv
QTY.
Model: DC4D12 Jet Pulse Cartridge Filter 1
CFM: 4500 CFM 3.1:1 AIR TO CLOTH RATIO
Constructed From: HOT DIP GALVANIZE
Inlet Size: 14"
Outlet Size: 20"
Explosion Relief
Door: 34" x 38" - Hinged Panel Brixon Model #2 latch 1
Filters: 12 3/4" DIA X 36" PN: 8036120209B2 12

SPUN BOND POLYESTER MEDIA
Ventures: ALUMINUM pn: C14064 12

Clamp:
Pulse Valves: ASCO 8353H38 3
GOYAN 3-6VFD4000C-331
Pilot Valves: 24VDC 1
Sequential
Controller: DWYER DCT500A TIMING BOARD 24VDC 1
Magnehelic Gauge: DWYER Model 2015 1
Pressure Switch DWYER Model 1950-5-2F 1
Hopper Level
Switch Monitor Rotary Indicator - Model KAX 1-8401-1
General Notes:
FAN SPECIFICATION SHEET
Customer: GREENFILELD GLOBAL TIVERTON Date: June 2018

Job # 370724-20-1 Date Req'd
Re: DUST COLLECTOR FAN - BL-2101 Colour:
QTY.
Name of Fan: FILTER FAN 1
Constructed AMCA TYPE "C" SPARK RESISTANT
From: CONSTRUCTION
Fan Type: ARR, 4HM - CLOCKWISE UPBLAST

Model: CINCINNATI HDAF-180
Series: CLASS 2P DIRECT DRIVE
CFM: 4500
SP: 11.5"
Motor: 10 HP 3/60/460/3500 TEXP
Motor Guard:
Motor Sheave: Direct Drive
Motor Bushing:
Fan: HD AIRFOIL WHEEL

Fan Shaft:
Fan Sheave:
Fan Bushing:
Fan Inlet: 19 3/4"

Fan Outlet: 11 9/16" X 20 3/8"
Bearings:
Belts:
Coupling:
Fan Silencer: 77 dBA @ 5'
MODEL: 112-016035 RECTANGULAR SILENCER
ELECTRICAL COMPONENTS
ADB Series
ADJUSTABLE DEPTH BEARING
TEMPERATURE SENSORS
®
C US
APPROVED
Class II Div. 1
OPERATION MANUAL
Part No.’s - ADB20V3C & ADB29V3C
www.go4b.com/usa
TABLE OF CONTENTS
CUSTOMER SAFETY RESPONSIBILITIES Page 4 - 5

PRODUCT OVERVIEW Page 6
SPECIFICATIONS Page 6
DIMENSIONS Page 7
STANDARD WIRING DIAGRAM Page 7
INSTALLATION Page 8
TESTING & COMMISSIONING Page 10
PRODUCT WARRANTY Page 11
Dear 4B Customer:
Congratulations on your purchase. 4B appreciates your business and is pleased you
have chosen our products to meet your needs.
Please read in its entirety and understand the literature accompanying the product before
you place the product into service. Please read the safety precautions carefully before
operating the product. With each product you purchase from 4B, there are some basic
but important safety considerations you must follow to be sure your purchase is permitted
to perform its design function and operate properly and safely, giving you many years
of reliable service. Please read and understand the Customer Safety Responsibilities
listed below. Failure to follow this safety directive and the Operation Manuals and other
material furnished or referenced, may result in serious injury or death.
SAFETY NOTICE TO OUR CUSTOMERS
A. In order to maximize efficiency and safety, selecting the right equipment for each
operation is vital. The proper installation of the equipment, and regular maintenance
and inspection is equally important in continuing the proper operation and safety
of the product. The proper installation and maintenance of all our products is the
responsibility of the user unless you have asked 4B to perform these tasks.
B. All installation and wiring must be in accordance with Local and National Electrical
Codes and other standards applicable to your industry. (Please see the article
“Hazard Monitoring Equipment Selection, Installation and Maintenance” at www.
go4b.com.) The installation of the wiring should be undertaken by an experienced
and qualified professional electrician. Failure to correctly wire any product and/or
machinery can result in the product or machine failing to operate as intended, and can
defeat its design function.
C. Periodic inspection by a qualified person will help assure your 4B product is
performing properly. 4B recommends a documented inspection at least annually and
more frequently under high use conditions.
D. Please see the last page of this manual for all warranty information regarding this
product.
CUSTOMER SAFETY RESPONSIBILITIES
1. READ ALL LITERATURE PROVIDED WITH YOUR PRODUCT

Please read all user, instruction and safety manuals to ensure that you understand your
product operation and are able to safely and effectively use this product.
2. YOU BEST UNDERSTAND YOUR NEEDS
Every customer and operation is unique, and only you best know the specific needs
and capabilities of your operation. Please call the 24-hour hotline at 309-698-5611 for
assistance with any questions about the performance of products purchased from 4B.
4B is happy to discuss product performance with you at any time.
PAGE 4
3. SELECT A QUALIFIED AND COMPETENT INSTALLER
Correct installation of the product is important for safety and performance. If you have
not asked 4B to perform the installation of the unit on your behalf, it is critical for the
safety of your operation and those who may perform work on your operation that you
select a qualified and competent electrical installer to undertake the installation. The
product must be installed properly to perform its designed functions. The installer should
be qualified, trained, and competent to perform the installation in accordance with Local
and National Electrical Codes, all relevant OSHA Regulations, as well as any of your
own standards and preventive maintenance requirements, and other product installation
information supplied with the product. You should be prepared to provide the installer
with all necessary installation information to assist in the installation.
4. ESTABLISH AND FOLLOW A REGULAR MAINTENANCE AND INSPECTION

SCHEDULE FOR YOUR 4B PRODUCTS
You should develop a proper maintenance and inspection program to confirm that your
system is in good working order at all times. You will be in the best position to determine
the appropriate frequency for inspection. Many different factors known to the user will
assist you in deciding the frequency of inspection. These factors may include but are not
limited to weather conditions; construction work at the facility; hours of operation; animal
or insect infestation; and the real-world experience of knowing how your employees
perform their jobs. The personnel or person you select to install, operate, maintain,
inspect or perform any work whatsoever, should be trained and qualified to perform these
important functions. Complete and accurate records of the maintenance and inspection
process should be created and retained by you at all times.
5. RETAIN AND REFER TO THE OPERATION MANUAL FOR 4B’S SUGGESTED

MAINTENANCE AND INSPECTION RECOMMENDATIONS
As all operations are different, please understand that your specific operation may require
additional adjustments in the maintenance and inspection process essential to permit
the monitoring device to perform its intended function. Retain the Operation Manual
and other important maintenance and service documents provided by 4B and have
them readily available for people servicing your 4B equipment. Should you have any
questions, please call the free 24-hour hotline number (309-698-5611).
6. SERVICE REQUEST
If you have questions or comments about the operation of your unit or require the unit to
be serviced please contact the 4B location who supplied the product or send your request
via fax (309-698-5615) or call us via our 24-hour hotline number in the USA (309-698-
5611). Please have available product part numbers, serial numbers, and approximate
date of installation. In order to assist you, after the product has been placed into service,
complete the online product registration section which is accessed via our website
www.go4b.com/usa.
PAGE 5
PRODUCT OVERVIEW
The ADB series can be used on any application where bearing temperature monitoring is required. They
have been designed to allow the depth of the probe to be adjustable depending on the application. Probes
are available in 2, 3, 4, 6, 8, 10 and 12 inch lengths (special order lengths available on request).
The sensors screw directly into the bearing housing using the existing grease zerk. The body of the ADB
has a grease zerk, allowing lubrication of the bearing without the need to remove the sensor. The ADB
style sensors are available with a standard NTC thermistor for 4B’s Hotbus and Watchdog systems, or a
PT100 - RTD type for PLC and DCS systems. Both types allow for continuous temperature monitoring.
ADB cable connections are not polarity sensitive, so no special connection requirements are needed.
SPECIFICATIONS
ADB20V3C - NTC Sensors
Resistance at 77° F - 10,000 Ohms
Sensing Voltage - 5 to 24 VDC
Current Draw - 1 mA (Max. Recommended)
Maximum Power - 120 mW at 77° F (25° C)
Body Housing - 304 Stainless Steel
Fixing Thread - 1/8" NPT
Cable - 9 ft. (3 m) - 2 Conductor
Operating Temp. - Minimum: -22° F (-30° C) Maximum: 220° F (105° C)
Approvals - CSA Class II Div 1 Groups E, F and G (USA & Canada)
ADB29V3C - PT100 / RTD Sensors

Resistance at 77° F - 109.73 Ohms
Temp. Coefficient - 3850 PPM/K (385)
Sensing Voltage - 5 to 24 VDC
Current Draw - 1 mA (Max. Recommended)
Maximum Power 1 mW
Body Housing - 304 Stainless Steel
Fixing Thread - 1/8" NPT
Cable - 9 ft. (3 m) - 4 Conductor
Operating Temp. - Minimum: -22° F (-30° C) Maximum: 220° F (105° C)
Approvals - CSA Class II Div 1 Groups E, F and G (USA & Canada)
PAGE 6
DIMENSIONS
1/8 NPT 45° Grease Zerk (1/4 UNF Threads)

Threads
ALL DIMENSIONS
IN INCHES 1/2 NPT Conduit Entry
Probe Cable - 2 or 4 Core

6 Diameter
1-1/1 (Sensor Type Dependent)
3/16 3/8 1-1/2
WARNING
• Rotating machinery can cause serious injury or death
• Always lockout and tagout the machine prior to installation
STANDARD WIRING DIAGRAM

All wiring must be In accordance with local and national electrical codes and should be undertaken by
an experienced and qualified electrician.
Always use dust/liquid tight flexible metal conduit with approved fittings to protect the sensor cables.
Use rigid metal conduit to protect the cables from the sensors to the control unit. 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.
All ADB sensors are non-polarity sensitive, however 4B recommends wiring the sensors as outlined
below. For PT100 - RTD sensors, the resistance compensation wire used will be dependent on the
application. For example some PLC’s may require three wires, others may use all four.
BLACK - Input BLACK - Input

RED - Use for Wire Resistance Compensation
NTC
RTD
ORANGE - Use for Wire Resistance Compensation

BROWN - Power BROWN - Power
NTC WIRING PT100 - RTD WIRING
WARNING
Do not wire the sensor across the voltage source directly. Always ensure that the sensor is wired into
a signal conditioning circuit for the temperature measurement. Please note that if the power applied
across the sensor exceeds the specified maximum rated power or current, then the sensor may be
damaged beyond repair. When properly wired to 4B controllers, the power rating across the sensors
is kept at a safe level.
PAGE 7
INSTALLATION
1. Remove the existing grease zerk from the bearing housing.
2. Loosen the ADB probe nut and remove the sensor probe.
3. Screw the ADB sensor body in to the 1/8” NPT threaded hole in the bearing housing.
4. Re-insert the temperature probe into sensor body, and adjust the probe depth to suit the bearing. For
optimum temperature monitoring, the probe should be as close to the outer race as possible without
touching (Figures A and B).
5. Tighten the ADB probe nut using the recommended wrench (ADBW).
The maximum recommended torque for the probe nut is 18 in lb (2 Nm).
6. It is important to use liquid tight flexible conduit and fittings for the
installation (Figures C and D) to protect the sensor cables.
ADB Probe Wrench
(ADBW)
Grease Zerk
Outer Race
(Green Area)
Frame
Housing
(Red Area)
Figure A -
Pillow Block Bearing Cutaway
Available Probe Lengths -

2, 3, 4, 6, 8, 10 and 12 Inches
(Special Order Lengths Available)
Outer Race
(Green Area)
Figure B -
ADB Sensor Installation
PAGE 8
LIQUID TIGHT FLEXIBLE CONDUIT INSTALLATION -
Conduit systems can channel water directly to sensors from incorrectly sealed fittings and condensation.
Over time, water will adversely affect sensor performance. To prevent this type of damage, it is
important to properly install conduit and low point conduit drains. Use rigid metal conduit to protect the
cables from the sensors to the control unit.
Figure C illustrates the correct installation of liquid tight flexible conduit. Notice that the bearing sensor
is above the conduit drain and the water level.
Figure D shows that water, particularly condensation, can bypass the conduit drain and flow directly into
the sensor.
Liquid Tight
Flexible Conduit
Water Level
Figure C -
Correct Conduit Installation
Conduit Drain
Water Level
X
Figure D -
Incorrect Conduit Installation
PAGE 9
TESTING & COMMISSIONING
1. Check that the unit is correctly installed.
2. 4B’s ADB Sensor Tester can be used as a diagnostic tool to verify the alarm and shutdown
sequences of the control unit are functioning as expected.
3. Contact 4B for any questions regarding installation issues if sensor does not perform as expected.
The ADB Sensor Tester has been designed to test 4B adjustable
depth bearing (ADB) temperature sensors in the field. This hand held
test unit features an integrated heating block specifically designed
to have a 4B ADB sensor directly inserted. With integral controls
and temperature display, the unit heats the sensor to the desired trip
point, and allows quick and easy real life testing of the sensor and
temperature monitoring system.
During planned maintenance or periodic testing, the ADB Sensor
Tester can be used as a diagnostic tool to verify the alarm and
shutdown sequences of the control unit are
functioning as expected. To test, the heater
block should be set above the control units
alarm operating temperature. Remove
the ADB bearing sensor probe from
the housing and insert it into the heater
block. As the heater block reaches the
alarm temperature, the ADB sensor will
relay this data to the control unit, allowing
you to verify that the alarm and shutdown
sequences run as expected. When testing
ADB Bearing Sensor Tester
is complete, reinstall the probe back into the
bearing housing.
WARNING
If the system does not immediately shutdown as expected or alarm as required, then remove the
machine from service until the problem has been diagnosed and corrected.
PAGE 10
PRODUCT WARRANTY
1. EXCLUSIVE WRITTEN LIMITED WARRANTY

ALL PRODUCTS SOLD ARE WARRANTED BY THE COMPANY 4B COMPONENTS
LIMITED AND 4B BRAIME COMPONENTS LIMITED HEREIN AFTER REFERRED TO
AS 4B TO THE ORIGINAL PURCHASER AGAINST DEFECTS IN WORKMANSHIP OR
MATERIALS UNDER NORMAL USE FOR ONE (1) YEAR AFTER DATE OF PURCHASE
FROM 4B. ANY PRODUCT DETERMINED BY 4B AT ITS SOLE DISCRETION TO BE
DEFECTIVE IN MATERIAL OR WORKMANSHIP AND RETURNED TO A 4B BRANCH
OR AUTHORIZED SERVICE LOCATION, AS 4B DESIGNATES, SHIPPING COSTS
PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY, REPAIRED OR REPLACED AT
4B’S OPTION.
2. DISCLAIMER OF IMPLIED WARRANTY

NO WARRANTY OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER
THAN AS SET FORTH IN THE EXCLUSIVE WRITTEN LIMITED WARRANTY
STATEMENT ABOVE IS MADE OR AUTHORIZED BY 4B. 4B SPECIFICALLY
DISCLAIMS ANY LIABILITY FOR PRODUCT DEFECT CLAIMS THAT ARE DUE TO
PRODUCT MISUSE, ABUSE OR MISAPPLICATIONS, AS AUTHORIZED BY LAW,
4B SPECIFICALLY DISCLAIMS ALL WARRANTIES THAT THE PRODUCT IS FIT OR
MERCHANTABLE FOR A PARTICULAR PURPOSE.
3. NO WARRANTY “BY SAMPLE OR EXAMPLE”

ALTHOUGH 4B HAS USED REASONABLE EFFORTS TO ACCURATELY ILLUSTRATE
AND DESCRIBE THE PRODUCTS IN ITS CATALOGS, LITERATURE, AND WEBSITES,
SUCH ILLUSTRATIONS AND DESCRIPTIONS ARE FOR THE SOLE PURPOSE OF
PRODUCT IDENTIFICATION AND DO NOT EXPRESS OR IMPLY A WARRANTY
AFFIRMATION OF FACT, OF ANY KIND OR A WARRANTY OR AFFIRMATION
OF FACT THAT THE PRODUCTS WILL CONFORM TO THEIR RESPECTIVE
ILLUSTRATIONS OR DESCRIPTIONS. 4B EXPRESSLY DISCLAIMS ANY WARRANTY
OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER THAN AS
SET FORTH IN THE EXCLUSIVE WRITTEN LIMITED WARRANTY STATEMENT
ABOVE, INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
4. LIMITATION OF DAMAGES
ANY LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, SPECIAL, EXEMPLARY, OR
PUNITIVE DAMAGES, OR FOR LOSS OF PROFIT WHETHER DIRECT OR INDIRECT,
IS EXPRESSLY DISCLAIMED.
PAGE 11
With subsidiaries in North America, Europe,
Asia, Africa and Australia along with a worldwide
network of distributors, 4B can provide practical
solutions for all your applications no matter the
location.
4B BRAIME 4B DEUTSCHLAND 4B ASIA PACIFIC

COMPONENTS 9 Route de Corbie Build No. 899/1 Moo 20
Hunslet Road Lamotte Warfusée Soi Chongsiri, Bangplee-Tam Ru Road,
Leeds F-80800 Tanbon Bangpleeyai, Amphur Bangplee,
LS10 1JZ France Samutprakarn 10540
United Kingdom Tel: +49 (0) 700 2242 4091 Thailand
Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338
4B COMPONENTS LTD. 4B FRANCE 4B AFRICA 4B AUSTRALIA

625 Erie Avenue 9 Route de Corbie 14 Newport Business Park Unit 1/18 Overlord Place
Morton, IL 61550 80800 Lamotte Warfusée Mica Drive, Kya Sand Acacia Ridge
USA France 2163 Johannesburg Queensland 4110
Tel: 309-698-5611 Tel: +33 (0) 3 22 42 32 26 South Africa Australia
Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3711 2565
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3711 2574
www.go4b.com
Copyright © 2017 4B Group - All Rights Reserved REV061517
Product Datasheet
4B
Components
Bearing Temperature Sensors
Limited
ADB Series
Adjustable Depth Bearing Temperature Sensors
APPLICATION
For use on any application where bearing temperature monitoring is
desired or required.
METHOD OF OPERATION
The ADB series have been designed to allow the depth of the sensor to
be adjustable depending on your application.
The sensors screw directly into a bearing housing through the existing
grease zerk thread. Each sensor is fitted with a grease zerk to allow
lubrication of the bearing without the need for removal of the sensor.
The ADB style sensors are available with a standard NTC thermistor
for 4B’s Hotbus and Watchdog systems, or a 4-wire PT100 - RTD type
for PLC and DCS systems. Both types allow for continuous
temperature monitoring.
The sensors are supplied with a nine foot cable. The connections are
not polarity sensitive therefore special connection requirements are
eliminated, and the cable can be extended in the field.
FEATURES ATEX Approved

► Adjustable Sensor Depth Versions Available
► Screw in Positive Mount Installation

► Grease Zerk for Bearing Lubrication
► 1/2” NPT Conduit Entry
► 304 Stainless Steel Body
► NTC or PT100 - RTD Types
► CSA Class II Div 1 Approved
PART NUMBERS/ACCESSORIES
► ADB20V3C/D2 NTC Type: 2 Inch Probe
► ADB20V3C NTC Type: 4 Inch Probe
ADB Probe Wrench
ADB Sensor Tester
► ADB29V3C/D2 PT100 - RTD Type: 2 Inch Probe
During planned maintenance or
periodic testing, the ADB sensor
► ADB29V3C PT100 - RTD Type: 4 Inch Probe tester can be used as a diagnostic
► ADB29V3C/D6 PT100 - RTD Type: 6 Inch Probe tool to verify the alarm and
shutdown sequences of the control
► ADB29V3C/D8 PT100 - RTD Type: 8 Inch Probe unit are functioning as expected.
► ADBT4 ADB Sensor Tester
► ADBW ADB Probe Wrench
Copyright © 2017 4B Components Ltd. All rights reserved. Information is subject to change or modification without notice. Refer to instruction manual for installation information. RD061617
4B COMPONENTS LIMITED -
625 Erie Avenue, Morton, IL 61550 USA Tel: 309-698-5611 Fax: 309-698-5615 www.go4b.com/usa
Product Datasheet
4B
Components
Bearing Temperature Sensors
Limited
Available Probe Lengths -

2, 3, 4, 6, 8, 10 and 12 Inches
(Special Order Lengths Available)
Outer Race
(Green Area)
Bearing Sensor on Belt Conveyor
ADB Installation on Pillow Block Bearing
TECHNICAL SPECIFICATIONS
ADB Series - Bearing Temperature Sensors Example of Bearing Failure
NTC Type PT100 - RTD Type

Resistance at 77°F: 10,000 Ohms Resistance at 77°F: 109.73 Ohms
Sensing Voltage: 5 to 24 VDC Coefficient 3850 PPM/K (385)
Current Draw: 1 mA Sensing Voltage: 5 to 24 VDC
Fixing Thread: 1/8" NPT Current Draw: 1 mA
Minimum Temp: -22° F (-30° C) Fixing Thread: 1/8" NPT
Maximum Temp: 220° F (105° C) Minimum Temp: -22° F (-30° C)
CSA Class II Div 1 Groups E, F and Maximum Temp: 220° F (105° C)
Approvals:
G (USA & Canada) CSA Class II Div 1 Groups E, F and
Approvals:
G (USA & Canada)
Temperature Sensors can be used with an existing PLC/DCS or with the following 4B Hazard Monitoring Systems
T500 Hotbus Elite Watchdog Super Elite T400N Elite

214A
BUL L ET I N
INSTALLATION & OPERATION

Rotary Paddle Bin Monitors
Models KA and KAX
Model KA/KAX
Thank you for purchasing a quality product manufactured by Monitor

Technologies LLC. We realize that you do have a choice of vendors
when procuring rotary paddle bin level monitors and we sincerely appre-
ciate your business!
This manual contains the information necessary to ensure a safe and
successful installation. Please read and comply with the section on page
8 of this manual pertaining to SAFETY. Doing so will ensure proper oper-
ation of the equipment and the safety of all personnel.
Before discarding shipping container, please inspect it thoroughly and
verify that all parts ordered are accounted for. Sometimes smaller parts
become stuck under carton flaps and other packaging materials.
In the event that information contained herein does not completely sat-
isfy your requirements or answer your questions, you may contact
Technical Support on our website www.monitortech.com, by e-mail at
techsupport@monitortech.com or by telephone at 800-766-6486
(1-630-365-9403). If your KA/KAX ever requires service either in or out
of warranty, please contact us and obtain an RMA number prior to ship-
ping the unit to us.
www.monitortech.com
DIMENSIONS ARE SHOWN IN INCHES WITH MILLIMETER EQUIVALENT IN BRACKETS
PRE-INSTALL ATION CONSIDERATIONS
Choosing a Location: (See Figure 1)
1) Material Flow - When selecting a location for any rotary pad-
dle bin monitor, choose a point in the vessel where the paddle
will be out of the direct flow of incoming and outgoing materi-
al to prevent any mechanical damage that may be caused by
the pressure of the flow. This is particularly important for
materials with large, lumpy characteristics. The paddle unit
must be positioned at a point where incoming material will
reach and cover the paddle in its normal flow, and when
receding, will flow away from the paddle in an even manner.
2) Vibration Concerns - Mount at a location that is subject to
limited vibration, away from bin vibrators thereby attaining
maximum operational life. Consult the factory when ques-
tionable conditions exist.
3) Guard Reinforcement - When using rigid extensions and
guards in top mounted applications, select a location where it
is feasible to reinforce the guard to the vessel wall. See
Mechanical Installation for further details.
Figure 2
Rotary Paddle Bin Monitor Preparation: (See Figure 3)

1) Mounting Plate Attachment (if applicable)- After using the
mounting plate gasket as a mounting hole template, (see
Mechanical Installation portion of this bulletin), attach the
mounting plate to the rotary paddle bin monitor prior to
attaching to vessel. This is particularly advantageous if the
paddle to be used is not an "insertable" type. Grease the
paddle unit's threaded hub with anti-seize compound and
thread the mounting plate into place until snug.
2) Flexible Coupling Attachment (if applicable)- Remove lock
pin from rotary paddle bin monitor. Screw the flex coupling
into the coupling provided on the paddle unit. Align "through
hole" within the connection and secure with lock pin.
3) Extension Attachment (if applicable)- Remove lock pin from
rotary paddle bin monitor or flex coupling. Screw the exten-
Figure 1 sion into the coupling provided on the paddle unit, or flex cou-
pling. Align "through hole" within the connection and secure
Protective Baffles: (See Figure 2)
with lock pin. Guards should be used with rigid extensions
The installation of protective baffles for low level monitoring is
greater than 18 inches (457 mm) in length.
recommended for materials that weigh more than 65
4) Guard Attachment (if applicable)- In applications using a
lbs/ft3(1050kg/m3), have a tendency to pack, bridge, arch, or have
mounting plate with a full coupling, slide the 1-1/4" pipe over
unusual flow characteristics. This baffle can be created using a
the shaft extension and secure to mounting plate coupling.
number of materials including angle iron, welded plates and pipe
The shaft extension should protrude from guard a distance of
sections. This structure will keep the full weight of the material
approximately 4 inches (102 mm). When not using a mount-
from damaging the bin monitor. The baffle should be welded to
ing plate, the guard must be connected to paddle unit with a
the bin wall and should not extend more than 6 inches (152 mm)
1-1/4" full coupling and in some cases may require attach-
into the bin. Also, the lowest point of the baffle should be approx-
ment after rotary paddle bin monitor installation to vessel.
imately 6 inches (152 mm) above the top of the paddle arc.
5) Paddle Attachment (if applicable)- Paddle should be
attached at this time only if variety chosen is an "insertable"
type or if mounting plate is being utilized. Remove lock pin
from applicable connection point (i.e. bin monitor, flex cou-
pling, or extension). Screw the paddle into the applicable cou-
pling. Align "through hole" within the connection and secure
with lock pin.
2
MECHANIC AL INSTALL ATION
Side Mount / Top Mount:
1) Coupling Mounting - Cut a hole into the vessel that corre-
sponds to the outer diameter of the applicable pipe coupling.
In side mount applications, position a half-coupling flush with
the inside of the vessel and weld into place. In top mount
applications, position a full coupling halfway into the vessel
and weld into place. After greasing the mounting threads with
anti-seize compound, thread the KA/KAX into the coupling
and position the conduit entrance to prevent moisture infil-
tration. Attach paddle if applicable. (See Figure 2)
2) Plate Mounting - Using the gasket provided with the mount-
ing plate as a template, drill six holes at the diameter applicable
to the attachment method being used. Drill six clearance holes at
11/32 inch (9 mm) diameter for use with 5/16" bolts. The bolts
may be secured by tack welding the bolt heads to the vessel, or
by an adjoining nut. Cut a hole (suggested size 2-5 inches (50-
125 mm)) centered within the bolt circle to allow an attached
paddle to fit within the bin. Attach gasket and mounting plate to
the vessel positioning the conduit entrance to eliminate the
possibility of any and all moisture infiltration. (See Figure 4)
Figure 4
Extension/Guard Installation: (See Figure 5)

1) Typical Configuration - Rigid extensions are recommended
for top mount applications only and should be always accom-
panied by a flexible coupling. Shaft guards are recommend-
ed whenever extensions are longer than 18 inches (457 mm).
2) Guard Reinforcement - Mechanical reinforcement of the
shaft guard should be considered whenever a guard length
greater than 72 inches (1829 mm) is used. The guard should
be anchored to the sidewall with braces to reduce mechanical
stress at the connection point of the guard.
3) Guard/Extension Multi-Stage Assemblies - It may be nec-
essary to connect multiple short pieces to ultimately achieve
the desired length. In all cases, extensions and guards
should not exceed 144 inches (3658 mm). Shaft extensions
can be simply connected one to another. Guards must use a
1-1/4" full coupling as an interface between sections.
Couplings are available from Monitor.
4) Cable Extensions - Lengths up to 78 inches (1981 mm) are
permitted. Length can be shortened in the field as required.
See instructions provided with cable extension for details.
Figure 3
3
ELECTRIC AL INSTALL ATION
1) Hazardous Location Precautions - (See Safety and
Specifications sections of this manual before starting electri-
cal installation.) Observe all government regulations regard-
ing equipment in hazardous locations. In particular, for CSA
approved explosion-proof products, install a conduit seal fit-
ting within 2 inches (50 mm) of the rotary paddle bin monitor.
On all models ensure power is disconnected whenever the
cover is removed and upon completion ensure cover is com-
pletely re-attached.
2) Factory Wiring - The industry exclusive motor shutoff feature
is prewired at the factory and must not be altered in the field.
The jumper wire (s) from the main terminal block to the motor
switch must not be removed.
3) Permanently Connected Equipment - Disconnecting
devices shall be included in the system installation. In instal-
lations were multiple circuits are used, individual disconnects
Figure 5 are required. The disconnects shall be within close proximity
of the equipment, accessible to operators, and marked
High-Temp Models: appropriately as the disconnect for the associated circuit.
1) Mounting - Carefully handle the hi-temp. gasket provided Assure the disconnect ratings are appropriately sized for the
with the assembly. Using it as a template, mark the locations circuit protected (See Specifications).
of the six boltholes on the vessel. Drill six holes at the diam- 4) Circuit Separation - Since the KA/KAX's single wiring com-
eter applicable to the attachment method being used (i.e. partment can not absolutely protect against physical contact
tapped holes or clearance holes for bolt/nut combination). between multiple circuits, it is required that all wiring used
For example, drill six clearance holes at 11/32 inch (9 mm) must have an insulation rating of 300v minimum, and a tem-
diameter for use with 5/16" bolts. The bolts may be secured perature rating of 221˚F (105˚C) minimum.
by tack welding the bolt heads to the vessel, or by an adjoin-
ing nut. Cut a hole (suggested size 2-5 inches(50-125 mm)) 5) Protective Earthing - Each KA/KAX is provided with a
centered within the bolt circle to allow the paddle when "protective conductor terminal" which shall be terminated
attached to the bin monitor to fit within the bin. Attach gasket to the local earth ground potential to eliminate shock hazard.
and hi-temp. paddle unit to the vessel positioning the conduit Select wire size that can carry in excess of the sum of all cir-
entrance in a manner, which restricts moisture infiltration. cuit's maximum amperage.
2) Extensions/Guards - Use of extensions are permissible on 6) Power Input - Verify the intended voltage supply is compati-
Hi-Temp units also. (See Extension/Guard Installation sec- ble with the voltage configuration indicated on the external
tion). Installing guards on Hi-Temp models requires in-field nameplate. Connect power as shown in Figures 6-7.
modifications. Consult factory for guidance. 7) Output Contacts - (See Figures 6-7) Use Isolated Switch
3) Effective Cooling - The Hi-Temp. model includes a steel lag- for optimum performance. When the paddle is free
ging pipe, which thermally insulates (via lag pipe material and to turn, the two switches in the KA/KAX are in their normal
physical separation) the internal bin temperature from the condition (i.e. N.C. contacts are closed to COM, and N.O.
paddle unit thereby protecting its critical components. This contacts are open to COM). However, when material sur-
technique is very effective but is dependent on careful con- rounds the paddle preventing it from turning, the motor rotates
sideration of ambient air temperature surrounding paddle unit, on a switch actuating plate which activates the switches into
thermal conductivity of the material being sensed, and the opposite from normal condition (i.e. N.C. contacts are open to
actual temperature present at the mounting point. The follow- COM, and N.O. contacts are closed to COM). When select-
ing chart is intended to provide general guidance for installa- ing which switch to wire, the following should be considered:
tion. Each application should be evaluated to ensure that the Motor Switch:
KA/KAX operating temperature is not exceeded. In addition, a) The load must be capable of operating at the same
an air connection is provided on the lagged pipe to further voltage as the unit’s motor.
increase the cooling capacity of the system. When applicable, b) The load must be tolerant of periodic on and off
connect airline to 1/2" coupling provided on Hi-Temp. model switching which is caused by minor paddle motion
using only the recommended air pressure, which must exceed during sensing condition.
the bin pressure to be effective. The air should be clean and c) The load must not exceed the rated current capacity
dry and is required to be continually supplied to the Hi-Temp. of the switch (See Specifications).
model to assure cooling. Isolated Switch: (Use this switch for optimum performance)
a) Any voltage within limits of the switch
Internal Temp. Model Air Required CFM
(See Specifications) can be connected independent
< 300˚F (150˚C) standard none N/A
of the motor voltage.
300-500˚F (150-260˚C) Hi-Temp. none N/A
[without air-cooling] b) This switch permits minor amounts of paddle motion
500-750˚F (260-400˚C) Hi-Temp. 0.5 psig 2.14 without constant “on and off” signalling.
[with air-cooling] c) The load must not exceed the rated current capacity
4 of the switch (See Specifications).
SETUP
Paddle Selection
The best “calibration” can be achieved by proper paddle selec-
tion. Incorrect paddle selection may lead to false sensing and
therefore a poor “calibration”. Monitor offers a variety of inter-
changeable paddle assemblies to meet the needs of a wide vari-
ety of applications. Different material densities, particle sizes
and flow characteristics require specific paddles to provide opti-
mum performance. Ensure that the paddle being used for the
application corresponds with the recommendations found in
Monitor’s Material Characteristics Guide (Bulletin #115A).
Sensitivity Spring
1) Setting Upon Receipt - (See Figure 8) All rotary paddle bin
monitors are shipped from the factory with the spring tension
preset at the mid-range sensitivity setting. In most applica-
tions this setting results in acceptable operation assuming
proper paddle selection. Setting can be verified by locating
the cotter pin holding the spring to the switch bracket frame.
The cotter pin will be inserted into the middle hole.
2) Increased Sensitivity - When sensing extremely light mate-
rials (less than 10 lbs/ft3, 160kg/m3), it is desirable to move
the cotter pin to the hole which exerts minimum spring ten-
sion. The reduced spring tension will permit switch actuation
with less material restriction at the paddle.
3) Decreased Sensitivity - When sensing extremely heavy
materials (greater than 75 lbs/ft3, 1200kg/m3) or materials
Figure 6 which have a tendency to stick or build up around shaft seal,
it is desirable to move the cotter pin to the hole which exerts
maximum spring tension. The increased spring tension will
require greater material restriction at the paddle but will pre-
vent cases of the sensor remaining in the activated condition
when material is absent.
Figure 8
Figure 7
5
Motor Replacement: (See Figure 9)
TROUBLESHOOTING 1) Disconnect power source from rotary paddle bin monitor.
PROBLEM: The paddle does not rotate when material 2) Disconnect motor leads from incoming terminal block
is absent and the sensor is in "no (all models) and from motor switch (AC models only).
sensing" mode. 3) Remove the four screws holding the switch bracket assembly
CAUSE/SOLUTION: to the housing. Drape switch bracket over the side of the
1) Verify electrical power is connected to the proper ter- housing so the motor is completely accessible. Do not over
minations (See wiring diagrams) and that it is the extend the spring.
proper voltage as depicted on the cover. 4) Remove the two screws holding the motor to the actuator
2) Verify jumper wire is in place between the power ter- plate thereby freeing motor.
minal and the motor switch (See wiring diagrams). 5) Install new motor and retain with two screws.
3) Verify motor operation by connecting the two motor 6) Install the switch bracket and fasten with four screws.
leads directly to the incoming power. Motor will 7) Fasten motors leads to terminal block (all models) and motor
rotate if operational. Reconnect motor leads. switch (AC models only). Lead orientation does not matter.
4) Verify condition of motor switch by measuring volt- 8) Reconnect the power source to the rotary paddle bin monitor.
age between its COM and NC terminals. Replace
the switch if a voltage reading equivalent to the
power source exists.
5) Verify if motor is rotating. Replace the clutch mech-
anism if the motor is turning but the paddle is not.
PROBLEM: The paddle does not rotate when material

is absent and the sensor is in "sense"
mode.
CAUSE/SOLUTION:
1) Verify condition of sensitivity spring. It should not be
cut, broken or excessively stretched to the point that
it loses its ability to retract motor to "no sense" con-
dition. Replace if necessary.
2) Verify status of material around shaft and hub of
rotary paddle bin monitor. Excessive buildup may
restrict shaft from returning to "no sense" condtion.
Clean material buildup.
3) Verify if drive shaft is free to rotate by manually twist-
ing paddle. If rotation is restricted, replace the outer
seal and the two internal bearings.
Figure 9
PROBLEM: The paddle rotates but material is not
sensed when the paddle is covered. Switch Replacement or Addition: (See Figure 9)
CAUSE/SOLUTION: 1) Disconnect power source from the rotary paddle bin monitor.
1) Verify isolated switch is activated prior to the motor 2) Remove the four screws holding the switch bracket assembly
switch when the paddle is halted. If sequence is to the housing. Raise the bracket out of housing far enough
incorrect, realign switches on the bracket. Consult to access the switches. DO NOT over extend the spring.
the factory if problem persists. 3) Disassemble the switch from the switch bracket by removing
2) Verify switch operation by measuring continuity while the screws and nuts. Replace switch and reassemble using
in the “sense” and “no sense” modes. Replace the same insulation barriers and hardware.
switches if contact states are incorrect. 4) (Applicable to DPDT switches only) On the switch actuator
3) Verify that the paddle being used in the application plate, the ramp that causes the switch lever to be activated
follows the guidelines outlined in the Paddle must be bent downward on a 90 degree angle in order to pro-
Selection Guide (Bulletin #115A). Change paddle vide proper operation. If necessary, remove the motor and
to one capable of sensing lighter material. the switch actuator plate and bend the ramp with a pair of pli-
ers. The motor switch should not be changed to a DPDT type.
MAINTENANCE 5) Install the switch bracket and fasten with four screws. Twist
Cleaning Requirements the external drive shaft and verify both switches are actuating.
The hazardous and environmental protection techniques are The isolated switch should always activate before the motor
functional only when the cover is completely installed on to the switch.
housing. If necessary, clean the cover/housing threads to per- 6) Reconnect the power source to the rotary paddle bin monitor.
mit complete thread engagement. Do not alter the threads and
ensure O-ring is in place and free of contaminants.
This is a good opportunity to inspect the O-ring, clean and re-
lubricate with Silicone O-ring lubricant. Do NOT lubricate with a
petroleum-based grease or jelly.
6
MECHANICALS
Standard unit
Paddles
Mounting Plate
High temperature unit
Flexible coupling Extensions and guards

7
214A
B U L L E T I N
S P E C I F I C AT I O N S
Power Requirements: 115 VAC (+/- 10%), 50/60 Hz;
230 VAC (+/- 10%), 50/60 Hz;
24 VAC (+/- 10%), 48 VAC (+/- 10%), 50/60 Hz;
SAFET Y 12/24 VDC (10.2 ~ 27.6 VDC)
Power Consumption: 4W max.
Ambient Operating Temp: -40°F (-40°C) to +200°F (+93°C) ext. amb.
General Safety
}
Internal Bin Temp:
CAUTION: It is essential that all instructions in this manual be followed
Standard Unit: to +300°F (+150°C) See Table on
to ensure proper operation of the equipment and safety of operating
Hi-Temp Unit : to +750°F (+400°C) Page 4.
personnel. Use of equipment in a manner not specified by the manu-
facturer, may impair protection provided by equipment. The use of this
Conduit Connection: Two (2) 3/4" NPT; M20 cable glands (Model KA
symbol is used throughout manual to highlight important safety issues. units with 1-1/2” BSPT process connection only;
Not on KAX units)
Electrical Shock Caution: Outputs Contacts:
Certain KA/KAX bin monitors are powered with HIGH VOLTAGE. No 2-Circuit Configuration - Two SPDT 15A @ 250 VAC ea. max
operator serviceable parts are inside. All servicing is to be performed 3-Circuit Configuration - One SPDT 15A @ 250 VAC max
by qualified personnel. Each KA/KAX is provided with a "protective One DPDT 10A @ 250 VAC max
conductor terminal" which shall be terminated to earth ground poten- Maximum Pressure: 30 PSI (2 bar) maximum
tial (see Electrical Installation). This product's design complies with Sensitivity: 5 lb./ft3 (80 kg/m3) minimum material density
EN61010-1 installation category II and pollution degree 2. (when using large 3-vane paddle)
Housing: Die cast aluminum, NEMA 4X /
Hazardous Location Caution ENCLOSURE TYPE 4X, IP66
Certain KA/KAX bin monitors can be used in Hazardous Locations (See Housing Finish: Powder coating
Specifications). These models shall only be used in applications cov- Mounting Connection: 1-1/4" NPT or R 1-1/2 (BSPT 1-1/2)
ered by stated ratings or those considered non-hazardous. Failure to Weight: Approx. 5-1/2 lb. (2.5 kg) with paddle
comply could result in damage to personnel and property. The following
must be maintained to assure safe operation: Materials of construction/accessories:
1) Enclosure integrity - The KA/KAX is manufactured from alu- Flexible Coupling: 304 stainless steel
minum and stainless steel with nitrile rubber seals. The user or Mounting Plates: Powder coated carbon steel or plain 304 stainless steel
installer should consider the performance of these materials All Paddles except Ex-Flex: 304 stainless steel
with regard to attack by aggressive substances that may be Ex-Flex Belt: 304 stainless steel coupling, rubber/fabric blend belt
present in a hazardous location. The dimensions of the hou- Flexible Cable Extension: 304 stainless steel
sing, cover or drive-shaft shall not be altered. Solid Shaft Extension/Guards: Galvanized or 304 stainless steel
2) Maintenance - Power to all circuits must be disconnected Shaft Seal: Nitrile
before conducting any investigation, setup or maintenance.
Listings/Approvals:
Electromagnetic Compatibility (EMC) KA: UL and CSA: Ordinary Locations
The KA/KAX was tested and found to comply with the standards listed KAX: UL and CSA: Class I , Div. 1 & 2, Groups C, D;
below. The KA/KAX should not be used in the residential or commercial Class II , Div. 1 & 2, Groups E, F, G
environments. Compliance to the EMC standards was demonstrated ATEX: II 1/2 D c T 100˚C
by means of a test setup using the following installation methods. ExtD A20/A21 T 100˚C
1) KA/KAX enclosure was connected to protective earth ground. (Ta -40˚C to +93˚C)
2) No specific wiring convention was used to supply power or to IP6x
retrieve output signal from the KA/KAX. IEC Ex: DIP A21 IP6X TA 100˚C
-40˚C to +93˚C
EMC Emissions: All Models: CE Mark
Meets EN 61326-1 Electrical Equipment for Control Use, EMC
EN 55011 Radiated and conducted emissions
(Class A- industrial) CHINA RoHS 2
EN 61000-3 Fluctuations/Flicker
Meets FCC Part 15B: RF Devices, Unintentional Radiators

CISPR 11 Radiated and conducted emissions WA R R A N T Y
(Class A- industrial)
Monitor Technologies LLC warrants each rotary paddle bin indicator it
manufactures to be free from defects in material and workmanship under
EMC Immunity:
normal use and service within two (2) years from the date of purchase.
Meets EN 61326-1 Electrical Equipment for Control Use, EMC The purchaser must give notice of any defect to Monitor within the war-
IEC 1000-4-2 Electrostatic discharge (industrial) ranty period, return the product intact and prepay transportation charges.
IEC 1000-4-3 RF radiated EM fields (industrial) The obligation of Monitor Technologies LLC under this warranty is limited
IEC 1000-4-4 Electrical fast transients (industrial) to repair or replacement at its factory. This warranty shall not apply to
IEC 1000-4-5 Electrical surges (industrial) any product which is repaired or altered outside of the Monitor
IEC 1000-4-6 RF conducted EM energy (industrial) Technologies LLC factory, or which has been subject to misuse, negli-
IEC 1000-4-8 Power frequency magnetic fields (industrial) gence, accident, incorrect wiring by others or improper installation.
IEC 1000-4-11 Source voltage deviation Monitor Technologies LLC reserves the right to change the design and/or
specifications without prior notice.
Monitor Technologies LLC

44W320 Keslinger Rd. t Elburn, IL 60119 t 800-766-6486 (630-365-9403) t Fax: 630-365-5646 t E-mail: monitor@monitortech.com t www.monitortech.com
JCS JSC MAR 16 2018 DOC-001-214A 26

Pra ctica l so l ution s... at eeve
ve ry leve l!
Model KA & KAX

Rotary Paddle Bin Monitors
t FEATURES & ADVANTAGES
t Provides reliable indication of high, low or intermediate levels
of material in bins, silos and other storage vessels depending on mounting location.
t Output circuit options allow the sensor to be used to turn “on” or “off” other processes (Paddle ordered
based on the detected presence or non-presence of material. separately)
t Basic, easy to understand electro-mechanical design that is economical,

versatile and time tested.
t DC voltage model uses a brushless AC motor with a voltage converter
circuit to provide long motor life. See Bulletin #226A for more information.
t
Practical Tip
Motor shut-off feature maximizes sensor life.
t Ordinary location and Hazardous location models are available.
t
Rugged, aluminum enclosure is superior in
Rugged powder coated cast aluminum housing with
twist on/off cover provides easy and ample wiring access. applications where a fragile plastic enclosure is
vulnerable to harsh installation conditions.
t Wide array of paddles and other accessory options that allow
the sensor to be adapted to fulfill specific application requirements.
t PRINCIPLE OF OPERATION
The KA and KAX rotary paddle bin monitor is fundamentally a torque detector which provides an output switched condition when the
resistance of the material surrounding the paddle is greater than the drive mechanism used to rotate the paddle.
The rotary paddle bin monitor is installed to a vessel wall with a paddle protruding into vessel. A low-power, low-speed synchronous
motor drives a paddle which rotates freely in the absence of material. When the paddle rotation is impeded by the presence of material,
the motor actuates an output switch which is made available for customer connection to a control system. A moment later, the bin
monitor switches off the motor to prolong its life. When the material level drops below the paddle, a spring returns the motor to its
original position, re-energizing the motor, re-establishing paddle rotation, and returning output switch to its normal non-actuated status.
Sensitivity of the rotary paddle bin monitor is determined by the number of paddle vanes (single, 2-vane, 3-vane, etc) and the spring
tension setting within the sensor.
t PRACTIC AL APPLIC ATIONS t OPTIONS
t For applications when sensors that are not affected by t Hazardous location approvals for gases and dust (Model KAX).
t Choice of paddle accessories for reliable material detection and
electrical properties of target materials, such as
dielectric, are preferred.
application-specific material detection containing varying points /
t Excellent when facility personnel are expected to distances. (Please refer to Bulletin #216H for paddle selection guide.)
t High temperature unit available.
perform in-field troubleshooting and maintenance with
virtually no prior training.
t Up to 3 switched outputs.
t Reliable sensing of materials as light as 5 lbs/ft3 (80kg/m3)
with proper mounting location & proper paddle selection. t Variety of extensions, guards, couplings and mounting plates are
t Typical applications include, but are not limited to:
available to meet specific process condition requirements.
Grains, Feeds, Pet Food, Dry Food Ingredients, Spices, t Pipe extension models:
Cereals, Coffee, Silica Sand, Plastics, Rocks, Pellets, 144” (3.65m) maximum length.
Wood, Calcium Dust, Rubber, Metals, Regrind, Coal,
Peanuts, Malt, Clays, Resin, Limestone, Foundry Sand, t Field adjustable cable extensions:
Pre-Mix Ingredients, Rawhide, Sawdust and more. 78” (2m) maximum length.
For more detailed information, please contact a Monitor Scan this with a
representative or visit Monitor’s website at smartphone QR-Code app
http://www.monitortech.com/product_p_rotary.shtml for more product details.
L e ve l B log - ht t p: //m o n it o rt e ch.t y pe pa d. co m BULLETIN 213P

Visit www. monitortech. co m
t SPECIFIC ATIONS More product specifications can be found on Monitor’s Web site.
Power Requirements: 115 VAC, 50/60 Hz; 230 VAC, 50/60 Hz; Housing: Die cast aluminum, powder coated
24 VAC, 48 VAC 50/60 Hz; 12/24 VDC NEMA 4 / ENCLOSURE TYPE 4, IP66
Power Consumption: 4W max. Listings / Approvals:
Internal Bin Temperature: KA: UL and CSA: Ordinary Locations
KAX: UL and CSA: Class I, Div. 1 & 2, Groups C, D;
Class II, Div. 1 & 2, Groups E, F, G
Standard Unit: to 300˚F (+150˚C)
II 1/2 D c T 100˚C
Hi-Temp. Unit: 300 to 500˚F (150 to 260˚C) without air-cooling
to 750˚F (400˚C) with air-cooling [0.5 psig / 2.14 CFM] ATEX:
ExtD A20/A21 T 100˚C
Ambient Operating Temp.: -40˚F to +200˚F (-40˚C to +93˚C) ext. amb.
(Ta -40˚C to +93˚C)
Conduit Connection: Two (2) 3/4” NPT (for 1-1/4 NPT mounts) IP6x
Two (2) M20 (for 1-1/2 BSPT mounts) IEC Ex: DIP A21 IP6X TA 100˚C
Outputs Contacts: -40˚C to +93˚C
2-Circuit Configuration: Two SPDT 15A @ 250 VAC ea. max All Models: CE Mark
3-Circuit Configuration: One SPDT 15A @ 250 VAC max Material of Construction:
One DPDT 10A @ 250 VAC max Flexible Coupling: 304 stainless steel
Maximum Pressure: 30 PSI (2 bar) maximum Mounting Plates: Carbon steel or 304 stainless steel
Sensitivity: 5 lbs/ft3 (80 kg/m3) min. material density All Paddles except Ex-Flex: 304 stainless steel
Ex-Flex Belt: 304 stainless steel coupling, rubber/fabric blend belt
(when using large 3-vane paddle)
Flexible Cable Extension: 304 stainless steel
Mounting Connection: 1-1/4" NPT or 1-1/2” BSPT Solid Shaft Extension/Guards: Galvanized or 304 stainless steel
Shipping Weight-Approx.: 7 lbs (3.18 kg) - with optional paddle Shaft Seal: Nitrile
Shipping Dimensions: 9L x 9W x 12H” (229 x 229 x 305mm)
t ORDERING INFORMATION t MECHANICALS

NOTES:
1 Available with Model KAX only.
2 On all high temperature configurations a mounting plate (either #1-0102, CS or #1-0113, SS) is
automatically furnished as the process connection. Threaded mounts are not available. 1-1/2” BSPT
process connection is not available with high temperature style selection. (See I&O Bulletin #214A.)
ACCESSORIES:
Part # Description Part # Description Information on this sheet is subject
Mounting Plates: Flexible Coupling: to change without notice.
2-Year
1-0100 Mounting Plate, half coupling, 1-3335 Spring flex
Limited
CS, for R 1-1/2 (BSPT 1-1/2”) Paddles:
1-0115 Mounting Plate, full coupling, 1-4145 Paddle, 1-vane insertable
Warranty
CS, for R 1-1/2 (BSPT 1-1/2”) 1-4146 Paddle, 3-vane standard
1-0101 Mounting Plate, half coupling, 1-4141 Paddle, 3-vane large
CS, for 1-1/4” NPT 1-4193 Paddle, 1-vane scimitar
1-0102 Mounting Plate, full coupling, 1-4135 Paddle, 2-vane
CS, for 1-1/4” NPT 1-4156 Paddle, 4-vane
MONITOR TECHNOLOGIES, LLC

1-0112 Mounting Plate, half coupling, 1-4144 Paddle, 1-vane triangular
SS, for 1-1/4” NPT 1-4137 Paddle, ex-flex belt
1-0113 Mounting Plate, full coupling, 1-4161 Paddle, 2-vane collapsible
44W320 Keslinger Road t Elburn, IL 60119 USA

SS, for 1-1/4” NPT Cable Extension:
Tel: 1-630-365-9403 t In US/CAN 1-800-766-6486

1-3316 Mounting Plate, heavy duty 1-1176-2-78 Flexible Extension
alum., for 1-1/4” NPT (304 SS, 78” (2m) Length - Can be
Fax: 1-630-365-5646 t monitor@monitortech.com

Solid Shaft Extensions: modified in the field for a shorter length.)
* # = Extension and guard lengths -
www.monitortech.com t www.flexar.info
1-1175-1-#* 1/4" Pipe, SCH-40, Galvanized
1-1175-2-#* 1/4" Pipe, SCH-40, 304 SS not to exceed 144 inches
(3.6 m) in length.
Contact factory for
Blog: www.monitortech.typepad.com
Shaft Guards:
more details.
2
1-1174-1-#* 1-1/4" Pipe, SCH-40, Galvanized
1-1174-2-#* 1-1/4" Pipe, SCH-40, 304 SS
ISO 9001 Registered Quality System CRO GDR APR 24 2015-P DOC-000-213P 1
Product Datasheet
4B
Components
P800 Proxswitch
Limited
P800 Proxswitch
Inductive Proximity Sensor
APPLICATION
The P800 Proxswitch is an inductive sensor designed to detect
shaft speed, shaft position, gate position, or object presence.
METHOD OF OPERATION
The P800 Proxswitch is a CSA Class II, Division 1 approved
limit switch style 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 a maximum distance of 1/2” and a non-ferrous object
at 5/16”.
Three different sensor outputs are available -

1. P8002V10FC with changeover relay contact output. Best used for
shaft position, gate position or object presence.
2. P8003V10C with opto-isolated bilateral FET output (energized on).
Best used for speed monitoring.
3. P8004V10C with opto-isolated bilateral FET output (de-energized off).
Best used for speed monitoring.
All units are fully encapsulated and come with a 6 foot cable lead and
1/2 “conduit entry. Two LED’s show power supply and input status.
FEATURES
► No Contact Monitoring
► Dust Hazard Approved
► Totally Sealed Construction: Submersible
► CSA Class II Div. 1 Groups E, F & G Approved
► IP 67 Protection
► P8002V10FC Proxswitch (Contact Closure Version)
► P8003V10C Proxswitch (Opto-Isolated Bilateral FET Version)
► P8004V10C Proxswitch (Opto-Isolated Bilateral FET Version) The SpeedMaster™ is the only
► WG1-4B-4 Whirligig® (Target/Bracket/Guard) device that accurately tests the
► MAG2000 Mag-Con™ Magnetic Connector for Whirligig calibration of a speed switch,
► SM2 SpeedMaster™ Sensor Testing Device and allows testing of the alarm
and shutdown features of the
► TACH3V5 Tacho Display
sensor while installed on the
machine shaft.
To see it in action, visit:
www.go4b.com/speedmaster
Whirligig®
& Mag-Con™
Connector
Product Datasheet
4B
Components
P800 Proxswitch
Limited
DIMENSIONS
4-19/32 1/2 NPT

SENSING FACE
Conduit Entry
1-3/16
1-9/16
P800
6 ft. Installed on Shaft
1-5/32 2-3/8 Cable with Whirligig®
1-9/16
1/4
Diameter
All Dimension In Inches
P800 Proxswitch - Inductive Proximity Sensor
P8002V10FC P8003V10C P8004V10C
Typical Position & Object
Speed Monitoring
Applications - Monitoring
Voltage Free
Opto-Isolated Bilateral FET
Output - Changeover Relay
120 VAC/VDC 100 mA Max.
3A 240V Max.
Output De-Energized (Off) Output Energized (On) Output De-Energized (Off)
Output State -
with No Target with No Target with No Target
Relay Type - Mechanical Solid State
Max Input Speed - 5 Hz (300 ppm) 100 Hz (6,000 ppm)
Supply Voltage - 12 to 240 VDC / 24 to 240 VAC
LED Indication - Red and Green LED's for target detection
Operating Temperature - -13 °F (-25 °C) to 158 °F (70 °C)
Ferrous Target - 1/2 Inch (12 mm) Maximum
Sensitivity -
Non-Ferrous Target - 5/16 Inch (6 mm) Maximum
Body Construction - Nylon
Conduit Entry - 1/2 Inch NPT
Cable Length - 6 Feet (2 m) - 4 Core
Weight - 1 lb.
Protection - IP67
Approvals - CSA Class II Div 1 Groups E, F, and G (US and Canada)
P8001/P8002 Proxswitch
INDUCTIVE PROXIMITY SENSOR
®
C US
APPROVED
Class II Div. 1
OPERATION MANUAL
Part No’s. P8001V34FC, P8002V10FC
www.go4b.com/usa
TABLE OF CONTENTS

DIMENSIONS Page 7
INSTALLATION Page 7
STANDARD WIRING DIAGRAM Page 8
TROUBLESHOOTING GUIDE Page 10
WARNING
Rotating parts can crush,
cut and entangle.
Do NOT operate with
guard removed.
Lockout power before
removing guard or
servicing.
Dear 4B Customer:
product.

assistance with any questions about the performance of products purchased from 4B. 4B
is happy to discuss product performance with you at any time.
PAGE 4


6. SERVICE REQUEST
complete the online product registration section which is accessed via our website www.
go4b.com/usa.
PAGE 5
WARNING
PRODUCT OVERVIEW
The P800 Proxswitch is an inductive sensor designed to detect shaft speed, shaft position, gate position,
or object presence.
The P800 Proxswitch is a CSA Class II, Division 1 approved limit switch style 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”.
Two different Sensor outputs are available. One with changeover relay contact outputs which works
on a supply voltage of 24 to 240 VAC / 12 to 240 VDC and another with solid state NPN/PNP transistor
outputs which works on a supply voltage of 10 to 30 VDC.
Both units are fully encapsulated and come with a 6 foot cable lead and 1/2 inch conduit entry. Two
LED’s show power supply and input status.
SPECIFICATIONS
P8001V34FC P8002V10FC
Supply Voltage - 10 to 30 VDC 12 to 240 VDC / 24 to 240 VAC
NPN/PNP transistor rated at Voltage free change over
Output -
30 VDC 100 mA max. relay 3A 240V max.
Selected by supply polarity Output de-energized (off)
Output State -
connection with no target
Max. Input Speed - 250 Hz (15,000 PPM) 5 Hz (300 PPM)
Indication - Red and green LED’s for target detection
Operating Temperature - -13°F (-25°C) to 158°F (70°C)
Ferrous target - 1/2 inch (12 mm) maximum
Sensing Range -
Non-ferrous target - 5/16 inch (6 mm) maximum
Enclosure - Nylon
Conduit Entry - 1/2 inch NPT
Cable Length - 6 ft. (2 m)
Weight - 1 lb.
Protection - IP67
CSA Class II Div 1 Groups E, F and G (USA and Canada)
Approvals -
CE (Europe)
PAGE 6
DIMENSIONS
ALL DIMENSIONS IN INCHES 4-19/32” 1/2” NPT
Conduit Entry
Sensing Face Top Side
1-9/16” 1-3/16”
6 ft. Cable
1-5/32” 2-3/8”
1-9/16”
1/4” Dia.
INSTALLATION
The P800 should be wired as shown in the connections diagram on page 8. The two P800 models have
different connections, so make sure to use the correct diagram for your model.
Cable length can be extended to virtually any distance required. The proximity sensor is well protected
against electrical interference, but if long cable runs are used in very noisy environments, the cabling
should be segregated from any high current carrying conductors.
The sensing face of the sensor, should overhang at least 1-1/4 inches (31 mm) from any metalwork that
the unit is fixed to, otherwise the unit will stay in the “ON” state. Ensure that any background metalwork,
behind the target to be sensed, is at least 5/8 inches (15 mm) behind the target. This will prevent the
proximity sensor from detecting that background metalwork. Illustration A below denotes sensing ranges
for ferrous and non-ferrous targets.
NOTE - Red LED (input) indicates target sensed, and green LED (output) indicates output on. LED’s
are located on the top side of the P800 (Illustration A).
1/2” (12 mm) Max. (Ferrous Target)
5/16” (6 mm) Max. (Non-Ferrous Target)
Target
3/4” Dia.
(19 mm)
(Grey Area)
Metalwork
Shaft
5/8” Min.
(15 mm)
1/1/4” Min. ILLUSTRATION A - SENSING RANGES

(31 mm)
Ensure all connections are correct before applying power. Apply power to the P800 and machinery, then
check that the input and output LEDs are flashing “ON” and “OFF” indicating the target is being sensed.
WARNING
O.S.H.A. requires that all exposed rotating shafts are provided with a full guard. Therefore, this device
and its target must be equipped with a guard.
PAGE 7
Fasten the P800 to a suitable mounting bracket, such as 4B’s Whirligig® universal shaft sensor mount,
with the nose of the switch within the sensing range of the target, as shown below -
P800 Shown on Optional Whirligig® Shaft Sensor

Mount with Mag-Con™ Magnetic Connector
STANDARD WIRING DIAGRAM

P8001V34FC
+ VDC
Brown
Black Signal
Supply 100 mA
10 - 30 VDC White 30 VDC Max.
Blue
0 VDC
For NPN - Connect load between black and brown wires with white and
blue wire connected together.
For PNP - Connect load between white and blue wires with brown and
black wires connected together.
Connected as shown, output will be “ON” with object present. For output
“OFF” with object present, reverse brown and blue wire connections only.
P8002V10FC
Brown Black/Orange
Supply
12 - 240 VDC Black Signal
24 - 240 VAC Blue 3A 240V Max.
Black/Red
The connections above are shown with power switched off.

P8002V10FC output state is de-energized (off) with no target present.
PAGE 8
TESTING AND COMMISSIONING
1. Check that the unit is correctly installed (see standard wiring diagram).
2. Check that the distance between the target, stud or bolt head and sensing face of P800 is within the
minimum distance specified.
3. Start up machine.
4. If monitoring for speed see A, for proximity monitoring see B -
A. If the P800 is being used to monitor speed, 4B’s SpeedMaster™ calibration and testing device
can be used to insure the P800 shuts down the machine at the correct percentage of slip. Shut
down will depend on your specific monitoring setup. 4B recommends an instant shutdown on any
belts slipping 20% or more of normal speed.
B. If the P800 is being used as a proximity switch, be sure that the target is not within range of the
sensor prior to testing. Use a metal putty knife or a small piece of metal and place it between the
sensing face of the P800 and the target. This will cause the sensor to energize the output, and
both the green and red LEDs will go on. Removing the putty knife will de-energize the output
signal and both LEDs will go off.
SPEEDMASTER™
The SpeedMaster™ with Pulse Pilot is the only device that
accurately tests the calibration of a speed switch, and allows
testing of the alarm and shutdown features of the sensor while
installed on the machine shaft.
The SpeedMaster™ operates in two modes. Input mode
is used to measure the pulse rate at normal speed. Output
mode will allow the user to input pulses to the sensor for
testing purposes.
Patents - The Pulse Pilot fits between the gap between the sensor and
US8947073
MX321802
the target. The Pulse Pilot will have no effect on the operation
EP26223568 of the speed switch until it is connected to the SpeedMaster™
and set to “output” mode.
WARNING
PAGE 9
TROUBLESHOOTING GUIDE
FAULT REMEDY
• Check that the sensing face of the sensor is not bolted directly to metalwork
• Check that there is a space between the sensor face and any surrounding
Input and Output metalwork (1-1/4 inches - 31 mm minimum)
LED’s Stay “ON” • Check that the machinery is rotating and that the target is actually leaving the
sensor before reappearing
• Check that background metalwork, behind target, is far enough away so as

not to be detected
• Check supply voltage to the sensor.
Input and Output

• Check that target is within specified operating range of unit.
LED’s Stay “OFF”
• Check that machinery is rotating and that target is passing the sensing face of
the sensor.
PAGE 10
PRODUCT WARRANTY

ALL PRODUCTS SOLD ARE WARRANTED BY THE COMPANY (4B COMPONENTS
LIMITED, (4B) BRAIME ELEVATOR COMPONENTS LIMITED, AND (4B) S.E.T.E.M. Sarl
HEREIN AFTER REFERRED TO AS 4B TO THE ORIGINAL PURCHASER AGAINST
DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE FOR ONE (1)
YEAR AFTER DATE OF PURCHASE FROM 4B. ANY PRODUCT DETERMINED BY
4B AT ITS SOLE DISCRETION TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP
AND RETURNED TO A 4B BRANCH OR AUTHORIZED SERVICE LOCATION, AS 4B
DESIGNATES, SHIPPING COSTS PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY,
REPAIRED OR REPLACED AT 4B’S OPTION.


PAGE 11
location.
4B BRAIME ELEVATOR 4B DEUTSCHLAND 4B ASIA PACIFIC

COMPONENTS 9 Route de Corbie Build No. 899/1 Moo 20
Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338
4B COMPONENTS LTD. 4B SETEM SARL 4B AFRICA 4B AUSTRALIA

Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3711 2565
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3711 2574
www.go4b.com
Product Datasheet
4B
Components
Touchswitch™
Limited
Touchswitch™
Belt and Pulley Alignment Sensor
APPLICATION
Detects belt tracking and alignment problems on bucket elevators and
conveyors.
METHOD OF OPERATION
The Touchswitch is an electro-mechanical limit switch with no moving
parts, which detects tracking and misalignment problems on bucket
elevators and conveyors.
When a belt misaligns 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.
The face of the sensor is made from hardened stainless steel, not soft
brass or aluminum, so wear life is longer when a belt contacts it. The
sensor is not affected by dust or material build up and will still work
when completely covered by material. An external test knob allows for
quick and simple sensor/system testing.
The sensors are usually installed in pairs on opposite sides of the
machine. The sensors can be connected directly to a PLC input, or for
greater safety, to a central independent monitoring system, such as the
T500 Hotbus or Watchdog Elite.
FEATURES
► No Moving Parts U.S. Patent # 6,731,219
► Immediate Misalignment Signal Other Patents Pending
► Changeover Relay Contact Output
► External Test Function
► Not a “Rub” Block
► CSA Class II Div. 1 Approved (USA & Canada)
ATEX Approved
PART NUMBERS/ACCESSORIES Versions
Available
► TS2V3C Touchswitch 12 VDC
► TS2V4C Touchswitch 24 VDC
► PS3500V3 12 VDC Power Supply
► PS2000V4 24 VDC Power Supply
► TS202-CT5-2-1/4 Touchswitch Hole Saw
► T5004V46C T500 Hotbus Monitoring System
► WDC4V46C Watchdog Super Elite Monitoring System
► B4004V46C B400 Elite Misalignment Monitor
Touchswitch Hole Saw

TS202-CT5-2-1/4
Copyright © 2016 4B Components Ltd. All rights reserved. Information is subject to change or modification without notice. Refer to instruction manual for installation information. CRD090816
Product Datasheet
4B
Components
Touchswitch™
Limited
1-3/4”
Ø3-3/8”
3/4”
Sensor
Face
Ø2”
2-3/16”
3-3/8”
2” Diameter
Hardened
Stainless Steel
4 x 1/4” Fixing Holes

Test 1/2” NPT Equally Spaced on
Knob Conduit Entry 2-29/32” Diameter
Encapsulated
Electronics 9 ft. Cable
6 x 22 AWG Conductors
Connect the Touchswitch directly to a

PLC, or use with the optional T500
Hotbus and Watchdog Super Elite digital
monitoring systems for conveyors or
bucket elevators. Belt alignment, belt
speed, bearing temperature, pulley
alignment, and plug condition monitoring
in one complete standardized system.
TECHNICAL SPECIFICATIONS Enclosed Belt Conveyor

Application
TS2V3C or TS2V4C
Supply: 12 VDC (TS2V3C) or 24 VDC (TS2V4C)
Power Consumption: 60 mA (TS2V3C) or 50 mA (TS2V4C)
LED Indication: Red LED indicates unit is powered up and relay is energized
Adjustment: Factory set to 8 lb. (3.6 Kg) approximately
Voltage free changeover relay contact rated at 5A - 250 VAC,
Output:
non-inductive
Body Construction: Pressed seamless steel with epoxy paint
Face Construction: Hardened stainless steel
Conduit Entry: 1/2 in. NPT
Cable Length: 9 ft. (3m)
Conductors: 6 / 22 AWG
Weight: 3 lbs.
Protections: NEMA 4X, IP66 Open Belt Conveyor
CSA Class II Div 1 Groups E, F, G (US and Canada), Application
Approvals:
ATEX and CE (versions available)
Touchswitch™
BELT MISALIGNMENT SENSOR
®
C US
APPROVED
Class II Div. 1
U.S. Patent #6,731,219

Other Patents Pending
OPERATION MANUAL
BELT MISALIGNMENT SENSOR - PART NO. TS2V4C & TS2V3C
www.go4b.com/usa
TABLE OF CONTENTS

DIMENSIONS Page 6
INSTALLATION Page 7
STANDARD WIRING Page 8
SENSOR PLACEMENT DIAGRAMS Page 10
- Determining Left & Right Side of Bucket Elevator Page 10
- Typical Mounting Positions on a Bucket Elevator Page 11
- Typical Mounting Positions of a Bucket Elevator with a Knee or Bend Pulley Page 12
- Typical Mounting Positions on Tail/Boot Section of Bucket Elevator Page 13
- Typical Mounting Positions on an Open Belt Conveyor Page 14
- Typical Mounting Positions on an Enclosed Belt Conveyor Page 15
INSTALLATION PHOTOS Page 16
DANGER
Exposed buckets and

moving parts will cause
severe injury or death.
removing cover of
inspection door.
Dear 4B Customer:
product.

assistance with any questions about the performance of products purchased from 4B. 4B
is happy to discuss product performance with you at any time.
PAGE 4


6. SERVICE REQUEST
complete the online product registration section which is accessed via our website www.
go4b.com/usa.
PAGE 5
WARNING
PRODUCT OVERVIEW
The Touchswitch™ is an electronic limit switch. When a belt misaligns 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. The face of the sensor is made from hardened stainless steel, so that there is
virtually no wear when a belt contacts it. The sensor is not affected by dust or material build up and will
still work when completely covered by material. Sensors are normally installed in pairs on opposite sides
of the machine. Usually a pair of sensors at each pulley is used, but additional pairs can be installed as
required. An external test knob allows for quick and simple sensor / system testing.
SPECIFICATIONS
Supply - 24 VDC (TS2V4C) / 12 VDC (TS2V3C)
Power Consumption - 50 mA (TS2V4C) / 60 mA (TS2V3C)
LED Indication - Red LED indicates unit is powered up and relay is energized
Sensing Force - Factory set to 8 lb. (3.6 Kg) approximately
Output - Voltage free changeover relay contact rated at 5A - 250 VAC, non-inductive
Construction - Hardened stainless steel (face) and seamless steel with epoxy paint (body)
Conduit Entry - 1/2” NPT
Cable - 9 ft. long (3 m) - 6 x 22 AWG Conductors
Weight - 3 lbs.
Protection - NEMA 4X, IP66
CSA Class II Div 1 Group E, F, and G (USA & Canada)
Approvals -
ATEX and CE (Versions Available)
DIMENSIONS
1-3/4” 3/4” Ø 3-3/8”
Test Knob Sensor Face -

2” Diameter
Hardened
Stainless Steel
2-3/16”
3-3/8”
Output
LED
1/2” NPT Conduit Entry 4 x 1/4” Fixing Holes -

9 ft. Long Cable Equally Spaced on
6 x 22 AWG Conductors 2-29/32” Diameter
PAGE 6
INSTALLATION
The 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 may be. Typical Touchswitch™ mounting
positions are illustrated on pages 10 - 15.
The Touchswitch™ hole should be cut into the housing with a 2-1/4” diameter hole saw (Image A),
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. You can mount the Touchswitch™ with 2 of the 4
flange holes, provided they are diagonal from one another. The enclosed flange shims can be used as a
template to properly place the flange holes. The Touchswitch™ needs to be mounted on a flat surface,
preferably with the conduit entrance between the 3 to 9 o’clock position to minimize the entrance of
water thru the conduit threads.
The Touchswitch™ can be mounted using one of the following three methods -
1. Drill and tap the machine casing for 1/4” threaded bolts. Make sure that the bolts used to secure the
Touchswitch™ are short enough that they do not interfere with the operation of the machine.
2. Use threaded rivet nuts for 1/4” threads. The length of the rivet nut will depend on the thickness
of the machine’s casing. Make sure that the bolts used to secure the Touchswitch™ are short
enough that they do not interfere with the operation of the machine.
3. CD weld 1/4” x 1-1/4” threaded welding studs to the machine casing.
When placing flange shims on Touchswitch™ make certain belt and or pulley contacts the
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 than 1- 1/4 to 1-1/2” to the face of the Touchswitch™.
Pulley
Image B
Image A
Proper Hole
2-1/4 Diameter Position for
Hole Saw Mounting
Belt Touchswitch™
When mounting on the head section of a leg or belt conveyor try to catch the belt and the pulley. On a
leg, mount the 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 an inspection door, X-PAC or other obstruction.
In this case, the Touchswitch™ can be mounted on the top or up side of the head pulley. Try to mount
Touchswitches so they are accessible from the head section walkway. Be sure to mount Touchswitches
directly across from one another. On a conveyor head section mount the Touchswitch™ forward of
the head shaft in order to monitor for misalignment on the head pulley and belt. For typical mounting
positions on a bucket elevator, see illustrations on pages 10 - 13.
On a leg boot, mount the Touchswitch™ on the up side of the tail pulley if there are no obstructions. If
obstructions are encountered, use the down side of the pulley, but be sure to have the Touchswitches
mounted directly across from one another. Mount the Touchswitch™ above the center line of the
boot shaft at the shaft’s highest possible position (see illustration - page 13). You may not be able to
catch the leg boot pulley in all positions with a Touchswitch™. If desired, you can install additional
Touchswitches™ along the travel of the boot pulley.
PAGE 7
When mounting Touchswitches on open belt conveyors, brackets will usually 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 will allow the Touchswitch™ to move with the pulley when belt adjustments
are made. For typical mounting positions on an open belt conveyor, see illustration - page 14.
On enclosed belt conveyor tail sections, mount Touchswitches to catch the top side of the belt on the
vertical angle just ahead of tail pulley. You will not be able to catch the tail pulley with a Touchswitch™
on an enclosed belt conveyor due to the flippers on the pulley. 4B recommends that some other device
be installed to catch the tail pulley, such as a surface mount temperature sensor (WDB70V3C). When
installing Touchswitches on the tail section, some tail adjustment will be sacrificed. For typical mounting
positions on an enclosed belt conveyor, see illustration - page 15.
When connecting liquid tight conduit to Touchswitches, limit the length to NEC requirements. However,
when installed on an adjustable pulley or section be certain enough conduit is installed to allow for pulley
adjustments.
WARNING
• Touchswitch™ wiring is low voltage DC.
• Use shielded cable and keep separate from high voltage cable.
• Never run Touchswitch™ cables in the same conduit as 3-phase motor cables.
• Track belts and commission plant prior to installing Touchswitches.
• Fabricated brackets must be built rigid enough to take pressure from a misaligned belt.
NOTE
Install Touchswitches on machinery only after they have been wired to a power source, and can
alarm / shutdown the equipment being monitored.
STANDARD WIRING
Mount a suitable junction box within 9 ft. of the sensor, and using a suitable conduit to protect the
cables, make the necessary wiring connections inside this junction box. A 9 foot PVC coated cable
connected to the sensor contains the following 22 AWG wires:
RED - 24 VDC (TS2V4C) or 12 VDC (TS2V3C)

BLACK - 0 VDC
GREEN - Ground
WHITE - Relay Common Connection
BLUE - Relay Contact, Normally Open (Sensor Output)
ORANGE - Relay Contact, Normally Closed (Not Normally Used)
PAGE 8
NOTE
The orange wire is not normally used and should be cut back and insulated.
SENSOR OPERATION:
The Touchswitch™ is an electronic limit switch that reacts when pressure is applied to the sensor face.
If the pressure exceeds 8 lbs. (3.6 kg), the sensor relay goes into an alarm condition (Illustration D).
Illustration C denotes normal running conditions, with no pressure applied.
BLUE BLUE
WHITE WHITE
ORANGE No ORANGE
Belt
Contact
RED LED ON: RED LED ON:

Indicates power and relay Indicates power and relay
energized, no belt contact. energized, no belt contact.
Illustration C
Normal Running Condition
BLUE BLUE
WHITE WHITE
ORANGE Belt ORANGE

Contact
RED LED ON: RED LED OFF:

Indicates power and relay Indicates relay de-energized,
energized, no belt contact. belt contact or no power.
Illustration D
Alarm Condition, Belt Misaligned to the Right
NOTE
• The Touchswitch is factory pre-calibrated and no sensitivity adjustment is necessary. The sensor
is calibrated to switch to the alarm state when belt lateral force exceeds 8 lbs. (3.6 kg).
• The Touchswitch contains a non-replaceable permanent 160 mA fuse and a thermal fuse set at
163° F (73° C).
• 4B recommends that the machine shuts down when the belt contacts the Touchswitch. If the
machine does not shut down and the belt is allowed to continue to rub against the face of the
Touchswitch, the hardened stainless steel sensor puck may wear and the heat generated by the
friction may cause the thermal fuse to blow. This fuse is non-replaceable and non-repairable.
PAGE 9
SENSOR PLACEMENT DIAGRAMS
DETERMINING LEFT & RIGHT SIDE OF BUCKET ELEVATOR:
VIEW OF LEFT SIDE VIEW OF RIGHT SIDE
NOTE: LEFT AND RIGHT SIDES ARE DETERMINED WHEN FACING

THE DIRECTION THAT THE BUCKET ELEVATOR DISCHARGES.
TOUCHSWITCH™ PLACEMENT ON THE LEFT SIDE WILL MIRROR
THE RIGHT SIDE.
PAGE 10
TYPICAL MOUNTING POSITIONS ON A BUCKET ELEVATOR:
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 O’CLOCK
AND 3 O’CLOCK POSITION ON THE DISCHARGE
(DOWN) SIDE OF THE LEG - IF 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.
VIEW OF LEFT SIDE
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.
PAGE 11
TYPICAL MOUNTING POSITIONS ON A BUCKET ELEVATOR WITH A KNEE OR BEND PULLEY:
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.
VIEW OF LEFT SIDE
TOUCHSWITCH™ MUST BE
INSTALLED ABOVE THE HEAD
SHAFT BETWEEN THE 9 O’CLOCK
AND 3 O’CLOCK POSITION ON THE
DISCHARGE (DOWN) SIDE OF THE
LEG - IF 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
MOUNT BUCKET ELEVATOR.
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.
PAGE 12
TYPICAL MOUNTING POSITIONS ON TAIL/BOOT SECTION OF BUCKET ELEVATOR:
VIEW OF LEFT SIDE
MOUNT TOUCHSWITCH™ ON
UPSIDE OF LEG (IF POSSIBLE) AT
THE HIGHEST POINT THAT THE
BOOTSHAFT CAN BE ADJUSTED TO.
ADDITIONAL TOUCHSWITCH™ CAN

BE INSTALLED TO ACCOMMODATE
FOR BOOT TAKE-UP. OR A SLOT FOR
THE TOUCHSWITCH CAN BE MADE
IN THE BOOT CASING SO THAT THE
TOUCHSWITCH™ TRAVELS WITH THE
BOOT TAKE -UP.
Bootshaft
Belt
MOUNT TOUCHSWITCHES
DIRECTLY ACROSS
FROM EACH OTHER AND
INLINE WITH THE PULLEY
AND BELT TO DETECT
MISALIGNMENT OF EITHER
THE PULLEY OR THE BELT.
Pulley
PAGE 13
NOTE: TOUCHSWITCH™ MOUNTING
BRACKETS WILL NEED TO BE
FABRICATED TO WITHSTAND THE
FORCE OF A MISALIGNED BELT.
RIGHT
SIDE
LEFT NOTE: MOUNT PAIR OF

SIDE TOUCHSWITCHES DIRECTLY
ACROSS FROM EACH OTHER NOTE: ON TAIL PULLEYS OF OPEN BELT CONVEYORS
ON LEFT AND RIGHT SIDE OF THAT ARE TAKE UP PULLEYS MOUNT THE
CONVEYOR. TOUCHSWITCH™ BRACKET OFF OF BEARING
PAGE 14
MOUNTING BOLTS WHEN POSSIBLE.
TYPICAL MOUNTING POSITIONS ON AN OPEN BELT CONVEYOR:
NOTE: MOUNT TOUCHSWITCHES INLINE WITH BOTH NOTE: WHEN CONVEYOR

THE PULLEY AND BELT WHEN POSSIBLE. HAS IDLER PULLEY
INSTALL ADDITIONAL
TOUCHSWITCHES AND
BEARING SENSORS.
ON ENCLOSED BELT CONVEYOR TAIL
NOTE: MOUNT PAIR OF TOUCHSWITCHES SECTION MOUNT TOUCHSWITCHES
DIRECTLY ACROSS FROM EACH OTHER ON LEFT ALIGNED WITH TOP SIDE OF BELT ON
AND RIGHT SIDE OF CONVEYOR. MOVEABLE SECTION JUST IN FRONT
OF VERTICAL ANGLE AHEAD OF TAIL
NOTE: FOR INCREASED PROTECTION
PULLEY.
ADDITIONAL TOUCHSWITCHES MAY BE
ADDED TO THE HEAD AND TAIL.
LEFT
SIDE
RIGHT
PAGE 15
SIDE
PLACE
TOUCHSWITCHES
TYPICAL MOUNTING POSITIONS ON AN ENCLOSED BELT CONVEYOR:
ANYWHERE
BETWEEN 6
O’CLOCK AND 12
O’CLOCK IN FRONT
OF HEADSHAFT.
TYPICAL INSTALLATION PHOTOS
Touchswitch
Face / Puck
Conveyor Belt
Touchswitch™ Installed at Drive End of

Enclosed Belt Conveyor (Inside View)
Touchswitch
Mounted to
Fabricated Bracket
Pulley
Touchswitch™ Installed at
Tail of Open Belt Conveyor
Touchswitch
Speed Sensor
Bearing
Temperature
Sensor
Touchswitch™ Installed
on Bucket Elevator
PAGE 16
TESTING & COMMISSIONING
Periodically test the sensor and the system to ensure both are operating correctly.
The Touchswitch™ has a built in test knob that allows for quick and easy operation verification without
removing the sensor from the mounting hole. The testing procedure is outlined below:
1. Observe that the red output LED on the sensor housing is on and the belt or pulley is not touching
the sensor.
2. Slowly turn the test knob clockwise by hand, until the LED goes out.
3. Check that the alarm and shutdown procedures work as expected.
a. If OK, continue to step 4.
b. If the system does not immediately shutdown as expected or alarm as required, then remove the
4. Turn the test knob back to its original position (about 1/4 turn). Make sure that the knob is loose,
meaning not turned all the way to the left or right.
5. Observe that the LED is now on, indicating the sensor has power and is not in alarm.
As part of your ongoing maintenance program, periodically test the sensor and system, and visually
inspect the contact surface of the sensor and the sealtite, the wires, junction box and conduit.
WARNING
FAULT CAUSE REMEDY

Belt Misaligning • Check Belt Alignment
Touchswitch™
• Check Hole Diameter is 2-1/4 Inches and is De-burred
Touchswitch™ Binding Against
• Check Touchswitch™ is Centered in the Hole
Signalling an Alarm Leg Casing
Condition and / or
Red Output LED is Test Knob • Loosen Knob (Rotate Counterclockwise 1/4 Turn Until
Off Active Loose)
• Check that the Touchswitch™ has the Correct Voltage
No Power Supply (24 VDC - TS2V4C or 12 VDC - TS2V3C)
• Check Orange Wire is Insulated
PAGE 17
NOTES
PAGE 18
PRODUCT WARRANTY
ALL PRODUCTS SOLD ARE WARRANTED BY THE COMPANY (4B COMPONENTS
LIMITED, (4B) BRAIME ELEVATOR COMPONENTS LIMITED, AND (4B) S.E.T.E.M. Sarl
HEREIN AFTER REFERRED TO AS 4B TO THE ORIGINAL PURCHASER AGAINST
DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE FOR ONE (1)
YEAR AFTER DATE OF PURCHASE FROM 4B. ANY PRODUCT DETERMINED BY
4B AT ITS SOLE DISCRETION TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP
AND RETURNED TO A 4B BRANCH OR AUTHORIZED SERVICE LOCATION, AS 4B
DESIGNATES, SHIPPING COSTS PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY,
REPAIRED OR REPLACED AT 4B’S OPTION.


PAGE 19
location.

COMPONENTS LTD. 9 Route de Corbie Build No. 899/1 Moo 20
Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338

Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3711 2565
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3711 2574
www.go4b.com
Watchdog™ Super Elite
BUCKET ELEVATOR & BELT CONVEYOR
HAZARD MONITORING SYSTEM
®
C US
OPERATION MANUAL
Part No.’s - WDC4V4C, WDC4V46C
Hardware Version R4 - Software Version 4.7.X
www.go4b.com/usa
TABLE OF CONTENTS
1. CUSTOMER SAFETY RESPONSIBILITIES Page 6 - 7

2. PRODUCT OVERVIEW Page 8
3. SPECIFICATIONS Page 8
4. FEATURES Page 9 - 10
5. DIMENSIONS Page 11
6. INSTALLATION Page 11
7. SENSOR PLACEMENT DIAGRAMS Page 12
8. ELECTRICAL CONNECTION Page 13 -14
9. WIRING DIAGRAMS Page 15 - 25
9.1 Wiring Block Diagram for Bucket Elevator & Belt Conveyor Page 15
9.2 Control Wiring Diagram (120 - 240 VAC) Page 16
9.3 Control Wiring Diagram (24 VDC) Page 17
9.4 Control Wiring Diagram for Multiple Units Page 18 - 19
9.5 Select New Profile Page 20
9.6 WDC3 to WDC4 Sensor Wiring Diagram Page 21
9.7 Sensor Wiring Diagram Profile with Touchswitches Page 22
9.8 Sensor Wiring Diagram Profile with Rub Blocks Page 23
9.9 Sensor Wiring Diagram Profile with Motion Alignment Sensors Page 24
9.10 Sensor Wiring Diagram Profile with Knee or Idler Pulleys Page 25
10. WATCHDOG MAIN LCD SCREEN Page 26 - 31
10.1 Start Up Screen (Initial Power Up) Page 26
10.2 Main LCD Screen & Sensor LEDs Page 27
10.3 Alarm Log Button Page 28
10.4 Menu Button Page 28
10.5 System Info Button Page 28
10.6 Speed Info (1 of 7) Page 28
10.7 Head Align Info (2 of 7) Page 29
10.8 Tail Align Info (3 of 7) Page 29
10.9 HBS Info (4 of 7) Page 30
10.10 Aux Sensor Info (5 of 7) Page 30
10.11 System Info (6 of 7) Page 31
10.12 Network Info (7 of 7) Page 31
11. VIEW SETTINGS Page 32
12. SETUP Page 33
12.1 Password Page 33
13. RESET ENGINEERING PASSWORD Page 34
14. PROFILE Page 35 - 52
14.1 Edit Selected Profile Page 35
TABLE OF CONTENTS
14.2 Calibrate System Page 36

14.2.A - System Recalibration Page 36
14.2.B - Incorrect Calibration Page 36
14.2.C - Start Up Timer Page 36
14.3 Full System Setup Page 37
14.4 System Page 37
14.4.A - Temperature Units Page 37
14.4.B - Pre Abs Alarm Page 37
14.4.C - Negative Differential Alarm Page 37
14.4.D - Rate of Rise Start Up Delay Page 37
14.4.E - Expansion 1 - Optional Expansion Board Page 38
14.4.F - Expansion 2 - Optional Expansion Board Page 38
14.5 Speed Page 39
14.5.A -Speed Monitoring Page 39
14.5.B - Scaling Units Page 39
14.5.C - Scaling Factor Page 39
14.5.D - Speed Detection Source Page 39 - 41
14.5.E - Acceleration Monitoring Level Page 41
14.5.F - Number of Starts / Minute Page 42
14.5.G - Start Up Delay Page 42
14.5.H - Underspeed Alarm Page 42
14.5.I - Severe Underspeed Page 42
14.5.J - Underspeed Alarm Delay Page 42
14.5.K - Underspeed Stop Delay Page 42
14.5.L - Overspeed Page 43
14.5.M - Severe Overspeed Page 43
14.5.N - Overspeed Alarm Delay Page 43
14.5.O - Overspeed Stop Delay Page 43
14.6 Alignment (Head) Page 43
14.6.A - Head Sensor Pair Page 44
14.6.B - Head Trigger Alarm Page 44
14.6.C - Absolute Alarm Page 44
14.6.D - Relative Alarm Source Page 44
14.6.E - Relative Alarm Page 44
14.6.F - Head: Rate of Rise Page 44
14.6.G - Head Alarm Delay Page 45
14.6.H - Head Stop Delay Page 45
14.7 Alignment (Tail) Page 46
TABLE OF CONTENTS
14.7.A - Tail Sensor Pair Page 46

14.7.B - Tail Trigger Alarm Page 36
14.7.C - Absolute Alarm Page 36
14.7.D - Relative Alarm Source Page 36
14.7.E - Relative Alarm Page 46
14.7.F - Tail: Rate of Rise Page 47
14.7.G - Tail Alarm Delay Page 47
14.7.H - Tail Stop Delay Page 47
14.8 Temperature Page 48
14.8.A - HBS Page 48
14.8.B - HBS: Absolute Alarm Page 48
14.8.C - HBS: Relative Alarm Source Page 48
14.8.D - HBS: Relative Alarm Page 48
14.8.E - HBS: Rate of Rise Page 49
14.8.F - HBS: Alarm Delay Page 49
14.8.G - HBS: Stop Delay Page 49
14.8.H - AMB Page 49
14.8.I - AMB: Absolute Alarm Page 49
14.8.J - AMB: Rate of Rise Page 49
14.8.K - AMB: Alarm Delay Page 50
14.8.L - AMB: Stop Delay Page 50
14.9 Auxiliary Page 50
14.9.A - Plug Enabled Page 50
14.9.B - Plug Trigger Alarm When Page 50
14.9.C - Plug Alarm Delay Page 50
14.9.D - Plug Stop Delay Page 51
14.9.E - Pulley Enabled Page 51
14.9.F - Pulley Trigger Alarm When Page 51
14.9.G - Pulley Alarm Delay Page 51
14.9.H - Pulley Stop Delay Page 51
14.10 Restore Defaults Page 52
15. TEST Page 53 - 54
15.1 Alarm Relay Page 53
15.2 Alignment Page 53
15.3 Over Speed Page 53
15.4 Under Speed Page 54
15.5 Hot Bearing Sensor Page 54
TABLE OF CONTENTS
16. FACTORY SETTINGS Page 54 - 55

16.1 Edit Selected Profile Page 55
16.2 Restore Defaults Page 55
17. SD CARD Page 56
18. TIME & DATE Page 57
19. CHANGE PASSWORD Page 57
20. NETWORK Page 58
21. TROUBLESHOOTING GUIDE Page 59
22. APPENDIX A - MENU TREE Page 60
23. APPENDIX B - FACTORY DEFAULT SETTINGS Page 61 - 62
24. APPENDIX C - WDC4 CONFIGURATOR SOFTWARE Page 63
25. APPENDIX D - WDC4 SOFTWARE UPDATE Page 64
26. PRODUCT WARRANTY Page 65
WARNING
cut and entangle.
Do NOT operate with
guard removed.
removing guard or
servicing.
DANGER DANGER
Exposed buckets and Exposed moving parts

moving parts will cause will cause severe injury
severe injury or death. or death.
Lockout power before Lockout power before

removing cover or removing cover or
inspection door. inspection door.
Dear 4B Customer:
product.

PAGE 6


6. SERVICE REQUEST
www.go4b.com/usa.
PAGE 7
WARNING
2. PRODUCT OVERVIEW
The Watchdog Super Elite (WDC4) is a user-programmable, microprocessor controlled bucket elevator and
belt conveyor monitor. The control unit accepts signals from sensors for belt misalignment, belt speed &
slip, continuous bearing temperature, pulley misalignment and plug condition monitoring. The unit 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 mounted control unit. An LCD screen
on the front of the unit displays system status. Calibration and set-up parameters are accessed via a
password and front panel touch buttons.
The Watchdog Super Elite can also integrate into HazardMon.com®, which is a secure cloud based hazard
monitoring solution providing status notifications and data logging for bucket elevators and conveyors. Live
system status, graphs and historical data can be viewed on any web-enabled device (smartphone, tablet
PC, desktop or laptop computer). Emails can be sent to notify users whenever a change in the system’s
health is detected. An automated maintenance feature allows site operators to verify that all sensors on
the system are operational and working correctly.
3. SPECIFICATIONS
120 to 240 VAC or 24 VDC (WDC4V46C)
Supply Voltage -
24 VDC (WDC4V4C)
Power Consumption (Max.) - 12 Watts
Power Terminals - 14 AWG / 4 mm²
Signal Terminals - 16 AWG / 2.5 mm²
Alarm Relay Contacts - 1 Pole Normally Open - 8A @ 250 VAC Voltage Free Changeover
Stop Relay Contacts - 1 Pole Normally Open - 8A @ 250 VAC Voltage Free Changeover
Sensor Supply - 24 VDC @ 800 mA (Across F1, F2 and F3)
Sensor Inputs - 15 (Expandable to 27 with Auxiliary Boards)
Interlock Input - 24 VDC or 120 to 240 VAC
Dimensions (H x W x D) - 11-3/4 x 9-1/2 x 5-1/4 (inches) / 298 x 241 x 133 (mm)
Fixing Centers (H x W) - 10-7/8 x 6 (inches) / 276 x 152 (mm)
Cable Entry - 2 Holes 1-1/8 in. Diameter (28 mm)
Weight - 3 lbs / 1.3 kg
Protection - IP66
• CSA Class II Div 2 Groups F & G (WDC4V46C)
• CSA Class II Div 1 Groups E, F & G
Approvals -
(WDC4V4C - When Powered with a Class 2 Power Supply)
• ATEX & CE (Versions Available)
• Modbus TCP/IP (Standard)
PLC Communications -
• ControlLogix® (See ProSoft® Technical Note - Available Online)
PAGE 8
4. FEATURES
BELT MISALIGNMENT DETECTION -
The Watchdog Super Elite offers greater flexibility for belt misalignment monitoring. The supported methods
are:
METHOD DESCRIPTION APPLICATION
Force activated contact signal.

Standard method, most reliable for
Contact When contact from the belt occurs
misalignment detection.
an alarm is generated.
Continuous pulses are generated

by detecting a ferrous metal
Used for applications requiring
Pulse source (bolts, buckets, chain).
non-contact sensors.
Absence of pulses generates an
alarm condition.
Processes temperature
information from brass blocks
to detect belt misalignment. Alternative detection method, not
Rub Block
When the belt rubs against the recommended due to unreliability.
brass block heat from friction is
generated.
BELT SPEED / SLIP DETECTION -

The Watchdog Super Elite also offers greater flexibility for belt speed / slip monitoring. The supported
methods are:

Shaft rotation speed Standard method, most commonly
Dedicated Speed
measurement. used.
Speed determined by the detection

Used for applications requiring
of ferrous metal (bolts, buckets,
Highest Pulse Rate non-contact belt alignment
chain) passing by the alignment
sensors.
sensors.
A combination of both methods Used with variable speed drives

Differential Speed
listed above. (VSD).
PAGE 9
HOT BEARING DETECTION -
The Watchdog Super Elite can monitor up to 8 NTC type temperature sensors (standard). This can be
expanded to a total of 20 NTC sensors with optional auxiliary boards. The supported alarm methods are:

An alarm is raised if the sensed
Simple bearing detection for over
Absolute Temperature (ABS) temperature exceeds the pre-set
heating, most commonly used.
trip point.
Used in addition to the first method

An alarm is raised if the difference and provides much earlier fault
between the sensed temperature detection. Especially useful in
Relative Temperature (REL) and the selected relative or cold weather as it is no longer
ambient source temperature is necessary to wait until the bearing
greater than the pre-set trip point. gets to a very high temperature
before a failure detected.
An alarm is detected if the bearing Used in addition to the two

starts to heat up at a rate higher methods above, and provides for
Rate of Rise (dR - delta R)
than the pre-set value in degrees an alternative fault detection for a
per minute. failing bearing.
AUXILIARY INPUTS -
The Watchdog Super Elite also has auxiliary inputs for pulley misalignment, plug condition or blocked chute
monitoring. These offer additional protection and prevent unnecessary costly downtime.
SETTINGS BACKUP & TRANSFER -

The controller is equipped with an SD card slot, and supports the ability to save and restore the system
settings from the memory card. This also allows system settings from one unit to be copied to another,
which is especially useful to duplicate settings on multiple controllers at the same location.
WDC4 CONFIGURATOR SOFTWARE -

The Watchdog Super Elite can be programed directly thought the controller’s LCD menu screen, or by using
the WDC4 Configurator Software (Appendix C). The software tool makes programming the Watchdog
easier by providing all the system settings for each profile menu into one screen. Once a profile setup file
has been created, it can be saved to an SD card and then uploaded to the Watchdog. For remote sites,
the file can be emailed to an on-site technician, who can upload the file.
EVENT & ALARM LOGGING -

The last 40 events and alarms are logged, and can be viewed directly from the Watchdog’s main LCD
screen. If an SD card is installed, all events and alarms (not just the last 40) are saved on the card. The
file can be imported into a spread sheet program to create more detailed logging and trending reports.
HAZARDMON.COM CONNECTIVITY -
The Watchdog Super Elite has in-built network support for Hazardmon.com service connectivity. HazardMon
is a secure cloud based hazard monitoring solution providing status notifications and data logging for
bucket elevators and conveyors. Live system status, graphs and historical data can be viewed on any
web-enabled device (smartphone, tablet PC, desktop or laptop computer). Emails can be sent to notify
users whenever a change in the system’s health is detected. An automated maintenance feature allows
site operators to verify that all sensors on the system are operational and working correctly.
To review of all the available features, and to see how the systems works for yourself register for a free
demo account at: www.hazardmon.com.
PAGE 10
5. DIMENSIONS
6 ALL DIMENSIONS IN INCHES
9-1/2
Ø 1-1/8 x 2
10-7/8
11-3/4
5-1/4
3-1/2
Ø 5/16 x 4
6. INSTALLATION
The WDC4 should be installed in a suitable control or switch room, and mounted at an eye level so that
the warning lights and LED screen can be readily seen.
ENCLOSURE INSTALLATION -
1. Use the correct cable, glands and sealing arrangement in accordance with all installation codes.
2. 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.
3. The box is supplied with 2 x 1-1/8 inch (28.5 mm) pre drilled holes in the bottom face. All
unused entry apertures must be sealed using component certified stopping plugs. The end user
must install component or apparatus certified stopping plugs and cable glands/conduit in strict
accordance with the manufacturer’s instructions. In order to connect conduit to the control unit
enclosure, use a CSA and/or UL certified Class II conduit hub (for example, a Myers™ hub) with a
suitable bonding (grounding) connection that is rated for the installation environment.
4. The enclosure must not be modified in any way, as this will invalidate the certification.
5. All wiring must be carried out in accordance with relevant codes of practice and / or instructions.
6. The voltage, current and maximum power dissipation shown on the label must not be exceeded.
7. The wiring installation must extend to within 1 mm of the metal face of the terminal.
8. All leads must be insulated for the appropriate voltage.
9. 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.
10. A flat-head or straight screwdriver of the correct size should be used to tighten terminals.
SENSOR INSTALLATION -
Follow the installation instructions for each sensor as provided in each individual product manual.
WARNING
The Control Unit is susceptible to static voltage, static handling precautions should be taken. Connection
of a clean ground to terminal 16 is essential for optimum performance. Since the enclosure is a static
hazard, it should only be cleaned with a damp cloth.
PAGE 11
7. SENSOR PLACEMENT DIAGRAMS
4
5
2
3 3
2 1
3
2
TYPICAL SENSOR PLACEMENT
FOR BUCKET ELEVATORS &
ENCLOSED BELT CONVEYORS
SPEED MONITORING
1 4
Qty 1 - One sensor located on either
side of the tail or boot shaft.
BEARING TEMPERATURE
2
Qty. 4 - One sensor for the bearings
at each end of the drive and tail or
head and boot shafts.
BELT MISALIGNMENT
3
Qty. 4 - Sensors work in pairs, one
for each side of the belt on the drive
and tail or head and boot sections.
PLUG INDICATION
4
Qty. 1 - One sensor located near the
top of the drive section or spouting
by the discharge.
TAIL PULLEY MISALIGNMENT

5
(Enclosed Belt Conveyor)
Qty. 2 - One sensor located on each
3
side of the housing on the conveyor 2
tail section.
1
PAGE 12
8. ELECTRICAL CONNECTION
All wiring must be in accordance with local and national electrical codes and should be undertaken by
All electrical connections are made via 3 sets of terminals provided as shown in image 1.
FUSE RATINGS -
In order to maintain the product certification, all 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.
Model WDC4V4C -
• F1, F2, F3, F5 200 mA maximum.
• F1 to F3 are used to limit the current available to the sensor inputs.
• F5 is used to limit the current available to the internal electronics.
• F6 is not used.
Model WDC4V46C -
• F1 to F3 2 amp maximum, used to limit the current available to the sensor inputs.
• F5 200 mA, used to limit the current available to the internal electronics.
• F6 2 amp maximum, used to protect the AC power supply.
NOTE
To calibrate speed and utilize the Watchdog’s built-in alarm and shut-down capabilities, a motor
interlock (run) signal is required. For typical motor interlock wiring examples, review the wiring
diagrams for terminals 6 & 7.
NOTE
Recommended cable type is Belden 5508FE with 10 conductors each 22 AWG, shielded. Overall
outer diameter is 0.23 inches. Belden 5508FE wire colors are used in all of the sensor wiring
diagrams in section 9.
PAGE 13
WARNING
The unit should ONLY be powered with either a main supply (WDC4V46C model) OR a 24 VDC
(WDC4V4C and WDC4V46C models) NOT BOTH (see specifications).
FIELD WIRING
CONNECTIONS
44 - 0 VDC
43 - Speed Sensor
42 - Pulley Sensor
41 - Plug Sensor
40 - Head Rub - Right
39 - Head Rub - Left
38 - Head Align - Right
37 - Head Align - Left
36 - 24 VDC (Fuse F1)
35 - 0 VDC
34 - Tail Rub - Right
33 - Tail Rub - Left
32 - Tail Align - Right
31 - Tail Align - Left
30 - 24 VDC (Fuse F2)
29 - 0 VDC
28 - Bearing Sensor 6
22 - Ambient Sensor 2
20 - 24 VDC (Fuse F3)
POWER & RELAY CONNECTIONS
06 - Motor Starter Interlock (-)

07 - Motor Starter Interlock (+)
08 - Alarm Relay Normally Open
Image 1 - 09 - Alarm Relay Normally Closed
Inside View - Bottom Board 10 - Alarm Relay Common
WDC4 Wiring Connections 11 - Stop Relay Normally Open
12 - Stop Relay Normally Closed
13 - Stop Relay Common
14 - 120 to 240 VAC Connection
15 - VAC Neutral Connection
16 - Ground or 0 Volt Connection
17 - 24 VDC Connection (+)
18 - 24 VDC Connection (-)
PAGE 14
9. WIRING DIAGRAMS
9.1 WIRING BLOCK DIAGRAM FOR BUCKET ELEVATOR & BELT CONVEYOR -
Plug Switch
(Optional)
Hot Bearing Hot Bearing

Sensor Sensor
Junction
Box
Alignment HEAD / DRIVE Alignment
Top Left Top Right
BELDEN 5508FE
Denotes shielded
cable. Shield to
be grounded at WDC4
one end only. Control Unit
Alignment BOOT / TAIL Alignment
BELDEN 5508FE
Bottom Left Bottom Right
Junction
Hot Bearing Hot Bearing
Ethernet
Box
Sensor Sensor
Speed
Sensor
RJ45
Hazardmon.com Motor Start Switch & Fused
Connection Equipment Supply
(Optional)
NOTE
• Metal conduit and liquid tight should be used to protect the cables from physical damage.
• Left and right are determined when facing the direction the bucket elevator discharges.
PAGE 15
9.2 CONTROL WIRING DIAGRAM FOR WDC4V46C (120 to 240 VAC) -
Alarm and Stop Relays are Shown Energized in the Normal Running Condition
24 VDC
Watchdog Watchdog Supply
Alarm Relay Stop Relay
N/O N/O + -
COM COM 17 18
100 to 240 VAC 120 to 240 VAC
Interlock Watchdog No Connection
N/C N/C
Signal Supply
6 7 8 9 10 11 12 13 14 15 16
The Unit Must

be Grounded
Fuse
2 Amp (Diagram A)
Motor
C Contactor
Stop Start
Overload
Motor Alarm
Contactor Light
(Holding Contact)
Audible
Warning
120 to 240 VAC ± 50/60 Hz Supply
L AC Connection for Model WDC4V46C N
Diagram A: Automatic Shutdown

Control Signal to Feed Equipment
8 CR1
Stop Start
C1
CR1 C1
L N
NOTE
PAGE 16
9.3 CONTROL WIRING DIAGRAM FOR WDC4V4C (24 VDC) -
24 VDC
Watchdog Watchdog Supply
Alarm Relay Stop Relay
N/O N/O + -
COM COM 17 18
24 VDC 120 to 240 VAC
Interlock Supply
N/C N/C
Signal Not Connected
6 7 8 9 10 11 12 13 14 15 16
The Unit Must

be Grounded
Fuse
2 Amp (Diagram A)
Motor
C Contactor
Stop Start
Overload
Motor Alarm
Contactor Light
(Holding Contact)
Audible
Warning
24 VDC Supply
24 VDC DC Connection for Model WDC4V4C 0V

8 CR1
Stop Start
C1
CR1 C1
24 VDC 0V
NOTE
PAGE 17
9.4 CONTROL WIRING DIAGRAM FOR MULTIPLE UNITS WIRED TO THE SAME ALARM -
WATCHDOG CONTROL UNIT #1

Watchdog Watchdog 24 VDC
Alarm Relay Stop Relay Supply
N/O N/O + -
100 to 240 VAC
COM COM
120 to 240 VAC
17 18
N/C N/C
Signal Supply
6 7 8 9 10 11 12 13 14 15 16
The Unit Must

be Grounded
Fuse
(Diagram A)
2 Amp Motor
C Contactor
Stop Start
Overload
Motor Alarm
Contactor Light
(Holding Contact)
External
R1 Relay #1
(Diagram B)

8 CR1
Stop Start
C1
CR1 C1
L N
NOTE
PAGE 18
WATCHDOG CONTROL UNIT #2
Watchdog Watchdog 24 VDC
Alarm Relay Stop Relay Supply
N/O N/O + -
100 to 240 VAC
COM COM
120 to 240 VAC
17 18
N/C N/C
Signal Supply
6 7 8 9 10 11 12 13 14 15 16
The Unit Must

be Grounded
Fuse
(Diagram A)
2 Amp Motor
C Contactor
Stop Start
Overload
Motor Alarm
Contactor Light
(Holding Contact)
External
R2 Relay #2
(Diagram B)
Diagram B: Multiple Watchdog

Relays Linked to Audible Warning
R1
L R2 N
NOTE
outer diameter is 0.23 inches. The shield is to be connected to ground at the Watchdog only.
PAGE 19
Leg (TS) / 1SP, 4BS, 4TS
Leg (RB) / 1SP, 4BS, 4RB
Leg (WDA) 4MA, 4BS
Back OK Image 2
Profile - Select New Profile
9.5 SELECT NEW PROFILE -

MENU > SETUP (PASSWORD) > PROFILE > SELECT NEW PROFILE
To help make the set up process easier for bucket elevator legs, four pre-set program profiles are
available to choose from (Image 2). All four profiles are highlighted in RED at the top of each wiring
diagram (9.7 - 9.10). Refer to section 14 for more information regarding sensor settings.
1. LEG (TS) / 1 SP, 4BS, 4TS 3. LEG (WDA) 4MA, 4BS

• 1 Speed Sensor • 4 Motion Alignment Sensors
• 4 Bearing Temperature Sensors • 4 Bearing Temperature Sensors
• 4 Touchswitch Sensors (Alignment)
4. LEG (TS) / 1SP, 6BS, 6TS
2. LEG (RB) / 1SP, 4BS, 4RB • 1 Speed Sensor
• 1 Speed Sensor • 6 Bearing Temperature Sensors
• 4 Bearing Temperature Sensors • 6 Touchswitch Sensors (Alignment)
• 4 Rub Block Sensors (Alignment)
NOTE
All pre-set program profiles default to the factory settings. To modify settings from the factory
defaults, go to the EDIT SELECTED PROFILE menu.
Wiring diagrams for the four pre-programmed profiles are shown in sections 9.6 - 9.9. More wiring
diagrams are available online, please refer to the WATCHDOG SUPER ELITE SENSOR WIRING
DIAGRAMS manual that can be found at www.go4b.com/usa. This online manual will continue to be
updated as new wiring diagrams are completed and added.
PAGE 20
9.6 WDC3 (RETIRED MODEL) TO WDC4 SENSOR WIRING DIAGRAM
MENU > SETUP (PASSWORD) > PROFILE > SELECT NEW PROFILE > LEG (WDA) 4MA, 4BS
NOTE
Wiring diagram 9.5 is for end users upgrading their WDC3 Watchdog to the WDC4 Watchdog Super
Elite. This basic diagram provides a quick terminal reference between the two models.
WDC3 WDC4 WDC4 Terminal
1 44 0 VDC
---- 43 Speed Sensor

Right
Sensor ---- 42 Pulley Sensor
---- 41 Plug Sensor

Alignment
Top (Head) ---- 40 Head Rub - Right (T#12)
Left ---- 39 Head Rub - Left (T#11)

Sensor
3A 38 Head Align - Right
2A 37 Head Align - Left
5 (1) 36 +24 VDC (F1)
Right 1 35 0 VDC
Sensor
---- 34 Tail Rub - Right (T#10)
Alignment
---- 33 Tail Rub - Left (T#9)
Bottom (Tail)
3B 32 Tail Align - Right
Left
Sensor 2B 31 Tail Align - Left
5 (1) 30 +24 VDC (F2)
---- 29 0 VDC
---- 28 Bearing Temp Sensor (T#6)

RIGHT
Bearing ---- 27 Bearing Temp Sensor (T#5)

Top (Head)
4D 26 Bearing Temp Sensor (T#4)
LEFT
4C 25 Bearing Temp Sensor (T#3)
4B 24 Bearing Temp Sensor (T#2)

RIGHT
4A 23 Bearing Temp Sensor (T#1)
Bearing
Bottom (Tail) ---- 22 Ambient Sensor 2 (T#8)
LEFT
---- 21 Ambient Sensor 1 (T#7)
---- 20 +24 VDC (F3)
PAGE 21
9.7 SENSOR WIRING DIAGRAM PROFILE WITH TOUCHSWITCHES -
MENU > SETUP (PASSWORD) > PROFILE > SELECT NEW PROFILE > LEG (TS)/ 1SP, 4BS, 4TS
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Blue Red
Red 42 Pulley Sensor
Green
Alignment X 41 Plug Sensor
Top (Head) Black
Orange
40 Head Rub - Right (T#12)
White Blue
X
39 Head Rub - Left (T#11)
LEFT
Blue
Red
38 Head Align - Right
Green
X
37 Head Align - Left
36 +24 V (F1)
Black Black
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Bottom (Tail) 35 0 VDC
Black
Orange
X 34 Tail Rub - Right (T#10)
White Blue
LEFT
Blue 33 Tail Rub - Left (T#9)

Red
Green 32 Tail Align - Right
X
31 Tail Align - Left
White
30 +24V (F2)
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Black 28 Bearing Temp Sensor (T#6)
Brown
RIGHT 27 Bearing Temp Sensor (T#5)
Bearing
Top (Head) LEFT Orange
Brown
25 Bearing Temp Sensor (T#3)
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Orange 22 Ambient Sensor 2 (T#8)
Brown
21 Ambient Sensor 1 (T#7)
20 +24V (F3)
PAGE 22
9.8 SENSOR WIRING DIAGRAM PROFILE WITH RUB BLOCKS -
MENU > SETUP (PASSWORD) > PROFILE > SELECT NEW PROFILE > LEG (RB)/ 1SP, 4BS, 4RB
44 0 VDC
RIGHT Black
Brown 43 Speed Sensor
Red
Brown
42 Pulley Sensor
Alignment 41 Plug Sensor

Top (Head)
Blue
Black
LEFT

Brown
36 +24 V (F1)
Brown
Black
RIGHT
Red
Brown
Alignment
Black
Blue 34 Tail Rub - Right (T#10)
LEFT
Brown
33 Tail Rub - Left (T#9)
32 Tail Align - Right
30 +24V (F2)
White
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 23
9.9 SENSOR WIRING DIAGRAM PROFILE WITH MOTION ALIGNMENT SENSORS -
Red
44 0 VDC
Red
Orange 43 Speed Sensor
Motion
RIGHT
Green
Alignment Black
Black 42 Pulley Sensor
Sensor Brown
Blue
White X 41 Plug Sensor
Alignment
Top (Head) Red 40 Head Rub - Right (T#12)
Orange
Motion Green
LEFT
Alignment
Black
Sensor Blue 38 Head Align - Right
Blue
White X 37 Head Align - Left
36 +24 VDC (F1)
Red
Red
Orange
Motion Green
RIGHT
Alignment Black
Sensor
Black 35 0 VDC
Brown
Blue
White X 34 Tail Rub - Right (T#10)
Alignment
Bottom (Tail) Red 33 Tail Rub - Left (T#9)
Orange
Motion Green 32 Tail Align - Right
LEFT
Alignment
Black
Sensor Blue 31 Tail Align - Left
Blue
White X 30 +24 VDC (F2)
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 24
9.10 SENSOR WIRING DIAGRAM PROFILE WITH KNEE OR IDLER PULLEYS -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Alignment Top (Head)
Blue Red
Green
X 41 Plug Sensor
Black
Orange
White Blue
X
LEFT
Black Blue
Orange
X Red 38 Head Align - Right
Alignment Knee or Idler Pulley
White Green
RIGHT
Blue X
Red
Green 36 +24 VDC (F1)
X
Black Black Black
Orange Orange
White
X White Brown
X
RIGHT
LEFT
Alignment Bottom (Tail)
Blue Blue Red

Red Red
Green Green
X X 35 0 VDC
Black
34 Tail Rub - Right (T#10)
Orange
White Blue
X
LEFT
X No Connection Blue
Insulate and Do
Red 32 Tail Align - Right
Green
NOT Connect X 31 Tail Align - Left
30 +24 VDC (F2)
White
White
Blue
Speed
Brown
Black
Yellow 29 0 VDC
Black
Brown
Bearing
Top (Head) LEFT Orange 27 Bearing Temp Sensor (T#5)
Black
Brown
Yellow 25 Bearing Temp Sensor (T#3)

Black
Brown 24 Bearing Temp Sensor (T#2)

RIGHT
Bearing
Bottom (Tail) LEFT Orange 23 Bearing Temp Sensor (T#1)
Black
Brown 22 Ambient Sensor 2 (T#8)
Gray 21 Ambient Sensor 1 (T#7)

Black
Brown 20 +24 VDC (F3)

RIGHT
Bearing
Knee / Idler LEFT Purple
Black
Brown
PAGE 25
WARNING
For any new installation go through a FULL SYSTEM SETUP or select a pre-installed NEW
PROFILE, and then choose CALIBRATE SYSTEM before using the Watchdog for the first time.
NOTE
Appendix A provides a menu tree to help guide you through all of the Watchdog’s available menu
screens and settings.
All new Watchdogs are pre-set to the factory default values (Appendix B).
10. WATCHDOG MAIN LCD SCREEN
WDC4 - Super Elite

www.go4b.com
Initializing...
Firmware Versions:
Main IC (U102): 4.X.X
Graphics IC (U201): 4.X.X
Support IC (U400): 4.X.X
Graphics DB Size: 537

Main DB Size: 537 Image 3
Initial Power Up Screen
10.1 START UP SCREEN (INITIAL POWER UP) -

When power is first applied to the Watchdog WDC4, an opening start-up screen will be displayed for
around 5 seconds (Image 3). The software version (Main IC) for the Watchdog will be listed during start-
up, this will be required should you need to contact 4B for technical support.
The WDC4 is normally supplied with its programmable parameters preset to factory default settings.
Appendix B consists of a number of tables giving all the allowable values. The adjustment of each
parameter is accessed through the EDIT SELECTED PROFILE menu. This menu requires an
engineering password to access and change any system settings.
NOTE
Image 3 shows generic firmware versions and database sizes for illustration purposes, actual screen
information will vary.
PAGE 26
Calibrated
Speed %: 100.0
System RUNNING
Status: No Alarms Detected
Alignment Head: Tail:

HBS:
AUX:
Alarm Log Menu System Info Image 4

Main LCD Screen
10.2 MAIN LCD SCREEN & SENSOR LEDS -

The Watchdog’s LCD screen is not touch sensitive, do not confuse the blue text menus on the LCD with
the actual push buttons (shown in grey). The function of a button is indicated by the blue text menu
displayed on the LCD screen immediately above or to the left of each button and varies according to the
screen being displayed.
The main LCD screen (Image 4) shows the overall status of the Watchdog. The top line shows the
running speed. In this instance it shows the speed of the elevator or conveyor as a percentage of the
total calibrated speed. The next line shows the system status and any current faults or alarm conditions.
Under system status you can see the status for all of the sensors: alignment, bearing temperature and
auxiliary sensors. Disabled sensors are grey, if a sensor is enabled it becomes highlighted in red, green
or amber. Green signifies the sensor is in a normal state. Red indicated the sensor is in Alarm. Amber
relates to the temperature sensors and indicates a fault with the sensor or the sensor wiring.
Head & Tail Bearing Pulley Plug Ambient

Alignment Temperature Alignment Sensor Temperature
The sensor LEDs provide a quick view status of the head and tail alignment sensors (top left, top right,
bottom left, bottom right), along with pulse indication and alarm and stop status (Image 5).
SENSORS
HEAD
TAIL
PULSE
ALARM
Image 5
Sensor LEDs
STOP
PAGE 27
10.3 ALARM LOG BUTTON -
To view the last 40 events and alarms, press the ALARM LOG button on the main screen (Image 3).
The alarm log screen should now appear (Image 5). Pressing the UP and DOWN arrows allows you
to scroll through the alarms. Pressing the MORE INFO button gives details of the highlighted alarm.
Cleared alarm conditions are also logged. If an SD card is installed, all alarm details (not just the last
40) will be stored on the card.
WARNING
If the SD card is removed and more alarms occur, they will not be logged when the SD card is re-
inserted. For uninterrupted historical data logging, 4B recommends using HazardMon.com.
! #29 26/02/16 19:16:47 - AMB1 dR Date: Fri, Feb 26 2016

Time: 20:25:57
! #30 26/02/16 20:25:57 - HBS2 dR Entry Type: Alarm Detected
! #31 26/02/16 20:35:27 - AMB2 S/C Entry Source: HBS2
Condition: Absolute Alarm
#32 26/02/16 20:55:12 - HBS3 OK Temperature unites: Deg F
#33 26/02/16 21:10:55 - AMB1 OK Sensor Temperature [Deg]: 163
Absolute Alarm [Deg]: 140
! #34 26/02/16 21:15:35 - AMB1 dR
#35 26/02/16 22:35:32 - AMB1 OK
#36 26/02/16 22:45:57 - HBS1 OK
Back More Info Back Image 6

Alarm Log / More Info
10.4 MENU BUTTON -

The MENU button allows access to all of the sub menu functions. Most of the sub menu areas require
the entry of a password. Please refer to section 12.1 for information about the password.
10.5 SYSTEM INFO BUTTON -

The SYSTEM INFO button allows the viewing of the system information screens (1 - 9). No password is
required to enter these screens. Press NEXT or PREVIOUS to scroll forward or backward through the
each of the screens. The EXIT button terminates the function and returns you back to the main screen.
See pages 28 - 31 for screen images for each of the seven system info screens.
1 of 9: Speed Info
Type Value
Calibration Speed [PPM]: 199.7

Current Speed [PPM]: 200.0
Current Speed [%]: 100.3
Speed Source: Dedicated
Previous Next Exit Image 7

Speed Info
10.6 SPEED INFO (1 OF 9) -

The speed info screen (Image 7) shows information regarding the calibrated speed (PPM - pulses per
minute), current speed (PPM - pulses per minute), current speed (percentage) and the speed source
(detection method). Refer to 14.5 for more detail about speed settings.
PAGE 28
2 of 9: Head Align Info
Type: PULSED
Current Value [%]: 0 2 of 9: Head Align Info
Alarm Value [%]: 66
Left Pulse Rate [PPM]: 0
Right Pulse Rate [PPM]: 0 Type: CNT 2 of 9: Head Align Info
Current State Left: ON
Current State Right: ON Type: RUB
Previous Next Exit Alarm State: OFF
Sensor Value Abs Rel Trip

Image 8-A T#11 35 140 30 AMB1
Head Align Info - Pulsed Sensor Previous Next Exit T#12 69 140 30 AMB1
Image 8-B
Head Align Info - Contact Sensor Previous Next Exit
Image 8-C
Head Align Info - Rub Block Sensor
10.7 HEAD ALIGN INFO (2 OF 9) -

The head align info screen shows the head alignment sensor type and the current values for the sensor.
The sensor type can be off, pulsed, contact (CNT) or rub block (RUB). The display will vary depending
upon the sensor type (Image 8 A-C). Refer to section 14.6 for more information about head alignment
settings.
3 of 9: Tail Align Info
Type: PULSED
Current Value [%]: 0 3 of 9: Tail Align Info
Alarm Value [%]: 66
Left Pulse Rate [PPM]: 0
Right Pulse Rate [PPM]: 0 Type: CNT 3 of 9: Tail Align Info
Current State Left: ON
Current State Right: ON
Type: RUB
Previous Next Exit Alarm State: OFF

Image 9-A T#11 35 140 30 AMB1
Tail Align Info - Pulsed Sensor Previous Next Exit T#12 69 140 30 AMB1
Image 9-B
Tail Align Info - Contact Sensor Previous Next Exit
Image 9-C
Tail Align Info - Rub Block Sensor
10.8 TAIL ALIGN INFO (3 OF 9) -

The tail align info screen shows the tail alignment sensor type and the current values for the sensor.
The sensor type can be off, pulsed, contact (CNT) or rub block (RUB). The display will vary depending
upon the sensor type (Image 9 A-C). Refer to section 14.7 for more information about tail alignment
settings.
PAGE 29
AMB 1: 86.4
4 of 9: HBS Info AMB 2: 87.6
Sensor Value Abs. Rel. Trip
HBS#1 112 140 30 N/A

HBS#2 102 140 30 N/A
HBS#3 112 140 30 N/A
HBS#4 163 140 30 N/A
HBS#5 OFF N/A N/A N/A
Image 10
Previous Next Exit HBS Info
Temperature Sensors
10.9 HBS INFO (4 OF 9) THRU (6 of 9) -

The hot bearing sensor (HBS) screens show the actual temperature value (Value) of all the enabled
bearing sensors and any selected absolute (Abs.) and relative (Rel.) alarm trip points. Where bearing
sensors are not selected, the value will show OFF and the remaining information will be displayed in
grey. Normal temperature values are displayed in green, and will change to red when the sensor value
is in an alarm state.
• Screen 4 shows information for sensors HBS#1 - HBS#6
• Screen 5 shows information for sensors HBS#7 - HBS#12 (NTC expansion board required)
• Screen 6 shows information for sensors HBS#13 - HBS #18 (NTC expansion board required)
Refer to section 14.8 for more information regarding temperature settings.
NOTE
HBS INFO can refer to any NTC type temperature sensor. While originally developed for displaying
hot bearing sensors (HBS), these menus can refer to any NTC type temperature sensor such as
those used with brass rub blocks (ADB Series) or surface temperature sensors (WDB7 Series).
7 of 9: AUX Sensor Info
Plug
Current State: -
Alarm State: -
Pulley
Current State: -
Alarm State: -

AUX Sensor Info
10.10 AUX SENSOR INFO (7 OF 9) -

The Watchdog supports two auxiliary sensors, pulley alignment “Pulley” and plug condition “Plug”. The
AUX Sensor Info screen (Image 11) shows the current enabled and alarm state for these sensors. Refer
to section 14.9 for more information regarding the auxiliary sensors.
PAGE 30
8 of 9: System Info
Date: 21 Feb 2016

Time 08:08:37
Runtime Hours: 66:47
Main Version: 4.5.1
Graphics Version: 4.5.1
Btm Version: 4.3.9
DB Size: 537

System Info
10.11 SYSTEM INFO (8 OF 9) -

The system info screen (Image 12) shows the time and date along with the number of runtime hours
elapsed. The runtime is the actual number of run hours that the equipment has been running and not
how long the Watchdog has been switched on. Refer to section 18 for more information about setting
the time and date. This screen also shows the software versions and database size.
9 of 9: Network Info
IP SETTINGS
DHCP: ON
IP Address: 192.168.1.4 ®
HAZARDMON
Status: CONNECTED
ID: 4B:19:4B:84

Network Info
10.12 NETWORK INFO (9 OF 9) -

The Watchdog has an advanced interface to allow the remote monitoring of data through an Ethernet
connection. This cloud based monitoring system is known as HazardMon.com, and the network info
screen (Image 13) shows the settings required to use HazardMon.com. These settings are adjustable
and the information is made available for the purposes of diagnostics.
HazardMon.com network settings can be found in the Network Settings Menu (Section 20).
For more information about HazardMon.com, contact 4B or visit us on the web at www.go4b.com/usa.
PAGE 31
11. VIEW SETTINGS
View Settings
Setup
Reset Eng. Password
Exit OK Image 14
View Settings
11. VIEW SETTINGS -

MENU > VIEW SETTINGS
Due to the total number of screens used within the view settings menu, not all will be illustrated.
You can view the system settings on the Watchdog without a password by choosing VIEW SETTINGS
from the menu (Image 14). This will allow you to scroll through all of the current settings for the
SYSTEM, SPEED, ALIGNMENT, TEMPERATURE and AUXILIARY menus.
The number of pages and information in each section will vary depending upon what settings are
chosen for each section. For example, in the TEMPERATURE menu, if HBS1 (hot bearing sensor) is
not enabled, then the setting details for HBS1 will not be displayed.
This is a read only area, no changes can be made within the VIEW SETTINGS menu. Changes can
only be made under SETUP or FACTORY SETTINGS, which are password protected menus.
NOTE
Settings shown in yellow text indicate that the value is locked. The value can only be modified within
the FACTORY SETTINGS menu, which requires an administrator password.
PAGE 32
12. SETUP
View Settings
Setup
Reset Eng. Password
Exit OK Image 15
Setup
12. SETUP -
MENU > SETUP (PASSWORD)
There are seven password protected settings within the setup menu (Image 15): PROFILE, TEST,
FACTORY SETTINGS, SD CARD, TIME & DATE, CHANGE PASSWORD and NETWORK. All of these
settings are explained in detail within individual sections of this manual.
12.1 PASSWORD -
In order to make any system changes to the Watchdog, an engineering password is required. The
default engineering password set at the factory is BBBB.
You can change the password from the factory setting within this menu by choosing CHANGE
PASSWORD. The password is from 1 to 8 characters long, and can be any combination of the letters A,
B and C. If you change the password from the factory default, make a note of your new password.
NOTE
If the engineering password has been changed from the factory default and you have forgotten your
new password, contact 4B for assistance.
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 16
Setup Menu
NOTE
PAGE 33
13. RESET ENGINEERING PASSWORD
View Settings
Setup
Reset Eng. Password
Exit OK Image 17
Reset Engineering Password
13. RESET ENGINEERING PASSWORD -

MENU > RESET ENG. PASSWORD
If the engineering password has been changed from the factory default and you have forgotten your new
password, it can be reset. In order to perform a password reset, you will need to contact 4B technical
support and supply them with the four digit code displayed on the RESET ENG. PASSWORD screen
(Image 18). Once your code has been verified by the 4B technician, they will provide a secondary code
to enter into your unit which will reset the engineering password back to the factory default of BBBB).
Please note the code number

and phone 4B X
8855
OK
Image 18
A B C Reset Engineering
Password Screen
PAGE 34
14. PROFILE
14. PROFILE -
MENU > SETUP (PASSWORD) > PROFILE
The first choice under the SETUP menu is PROFILE (Image 16), which allows you to edit individual
section settings without having to go through the entire FULL SYSTEM SETUP. Once PROFILE has
been selected, you will see the next sub-menu (Image 19) where you can EDIT SELECTED PROFILE,
RESTORE DEFAULTS or SELECT NEW PROFILE.
Edit Selected Profile

Restore Defaults
Select New Profile
Back OK Image 19
Profile Menu
14.1 EDIT SELECTED PROFILE -

MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE
Menu choices in this sub-menu (Image 20) include: CALIBRATE SYSTEM, FULL SYSTEM SETUP,
SYSTEM, SPEED, ALIGNMENT, TEMPERATURE and AUXILIARY.
Calibrate System
Full System Setup
System
Speed
Alignment
Temperature
Auxiliary
Back OK Image 20
Edit Selected Profile Menu
NOTE
WARNING
When you have completed making changes to the Watchdog profile setup, you will be prompted to
save your changes. You must enter YES, or your changes will not go into effect.
PAGE 35
NOTE
When the Watchdog is powered up it reads the stored setup parameters from its memory. These will
be used during operation. New Watchdogs are set to the factory default values (Appendix B).
14.2 CALIBRATE SYSTEM -

MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > CALIBRATE SYSTEM
The Watchdog must to be calibrated to correctly monitor the speed of an elevator or conveyor belt.
Select CALIBRATE SYSTEM in the menu section (Image 20). Press the CALIBRATE button, you will
then be asked to start the elevator or conveyor. A progress bar will display the calibration percentage
(Image 21). After calibration is complete, the screen will display CALIBRATION SUCCESSFUL and
the LCD will return to the main screen. If the calibration procedure fails, the screen will display NOT
CALIBRATED CALIBRATION FAILED! If this occurs, follow the SYSTEM RECALIBRATION instructions
below.
Press “Calibrate”
to start the calibration process.
Warning: This action will
erase current system settings.
Startup Delay [s]:
Current Speed [PPM]:
0%
Image 21
Cancel Calibrate Edit Selected Profile -
Calibrate System
• 14.2.A SYSTEM RECALIBRATION - The Watchdog can be re-calibrated at any time while the
machine is running normally by selecting the CALIBRATE SYSTEM option as described above. You
are strongly advised against indiscriminate re-calibration, as you may be attempting to calibrate the
unit when the machine is not running normally. If you have persistent alarm/stop conditions there is
something wrong with the machine or with the adjustment of the system.
If the STOP button is operated on the motor starter (interlock signal removed) during calibration,
the Alarm and Stop relays will be de-energized and calibration will be aborted. Calibration will also
be aborted if any fault conditions occur, i.e. the elevator fails to start, or stops during the procedure.
Start calibration again if this happens, proceed from section 14.2 above, after rectifying the fault
condition.
• 14.2.B INCORRECT CALIBRATION - If the unit was calibrated at less than normal speed, it will
display an over speed alarm / stop condition and possibly stop the machine when running at normal
speed. This indicates that the calibration is incorrect and the belt tension should be checked and
adjusted as required. The unit should then be re-calibrated (see section 14.2.A).
• 14.2.C START UP TIMER - When the equipment being monitored starts, the Watchdog’s motor
interlock input is energized and a start-up timer begins to time out. When the start-up timer expires,
the input speed is compared to the calibrated speed. If the input speed is within the preset limits no
action is taken, however if it is not an alarm will occur.
NOTE
If you proceed with the calibration cycle, the current calibration settings will be erased. If you do not
wish to continue with the calibration cycle press the CANCEL button.
PAGE 36
Calibrate System
Full System Setup
System
Speed
Alignment
Temperature
Auxiliary
Image 22
Edit Selected Profile -
Back OK
Full System Setup
14.3 FULL SYSTEM SETUP -

MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > FULL SYSTEM SETUP
Watchdog control units are preset with factory default values (Appendix B). All new installations should
go through either a FULL SYSTEM SETUP or use one of the pre-installed profiles available under
SELECT NEW PROFILE (section 14.11) before using the Watchdog for the first time.
FULL SYSTEM SETUP will guide you through each of the five sections: SYSTEM, SPEED,
ALIGNMENT, TEMPERATURE, and AUXILIARY. These can also be accessed individually as outlined
below.
After the Watchdog has been setup, all settings will be stored within the controller’s memory.
Calibrate System
Full System Setup
System
Speed
Alignment
Temperature
Auxiliary
Image 23
Back OK
System
14.4 SYSTEM -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > SYSTEM
• 14.4.A TEMPERATURE UNITS (1 of 6) - Fahrenheit (°F) or Celsius (°C) can be selected. The
default is Fahrenheit. The Watchdog will reset temperatures to the factory default settings if the
temperature unit is changed, be sure to check all settings if this occurs to ensure proper operation.
• 14.4.B PRE ABS ALARM (2 of 6) - Can be turned ON or OFF (default). If turned ON, and the
bearing temperature increases to within 10° F (5° C) of either the RUB BLOCK ABSOLUTE ALARM
(section 14.6.C), the HBS ABSOLUTE ALARM (section 14.8.B), or the AMB ABSOLUTE ALARM
(section 14.8.I) an alarm will occur. The system will not shut down due to this alarm, however if the
equipment is stopped it can not be re-started until this alarm has been cleared. The alarm event is
also logged in the ALARM LOG.
• 14.4.C NEGATIVE DIFFERENTIAL ALARM (3 of 6) - Can be turned ON or OFF (default), and is
used when monitoring temperature using a relative ambient temperature alarm source. During
normal operation, it would be unusual for the bearing temperature value to be below that of the
ambient temperature source (default OFF). If turned ON, and a bearing temperature value drops
below the value of the ambient source by an amount greater than the relative alarm value, an alarm
will occur. The alarm is logged in the ALARM LOG.
• 14.4.D RATE OF RISE START UP DELAY [MIN] (4 of 6) - Allows a delay when the system is
started before any rate of rise in temperature is monitored. This allows the system to reach a steady
state before alarming. This level setting can be set from 0 - 5 minutes, the default is 5.
PAGE 37
Additional expansion boards can be installed inside the Watchdog WDC4 in positions EXP1 and EXP2.
1. NTC expansion board (WDC4-AUXI-6NTC) provides the ability to connect 6 additional NTC
temperature sensors to the WDC4. A maximum of two can be installed, providing a total of 12
additional NTC inputs.
2. PLC expansion board (WDC4-AUXO-4SSR) provides the ability to connect additional signals
from the WDC4 to a PLC. The board has 4 Solid State Relays that can be used to indicate alarm
conditions related to speed, alignment, temperature and auxiliary alarms as four separate signals. A
maximum of two can be installed, providing a total of 8 separate alarm signals.
Board types can be installed in pairs as describe above, or mixed (1 NTC and 1 PLC). Boards can be
pre-installed at the factory when ordering a new Watchdog WDC4, or installed into existing control units
already in the field. For installation instructions and board specifications, refer to either the NTC or PLC
expansion board manual.
• 14.4.E EXPANSION 1 (5 of 6) - Choices are NTC BOARD, RELAY BOARD or OFF (default) as
shown in the system settings screen (Image 24). If NTC BOARD or RELAY BOARD are selected,
you will need to confirm your selection by choosing YES to save the new setting (Image 25).
• 14.4.F EXPANSION 2 (6 of 6) - Choices for expansion board 2 are the same as expansion board 1
above (14.4.E).
NOTE
For NTC expansion boards, you will need to edit the profile settings for temperature sensors (14.8).
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > TEMPERATURE
System Settings
Expansion 1
OFF
NTC Board
Relay Board
05 of 06
Previous Cancel Next

Image 24
Expansion Boards (1 of 2 Shown)
Save
This will overwrite existing data.
No Yes
Image 25
Expansion Board Confirmation
WARNING
Expansion boards are NOT suitable for HOT INSTALL. Expansion boards should NOT be installed
while the WDC4 is powered. Refer to the board’s manual for installation information or contact 4B.
PAGE 38
Calibrate System
Full System Setup
System
Speed
Alignment
Temperature
Auxiliary
Image 26
Back OK
Speed
14.5 SPEED -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > SPEED
• 14.5.A SPEED MONITORING - This section allows you to enable or disable speed monitoring. The
default setting is ON, but it can only be disabled by selecting OFF in the FACTORY SETTINGS menu
(Section 16).
• 14.5.B SCALING UNITS - Allows the selection of the main screen speed units. Four options are
available:
1. PPM - Pulses Per Minute
2. RPM - Revolutions Per Minute
3. USR - User Defined
4. % - Percentage of Calibrated Speed (Default)
• 14.5.C SCALING FACTOR - If either RPM or USR is selected then a scaling factor must be entered.
The default value is 20.
PPM and % are automatically calculated. Display = (Input PPM X Scale factor) / 12.
1. Example: Tons / Hour -
If the elevator normal speed is 420 pulses per minute (PPM) and the desired display is 3000
tons /hour then the scale factor = (3000 X 12) / 420 = 85.71.
2. Example: Feet / Min -
If there are 9 inches between each bucket and you wish to display speed in feet / minute then set
the scale factor to 9. This is a special case of when the scale factor is set to the bucket spacing
in inches then the display will show belt speed in feet / minute.
3. Example: Meters / Min -
Scale factor = 12 X bucket pitch in meters. If the pitch is 23 cm, then the scale factor =
(12 X 0.23) = 2.76.
• 14.5.D SPEED DETECTION SOURCE - Three options determine the different ways to measure
speed.
1. MAS SPEED INPUT -
This option is selected when you intend to use multiple speed detectors such as WDA. MAS
(Motion and Alignment Sensor) detectors are usually used to detect the passage of buckets when
the elevator belt is in motion. As each bucket passes the sensors a pulse is generated and the
Watchdog uses these pulses to measure speed and the alignment of belt between the sensors.
2. DEDICATED SPEED INPUT (Default) -
The dedicated speed input is selected when a single speed sensor is to be used. Usually this
sensor is used with a Whirligig and is connected to the boot / tail end of the elevator or conveyor
belt. The Watchdog uses the pulses from the sensor to determine speed.
PAGE 39
3. DIFFERENTIAL SPEED -
Differential speed monitoring is selected when you intend to monitor an elevator or conveyor belt
that may intentionally vary in speed as part of the process or when that belt is driven by a variable
speed controller.
The monitoring of differential speeds usually takes place between the top of the elevator (the
drive end) and the bottom (the driven end). This allows the varying speed to be monitored while
comparing the drive speed with the driven speed, differences between the two being the result of
belt slippage.
Once differential speed is enabled the Watchdog expects 2 independent signals by which to
measure the speed of an elevator or conveyor belt. This method allows the monitoring of both
fixed and variable speed elevators.
The 2 speed inputs are connected in the following manner.
Speed 1 is connected to the dedicated speed input. The source for the pulses is usually a
Whirligig mounted on the head (or main) drive assembly.
Speed 2 can be derived from a number of different sources but will usually be connected to either
the head alignment sensor inputs, tail alignment sensor inputs or both head and tail together.
The source for the speed can also be derived from a Whirligig connected to the tail shaft (or
driven), the pulsed output being passed through the Touchswitch alignment sensor pairs into the
Watchdog alignment inputs.
An alternative speed source could be from WDA alignment sensors (MAS) installed to detect
buckets on the elevator belt. When MAS are used the Watchdog always uses the highest speed
input for speed 2.
For the differential speed option to work correctly it is necessary to enable alignment monitoring
on either the tail and/or head and for them to be set as “Pulsed” inputs.
The speed monitoring is performed by comparing the two different speed sources. They do not
need to be the same speed since the speed is determined by checking the difference between
the two speeds or rather the ratio of one speed to the other. Because speed 2 is connected to 2
or 4 inputs, the highest measured speed is always used.
Although calibration is not required in the usual way on a variable speed elevator it is used to
determine the ratio of speed 1 to speed 2. This approach allows two completely different pulse
rates to be compared and if either changes in relationship to the other action can be taken.
During the calibration cycle the Watchdog checks the two different speeds and calculates the
RATIO of one to the other. After the calibration cycle is complete this ratio is used to determine if
there is any difference in relationship between the speeds. If this difference is sufficient then the
Watchdog reacts in the usual manner and will generate an alarm or stop action depending upon
the outcome of the compare.
Because the relationship between the two speeds determines the action to be taken the speed of
the elevator can rise and fall (variable speed) and as long as the two speeds are in the same
relationship (ratio) to each other, the Watchdog will not generate a fault condition.
The permitted ratio is 0.1 to 10.0, values outside this range will result in a calibration failure.
WARNING
PAGE 40
Below are examples of how the Watchdog sees the two speeds:
• Example 1:
Speed 1 - 426 PPM
Speed 2 - 987 PPM
Ratio of speed 2 to speed 1 = 2.316 (987/426)
If the elevator was to increase in speed so that speed 1 was now 556 PPM then speed 2 should
be speed (556 X 2.316) or 1288 PPM (these figures are rounded).
Speed 1 at 426 PPM and speed 2 at 987 PPM has the same relationship as speed 1 at
556 PPM and speed 2 is 1288 PPM. In both cases the elevator is running at 100% or the
relationship of the two speeds is 100% of the expected ratio.
• Example 2:
Speed 1 - 583 PPM
Speed 2 - 416 PPM
Ratio of speed 2 to speed 1 = 0.713 (416/583)
If the elevator was to decrease in speed so that speed 1 was now 480 PPM then speed 2
should be speed (480 X 0.713) or 342 PPM (these figures are rounded).
Speed 1 at 583 PPM and speed 2 at 416 PPM has the same relationship as speed 1 at
480 PPM and speed 2 as 342 PPM. In both cases the elevator is running at 100% or the
relationship of the two speeds is 100% of the expected ratio.
Once the ratio between speed 1 and 2 is established then it is possible to determine if the
belt is slipping. Because speed 1 is derived from the head pulley drive it can be considered a
reference because it will only normally vary as a result of deliberate action to speed up or slow
down the elevator belt. Speed 2 can vary either because of a variation in speed 1 or if the belt
begins to slip for any reason. Because we know the ratio of speed 1 to speed 2 then we can
check to see the amount of belt slip.
• Example 3:
Speed 1 is 350 PPM. The ratio after calibration is 1.256 therefore speed 2 should be 440 but it
is currently 405. This means that he belt is running at 92% of the expected speed (or slipping
by 8% (405/440 X 100)). The default alarm level for under-speed is 10% so as yet the slip
isn’t a problem. If speed 2 was to drop to 390 then the error is 88% of the expected speed (or
slipping by 12%) therefore the Watchdog will generate an under speed alarm.
The same principle applies no matter what the elevator speed is providing that the values
measured for speed 1 and speed 2 remain within the maximum and minimum speed limits of
the Watchdog.
• 14.5.E ACCELERATION MONITORING LEVEL - When disabled (0), the Watchdog will not monitor
speed during the start-up delay. When enabled, the Watchdog will monitor the speed during start-
up delay and initiate a stop condition if the system speed is not increasing according to the set
acceleration value.
Level settings range from 0 - 9, the default is 5. See below for more information on acceleration
monitoring values:
0 - Off, no monitoring will take place.
1 - System speed should reach at least 10% of calibrated speed by 90% of start-up delay.
5 - Default setting, system speed should reach 10% of calibrated speed by 10% of start-up delay,
20% by 20% of start-up delay, etc.
9 - System speed should reach at least 90% of calibrated speed by 10% of start-up delay.
PAGE 41
• 14.5.F NUMBER OF STARTS / MINUTE - This function is used to prevent damage to the motor
and motor start circuitry by limiting the number of times in a minute the system can be started. This
setting can range from 1 to 10, the default is 3.
When the Watchdog is started and a shutdown fault occurs, a jog delay is introduced. For example,
if the “Number of Starts / Minute” is set to 4, then a delay of 15 seconds before restarting would be
introduced (60 seconds / 4 starts per minutes = 15 seconds between starts).
The jog countdown is shown under SYSTEM STATUS on the Watchdog’s main screen.
• 14.5.G START UP DELAY [S] - The delay in seconds before the system starts to fully monitor the
system for possible alarm conditions. This setting can range from 1 to 15 seconds, the default is 5.
A countdown is shown on the status screen.
This delay allows elevator or conveyor belts to start-up and achieve a correct running state before
the general alarm conditions are monitored. The exceptions to this are acceleration monitoring,
bearing temperature and plug condition.
If acceleration monitoring is enabled (a value other than 0), and the acceleration speed is outside of
the permitted parameters, the Watchdog will stop the elevator or conveyor in accordance with the
acceleration monitoring level.
• 14.5.H UNDERSPEED ALARM [%] - The percentage of underspeed at which the system will cause
an alarm. The percentage can be set from 1% to 10%, the default is 10%.
If the measured speed falls below the calibrated speed by this preset percentage, the Watchdog
will generate an underspeed alarm condition. If this alarm persists longer than the underspeed stop
delay, then the Watchdog will stop the elevator or conveyor.
• 14.5.I SEVERE UNDERSPEED [%] - The percentage of severe under speed at which the system
will shut down. The percentage can be set from 1% to 20%, the default is 20%.
If the measured speed falls below the calibrated speed by this preset percentage, the Watchdog will
generate a severe underspeed condition and stop the elevator or conveyor.
• 14.5.J UNDERSPEED ALARM DELAY [S] - The delay in seconds before the system alarms after
a sensor trips. The delay can be set from 0 to 10 seconds, the default is 1. Configuring the delay
above zero can help prevent nuisance alarms.
When a sensors trips, a cumulative alarm delay counter starts to count down. If the alarm condition
ends before the delay counter reaches zero, the delay counter starts to count back up to the original
alarm delay value and the Watchdog will not alarm.
If the system reaches the UNDERSPEED ALARM DELAY time, the alarm relay is de-energized, the
ALARM LED on the Watchdog lights up amber, and a warning showing the source of the alarm is
displayed in red on the main LCD screen. The alarm event is also logged in the ALARM LOG.
• 14.5.K UNDERSPEED STOP DELAY [S] - The delay in seconds before the system shuts down.
The delay can be set from 0 to 60 seconds, the default is 60.
A cumulative stop delay counter starts to count down simultaneously with the alarm delay. If the
alarm condition ends before the delay counter reaches zero, the counter starts to count back up to
the original stop delay value and the Watchdog will not stop the system.
After the alarm delay time has elapsed and the alarm has been triggered, the stop delay timer will be
displayed on the main LCD. If the Watchdog reaches the UNDERSPEED STOP DELAY time, the
stop relay is de-energized, the STOP LED on the Watchdog lights up red, and a warning showing
the source of the stop condition is displayed in red on the main LCD screen. The stop event is also
logged in the ALARM LOG.
The stop delay does not apply to SEVERE UNDERSPEED[%] conditions. If equipment reaches the
set severe percentage, it will stop immediately without any delay.
PAGE 42
• 14.5.L OVERSPEED [%] - The percentage of over speed at which the system will cause an alarm.
The percentage can be set from 1% to 10%, the default is 10%.
If the measured speed rises above the calibrated speed by this preset percentage, the Watchdog will
generate an overspeed alarm. If this alarm persists longer than the “Overspeed Stop Delay” time,
then the Watchdog will stop the elevator or conveyor.
• 14.5.M SEVERE OVERSPEED [%] - The percentage of severe overspeed at which the system will
shut down. The percentage can be set from 1% to 20%, the default is 20%.
If the measured speed rises above the calibrated speed by this preset percentage, the Watchdog
will generate a severe overspeed stop condition. This condition results in an immediate stop of the
elevator or conveyor.
• 14.5.N OVERSPEED ALARM DELAY [S] - The delay in seconds before the system alarms after
a sensor trips. The delay can be set from 0 to 10 seconds, the default is 1. Configuring the delay
above zero can help prevent nuisance alarms.
If the system reaches the OVERSPEED ALARM DELAY time, the alarm relay is de-energized, the
ALARM LED on the Watchdog lights up amber, and a warning showing the source of the alarm is
displayed in red on the main LCD screen. The alarm event is also logged in the ALARM LOG.
• 14.5.O OVERSPEED STOP DELAY [S] - The delay in seconds before the system shuts down. The
delay can be set from 0 to 60 seconds, the default is 60.
After the alarm delay time has elapsed and the alarm has been triggered, the stop delay timer will
be displayed on the main LCD. If the Watchdog reaches the OVERSPEED STOP DELAY time, the
stop relay is de-energized, the STOP LED on the Watchdog lights up red, and a warning showing
the source of the stop condition is displayed in red on the main LCD screen. The stop event is also
logged in the ALARM LOG.
The stop delay does not apply to SEVERE OVERSPEED[%] conditions. If equipment reaches the
set severe percentage, it will stop immediately without any delay.
Calibrate System
Full System Setup
System
Speed
Alignment
Temperature
Auxiliary
Image 27
Back OK Edit Selected Profile -
Alignment
14.6 ALIGNMENT (HEAD) -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > ALIGNMENT
Settings in this menu allow you to monitor alignment at the head and/or tail sections of your equipment.
Sensors are installed in pairs (left side - right side) at the head and/or tail sections.
PAGE 43
• 14.6.A HEAD SENSOR PAIR - This section allows you to enable or disable head alignment
monitoring. Four options are available:
1. OFF
2. Pulsed
3. Contact (Default Setting)
4. Rub Block
PULSED - Choose this option if using 4B WDA Motion Alignment Sensors, or Touchswiches that
are receiving pulses from a P800. The number of pulses detected between the sensors from the
right and left sides are compared, if the ratio between the two is less than 66% an alarm condition is
generated. The value of 66% is fixed and cannot be altered by the user.
CONTACT (Default) - Choose this option if using 4B Touchswitch sensors (not receiving pulses
from a P800). In this mode, the Watchdog looks for a change in signal level representing the belt
alignment condition.
- ON: +24V into the terminal is seen as Normal (no belt misalignment).
- OFF: 0V into the terminal is seen as a belt misalignment condition.
RUB BLOCK - Choose this option if using rub blocks to detect belt misalignment. A rub block
is basically a temperature sensor mounted to a special block (usually brass). If the belt rubs
constantly against the rub block, heat from friction will cause the rub block’s temperature to rise. If
the temperature rises above the pre-set limit, a misalignment alarm will be generated. There are a
number of settings available for use with the rub block.
• 14.6.B HEAD TRIGGER ALARM - If CONTACT is selected within the HEAD SENSOR PAIR menu,
a trigger alarm must be selected. The default is OFF, meaning that an alarm will be triggered when
the contact is off (0V). If ON is selected, the alarm will be triggered when the contact is on (+24V),
this option (ON) is only available under FACTORY SETTINGS.
• 14.6.C ABSOLUTE ALARM [DEG] - If RUB BLOCK is selected within the HEAD SENSOR PAIR
menu, an absolute temperature value must be selected. If the measured temperature of the rub
block exceeds this value, an alarm is generated. This level setting ranges from 32° to 230° F (1° to
110° C), the default is 140° F (60° C). For PRE ABS ALARM information, refer to section 14.4.B.
• 14.6.D RELATIVE ALARM SOURCE - If RUB BLOCK is selected within the HEAD SENSOR PAIR
menu, a relative alarm source must be selected. Choices are OFF, AMB1, AMB2 or OPPOSITE, the
default is OFF.
If either AMB1 or AMB2 are selected, the relative alarm temperature is relative to the ambient
temperature. If OPPOSITE is selected, then the relative alarm for each sensor is relative to the
opposite sensor’s temperature.
• 14.6.E RELATIVE ALARM - If RUB BLOCK is selected within the HEAD SENSOR PAIR menu
and RELATIVE ALARM SOURCE is set to AMB1, AMB2 or OPPOSITE, a relative alarm must be
selected.
If the measured temperature of the rub block exceeds the relative temperature value, an alarm is
generated. This level setting ranges from 2° to 90° F (1° to 50° C), the default is 30° F (15° C).
• 14.6.F HEAD: RATE OF RISE [DEG/MIN] - If RUB BLOCK is selected within the HEAD SENSOR
PAIR menu and RELATIVE ALARM SOURCE is set to AMB1, AMB2 or OPPOSITE, you can choose
to turn the rate of rise ON (default) or OFF. If RELATIVE ALARM SOURCE is set to OFF, you will not
be able to choose RATE OF RISE.
If turned ON, this setting monitors the rub block’s rate of rise of temperature in degrees per minutes.
If a rate of rise is detected equal to or greater than this value, an alarm will be generated and the
alarm relay being de-energized. This level setting ranges from 2.0 to 5.0, the default is 3.0.
PAGE 44
NOTE
The temperature setting can be set to either Fahrenheit or Celsius, see FULL SYSTEM SETUP.
NOTE
On the HEAD ALIGN INFO screen (Image 28), T#11 is the sensor on the head left and T#12 is head
right.
2 of 7: Head Align Info
Type: RUB

T#11 35 140 30 AMB1
T#12 78 140 30 AMB1
Image 28
Previous Next Exit System Info Screen
Head Align Info - AMB1
Image 28 shows the SYSTEM INFO screen for HEAD ALIGN INFO when AMB1 has been selected.
In the example above, an alarm will be generated when the rub block’s temperature is equal to or
greater than AMB1 +30º, or if the value exceeds the absolute value of 140°. T#12 is shown in red since
it is in an alarm state.
• 14.6.G HEAD ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
trips. The delay can be set from 0 to 10 seconds, the default is 1. Configuring the delay above zero
can help prevent nuisance alarms.
If the system reaches the HEAD ALARM DELAY time, the alarm relay is de-energized, the ALARM
LED on the Watchdog lights up amber, and a warning showing the source of the alarm is displayed in
red on the main LCD screen. The alarm event is also logged in the ALARM LOG.
• 14.6.H HEAD STOP DELAY [S] - The delay in seconds before the system shuts down. The delay
can be set from 0 to 60 seconds, the default is 60.
displayed on the main LCD. If the Watchdog reaches the HEAD STOP DELAY time, the stop relay
is de-energized, the STOP LED on the Watchdog lights up red, and a warning showing the source of
the stop condition is displayed in red on the main LCD screen. The stop event is also logged in the
ALARM LOG.
WARNING
PAGE 45
14.7 ALIGNMENT (TAIL) -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > ALIGNMENT
Settings in this menu allow you to monitor alignment at the head and/or tail sections of your equipment.
Sensors are installed in pairs (left side - right side) at the head and/or tail sections.
• 14.7.A TAIL SENSOR PAIR - This section allows you to enable or disable tail alignment monitoring.
Four options are available:
1. OFF
2. Pulsed
3. Contact (Default Setting)
4. Rub Block
PULSED - Choose this option if using either 4B’s WDA Motion Alignment Sensors, or Touchswiches
that are receiving pulses from a P800. The number of pulses detected between the sensors from the
right and left sides are compared, if the difference between the two exceeds 66% an alarm condition
is generated. The value of 66% is fixed and cannot be altered by the user.
CONTACT (Default) - Choose this option if using 4B Touchswitch sensors (not receiving pulses
from a P800). In this mode, the Watchdog looks for a change in signal level representing the belt
alignment condition.
- ON: +24V into the terminal is seen as normal (no belt misalignment).
- OFF: 0V into the terminal is seen as a belt misalignment condition.
RUB BLOCK - Choose this option if using rub blocks to detect belt misalignment. A rub block
is basically a temperature sensor mounted to a special block (usually brass). If the belt rubs
constantly against the rub block, heat from friction will cause the rub block’s temperature to rise. If
the temperature rises above the pre-set limit, a misalignment alarm will be generated. There are a
number of settings available for use with the rub block.
• 14.7.B TAIL TRIGGER ALARM - If CONTACT is selected within the TAIL SENSOR PAIR menu, a
trigger alarm must be selected. The default is OFF, meaning that an alarm will be triggered when the
contact is off (0V). If ON is selected, the alarm will be triggered when the contact is on (+24V), this
option (ON) is only available under FACTORY SETTINGS.
• 14.7.C ABSOLUTE ALARM [DEG] - If RUB BLOCK is selected within the TAIL SENSOR PAIR
menu, a absolute temperature value must be selected.
If the measured temperature of the rub block exceeds this value, an alarm is generated. This level
setting ranges from 32° to 230° F (1° to 110° C), the default is 140° F (60° C).
• 14.7.D RELATIVE ALARM SOURCE - If RUB BLOCK is selected within the TAIL SENSOR PAIR
menu, a relative alarm source must be selected. Choices are OFF, AMB1, AMB2 or OPPOSITE, the
default is OFF.
If either AMB1 or AMB2 are selected, the relative alarm temperature is relative to the ambient
temperature. If OPPOSITE is selected, then the relative alarm for each sensor is relative to the
opposite sensor’s temperature.
• 14.7.E RELATIVE ALARM - If RUB BLOCK is selected within the TAIL SENSOR PAIR menu
and RELATIVE ALARM SOURCE is set to AMB1, AMB2 or OPPOSITE, a relative alarm must be
selected.
If the measured temperature of the rub block exceeds the relative temperature value, an alarm is
generated. This level setting ranges from 2° to 90° F (1° to 50° C), the default is 30° F (15° C).
PAGE 46
• 14.7.F TAIL: RATE OF RISE [DEG/MIN] - If RUB BLOCK is selected within the TAIL SENSOR PAIR
menu and RELATIVE ALARM SOURCE is set to AMB1, AMB2 or OPPOSITE, you can choose to
turn the rate of rise ON (default) or OFF. If RELATIVE ALARM SOURCE is set to OFF, you will not
be able to choose RATE OF RISE.
If turned ON, this setting monitors the rub block’s rate of rise of temperature in degrees per minutes.
If a rate of rise is detected equal to or greater than this value, an alarm will be generated and the
alarm relay being de-energized. This level setting ranges from 2.0 to 5.0, the default is 3.0.
NOTE
The temperature setting can be set to either Fahrenheit or Celsius, see FULL SYSTEM SETUP.
NOTE
On the TAIL ALIGN INFO screen (Image 29), T#9 is the sensor on the tail left and T#10 is tail right.
3 of 7: Tail Align Info
Type: RUB

T#9 80 140 30 T#10
T#10 40 140 30 T#9
Image 29
Previous Next Exit System Info Screen
Tail Align Info - Opposite
Image 29 shows the SYSTEM INFO screen for TAIL ALGIN INFO when OPPOSITE has been selected,
meaning that the relative alarm temperature for sensor T#9 is T#10 and vise versa. For instance, an
alarm will be generated when the actual temperature of T#9 exceeds the temperature of T#10 by +30°.
T#9 is shown in red since it is in an alarm state.
• 14.7.G TAIL ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
If the system reaches the TAIL ALARM DELAY time, the alarm relay is de-energized, the ALARM
LED on the Watchdog lights up amber, and a warning showing the source of the alarm is displayed in
red on the main LCD screen. The alarm event is also logged in the ALARM LOG.
• 14.7.H TAIL STOP DELAY [S] - The delay in seconds before the system shuts down. The delay can
be set from 0 to 60 seconds, the default is 60.
displayed on the main LCD. If the Watchdog reaches the TAIL STOP DELAY time, the stop relay is
de-energized, the STOP LED on the Watchdog lights up red, and a warning showing the source of
ALARM LOG.
PAGE 47
14.8 TEMPERATURE -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > TEMPERATURE
The Watchdog can monitor up to 8 NTC type temperature sensors (standard) or up to 20 with additional
NTC expansion boards. In the Watchdog system, 6 of these sensors are referred to as hot bearing
sensor 1 (HBS1) through hot bearing sensor 6 (HBS6). The other 2 sensors are referred to as ambient
sensor 1 (AMB1) and ambient sensor 2 (AMB2). Each sensor can be switched ON or OFF as required
and they can be used in any combination.
If NTC expansion boards have been installed (see 14.4.E & 14.4.F), an expanded menu will be available
to configure up to 12 additional temperature inputs.
• If expansion board 1 (EXP1) has been installed, then HBS7 - HBS12 will be available.
• If expansion board 2 (EXP2) has been installed, then HBS13 - HBS18 will be available.
NOTE
While originally developed for displaying hot bearing sensors (HBS), menus displaying HBS can
refer to any NTC type temperature sensor such as those used with brass rub blocks (ADB Series) or
surface temperature sensors (WDB7 Series).
Since the menus are the same for each NTC sensor, HBS1 will be used as a template for all HBS
sensors in this manual.
• 14.8.A HBS1 - Choices are OFF or NTC. Select OFF to disable the sensor or NTC to enable the
sensor. The default setting for HBS1 through HBS4 is NTC, while the default for HBS5 and HBS6 is
OFF.
• 14.8.B HBS1: ABSOLUTE ALARM [DEG] - This is the absolute maximum temperature at which
the Watchdog will generate an alarm. If an alarm is generated, the effected bearing sensor icon will
change from green to red on the main LCD screen. The alarm condition is also logged in the ALARM
LOG. This level setting ranges from 32° to 230° F (1° to 110° C), the default is 140° F (60° C). For
PRE ABS ALARM information, refer to section 14.4.B.
• 14.8.C HBS1: RELATIVE ALARM SOURCE - Allows you to select a relative alarm source. Choices
are OFF, AMB1 or AMB2, the default is OFF. This option creates a relationship between two different
temperature sensors. When using the setup screen on the Watchdog, HBS1 - HBS6 can only be
related to ambient sensor 1 (AMB1) or ambient sensor 2 (AMB2). By using the advanced setup
features within the WDC4 Configurator Software, any hot bearing sensor can alarm relative to any
other.
For example - If you use the configuration software, you can set a RELATIVE ALARM SOURCE
between HBS1 and HBS4. Once the relationship is set you can specify a RELATIVE ALARM value.
This value is used to set the alarm level of one temperature to another. If HBS1 is related to HBS4
and the RELATIVE ALARM value is set to 15° F, then a temperature alarm would be generated when
the temperature of HBS1 exceeded the temperature of HBS4 by 15° F.
When you select a RELATIVE ALARM SOURCE, the appropriate sensor is automatically enabled.
Setting HBS4 as the RELATIVE ALARM SOURCE for HBS1 will automatically enable HBS4. When
a sensor is automatically enabled, the default values are used for that sensor, so make sure that the
settings are appropriate for your intended use.
• 14.8.D HBS1: RELATIVE ALARM [DEG] - If AMB1 OR AMB2 is selected within the RELATIVE
ALARM SOURCE menu, a relative temperature value must be selected.
If the measured temperature of the bearing sensor exceeds the relative temperature value, an alarm
is generated. This level setting ranges from 2° to 90° F (1° to 50° C), the default is 30° F (15° C).
PAGE 48
• 14.8.E HBS1: RATE OF RISE [DEG/MIN] - You can choose to turn the rate of rise ON (default) or
OFF. If turned OFF, the rate of rise is ignored and no alarm will be generated.
If turned ON, this setting monitors the rate of rise of the bearing sensor temperatures. It is designed
to detect when temperature rises are in excess of what might be considered normal. If the sensor
temperature rises more than 3 degrees (default) per minute, then a RATE OF RISE alarm will be
generated. If an alarm is detected, the alarm relay will be de-energized until the rate of rise drops
below the set target. The process of monitoring the rate of rise can be delayed at start-up by setting
the RATE OF RISE START UP DELAY in the SYSTEM SETTINGS menu. This level setting ranges
from 2.0 to 5.0, the default is 3.0.
• 14.8.F HBS1 ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
If the system reaches the ALARM DELAY time, the alarm relay is de-energized, the ALARM LED on
the Watchdog lights up amber, and a warning showing the source of the alarm is displayed in red on
the main LCD screen. The alarm event is also logged in the ALARM LOG.
• 14.8.G HBS1 STOP DELAY [S] - The delay in seconds before the system shuts down. The delay
be displayed on the main LCD. If the Watchdog reaches the STOP DELAY time, the stop relay is
ALARM LOG.
Since the menus are the same for both AMB1 and AMB2, AMB1 will be used as a template in this
manual.
• 14.8.H AMB1 - Up to 2 ambient temperature sensors may be used with the Watchdog. These can
be used to monitor the temperature of additional bearings, motors or gearboxes. These sensors are
referred to as AMB1 and AMB2. Each sensor can be switched OFF (default) or NTC as required and
they can be used in any combination.
• 14.8.I AMB1: ABSOLUTE ALARM [DEG] - This is the absolute maximum temperature at which the
Watchdog will generate an alarm. The appropriate ambient sensor icon will change from green to
red on the main LCD screen, and the alarm condition will be logged in the ALARM LOG. This level
setting ranges from 32° to 230° F (1° to 110° C), the default is 140° F (60° C). For PRE ABS ALARM
information, refer to section 14.4.B.
• 14.8.J AMB1: RATE OF RISE [DEG/MIN] - You can choose to turn the rate of rise ON (default) or
OFF. If turned OFF, the rate of rise is ignored and no alarm will be generated.
If turned ON, this setting monitors the rate of rise of the ambient sensor temperatures. It is designed
to detect when temperature rises are in excess of what might be considered normal. If the sensor
temperature rises more than 3 degrees (default) per minute, then a RATE OF RISE alarm will be
generated. If an alarm is detected, the alarm relay will be de-energized until the rate of rise drops
below the set target. The process of monitoring the rate of rise can be delayed at start-up by setting
the RATE OF RISE START UP DELAY in the SYSTEM SETTINGS menu. This level setting ranges
from 2.0 to 5.0, the default is 3.0.
PAGE 49
• 14.8.K AMB1: ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
• 14.8.L AMB1: STOP DELAY [S] - The delay in seconds before the system shuts down. The delay
ALARM LOG.
14.9 AUXILIARY -
MENU > SETUP (PASSWORD) > PROFILE > EDIT SELECTED PROFILE > AUXILIARY
The Watchdog is capable of monitoring for plug conditions (PLUG) and pulley misalignment (PULLEY).
To enable these functions, sensors must be installed and turned on within the AUXILIARY menu.
• 14.9.A PLUG ENABLED - Choices are YES or NO (default). A plug or choke sensor is usually used
for blocked chute detection. A Binswitch Elite is most commonly used, however an Auto-Set™ flush
probe can also be installed depending on the application.
When a plug sensor is installed and PLUG ENABLED is YES, the Watchdog looks for a change in
signal level representing the plug condition.
- ON: +24V into the terminal is seen as normal (no plug detected).
- OFF: 0V into the terminal is seen as blockage (plug) detected condition.
• 14.9.B PLUG TRIGGER ALARM WHEN - Choices are ON or OFF (default). Allows you to choose
to trigger an alarm when the sensor contact is on, or trigger an alarm when the sensor contact is off.
The default is OFF, in order to switch this setting to ON, you must go to the FACTORY SETTINGS
menu.
• 14.9.C PLUG ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
PAGE 50
• 14.9.D PLUG STOP DELAY [S] - The delay in seconds before the system shuts down. The delay
ALARM LOG.
• 14.9.E PULLEY ENABLED - Choices are YES or NO (default). The pulley sensor is usually used
to detect if the drive pulley has moved position (misaligned). Typically a Touchswitch contact sensor
would be used for application.
When a pulley sensor is installed and PULLEY ENABLED is YES, the Watchdog looks for a change
in signal level representing the misaligned pulley condition.
- ON: +24V into the terminal is seen as normal (no pulley movement).
- OFF: 0V into the terminal is seen when pulley movement has been detected.
• 14.9.F PULLEY TRIGGER ALARM WHEN - Choices are ON or OFF (default). Allows you to choose
to trigger an alarm when the sensor contact is on, or trigger an alarm when the sensor contact is off.
The default is OFF, in order to switch this setting to ON, you must go to the FACTORY SETTINGS
menu.
• 14.9.G PULLEY ALARM DELAY [S] - The delay in seconds before the system alarms after a sensor
• 14.9.H PULLEY STOP DELAY [S] - The delay in seconds before the system shuts down. The delay
ALARM LOG.
WARNING
PAGE 51
X
Over Write Existing

Settings?
OK Image 30
Profile - Restore Defaults
14.10 RESTORE DEFAULTS -

MENU > SETUP (PASSWORD) > PROFILE > RESTORE DEFAULTS (PASSWORD)
All settings in the Watchdog can be restored to the factory default settings as described in Appendix B.
Before allowing the settings to be reset, the user is prompted to enter the engineering password again
and a final confirmation screen to confirm the action is displayed (Image 30). The menu choices are: X
(No) terminate without taking action, or OK (Yes), restore the factory defaults.

Leg (WDA) 4MA, 4BS
Back OK Image 31

available to choose from (Image 31). All four profiles are also listed in the WIRING DIAGRAMS section.

NOTE
PAGE 52
15. TEST
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 32
Setup Menu - Test
15. TEST -
MENU > SETUP (PASSWORD) > TEST
A number of test functions are available to simulate various fault conditions to validate the functionality
of the alarm and stop relays (Image 32). The testing function is not designed to test the sensors on
the equipment, it allows you to insure that your control wiring, PLC or HazardMon.com connectivity are
functioning. None of the tests will function if the Watchdog is in an alarm condition, or if the system has
not been calibrated. Testing can be run for the following: ALARM RELAY, ALIGNMENT, OVER SPEED,
UNDER SPEED and HOT BEARING SENSOR.
NOTE
Only the ALARM RELAY test can be started while the equipment is running. All of the other tests
require the equipment to be stopped prior to testing.
• 15.1 ALARM RELAY - Toggles the alarm relay 5 times at a rate of once per second. The display
prompts you to “Press OK to Start the Test and Then Start the Elevator”. If the elevator is already
running, the test will begin immediately. If the elevator is stopped, the test will begin the next time
the elevator is started. When testing begins, “ALARM TEST” will appear under SYSTEM STATUS
on the main LCD screen. The elevator will remain running after the test is concluded.
• 15.2 ALIGNMENT - Simulates an alignment fault condition by introducing a head alignment fault.
The values used for alarm and stop delays will be the current settings. The display prompts you
to “Press OK to Start the Test and Then Start the Elevator”. The test will begin the next time the
elevator is started. When testing begins, “ALIGN. TEST” will appear under SYSTEM STATUS on
the main LCD screen. The elevator will be in the stopped condition after the test is concluded. If the
alarm and stop delays are excessive, then it will take a long time to perform the test.
• 15.3 OVER SPEED - Simulates an over speed fault condition by simulating an increase in speed
by 15%, introducing an over-speed condition. The values used for alarm and stop delays will be
the current settings. The display prompts you to “Press OK to Start the Test and Then Start the
Elevator”. The test will begin the next time the elevator is started. When testing begins, “O/S TEST”
will appear under SYSTEM STATUS on the main LCD screen. The elevator will be in the stopped
condition after the test is concluded. If the alarm and stop delays are excessive, then it will take a
long time to perform the test.
PAGE 53
• 15.4 UNDER SPEED - Simulates an under speed fault condition by simulating a decrease in speed
by 15%, introducing an under speed condition. The values used for alarm and stop delays will be
the current settings. The display prompts you to “Press OK to Start the Test and Then Start the
Elevator”. The test will begin the next time the elevator is started. When testing begins, “U/S TEST”
will appear under SYSTEM STATUS on the main LCD screen. The elevator will be in the stopped
condition after the test is concluded. If the alarm and stop delays are excessive, then it will take a
long time to perform the test.
• 15.5 HOT BEARING SENSOR - Simulates a hot bearing sensor exceeding the trip value. The test
is always on HBS1. If HBS1 is not enabled, the firmware will enable it for the duration of the test and
then switch it back off when the testing has been completed. The values used for alarm and stop
delays will be the current settings. The display prompts you to “Press OK to Start the Test and Then
Start the Elevator”. The test will begin the next time the elevator is started. When testing begins,
“HBS TEST” will appear under SYSTEM STATUS on the main LCD screen. The elevator will be in
the stopped condition after the test is concluded. If the alarm and stop delays are excessive, then it
will take a long time to perform the test.
16. FACTORY SETTINGS
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 33
Factory Settings Menu
16. FACTORY SETTINGS -

MENU > SETUP (PASSWORD) > FACTORY SETTINGS (PASSWORD)
The changes that can be made through the PROFILE menu have been deliberately limited to safe
values. The FACTORY SETTINGS option allows a wider range of adjustments to be made, and should
be used with extreme caution.
The FACTORY SETTINGS menu can only be accessed by calling 4B technical support and getting an
administrator password. When this menu is selected, the screen will display a 4 digit number generated
by the Watchdog (Image 33). You must give this code to a 4B technical support representative, and
after they verify that the changes you intend to make will leave the Watchdog in a safe working condition
will in return give you a 4 digit administrator password. The password expires after one use.
Once saved, any changes will become the new set limits and you will automatically exit the FACTORY
SETTINGS menu and be taken back to the PROFILE menu. Since only one setting can be changed
per access within FACTORY SETTINGS, you may need to contact 4B on more than one occasion. This
may seem to be a nuisance, but the intention is to reduce the risk that some incorrect adjustment may
cause the Watchdog to function in an undesirable and potentially unsafe way.
DANGER
Improper changes made to the Watchdog’s FACTORY SETTINGS menus can be potentially unsafe.
Always consult with 4B technical support to confirm any change prior to implementation.
PAGE 54
Please note the code number
and phone 4B X
8855
OK
Image 34
A B C Factory Settings -
Password Screen
16.1 EDIT SELECTED PROFILE -

MENU > SETUP (PASSWORD) > FACTORY SETTINGS (PASSWORD) > EDIT SELECTED PROFILE
The EDIT SELECTED PROFILE menu within FACTORY SETTINGS is almost an exact duplicate of the
menus found under PROFILE. FACTORY SETTINGS allow for a wider range of system adjustments
which should only be changed by advanced users. 4B recommends using the standard settings found
within the PROFILE menu. Refer back PROFILE for more details.
16.2 RESTORE DEFAULTS -

MENU > SETUP (PASSWORD) > FACTORY SETTINGS (PASSWORD) > RESTORE DEFAULTS
The RESTORE DEFAULTS menu within FACTORY SETTINGS is an exact duplicate of the same menu
found under PROFILE. Refer back PROFILE for more details.

MENU > SETUP (PASSWORD) > FACTORY SETTINGS (PASSWORD) > SELECT NEW PROFILE
The SELECT NEW PROFILE menu within FACTORY SETTINGS is an exact duplicate of the same
menu found under PROFILE. Refer back PROFILE for more details.
Image 35
Inside View -
SD Cards (2) & Ethernet Port
PAGE 55
17. SD CARD
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 36
Setup Menu - SD Card
17. SD CARD -
MENU > SETUP (PASSWORD) > SD CARD
All of the settings in the Watchdog can be saved to and loaded from an SD card inserted into the System
Card / SD Card 1 slot (Image 35) inside the control unit. The setup file will have an extension of .wd4.
An SD card will be required if you are using the WDC4 Configurator software to setup the Watchdog
(Appendix C).
The SD CARD menu has two options -
• LOAD FILE .WD4 - If loading the file is successful an entry will be made in the ALARM LOG
“Settings<-SD” (indicating that data was loaded form the SD card). Along with the date and time the
load was performed. If the SD card is missing or an error occurred it will be recorded in the alarm
log as “SD No Media”. Before loading the settings you will be given a warning stating that all your
current settings will be overwritten. You can then continue with the load or cancel.
• SAVE FILE .WD4 - Any existing file with the .wd4 extension will be destroyed and replaced. If saving
the file is successful an entry will be made in the ALARM LOG “Settings>-SD” (indicating that data
was saved to the SD card). Along with the date and time the save was performed. If the SD card is
missing or an error occurred it will be recorded in the alarm log as “SD No Media”.
If an SD card is present, a file named WDC4.csv will be created. This file will contain all the logging
information regarding the status of the Watchdog. Any run / stop request and alarm / stop conditions are
logged. If a WDC4.csv file already exists on the SD card, the data will be appended to the existing data
in the file.
If the file size of WDC4.csv exceeds 10 MB, a warning will be reported in the ALARM LOG. If using a
program such as Microsoft Excel, the file size is important since versions before 2008 can have issues
importing large file sizes.
WARNING
Power down the Watchdog before inserting or removing the SD card from either the SD CARD 1 or
SD CARD 2 slots to prevent system errors.
PAGE 56
18. TIME & DATE
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 37
Setup Menu - Time & Date
18. TIME & DATE -

MENU > SETUP (PASSWORD) > TIME & DATE
The time can be set by pressing the HRS, MIN or SEC keys at the bottom of the screen. One press
will increment the chosen value by one count. When you have completed the time settings press the
“OK” button to save the changes. Pressing the “X” button will exit the setting mode without saving the
changes.
The date can be set by pressing the DAY, MONTH or YEAR keys at the bottom of the screen. One
press will increment the chosen value by one count. When you have completed the date settings press
the “OK” button to save the changes. Pressing the “X” button will exit the setting mode without saving
the changes.
19. CHANGE PASSWORD
Profile
Test
Factory Settings
SD Card
Time & Date
Change Password
Network
Back OK Image 38
Setup Menu - Change Password
19. CHANGE PASSWORD -

MENU > SETUP (PASSWORD) > CHANGE PASSWORD
In order to make any system changes to the Watchdog, an engineering password is required. This is
to ensure that only authorized people can change important settings that may lead to inappropriate
operation of the Watchdog. The default engineering password set at the factory is BBBB.
You can change the password from the factory setting within this menu by choosing CHANGE
PASSWORD. The password is from 1 to 8 characters long, and can be any combination of the letters
A, B and C. If you change the password from the factory default, make a note of your new password
because if you lose it you will not be able to make changes to the Watchdog. If you do lose the
password, contact 4B technical support.
PAGE 57
20. NETWORK
Profile
Test
Factory Settings
SD Card
Time & Date ®
Change Password
Network
Back OK Image 39
Setup Menu - Network
20. NETWORK -
MENU > SETUP (PASSWORD) > NETWORK
• Hazardmon - The Watchdog Super Elite can be integrated into HazardMon.com®, which is a secure
cloud based hazard monitoring solution providing status notifications and data logging for bucket
elevators and conveyors. Live system status, graphs and historical data can be viewed on any web-
enabled device (smartphone, tablet PC, desktop or laptop computer). Emails can be sent to notify
users whenever a change in the system’s health is detected. An automated maintenance feature
allows site operators to verify that all sensors on the system are operational and working correctly.
You can choose to turn Hazardmon ON (default) or OFF. In order to establish a connection to
HazardMon.com, you will need to configure a network connection. Contact 4B technical support
prior to turning on this feature, 4B will work with your internal IT department to properly configure the
required network settings.
• DHCP (Dynamic Host Configuration Protocol) - A network protocol that enables a server to
automatically assign an IP address and other related configuration information to a computer from a
defined range of numbers configured for a given network.
You can choose to turn DHCP ON or OFF (default). If you choose ON, the network settings will be
automatic. If you choose OFF, you will need to manually enter all of the network settings.
• Ethernet IP - Is the numerical address of a device on the local computer network.
• Gateway - Is a node (router) on a network that serves as an access point to give entry into different
networks to send email, view web pages, etc.
• Subnet Mask - The subnet mask is a network generated number that identifies the network to
which an IP address belongs. This allows your computer to determine if it is speaking with another
computer within the same network or on a remote network and dictates how your computer
communicates with other computers it encounters. Subnetting is used to improve network security
and performance.
• DNS1 - A domain name server (DNS) is the Internet’s equivalent of a phone book. They maintain a
directory of domain names (URL) and translate them to Internet Protocol (IP) addresses. DNS is
required for translation of hostnames to IP addresses and vice versa; this translation is what makes
sending and receiving email, browsing the web, and numerous other network services work.
• DNS2 - A backup server to DNS1 just in case it were to become unavailable for whatever reason.
PAGE 58
21. TROUBLESHOOTING GUIDE
For details on specific alarms, go to the ALARM LOG and choose MORE INFO. This will provide you
with details on the alarm such as: date, time, entry type, entry source, condition and data that is alarm
dependent by type.
Head & Tail Bearing Pulley Plug Ambient

Alignment Temperature Alignment Sensor Temperature
LCD Icon LCD Status FAULT CAUSE / REMEDY
Alarm: HBS(1) ABS Hot bearing sensor 1 trip Excessive temperature, check
(Could be HBS 1-6) exceeded bearing
Alarm: HBS(1) O/C Hot bearing sensor 1

Faulty sensor or wiring
(Could be HBS 1-6) open circuit
Alarm: HBS(1) S/C Hot bearing sensor 1

Faulty sensor or wiring
(Could be HBS 1-6) short circuit
Alarm: AMB(1) Ambient sensor trip Excessive temperature, check

(Could Be AMB1 or 2) exceeded bearing
Plug sensor has been

Alarm: PLUG Blocked chute
activated
Pulley sensor has been Pulley has misaligned, repair before

Alarm: PULLEY
activated running.
Head misalignment
Alarm: MIS HEAD Belt slippage, check belt tension
condition
Tail misalignment
Alarm: MIS TAIL Belt slippage, check belt tension
condition
Jog delay timer has activated to keep

Shutdown: Jog Event Too many equipment start
motor starter from overheating. Wait
or attempts during a short
for jog delay timer to expire before
Jog Delay period of time
restarting equipment
Equipment is running at excessively
Severe overspeed
Shutdown: SPEED SOS high speeds, check belt tension and
condition
calibration
Equipment is running faster than
Shutdown: SPEED OS Overspeed condition the set limit, check belt tension and
calibration
Equipment is running at excessively
Severe underspeed
Shutdown: SPEED SUS low speeds, check belt tension and
condition
load
Equipment is running slower than the

Shutdown: SPEED US Underspeed condition
set limit, check belt tension and load
PAGE 59
22. APPENDIX A - MENU TREE
Watchdog
Main Screen
Alarm Log Menu System Info
View Settings Setup Speed Info

Reset Eng. Password
(No Password) (Eng. Password) Head Align Info
Tail Align Info
HBS Info
AUX Sensor Info
System Settings System Info
Speed Settings Network Info
Alignment Settings
Temperature Settings
Auxiliary Settings
Factory Time & Change

Profile Test Settings SD Card Network
(Admin.Password)
Date Password
Edit Edit DHCP

Selected Selected Ethernet IP
Profile Profile Gateway
Subnet Mask
DNS1
Restore Restore DNS2
Defaults Defaults
(Eng.Password)
Select Select NOTE

New New
Profile Profile Factory Settings
provides full system
administrator
Calibrate System Alarm Relay Calibrate System access to the entire
Full System Setup Alignment Full System Setup Watchdog system.
System Over Speed System
Speed Speed Profile allows only
Under Speed
Alignment Alignment limited access to
Hot Bearing Sensor
Temperature Temperature end users for select
Auxiliary Auxiliary settings.
PAGE 60
23. APPENDIX B - FACTORY DEFAULT SETTINGS
Some settings are dependent on others, so not all may be displayed or available to select.
SYSTEM DEFAULT OPTIONS
• Temperature Units °F °F / °C
• Negative Differential Alarm Off On / Off
• Rate of Rise Start Up Delay [Min] 3 0-5
SPEED DEFAULT OPTIONS
• Speed Monitoring On On / Off
• Scaling Units % PPM / RPM / USR / %
• Scaling Factor 20 User Defined
• Speed detection Source Dedicated MAS / Dedicated / Differential
• Acceleration Monitoring Level 5 0-9
• Number of Starts / Minute 3 1 - 10
• Start Up Delay [S] 5 1 - 15
• Underspeed Alarm [%] 10 1 - 10
• Severe Underspeed [%] 20 1 - 20
• Underspeed Alarm Delay [S] 1 0 - 10
• Underspeed Stop Delay [S] 60 0 - 60
• Overspeed [%] 10 1 - 10
• Severe Overspeed [%] 20 1 - 20
• Overspeed Alarm Delay [S] 1 0 - 10
• Overspeed Stop delay [S] 60 0 - 60
ALIGNMENT (HEAD & TAIL) DEFAULT OPTIONS
• Sensor Pair Contact Off / Pulsed / Contact / Rub Block
• Trigger Alarm Off On / Off
• Absolute Alarm [Deg] 140 °F 32 - 230 °F
• Relative alarm Source Off Off / AMB1 / AMB2 / Opposite
• Relative Alarm [Deg] 30 °F 2 - 90 °F
• Rate of Rise [Deg / Min] 3.0 2.0 - 5.0
• Alarm Delay [S] 1 0 - 10
• Stop Delay [S] 60 0 - 60
PAGE 61
Some settings are dependent on others, so not all may be displayed or available to select.
TEMPERATURE DEFAULT OPTIONS
• HBS1 - HBS4 (Sensors 1 - 4) NTC Off / NTC
• HBS5 - HBS6 (Sensors 5 - 6) OFF Off / NTC
• HBS7 - HBS12 (Sensors 7 - 12)* OFF Off / NTC Board / PLC Board
• HBS13 - HBS18 (Sensors 13 - 18)* OFF Off / NTC Board / PLC Board
• HBS Absolute Alarm [Deg] 140 °F 32 - 230 °F
• HBS Relative Alarm Source Off Off / AMB1 / AMB2
• HBS Relative Alarm [Deg] 30 °F 2 - 90 °F
• HBS Rate of Rise [Deg / Min] 3.0 2.0 - 5.0
• HBS Alarm Delay [S] 1 0 - 10
• HBS Stop Delay [S] 60 0 - 60
• AMB1 & AMB2 Off On / Off
• AMB Absolute Alarm [Deg] 140 °F 32 - 230 °F
• AMB Rate of Rise [Deg / Min] 3.0 2.0 - 5.0
• AMB Alarm Delay [S] 1 0 - 10
• AMB Stop Delay [S] 60 0 - 60
* HBS7 - HBS18 (Sensors 7 - 18) require optional NTC expansion boards to be installed.
AUXILIARY DEFAULT OPTIONS
• Plug Enabled No Yes / No
• Plug Trigger Alarm When Off On / Off
• Plug Alarm Delay [S] 1 0 - 10
• Plug Stop Delay [S] 3 0 - 60
• Pulley Enabled No Yes / No
• Pulley Trigger Alarm When Off On / Off
• Pulley Alarm Delay [S] 1 0 - 10
• Pulley Stop Delay [S] 5 0 - 60
NOTE
If SELECT NEW PROFILE has been chosen under the PROFILE menu, factory defaults may change
depending on the profile selected.
PAGE 62
24. APPENDIX C - WDC4 CONFIGURATOR SOFTWARE
The Watchdog Super Elite can be programed directly thought the controller’s LCD menu screen, or by
using the WDC4 Configurator Software. The software tool makes programming the Watchdog easier by
providing all the system settings for each profile menu into one screen (Image 40).
Once a profile setup file has been created, it can be saved to an SD card and then uploaded to the Watchdog
by inserting the card into the System Card / SD Card 1 slot (Image 41) inside the control unit. For remote
sites, the file can be emailed to an on-site technician, who can upload the file.
The software does not ship with the Watchdog, it is available as a free download at: www.go4b.com/software.
Image 40
WDC4 Configurator Screen Shot
Image 41
Inside View -
SD Card 1 & 2
WARNING
PAGE 63
25. APPENDIX D - WDC4 SOFTWARE UPDATE
In order to receive software update notifications by email, please be sure to register your Watchdog Super
Elite online at: http://www.go4b.com/usa and choose the “Product Registration” link.
BEFORE YOU START -

Make sure to backup the system configuration settings currently installed on your Watchdog by following
these steps:
1. Install an SD card into the SD CARD 1 slot (Image 41).
2. From the Watchdog’s main LCD screen, choose MENU > SETUP (PASSWORD) > SD CARD.
3. Select SAVE FILE .WD4.
4. Remove the SD card when the file has been saved, and keep it in a safe place.
HOW TO UPDATE -
Download the latest software version to your PC, there will be two files: U102.hex and U201.hex. To install
the update to the Watchdog, follow these steps:
1. Load the software onto an SD card, make sure it is not the same card that contains the backup copy.
2. Open the lid of the Watchdog by loosening the two outside screws on the right hand side. Be careful
not to touch any of internal wiring, especially the power supply.
3. Place the SD card into the LANGUAGE / SD CARD 2 slot (Image 41) located on the inside lid and
press the RESET button on the circuit board (Image 42).
4. Wait for the unit to power up and display the main LCD screen.
5. Place the SD card into the SYSTEM / SD CARD 1 slot and press the RESET button again.
6. During the initial power up (Image 43) check that the new software version has been successfully
loaded (Main IC).
7. After the update has successfully loaded, remove the SD card.
8. Secure the lid of the unit by re-tightening the screws.
If the new software did not install, repeat the software update process. If the upload continues to fail,
contact 4B.
WDC4 - Super Elite

www.go4b.com
Initializing...
Firmware Versions: Image 42

Main IC (U102): 4.X.X Reset Button
Graphics IC (U201): 4.X.X
Support IC (U400): 4.X.X
Graphics DB Size: 537

Main DB Size: 537 Image 43
Initial Power Up Screen
WARNING
PAGE 64
26. PRODUCT WARRANTY

4B’S OPTION.


PAGE 65
NOTES
PAGE 66
NOTES
PAGE 67
location.

Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338

Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3711 2565
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3711 2574
www.go4b.com
Product Datasheet
4B
Components
Watchdog Super Elite
Limited

Bucket Elevator / Conveyor Monitoring System
NEW
Enhanced Preventative
APPLICATION Maintenance Tool
Combined belt alignment, belt speed, belt slip, continuous bearing
temperature, pulley alignment and plug condition monitor for bucket
elevators and conveyors.
METHOD OF OPERATION
The Watchdog Super Elite (WDC4) is easy to install and simple to set-
up. The system processes signals from sensors for belt misalignment,
belt speed & slip, continuous bearing temperature, pulley misalignment
and plug condition. When an alarm is detected it will sound an alarm and
provide shutdown control of the elevator/conveyor and feeding system.
A 3.5” LCD screen displays the entire system status at a glance.
Password protected controller settings can be set up either directly on
the LCD screen, or by a PC application and transferred to the WDC4 via
an SD card.
The Watchdog Super Elite can be connected directly to a PLC using the
Modbus TCP/IP protocol, or integrated into HazardMon.com®. This
secure cloud based solution provides live system status, graphs and
historical data that is viewable on any web-enabled device (smartphone,
tablet, desktop PC).
FEATURES
► Belt Speed Monitoring (Including VFD’s)
► Belt Alignment Monitoring (Including Rub Blocks)
► Temperature Monitoring (More Inputs)
► Pulley Alignment Monitoring
► Plug Condition Monitoring
► Jog & Acceleration Monitoring
► Large Color Graphics Display
► System Settings Backup & Transfer (SD Card) ATEX & CE Versions Available
► PLC Communications (Modbus TCP)
► Event & Alarm Logging ® ®
► HazardMon.com Connectivity
PART NUMBERS / ACCESSORIES

► WDC4V46C Watchdog Control Unit (120 - 240 VAC / 24 VDC)
NEW SUPER ELITE FEATURES
► WDC4V4C Watchdog Control Unit (24 VDC) VS. PREVIOUS WDC3 VERSION
► WDC4-AUXO-4SSR PLC Board (Optional)
► Belt Speed Monitoring for VFD Drives
► WDC4-AUXI-6NTC NTC Expansion Board (6 Inputs) ► Belt Alignment Monitoring Using Rub Blocks
► TS2V4C Touchswitch - Belt Misalignment ► More Temperature Monitoring Inputs
► RB2W4L Rub Block 2” x 4” - Belt Misalignment ► Jog Monitoring

► 3.5” Color Graphics LCD Display
► P8004V10C P800 Proxswitch - Belt Speed
► System Settings Backup & Transfer (SD Card)
► WG1-4B-4 Whirligig Sensor Mount (P800) ► PLC Communications (Modbus TCP)
► ADB20V3C/D3 Adjustable Depth Bearing Temp. Sensors ► Event & Alarm Logging
► WDB70V3C Surface Mount Temperature Sensor ► HazardMon.com Connectivity
► BSE1V10C Binswitch Elite - Plug Indication

Product Datasheet
4B
Components
Limited
Watchdog Main LCD Screen
Sensor Alarm Icons
The main LCD screen (above)

provides an overview of system status
including any current faults or alarm
conditions.
The sensor LEDs Easily identifiable status icons display

provide a quick view the condition of all the belt alignment,
status of the head and bearing temperature, and auxiliary
tail alignment sensors sensors whether they are active, not
(top left, top right, active, normal or in an alarm condition.
bottom left, bottom
right), along with speed A grey icon indicates not active.
pulse indication and A green icon indicates a normal state.
alarm and stop status. A red icon indicates an alarm state.
Sensor Menu and Alarm Log
Main LCD Hot Bearing Information Alarm Log Detail
The Main LCD screen above is indicating a hot bearing sensor alarm. The next screen shows all of the bearing
sensors, their current temperature values (Value), and their associated alarm trip points (Abs). Note that you can
easily see that HBS#2 is in an alarm state.
All alarms are date and time stamped, and can be viewed in the Alarm Log. Alarms are automatically saved onto
an SD card and can be imported into a spread sheet program to create more detailed logging and trending reports.
If using HazardMon.com, the alarms are accessible from any web-enabled device.
Product Datasheet
4B
Components
Limited
Typical Sensor Placement Diagrams

(Belt Conveyors & Bucket Elevators)
5
4
3 3
2
2 1
Drive Section Tail Section
BELT SPEED
Head
1 Qty. 1 - One sensor located on either side of Section
3
the tail or boot shaft. 2 5
BEARING TEMPERATURE
2 Qty. 4 - One sensor for the bearings at each
end of the drive and tail or head and boot
4
shafts.
BELT MISALIGNMENT
3 Qty. 4 - Sensors work in pairs, one for each
side of the belt on the drive and tail or head
and boot sections.
PLUG INDICATION
4 Qty. 1 - One sensor located near the top of the
drive section or spouting by the discharge.
SURFACE TEMPERATURE (ELEVATOR)

5 TAIL PULLEY MISALGNMENT (CONVEYOR)
Qty. 2 - One sensor located on each side of
the conveyor housing on the tail section to
detect heat generated by a pulley
misalignment. It is also used to detect
overheating motors and gearboxes.
2 3
Easy order kits are available for the most common monitoring 1 Boot
configurations. Visit www.go4b.com/watchdog for details. Section
Not sure what you need for your equipment? No problem, 4B

Engineers can help you design the right system for your specific
application.
Product Datasheet
4B
Components
Limited
HazardMon.com
The Watchdog Super Elite has built in network support for
HazardMon.com. HazardMon is a secure cloud based hazard
monitoring solution providing status notifications and data
logging for bucket elevators and conveyors. Live system status,
graphs and historical data can be viewed on any web-enabled
device (smartphone, tablet PC, desktop or laptop computer).
Emails can be sent to notify users whenever a change in the
system’s health is detected. An automated maintenance
feature allows site operators to verify that all sensors on the
system are operational and working correctly.
FEATURES
► Alert Email Notifications
► Real Time System Status
► Data Logged Automatically
► Automated Maintenance
► Password Protected Network
► Constantly Evolving Features
Watchdog Super Elite - Control Unit
WDC4V46C and WDC4V4C
120 to 240 VAC or 24 VDC (WDC4V46C)
Supply Voltage -
24 VDC (WDC4V4C)
Power Consumption (Max.) - 12 Watts
Power Terminals - 14 AWG / 4 mm²
Signal Terminals - 16 AWG / 2.5 mm²
Alarm Relay Contacts - 1 Pole Normally Open - 8A @ 250 VAC Voltage Free Changeover
Stop Relay Contacts - 1 Pole Normally Open - 8A @ 250 VAC Voltage Free Changeover
Sensor Supply - 24 VDC @ 800 mA (Across F1, F2 and F3)
Sensor InputsTECHNICAL
- SPECIFICATIONS
15 (Expandable to 27 with Auxiliary Boards)
Interlock Input - 24 VDC or 120 to 240 VAC
Dimensions (H x W x D) - 11-3/4 x 9-1/2 x 5-1/4 (inches) / 298 x 241 x 133 (mm)
Fixing Centers (H x W) - 10-7/8 x 6 (inches) / 276 x 152 (mm)
Cable Entry - 2 Holes 1-1/8 in. Diameter (28 mm)
Weight - 3 lbs / 1.3 kg
Protection - IP66
CSA Class II Div 1 Groups E, F & G (WDC4V4C)
Approvals - CSA Class II Div 2 Groups F & G (WDC4V46C)
ATEX, CE & INMETRO (Versions Available)
• WDC4-AUXO-4SSR - Discrete PLC input card providing 4 solid state relay
outputs for belt speed, belt misalignment, bearing temperature and plug indication.
Auxiliary Boards -
• WDC4-AUXI-6NTC - Adds 6 additional NTC temperature inputs. Two boards can
be added to expand temperature monitoring up to 20 points.
• Modbus TCP/IP (Standard)
PLC Connectivity -
• ControlLogix® (See ProSoft® Technical Note)
TECHNICAL BRIEF
Hazard Monitoring Controls
4B Components Limited
Watchdog™ Super Elite (WDC4)
Upgrade Compatibility & Advantages
Many of the key features for the Watchdog Super Elite (WDC4)
were developed from feedback received by 4B customers. The
table below details all of the key features between the previous
WDC3 model and the new WDC4 Watchdog Super Elite.
How easy is it to upgrade from the WDC3? If you already are
using NTC type temperature sensors, all you have to do is replace
the control unit. The wiring connections are the same.
If you are not using NTC type temperature sensors, then you will
have to upgrade some of the sensors too.
A 4B technical sales representatives can answer all your questions
to insure that the entire upgrade process is easy and hassle free.
Watchdog Super Elite - WDC4

WATCHDOG MODEL COMPARISON
KEY FEATURES WDC3 WDC4
Total Sensor Inputs 10 27* Calibrated
Speed %: 100.0
Push Button Controls (Non-Capacitance) û ü
Internal Event and Alarm Logging û ü System RUNNING
Status: No Alarms Detected
PLC Connectivity - Modbus TCP/IP or ControlLogix®** û ü
Alignment Head: Tail:
3.5" Color Graphics LCD Display û ü
System Settings Backup and Transfer HBS:
û ü
HazardMon.com Compatible - Cloud Based Monitoring AUX:
û ü
Alarm Log Menu System Info
OTHER FEATURES WDC3 WDC4
Continuous Temperature Inputs (NTC) 6 20* WDC4 LCD Screen
Touchswitch Belt Misalignment ü ü
Rub Block Belt Misalignment û ü
Belt Speed & Slip Monitoring for Variable Frequency Drives û ü
Ambient Temperature Monitoring û ü
Jog and Acceleration Monitoring û ü
Machine Run Time Monitoring û ü
System Status on LCD Display (At a Glance) Partial ü
System Setup via the Control Units LCD Menu ü ü
Remote System Setup with Configurator Software û ü
Preprogrammed Monitoring Configurations û ü
* WDC4 Auxiliary Boards Expand NTC Temperature Inputs from 8 to 20 Retired WDC3 Model
** ControlLogix® Integration requires ProSoft® gateway
4B COMPONENTS LIMITED
625 Erie Avenue • Morton, IL 61550 USA • Tel: 309-698-5611 www.go4b.com/usa
AMB 1: 86.4 Date: Fri, Feb 26 2016
HBS Info AMB 2: 87.6 Time: 20:25:57
Entry Type: Alarm Detected
Sensor Value Abs. Rel. Trip Entry Source: HBS2
Condition: Absolute Alarm
HBS#1 112 140 30 N/A Temperature unites: Deg F
HBS#2 163 140 30 N/A Sensor Temperature [Deg]: 163
Absolute Alarm [Deg]: 140
HBS#3 102 140 30 N/A
HBS#4 101 140 30 N/A
Previous Next Exit Back
The LCD screen indicates a hot The menu shows the alarm log HazardMon.com is a cloud based solution
bearing sensor (HBS#2). The left details which can be viewed directly that can be utilized to log alarms and
menu (HBS Info) shows the bearing from the Watchdog’s main LCD sensor data, graph trend lines, and send
sensor temperatures, and trip points. screen. email alerts.
RECENT CUSTOMER UPGRADES

These are just a few customer examples highlighting the simplicity of WDC4 system upgrades since the
release of the Watchdog Super Elite earlier this year.
1. Customer Upgrading from Trip Point (PTC) to Continuous Temperature (NTC) sensors -
The existing Watchdog (WDC3) control unit was replaced with the latest WDC4 Super Elite with minimal
wiring changes. All Control and sensor wiring remained the same and the old PTC sensors were easily
replaced. This provided the customer with continuous bearing temperature monitoring/logging of each
individual bearing allowing earlier indication of bearing issues and better preventative maintenance.
2. Customer upgrading to WDC4 for expanded monitoring capabilities -
The WDC3 with continuous Temperature (NTC) sensors was upgraded to the WDC4 Super Elite in order
to monitor additional bearings on a drag conveyor feeding an elevator leg. Similarly, another customer
upgraded to the WDC4 to monitor tail pulley misalignment on an enclosed belt conveyor with a snubber
pulley. Each application required additional continuous Temperature (NTC) sensors to be installed. Both
upgrades were simple and hassle free and the existing control wiring did not need to be altered. The new
WDC4 can actually monitor up to 20 continuous temperature inputs using expansion boards, thus providing
more options for the future.
3. Customer upgrading to WDC4 in order to connect to the plant’s new PLC -
The Upgrade was simple and with the WDC4’s in built MODBUS TCP/IP ®
connection, connectivity to the PLC was easy. ProSoft® has published a ®
technical note for interfacing ControlLogix® PLC’s to the new WDC4

control unit.
SENSOR & SYSTEM TESTING
The Speed Master™ The ADB Sensor Tester

accurately tests the tests 4B adjustable depth
underspeed alarm and bearing (ADB) temperature
shutdown trip points sensors in the field. The
and will verify the unit heats the sensor to
complete underspeed the desired trip point, and
system allowing you allows quick and easy real
to fully comply with life testing of the entire
OSHA 1910.272 for temperature monitoring
underspeed monitoring. system.
SENSOR WIRING OVERVIEW
WDC3 TO WDC4 UPGRADE
WDC4 PROFILE SELECTION (SEE MANUAL) -

WDC3 WDC4 WDC4 TERMINAL
1 44 0 VDC
Right ---- 43 Speed Sensor
Sensor
---- 42 Pulley Sensor
Alignment ---- 41 Plug Sensor

---- 39 Head Rub - Left (T#11)

Left
Sensor 3A 38 Head Align - Right
5 (1) 36 +24 VDC (F1)

Right
Sensor 1 35 0 VDC

Alignment ---- 33 Tail Rub - Left (T#9)
Bottom (Tail)
Left 2B 31 Tail Align - Left

Sensor 5 (1) 30 +24 VDC (F2)
RIGHT ---- 29 0 VDC

Top (Head) ---- 27 Bearing Temp Sensor (T#5)
LEFT

RIGHT
Bearing
LEFT ---- 21 Ambient Sensor 1 (T#7)
---- 20 +24 VDC (F3)
BUCKET ELEVATOR & BELT CONVEYOR
HAZARD MONITORING SYSTEM
®
C US
Operation Manual Supplement
SENSOR WIRING DIAGRAMS

Part No.’s - WDC4V4C, WDC4V46C
www.go4b.com/usa
WARNING
cut and entangle.
Do NOT operate with
guard removed.
removing guard or
servicing.
DANGER
Exposed moving parts

will cause severe injury
or death.

removing cover or
inspection door.
TABLE OF CONTENTS

ELECTRICAL CONNECTION Page 6 - 7
PRE-SET PROFILES Page 8
BUCKET ELEVATOR LEG WIRING DIAGRAMS
- Typical Sensor Placement for Bucket Elevators Page 9
1. WDC3 to WDC4 Sensor Wiring Diagram Page 10
2. Sensor Wiring Diagram Profile with Touchswitches Page 11
3. Sensor Wiring Diagram Profile with Rub Blocks Page 12
4. Sensor Wiring Diagram Profile with Motion Alignment
Page 13
Sensors
5. Sensor Wiring Diagram Profile with Knee or Idler Pulleys Page 14
6. Sensor Wiring Diagram with Ambient Sensor Page 15
7. Sensor Wiring Diagram with Touchswitches and Plug Switch Page 16
8. Sensor Wiring Diagram with Rub Blocks and Plug Switch Page 17
9. Sensor Wiring Diagram with Motion Alignment Sensors and
Page 18
Plug Switch
10. Sensor Wiring Diagram with Motion Alignments Sensors,
Page 19
Plug Switch and Head Pulley Sensors
11. Sensor Wiring Diagram with Touchswitches and Differential
Page 20
Speed
12. Sensor Wiring Diagram with Touchswitches, Differential
Page 21
Speed and Plug Switch
ENCLOSED BELT CONVEYOR WIRING DIAGRAMS
- Typical Sensor Placement for Enclosed Belt Conveyors Page 22
13. Sensor Wiring Diagram with 6 Rub Blocks, 4 Bearing
Temperature Sensors and 2 Lug Style tail Pulley alignment Page 23
Sensors
14. Sensor Wiring Diagram with Touchswitches, 4 Bearing
Temperature Sensors and 2 Lug Style tail Pulley alignment Page 24
Sensors
DRAG CHAIN CONVEYOR WIRING DIAGRAMS
- Typical Sensor Placement for Drag Chain Conveyors Page 26
15. Sensor Wiring Diagram for Slack Chain Detection with Plug
Page 27
Switch
16. Sensor Wiring Diagram for Slack Chain Detection without
Page 28
Plug Switch
Dear 4B Customer:
product.

PAGE 4


6. SERVICE REQUEST
date of installation.
PAGE 5
ELECTRICAL CONNECTION
All wiring must be in accordance with local and national electrical codes and should be undertaken by
All electrical connections are made via 3 sets of terminals provided as shown in image 1.
FUSE RATINGS -
In order to maintain the product certification, all 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.
Model WDC4V4C -
• F1, F2, F3, F5 200 mA maximum.
• F1 to F3 are used to limit the current available to the sensor inputs.
• F5 is used to limit the current available to the internal electronics.
• F6 is not used.
Model WDC4V46C -
• F1 to F3 2 amp maximum, used to limit the current available to the sensor inputs.
• F5 200 mA, used to limit the current available to the internal electronics.
• F6 2 amp maximum, used to protect the AC power supply.
NOTE
diagrams for terminals 6 & 7 in the WDC4 manual (section 9).
NOTE
outer diameter is 0.23 inches. Belden 5508FE wire colors are used in all of the sensor wiring
diagrams
PAGE 6
WARNING
The unit should ONLY be powered with either a main supply (WDC4V46C model) OR a 24 VDC
(WDC4V4C and WDC4V46C models) NOT BOTH.
FIELD WIRING
CONNECTIONS
44 - 0 VDC
43 - Speed Sensor
42 - Pulley Sensor
41 - Plug Sensor
40 - Head Rub - Right
39 - Head Rub - Left
38 - Head Align - Right
37 - Head Align - Left
36 - 24 VDC (Fuse F1)
35 - 0 VDC
34 - Tail Rub - Right
33 - Tail Rub - Left
32 - Tail Align - Right
31 - Tail Align - Left
30 - 24 VDC (Fuse F2)
29 - 0 VDC
20 - 24 VDC (Fuse F3)
POWER & RELAY CONNECTIONS
06 - Motor Starter Interlock (-)

07 - Motor Starter Interlock (+)
08 - Alarm Relay Normally Open
Image 1 - 09 - Alarm Relay Normally Closed
Inside View - Bottom Board 10 - Alarm Relay Common
WDC4 Wiring Connections 11 - Stop Relay Normally Open
12 - Stop Relay Normally Closed
13 - Stop Relay Common
14 - 120 to 240 VAC Connection
15 - VAC Neutral Connection
16 - Ground or 0 Volt Connection
17 - 24 VDC Connection (+)
18 - 24 VDC Connection (-)
PAGE 7
PRE-SET PROFILES

Leg (WDA) 4MA, 4BS
Back OK Image 2
SELECT NEW PROFILE -

available to choose from (Image 2). All four profiles are highlighted in RED at the top of each wiring
diagram (xxxxx). Refer to section 14 of the WDC4 Watchdog Super Elite product manual for more
information regarding sensor settings.
NOTE
PAGE 8
3
2

FOR BUCKET ELEVATORS
SPEED MONITORING
1
BEARING TEMPERATURE
2
at each end of the drive and tail or
head and boot shafts.
BELT MISALIGNMENT
3
Qty. 4 - Sensors work in pairs, one
for each side of the belt on the drive
and tail or head and boot sections.
PLUG INDICATION 3
4
Qty. 1 - One sensor located near the 2
top of the drive section or spouting
by the discharge. 1
PAGE 9
1. WDC3 (RETIRED MODEL) TO WDC4 SENSOR WIRING DIAGRAM
NOTE
This wiring diagram is for end users upgrading their WDC3 Watchdog to the WDC4 Watchdog Super
Elite. This basic diagram provides a quick terminal reference between the two models.
1 44 0 VDC
---- 43 Speed Sensor

Right
Sensor ---- 42 Pulley Sensor
---- 41 Plug Sensor

Alignment
Left ---- 39 Head Rub - Left (T#11)

Sensor
3A 38 Head Align - Right
5 (1) 36 +24 VDC (F1)
Right 1 35 0 VDC
Sensor
Alignment
---- 33 Tail Rub - Left (T#9)
Bottom (Tail)
Left
Sensor 2B 31 Tail Align - Left
5 (1) 30 +24 VDC (F2)
---- 29 0 VDC
---- 28 Bearing Temp Sensor (T#6)

RIGHT

Top (Head)
LEFT

RIGHT
Bearing
LEFT
---- 21 Ambient Sensor 1 (T#7)
---- 20 +24 VDC (F3)
PAGE 10
2. SENSOR WIRING DIAGRAM PROFILE WITH TOUCHSWITCHES -
Black Black
44 0 VDC
Orange
White Brown
X
RIGHT
43 Speed Sensor
Blue Red
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 V (F1)
Black Black
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange
White Blue
LEFT

Red
X
White
30 +24V (F2)
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
X No Connection 20 +24V (F3)
Insulate and Do
NOT Connect
PAGE 11
3. SENSOR WIRING DIAGRAM PROFILE WITH RUB BLOCKS -
MENU > SETUP (PASSWORD) > PROFILE > SELECT NEW PROFILE > LEG (RB)/ 1SP, 4BS, 4RB
44 0 VDC
Black
RIGHT
Red
Brown
42 Pulley Sensor

Top (Head)
Blue
Black
LEFT

Brown
36 +24 V (F1)
Brown
Black
RIGHT
Red
Brown
Alignment
Black
LEFT
Brown
30 +24V (F2)
White
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 12
4. SENSOR WIRING DIAGRAM PROFILE WITH MOTION ALIGNMENT SENSORS -
Red
44 0 VDC
Red
Motion
RIGHT
Green
Alignment Black
Sensor Brown
Blue
Alignment
Orange
Motion Green
LEFT
Alignment
Black
Blue
36 +24 VDC (F1)
Red
Red
Orange
Motion Green
RIGHT
Alignment Black
Sensor
Black 35 0 VDC
Brown
Blue
Alignment
Orange
LEFT
Alignment
Black
Blue
X No Connection
Insulate and Do
NOT Connect
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 13
5. SENSOR WIRING DIAGRAM PROFILE WITH KNEE OR IDLER PULLEYS -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Alignment Top (Head)
Blue Red
Green
X 41 Plug Sensor
Black
Orange
White Blue
X
LEFT
Black Blue
Orange
X Red 38 Head Align - Right
Alignment Knee or Idler Pulley
White Brown Green

RIGHT
Blue X
Red
Green 36 +24 VDC (F1)
X
Black Black Black
Orange Orange
White
X White
X
Blue
RIGHT
LEFT
Alignment Bottom (Tail)
Blue Blue Red

Red Red
Green Green
X X 35 0 VDC
Black
Orange
White
X
LEFT
X No Connection Blue
Insulate and Do
Red 32 Tail Align - Right
Green
NOT Connect X 31 Tail Align - Left
30 +24 VDC (F2)
White
White
Blue
Speed
Brown
Black
Yellow 29 0 VDC
Black
Brown
Bearing
Top (Head) LEFT Orange 27 Bearing Temp Sensor (T#5)
Black
Brown

Black

RIGHT
Bearing
Bottom (Tail) LEFT Orange 23 Bearing Temp Sensor (T#1)
Black
Brown 22 Ambient Sensor 2 (T#8)
Gray 21 Ambient Sensor 1 (T#7)

Black

RIGHT
Bearing
Knee / Idler LEFT Purple
Black
Brown
PAGE 14
6. SENSOR WIRING DIAGRAM WITH AMBIENT SENSOR -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT Blue Red
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 VDC (F1)

Black Black
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange
White Blue
LEFT

Red
X
White
30 +24 VDC (F2)
White
Blue
Speed
Brown
Black X No Connection
Insulate and Do
NOT Connect
Yellow
Black 29 0 VDC
Brown
RIGHT
Bearing 28 Bearing Temp Sensor (T#6)
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Orange 23 Bearing Temp Sensor (T#1)
Brown

Gray 20 +24 VDC (F3)
Ambient Black
Sensor Brown
PAGE 15
7. SENSOR WIRING DIAGRAM WITH TOUCHSWITCHES AND PLUG SWITCH -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Blue Red
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 V (F1)
Blue
Purple
Black / Red
Plug
Switch
Black / Orange X
Black
Brown
X No Connection
Black Black Insulate and Do
Orange NOT Connect
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange
White Blue
LEFT

Red
X
White
30 +24V (F2)
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 16
8. SENSOR WIRING DIAGRAM WITH RUB BLOCKS AND PLUG SWITCH -
44 0 VDC
Black
RIGHT
Red
Brown
42 Pulley Sensor

Top (Head)
Blue
Black
LEFT

Brown
36 +24 V (F1)
Blue
Purple
Black / Red
Plug
Switch
Black / Orange X
Black
Brown
Brown
Black
RIGHT
Red
Brown
Alignment
Black
LEFT
Brown
White 30 +24V (F2)

White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 17
9. SENSOR WIRING DIAGRAM WITH MOTION ALIGNMENT SENSORS AND PLUG SWITCH -
Red
44 0 VDC
Red
Motion
RIGHT
Green
Alignment Black
Sensor Brown
Blue
Alignment
Orange
Motion Green
LEFT
Alignment
Black
Blue
36 +24 VDC (F1)
Blue
Purple
Black / Red
Plug
Switch
Black / Orange X
X
Black
Brown No Connection
Insulate and Do
NOT Connect
Red
Red
Orange
Motion Green
RIGHT
Alignment Black
Sensor
Black 35 0 VDC
Brown
Blue
Alignment
Orange
LEFT
Alignment
Black
Blue
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 18
10. SENSOR WIRING DIAGRAM WITH MOTION ALIGNMENT SENSORS, PLUG SWITCH AND
HEAD PULLEY SENSORS -
Black Black Black

Orange
X
Orange
X X No Connection
LEFT / RIGHT
White White
Head Insulate and Do
Blue Blue Gray
Pulley NOT Connect
Red Red Red
Green Green
X X
Red
44 0 VDC
Orange
Motion
43 Speed Sensor
RIGHT
Green
Alignment
Black
Sensor Brown
Blue 42 Pulley Sensor
Alignment
White X
41 Plug Sensor
Top (Head) Red
Orange 40 Head Rub - Right (T#12)
Motion Green
LEFT
Alignment
Black
Sensor Blue
Blue
White X
Blue
Purple 36 +24 VDC (F1)
Black / Red
Plug
Switch
Black / Orange X
Black
Brown
Red
Red
Orange
Motion Green
RIGHT
Alignment Black
Sensor
Black 35 0 VDC
Brown
Blue
Alignment
Orange
LEFT
Alignment
Black
Blue
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 19
11. SENSOR WIRING DIAGRAM WITH TOUCHSWITCHES AND DIFFERENTIAL SPEED -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Blue
Red Red 42 Pulley Sensor
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 V (F1)
White
Blue
Speed
Brown
Black
X No Connection
Insulate and Do
Black Black NOT Connect
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange
White Blue
LEFT

Red
X
White
30 +24V (F2)
White
Blue
Speed
Brown
Black
29 0 VDC
Yellow
Brown
Bearing
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 20
12. SENSOR WIRING DIAGRAM WITH TOUCHSWITCHES, DIFFERENTIAL SPEED AND
PLUG SWITCH -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT
Blue
Red Red 42 Pulley Sensor
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 V (F1)
White
Blue
Speed
Brown
Black
Blue
Purple
Black / Red
Plug
Switch
Black / Orange
Black
X X No Connection
Brown
Insulate and Do
NOT Connect
Black Black
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange 34 Tail Rub - Right (T#10)
White Blue
X
LEFT

Red
X
White
White 30 +24V (F2)
Blue
Speed
Brown
29 0 VDC
Black

Yellow
Brown
Bearing RIGHT 26 Bearing Temp Sensor (T#4)
Brown
Black
Brown
RIGHT 22 Ambient Sensor 2 (T#8)
Bearing
Bottom (Tail) LEFT
Black
Brown
20 +24V (F3)
PAGE 21
4
5
2
3 3
2 1

FOR ENCLOSED BELT
CONVEYORS
SPEED MONITORING
1
BEARING TEMPERATURE
2
at each end of the drive and tail
shafts.
BELT MISALIGNMENT
3
Qty. 4 - Sensors work in pairs, one for
each side of the belt on the drive and
tail sections.
PLUG INDICATION
4
Qty. 1 - One sensor located near
the top of the drive section by the
discharge.
TAIL PULLEY MISALIGNMENT

5
Qty. 2 - One sensor located on each
side of the housing on the conveyor
tail section.
PAGE 22
13. SENSOR WIRING DIAGRAM WITH 6 RUB BLOCKS, 4 BEARING TEMPERATURE SENSORS
AND 2 LUG STYLE TAIL PULLEY ALIGNMENT SENSORS -
Brown
Alignment - Head Pulley

Black
RIGHT
Red 44 0 VDC
Brown
43 Speed Sensor
42 Pulley Sensor
Blue 41 Plug Sensor
Black
LEFT
Brown
Black
Green 40 Head Rub - Right (T#12)
RIGHT
Alignment - Head Belt
Brown

Gray
Black
LEFT
36 +24 V (F1)
Brown Brown
Black
RIGHT
Alignment - Tail Belt
Red
Brown
Blue
Black
LEFT
Brown 35 0 VDC

White
White
Black
Blue
Speed
Brown 30 +24V (F2)
Black
Yellow
Black
Brown
RIGHT
Bearing
Head LEFT
29 0 VDC
Orange
Black

Yellow
Black
Brown
RIGHT
Bearing
Tail LEFT Orange
Black
Brown

Green
Black
Brown
Alignment RIGHT 21 Ambient Sensor 1 (T#7)

Tail Pulley LEFT
Gray 20 +24V (F3)
Black
Brown
PAGE 23
14. SENSOR WIRING DIAGRAM WITH TOUCHSWITCHES, 4 BEARING TEMPERATURE SENSORS
AND 2 LUG STYLE TAIL PULLEY ALIGNMENT SENSORS -
Black Black
44 0 VDC
Orange
White Brown
X
43 Speed Sensor
RIGHT Blue Red
Green
Top (Head) Black
Orange
White Blue
X
LEFT
Blue
Red
Green
X
36 +24 VDC (F1)

Black Black
Orange
White Brown
X
RIGHT
Blue Red
Red
Green
Alignment X
Black
Orange
White Blue
LEFT

Red
X
White
30 +24 VDC (F2)
White
Blue
Speed
Brown
Black
Yellow
Black 29 0 VDC
Brown
RIGHT
Bearing 28 Bearing Temp Sensor (T#6)
Brown
Yellow
Brown
Bearing
Bottom (Tail) LEFT
Black
Orange 23 Bearing Temp Sensor (T#1)
Brown

Green
Black

Alignment RIGHT
Tail Pulley LEFT
Gray
Black
Brown
PAGE 24
NOTES
PAGE 25
3
2 4
2
1

FOR DRAG CHAIN CONVEYORS
SPEED MONITORING
1
BEARING TEMPERATURE
2
at each end of the drive and tail
shafts.
SLACK CHAIN DETECTION

3
Qty. 1 - One motion alignment sensor
near the drive end.
PLUG INDICATION
4
Qty. 1 - One sensor located near
the top of the drive section by the
discharge.
PAGE 26
15. SENSOR WIRING DIAGRAM FOR SLACK CHAIN DETECTION WITH PLUG SWITCH -
Red
44 0 VDC
Red
Motion Green
Alignment Black
Sensor Brown
Blue

White
White
Blue
Speed
Brown
Black
36 +24 VDC (F1)
Blue
Purple
Black / Red
Plug
Switch
Black / Orange X
Black
Brown X No Connection
Insulate and Do
NOT Connect
35 0 VDC
30 +24 VDC (F2)
29 0 VDC
Yellow
Brown
Drive
LEFT
Section Black
Orange
Brown
Yellow
Brown
Tail
LEFT
Section Black
Brown
20 +24V (F3)
PAGE 27
16. SENSOR WIRING DIAGRAM FOR SLACK CHAIN DETECTION WITHOUT PLUG SWITCH -
Red
44 0 VDC
Red
Motion Green
Alignment Black
Sensor Brown
Blue

White
White
Blue
Speed
Brown
Black
36 +24 VDC (F1)
X No Connection
Insulate and Do
NOT Connect
35 0 VDC
30 +24 VDC (F2)
29 0 VDC
Yellow
Brown
Drive
LEFT
Section Black
Orange
Brown
Yellow
Brown
Tail
LEFT
Section Black
Brown
20 +24V (F3)
PAGE 28
NOTES
PAGE 29
NOTES
PAGE 30
PRODUCT WARRANTY

4B’S OPTION.


PAGE 31
location.

Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338

Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3711 2565
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3711 2574
www.go4b.com
Product Datasheet
4B
Components Whirligig®
Limited
Whirligig®
Universal Shaft Sensor Mount
APPLICATION
The Whirligig is a fully guarded target for easy mounting of motion
sensors. It is a target, bracket and guard suitable for all industry standard
cylindrical or DIN style inductive sensors including 4B’s M100, M300, and
M800 Elite Speed Switches.
METHOD OF OPERATION
The sensor (sold separately) bolts to the Whirligig and the complete
assembly either bolts to the machines shaft through a 1/2” UNC tapped
hole, or is connected magnetically using 4B’s patented Mag-Con™
adaptor. Shaft or machine vibration does not affect the performance of the
sensor, as the whole assembly moves with the shaft. With the Whirligig,
installation of speed sensors is now simple, safe and reliable.
FEATURES
► For DIN Style and Standard Cylindrical Inductive Sensors
► Connects to Machine Shaft with 1/2” Tapped Hole or
Magnetically Install with Mag-Con Adaptor
► Bracket for 18/30 mm Diameter Sensor Included
► Available with 1, 2, 4 or 8 Targets
► Fully Enclosed Target for Safe Operation
► WG1-4B-1 Whirligig with 1 Target
► WG1-4B-2 Whirligig with 2 Targets
► WG4-4B-4 Whirligig with 4 Stainless Steel Targets*
► WGB1830 18 mm / 30 mm Bracket (Included)
► MAG2000 Mag-Con™ Magnetic Connector (Optional)
* For Highly Corrosive Environments
4B COMPATIBLE SENSORS
► MIL8001V4C Milli-Speed Switch (4-20 mA)
► M8001V10C M800 Elite Speed Switch
► M3001V10F M300 Slipswitch (2 Wire)
► M3005V10CA M300 Slipswitch (5 Wire) Whirligig Shown with M300 Slipswitch
(Sensors Sold Separately)
► M1001V10F M100 Stopswitch
► P8002V10FC P800 ProxSwitch U.S. Pat #6,109,120
► P8001V34FC P800 ProxSwitch (NPN/PNP)
► P3002V10C P300 ProxSwitch
► P300V34C P300 ProxSwitch (NPN/PNP) Mag-Con™
► P1002V10C P100 ProxSwitch (MAG2000)
► P100V34C P100 ProxSwitch (NPN/PNP) U.S. Pat #6,964,209 Zone 20
Please refer to instruction manual for correct installation.

CSA, CE and ATEX Approved Sensor Available
Information subject to change or correction. Jul 2018
Product Datasheet
4B
Components Whirligig®
Limited
3-1/16”
2-1/8” 3-1/2”
1”
Targets
2”
1/2” UNC
Optional Threads
Mag-Con 11/16” 1-3/16” 8”
Magnetic
Connector
1-5/8” 5/8”
Ø
11/16”
NOTE: Dimensions In Inches 1-3/4”
1-5/8”
5/8”
1-3/16”
1-5/8”
Ø
Whirligig Shown with
1-3/16”
8” M800 Elite Speed Switch
1-5/8”
(Sensor Sold Separately)
Mag-Con Mag-Con™ Magnetic Connector

(optional) Target This device screws onto the Whirligig and magnetically
couples to the shaft being monitored, simplifying
installation even further.
• Material: Stainless Steel
• Holding Force: Over 150 lbs.
• Maximum Speed: 300 RPM
U.S. Pat #6,964,209
Machine Shaft
Sensor
(Sold Separately)
Whirligig® - Universal Shaft Sensor Mount
Whirligig
Shaft Material: Stainless Steel
Body Material: Polypropylene
Bearing: Sealed Stainless Steel
Thread Size: 1/2" UNC
Hex Wrench Size: 5/8"
Maximum Speed: 1,500 RPM
Whirligig on Bucket Elevator with M800 Elite Speed Switch
Pulses / Targets: 1, 2, 4 or 8 (Must Specify)
Please refer to instruction manual for correct installation.
Information subject to change or correction. Jul 2018
Whirligig®
UNIVERSAL SHAFT SENSOR MOUNT
WITH FULLY GUARDED TARGET
Whirligig Shown with M300 Slipswitch

(All Sensors Sold Separately)
U.S. Patent #6,109,120
OPERATION MANUAL
Part No’s: WG1-4B-1, WG1-4B-2, WG1-4B-4, WG1-4B-8
www.go4b.com/usa
TABLE OF CONTENTS

DIMENSIONS Page 7
INSTALLATION INSTRUCTIONS Page 8
PART NUMBERS & ACCESSORIES Page 9
COMPATIBLE SENSORS Page 10
WARNING
cut and entangle.
Do NOT operate with
guard removed.
removing guard or
servicing.
Whirligig® and Mag-Con™ are trademarks 4B Components Ltd., a subsidiary of T.F. & J.H. BRAIME (HOLDINGS) P.L.C.
4B appreciates your business and is pleased you have chosen our products to meet your
needs.
product.

Please read all user, instruction and safety manuals to ensure that you understand
your product operation and are able to safely and effectively use this product. If the
equipment is used in a manner not specified in this manual, the protection provided by
the equipment may be impaired.
PAGE 4


6. SERVICE REQUEST
www.go4b.com/usa.
PAGE 5
WARNING
PRODUCT OVERVIEW
The Whirligig® is a fully guarded target for easy mounting of motion sensors. It is a target, bracket
and guard suitable for all industry standard cylindrical (18 and 30 mm) or DIN style inductive sensors
including 4B’s M100, M300, M800 Elite and Milli-Speed switches or P100, P300 and P800 proximity
sensors.
Sensors (sold separately) bolt to the Whirligig® and the complete assembly either bolts to the machines
shaft through a 1/2” UNC tapped hole, or is connected magnetically using 4B’s patented Mag-Con™
adaptor. Shaft or machine vibration does not affect the performance of the sensor, as the whole
assembly moves with the shaft. With the Whirligig, installation of speed sensors is now simple, safe and
reliable.
Mag-Con™
Magnetic Connector
(Optional)
Target
1, 2, 4 or 8 Pulse
Machine Shaft
Target Guard Cover
DIN Style Sensor Shown 18 mm Sensor Shown

(Sensors Sold Separately) (Sensors Sold Separately)
SPECIFICATIONS
Shaft Material - Stainless Steel
Body Material - Polypropylene
Bearing - Sealed Stainless Steel
Thread Size - 1/2” UNC
Hex Wrench Size - 5/8”
Maximum Speed - 1,500 RPM
Pulses / Targets - 1, 2, 4 or 8 (Must Specify)
PAGE 6
DIMENSIONS
3-1/16”
2-1/8” 3-1/2”
1”
Targets
2”
1/2” UNC
Threads
Mag-Con 11/16” 1-3/16” 8”
Magnetic
Connector
(Optional) 1-5/8” 5/8”
Ø 11/16”
1-3/4”
1-5/8”
5/8”
1-3/16”
1-5/8”
Ø 1-3/16” 8”
1-5/8”
Whirligig® on Bucket Elevator with M800 Elite Speed Switch
PAGE 7
WARNING
O.S.H.A. requires that all exposed rotating shafts are provided with a full guard. Therefore, this device
and its target must be equipped with a guard.
INSTALLATION
Do NOT remove the Whirligig® target guard cover. The rotating components under the cover could
cause serious injury.
1. There are two options to attach the Whirligig® to the machine’s shaft:
Option A - Use Mag-Con™ magnetic connector. Thread the Mag-Con™ onto the Whirligig® using a
thread locking adhesive (Loctite or similar) and attach the unit onto the machine shaft.
Option B - Drill and tap the center of the machine shaft for 1/2” UNC thread, ensure that the shaft is
tapped 1” deep. Thread the Whirligig® onto the machine shaft with a 5/8” open ended
wrench using suitable thread locking adhesive (Loctite or similar).
2. Fix the white flexible strap to the bottom of the Whirligig® base plate using the supplied screws.
3. Install the sensor to the base plate, leave a 2 mm (approximate) gap between the sensor face and
the target guard cover. Two sets of pre-drilled holes are provided for DIN style rectangular sensors.
For 18 or 30 mm cylindrical sensors, use the supplied universal stainless steel bracket and screws.
4. Wire the sensor in accordance with the manufacturer’s instructions while observing all relevant
electrical and OSHA regulations.
5. Fix the white flexible strap to the static structure (if required).
1/2” UNC Tapped Shaft*
Target Guard Cover
DIN Style
Rectangular
Sensor
Cylindrical Sensor
18/30 mm Stainless
Steel Bracket (Supplied)
10 mm Stainless Steel Screws

(4 - Supplied)
Base Plate
50 mm Stainless Steel Screws
(4 - Supplied)
Flexible
Conduit
Flexible Strap
*No need to drill and tap 1/2” UNC hole in shaft if using the optional Mag-Con™ Magnetic Connector
PAGE 8
FAULT REMEDY
1. Check the sensing range of the sensor being used, and move
sensor closer to the target.
Sensor does not Detect
2. Check to make sure the sensor being used can detect a moving
Whirligig® Target
non-ferrous metal target. If not, try WG4-4B-4 with 400 series
stainless steel target.
Whirligig® Unscrews from Use thread locking adhesive (Loctite or similar) on the threads of
the Machine’s Shaft the Whirligig®.
PART NUMBERS & ACCESSORIES
WG1-4B-1 Whirligig® with 1 Pulse / Target

WG1-4B-4 Whirligig® with 4 Pulse / Target (Standard)
WG4-4B-4 Whirligig® with 4 Pulse / Target (Stainless Steel)
WGB1830 18 / 30 mm Stainless Steel Bracket (Supplied)
MAG2000 Mag-Con™ Magnetic Connector (Optional)
Mag-Con™ Magnetic Connector

This optional accessory screws onto the Whirligig® and magnetically
couples to the shaft being monitored, simplifying installation.
Material: Stainless Steel
Holding Force: Over 100 lbs.
Maximum Shaft Speed: 300 RPM
Temperature Range: -40°F to 194°F (-40°C to 90°C)
U.S. Patent #6,964,209
Whirligig® Installed on the Tail Shaft of Enclosed

Conveyor with M800 Elite Speed Switch
PAGE 9
4B COMPATIBLE SENSORS
M8001V10C M800 Elite Speed Switch

MIL8001V4C Milli-Speed Switch (4-20 mA)
M3001V10F M300 Slipswitch (2 Wire)
M3005V10CA M300 Slipswitch (5 Wire)
M1001V10F M100 Stopswitch
P8004V10C P800 ProxSwitch (Output Off)
P3002V10C P300 ProxSwitch
P3001V34C P300 ProxSwitch (NPN/PNP)
P1002V10C P100 ProxSwitch
P1001V34C P100 ProxSwitch (NPN/PNP)
SpeedMaster™ Speed Switch
KIT-SM2
Calibration and Testing Device
For More Information on Whirligig® Accessories

and Compatible Sensors, Visit www.go4b.com/usa
Speed Switch Sensors

4B’s line of speed switches include: proximity, inductive,
zero speed and stop motion to monitor dangerous belt slip,
underspeed or stop conditions on conveyors, bucket elevators
and any other rotating machinery.
Inductive Proximity Sensors

4B’s line of inductive proximity sensors are designed to detect
shaft speed, shaft position, gate position, or object presence.
SpeedMaster™
The SpeedMaster with Pulse Pilot is the only device that
accurately tests the calibration of a speed switch, and allows
testing of the alarm and shutdown features of the sensor while
installed on the machine shaft.
The SpeedMaster operates in two modes. Input mode is used
to measure the pulse rate at normal speed. Output mode will
allow the user to simulate underspeed for testing purposes.
The Pulse Pilot fits in the gap between the sensor and the
Patents - target. The Pulse Pilot will have no effect on the operation of
US8947073 the speed switch until it is connected to the SpeedMaster and
MX321802
EP26223568
set to “output” mode.
PAGE 10
PRODUCT WARRANTY

4B’S OPTION.


PAGE 11
location.

Tel: +44 (0) 113 246 1800 Fax: +49 (0) 700 2242 3733 Tel: +66 (0) 2 173-4339
Fax: +44 (0) 113 243 5021 Fax: +66 (0) 2 173-4338

625 Erie Avenue 9 Route de Corbie 14 Newport Business Park Building 1, 41 Bellrick Street
Morton, IL 61550 80800 Lamotte Warfusée Mica Drive, Kya Sand Acacia Ridge, 4110
USA France 2163 Johannesburg Queensland
Fax: 309-698-5615 Fax: +33 (0) 3 22 42 37 33 Tel: +27 (0) 11 708 6114 Tel: +61 (0) 7 3216 9365
Fax: +27 (0) 11 708 1654 Fax: +61 (0) 7 3219 5837
www.go4b.com

New Receiving Addition - GGI PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

New Receiving Addition - GGI PDF

Uploaded by

Copyright:

Available Formats

THE SYMBOL SHOWN BELOW IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS

BE ALERT! YOUR SAFETY IS INVOLVED

RECEIVING MERCHANDISE & FILING CLAIMS

GENERAL SAFETY STATEMENT

OPERATIONAL SAFETY STATEMENT

3. Unqualified persons are to stay out of the work area.

DATE EMPLOYER SIGNATURE EMPLOYEE SIGNATURE

Standard “U” Trough Drag Conveyor

④ Trough Section ⑤ Inlet ⑥Self CleaningTail Section

Ultramax Drag Conveyor

Two Deck Drag Conveyor

Bone Drag Conveyor

HEAD AND DRIVE

6) Replace guard carefully and securely.

Welded Paddle Attachment UHMW Paddle

Welded Paddle Attachment

LINERS Lock Nut Bolt

LIFTING AND MOVING

COMPLETELY ASSEMBLED DRAG CONVEYOR

SITE ASSEMBLED DRAG CONVEYOR

When the internal flow control plate is lowered to its

When the internal flow control plate is set at its 60o

Ultra Clean (60o)

CONVEYOR FILL (Divided Flow)

B) Curved Slide (Standard “U” trough)

C) Ultramax Drop Door D) Bone Style Drop Door

NOTE (TO AVOID PLUGGING):

Lid Release Section

Self Cleaning Paddle Rails

Door Adjustment Linkeage (Note 1)

Internal View of “ACME” Thread

Chain Takeup Unit

Figure. 10 Head (MODEL 1)

Side View Alignment Procedure

Top View Alignment Procedure

START-UP FOR THE FIRST TIME

6. Measure and record the no load motor current.

5. Do not overload conveyor. Do not exceed conveyor speed, capacity, material

7. If the conveyor is to be inoperative for a prolonged period of time, operate

8. ULRAMAX CONVEYOR DROP DOOR DISCHARGE

4. Check chain return carrier tracks for excess wear.

5. Inspect the transmission v-belts or chain for tension and condition.

9. Check all hardware and tighten as required.

CONVEYOR CHAIN AND SPROCKET LIFE

Replace Drag Conveyor Chain When:

Extended Shutdown / Storage

B) Slow drag down. Consult MMS

Ultramax Drop Door

ring is firmly in place.

3. Inspect airlines, cylinder and solenoids.

4. Inspect air cylinder mounts.

1. Remove lock plate located on the face of the locknut.

NOTE: All Weight Must Be Removed from the Bearing

4. The “ZERO Reference Point” is defined as the point when

To reach the “ZERO Reference Point” rotate locknut Figure 3

Table 3 - Re-Lubrication Intervals (Months) Based on 12 hours per day, 150° F M

Customer: GREENFIELD GLOBAL TIVERTON Date: June 2018

INSTALLATION, OPERATION MAINTENANCE

THE SYMBOL SHOWN BELOW IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS

BE ALERT! YOUR SAFETY IS INVOLVED

Anyone who will operate or work around this equipment shall

RECEIVING MERCHANDISE & FILING CLAIMS