FIN

NAL OPERAT
TION AND MA
AINTENANCE MANUAL MINA MINIS
STRO HALES
S PROJECT

ORDEN DE COMPRA H336073-PM

M031/A 4501190525

FMC
C TECHNOLOGIES PROJJECT B6042

04EdificioStuddioLasCondesFono:56222
nologiesChileLLtda.Callao#2970Oficina70
FMCTechn 2320825

PRO-LINE
Motion Monitor
Model 60-200-1
(Single Channel)
REC 3774 Rev H Part Number 042700
 REVISION HISTORY

REVISION A JUNE 1992

REVISION B FEBRUARY 1993
REVISION C OCTOBER 1993
REVISION D APRIL 1994
REVISION E MAY 1995
REVISION F SEPTEMBER 1998
REVISION G AUGUST 2001
REVISION H FEBRUARY 2002

REC 3774 ii
About this Manual
This manual provides the information you need to install, operate, and maintain the
Single Channel Motion Monitor. This revision documents version H of the Single
Channel Motion Monitor manual.

Read this manual before working with the system. For personal and system safety, and
for the best product performance, make sure you thoroughly understand the manual
before installing, operating, or maintaining this machine.

Who Should Use this Manual?

The Single Channel Motion Monitor manual is a learning resource and reference for
anyone concerned with installing, operating, or maintaining the detector in a belt
conveyor system.

Organization of the Manual

This manual is organized into eight chapters.

Chapter 1: Introduction to the Single Channel Motion Monitor gives you general information
and specifications.

Chapter 2: Inspection gives direction for opening and inspection of the components for
broken or damaged parts.

Chapter 3:Installation provides information about setting up the Single Channel Motion
Monitor.

Chapter 4: Operation provides programming instructions for the Single Channel Motion Monitor.

Chapter 5: ,Theory of Operation provides operation theory for the Single Channel Motion
Monitor.

Chapter 6: Troubleshooting describes troubleshooting methods.

Chapter 7: Replacement Parts gives ordering information and a parts list for the Single
Channel Motion Monitor.

Chapter 8: Options contains the options available for the Single Channel Motion Monitor.

REC 3774 iii

Safety Messages

Instructions in this manual may require special precautions to ensure the safety of the personnel
performing the operations.

Please read the safety information before performing any operation preceded by this symbol.

There are two levels of safety messages: warnings and cautions. The distinction between the
two is as follows:

WARNING
Failure to observe could result in death or serious
injury.

CAUTION
Failure to observe may cause minor injury or
damage the equipment

General Precaution

Do not install, operate, or perform any maintenance procedures until you have read the
safety precautions presented.

WARNING
Failure to follow safe installation and servicing
procedures could result in death or serious injury.
Make sure only qualified personnel perform
installation and maintenance procedures in
accordance with the instructions in this manual.
Allow only qualified electricians to open and work in
the electronics cabinest, power supply cabinest,
control cabinets, or switch boxes.
Covers over the electronics and rotatingpartsmust
always remain in place during normalooperation
Remove only for maintenance, with the machines
power OFF. Replace all covers before resuming
operation.
During maintenance, a safety tag (not supplied by
the facotry) is to be displayed in the ON/OFF switch
areas instructing others not to operate the unit
(ANSI:B157.1).

REC 3774 iv
 WARNING
High voltage that may be present on leads could
cause electrical shock.
All switches must be OFF when checking input AC
electrical connections, removing or inserting printed
circuit boards, or attaching voltmeters to the
system.
Use extreme caution when testing in, on, or around
the electronics cabinet, PC boards, or modules.
There are voltages in excess of 115 V or 230 V in
these areas.

WARNING
Use only the procedures and new parts
specifically referenced in this manual to ensure
specification performance and certification
compliance. Unauthorized procedures or parts
can render the instrument dangerous to life, limb,
or property.

CAUTION
Keep hands and clothing away from all moving or
rotating parts.

CAUTION
Do not place or store objects of any kind on the
machine.

CAUTION
This machine should not be operated at more than
the production rate stated on your Equipment
Specification sheet or used in applications other
than those stated in the original order.

Occupational Safety and Health Act (OSHA)

The Occupational Safety and Health Act clearly places the burden of compliance on the
user of the equipment and the act is generalized to the extent that determination of
compliance is a judgment decision on the part of the local inspection. Hence, Thermo
Scientific will not be responsible for meeting the full requirements of OSHA in respect to
the equipment supplied or for any penalty assessed for failure to meet the requirements,
in respect to the equipment supplied, of the Occupational Safety and Health Act, as
interpreted by an authorized inspector. Thermo Scientific will use their best efforts to
remedy such violation at a reasonable cost to the buyer.

REC 3774 v
Thermo Scientific Warranty
The seller agrees, represents, and warrants that the equipment delivered hereunder shall
be free from defects in material and workmanship. Such warranty shall not apply to
accessories, parts, or material purchased by the seller unless they are manufactured
pursuant to seller's design, but shall apply to the workmanship incorporated in the
installation of such items in the complete equipment. To the extent purchased parts or
accessories are covered by the manufacturer's warranty, seller shall extend such
warranty to buyer.

Seller's obligation under said warranty is conditioned upon the return of the defective
equipment, transportation charges prepaid, to the seller's factory in Minneapolis,
Minnesota, and the submission of reasonable proof to seller prior to return of the
equipment that the defect is due to a matter embraced within seller's warranty hereunder.
Any such defect in material and workmanship shall be presented to seller as soon as
such alleged errors or defects are discovered by purchaser and seller is given
opportunity to investigate and correct alleged errors or defects and in all cases, buyer
must have notified seller thereof within one (1) year after delivery, or one (1) year after
installation if the installation was accomplished by the seller.

Said warranty shall not apply if the equipment shall not have been operated and
maintained in accordance with seller's written instructions applicable to such equipment,
or if such equipment shall have been repaired or altered or modified without seller's
approval; provided, however, that the foregoing limitation of warranty insofar as it relates
to repairs, alterations, or modifications, shall not be applicable to routine preventive and
corrective maintenance which normally occur in the operation of the equipment.

EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER

DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT
DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER ARISING
OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO
BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH
OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR
REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A
SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT IN
WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES.

Purchaser agrees to underwrite the cost of any labor required for replacement; including
time, travel, and living expenses of Thermo Scientific Field Service Engineer at closest
factory base.

THERMO SCIENTIFIC
501 90TH AVE. NW
MINNEAPOLIS, MN 55433
PHONE: (763) 783-2500
FAX: (763) 783-2525

REC 3774 vi
Disclaimer
Though the information provided herein is believed to be accurate, be advised that the
information contained herein is not a guarantee for satisfactory results. Specifically, this
information is neither a warranty nor guarantee, expressed or implied, regarding
performance, merchantability, fitness, or any other matter with respect to the products,
and recommendation for use of the product/process information in conflict with any
patent. Please note that Thermo Scientific reserves the right to change and/or improve
the product design and specifications without notice.

REC 3774 vii

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REC 3774 viii

 TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 INSPECTION

3.0 INSTALLATION

4.0 OPERATION

5.0 THEORY OF OPERATION

6.0 TROUBLESHOOTING

7.0 REPLACEMENT PARTS

8.0 OPTIONS
 This page left blank intentionally.

REC 3774 ii
 Chapter 1
INTRODUCTION
1.1 GENERAL

The 60-200-1 Motion Monitor is a micro-processor controlled speed monitoring device.

(See Figure 3-1B.) Thermo Scientific's standard sensors and a wide variety of other
NPN sensors provide a stream of pulses that represent velocity. The output consists of
one double pole double throw relay.

1.2 SPECIFICATIONS

(1) Input voltage: 120VAC/240VAC 10%

50/60HZ
NOTE: Unit may not operate below lower voltage limit.

(2) Outputs: a. 1 DPDT 230VAC/5A Relay.

Non-Inductive. (230VAC/2A Inductive.) (NC/NO selectable)
b. 0-2VDC that equates to 0-199% of speed.
(Standard)
c. 0-20/4-20mA output option replaces Item B (0-2VDC). 800 ohms
maximum load. Tracks 0-100% or 0-199%. Software selectable.

(3) Sensor inputs: NPN (up to 3KHZ)

Note: Frequency HZ = Pulses per revolution x RPM / 60.

Note: Min. limit = 0.4HZ.

(4) +12VDC output: (Sensor operation) +12VDC at .075A (not fused).

(5) Temperature: Electronics:

-40 C to +50 C
Standard Proximity Sensors: -25 C to +70 C.

WARNING
OPERATION ABOVE +50 C (122 F) MAY CAUSE THE UNIT TO FAIL.

(6) Enclosure: Material: Noryl GFN3

(polyphenylene oxide)
NEMA 4X

(7) Dimensions: See Figure 1-1

REC 3774 1-1

 MOTION MONITOR DIMENSIONS
FIGURE 1-1

REC 3774 1-2

 Chapter 2
INSPECTION
2.1 INSPECTION

Inspect the packages for external damage before opening as often times the carrier can
be held responsible for shipping damages. After unpacking, inspect the unit for broken
components, etc.

REC 3774 2-1

 This page left blank intentionally.

REC 3774 2-2

 Chapter 3
INSTALLATION
3.1 MOUNTING

Inside the cover is a gasket to insure that the 60-200-1 can be installed in wash down or
exterior environments. Insure that proper "seal tight" conduit fittings are also installed to
retain the watertight integrity of the unit. Fittings and gasket should be free from sand or
grit that could interfere with a proper seal.

Keep the unit out of heavily traveled pathways to avoid unintentional impact. Also keep
the unit out of standing water and above conduit to avoid water running down into the
enclosure. Figure 3-1A shows an example of a mounting configuration.

3.2 POWER WIRING

WARNING

NEVER REMOVE THE SAFETY BARRIER WITH POWER APPLIED TO THE UNIT.

All operating and switching power are brought into the power terminal strip. The strip is
located under the safety barrier.

For 120VAC power input operation, JUMP1 and JUMP2 are in position "A". For 240VAC
power input operation, JUMP1 and JUMP2 are in Position "B". A separate fused input is
provided for European applications.

Applications that require many wires can be difficult to install. Leave conduit fittings
unsecured until all wiring has been installed. See Figure 3-1C.

Power wiring configurations are illustrated in Figure 3-2A.

WARNING

INSURE THE EARTH GROUND IS CONNECTED. FOLLOW ALL LOCAL WIRING

REGULATIONS.

3.3 OUTPUT WIRING

There is one double pole double throw relay (K1) in the Single Channel Motion Monitor.
The conveyor speeds programmed for the program step B will control relay K1. The
relay has two independent outputs (A and B) that can be jumper configured as normally
open or normally closed. Changing the jumper positions changes the relay state. The
jumpers are factory set to:

K1A = A
K1B = C

Relay K1 is in the open configuration when energized.

The relay is de-energized when it is in an alarm condition or when power has been
disconnected from the Motion Monitor. The relays are energized when not in alarm
(normal operation).

REC 3774 3-1

 FIGURE 3-1

REC 3774 3-2

 WIRING CONFIGURATION
FIGURE 3-1A

WIRING CONFIGURATION
FIGURE 3-1B

WIRING CONFIGURATION
FIGURE 3-1C

REC 3774 3-3

 FIGURE 3-2A

FIGURE 3-2B

FIGURE 3-2C

REC 3774 3-4

3.4 SIGNAL WIRING

CAUTION

RADIO AND OTHER FREQUENCY TRANSMISSIONS CAN BRING UNWANTED NOISE

INTO THE MOTION MONITOR. IF YOUR APPLICATION IS NEAR SUCH FREQUENCIES,
SHIELDED CABLE MUST BE USED.

Figure 3-3 shows Thermo Scientific's standard NPN sensors' wiring connections for the
signal terminal strip of the 60-200-1.

NOTE: There should not be any power wiring to this side of the unit.

NOTE: Do not install signal wires with power wires together in the same conduit.

3.4.1 Sensor Types

Thermo Scientific's standard sensors are of the NPN type. The term NPN (also
PNP) originated with certain types of transistors that were used as output
switches for sensors. An NPN output switches between a high and low
resistance to common. This is also known as current sinking and low side
switching.

NOTE: The 60-200-1 supplies +12VDC at .075A for sensor operation.

NOTE: The 60-200-1 (single channel) motion monitor does not have a PNP
sensor type input.

NOTE: An internal filter conditions the signal before the microprocessor

measures the timing. The filter helps remove electrical noise, but also
limits the frequency of the signal to below 3,000 Hz.

REC 3774 3-5

 FIGURE 3-3

FIGURE 3-3A

FIGURE 3-3B

REC 3774 3-6

 FIGURE 3-3C

FIGURE 3-3D

FIGURE 3-3E

REC 3774 3-7

 DANGER

THE 60-200-1 MOTION MONITOR CANNOT BE INSTALLED IN ANY HAZARDOUS AREA.

IT IS NOT INTRINSICALLY SAFE AND MUST BE ASSOCIATED WITH AN APPROVED
SENSOR FOR A PARTICULAR HAZARDOUS AREA

3.5 Signal Wiring Application Examples

Figure 3-4B gives examples of the different signal wiring configurations that are possible
with the 60-200-1.

Monitor (Pin #7) - 0-2VDC output correlating to 0-199% of speed.

Inhibit (Pin #9) - Input pin from an external PC or controller to inhibit an alarm
condition. Used only when alarm control program step (d) = 2.

Reset (Pin #10) - Input pin for a remote reset. Input functional whether alarm
control: program step (d) = 1 or (d) = 2.

3.6 Speed Voltage Output Wiring

The 60-200-1 is constantly measuring the current speed against the reference speed.
For example, if the current speed is exactly the same as the reference speed, the speed
voltage output is 1 volt that equals 100% of speed. If the current speed was 90% of the
reference speed, the output voltage would be 0.9 volts.

The speed voltage output (Pin #7, see Figure 3-4B) can be connected to a display, such
as a digital panel meter, to show current percent of speed. The output is zero to 2 volts
at 1 milliampere of current. This output is for reference purposes only; accuracy may
vary 2%.

REC 3774 3-8

 FIGURE 3-4

FIGURE 3-4A

REC 3774 3-9

 SIGNAL WIRING CONFIGURATION
FIGURE 3-4B

REC 3774 3-10

 Chapter 4
OPERATION
4.1 Design Consideration

CAUTION

SOME APPLICATIONS CAN CAUSE PROBLEMS AND SHOULD BE AVOIDED.

For example, it is possible to design the 60-200-a motion monitor in a loop that removes
its own power when an alarm condition is detected. When power is restored, the 60-
200-1 will not remember the old alarm condition. The unit will attempt to start as if
nothing happened.

If an application requires that the 60-200-1 lose power during an alarm condition or be
subject to power interruption during an alarm, it is recommended that an electrical
contact be installed so the unit cannot be restarted without a manual switch operation.
Consider the design application when a start-up, momentary power failure, alarm, reset,
or other operational conditions result in unplanned equipment operation. NOTE: Start-
up or reset can cause a momentary operation of the alarms until power has stabilized.

4.2 Setup and Adjustments

When the 60-200-1 motion monitor has been installed and wired, the unit is ready to be
programmed. Since the power side protective barrier was removed to install power and
output wiring, insure the protective barrier has been re-installed.

WARNING

DO NOT APPLY POWER WITHOUT THE POWER SIDE PROTECTIVE BARRIER

BEING INSTALLED AND SECURED.

4.3 Programming

Figure 4-1 represents the programming label for the 60-200-1 located on the inside
cover of the motion monitor. The information contained on the label is detailed and
should be read before installation.

4.3.1 Factory Preset Values

When the 60-200-1 motion monitor is tested at the factory, the following values
are programmed into memory. The operator can change these values for
specific applications.

Start-Up Delay = 10 Seconds

Channel One Alarm Trip Point = 40%
Channel One Alarm Delay = 10 Seconds
Alarm Control = 1
Start-Up Delay Control = 1
Alarm Function = 1
Current Output = 4 (Standard)

REC 3774 4-1

 60-200-1 PROGRAMMING LABEL
FIGURE 4-1

REC 3774 4-2

 4.3.2 Display

The four digit, seven segment LED display provides three functions. First, it
allows the user to view and verify the conditions to be programmed. The second
function allows observance of the current speed as a percentage of a previously
programmed reference speed. The percent speed displayed can be from 0 to
199%. Speeds in excess of 199% are displayed as 199. The third function
displays any error message that occurs.

A timer automatically turns off the display after 65 seconds except when in
program mode. Do not leave the 60-200-1 in program mode for extended
periods. Touching any key reactivates the displays screen (if not in program
mode).

4.3.3 Keys

Function keys are located under the LEDs in the 60-200-1 control enclosure (see
Figure 4-2).

Three unlabeled keys (select, up and down) allow the user to program the 60-
200-1 motion monitor. See key description in Figure 4-2. Briefly touching any of
the keys causes the display to show current speed percentage (calculated from
the reference speed kept in memory).

Select Key - Enters the value for the step shown on the display into
non-volatile memory and advances to the next step.

Up Key - At each select key step, the up key allows the user to
increment that step input value.

Down Key - A each select key step, the down key allows the user to
decrement that step input value.

PROGRAM KEY DESCRIPTIONS

FIGURE 4-2

REC 3774 4-3

 FIGURE 4-3

4.3.4 Starting the Program Mode

The program mode can be started by two methods.

By holding the select key down for 5 seconds, the 60-200-1 learns the existing
speed input as a new reference speed. If the key is released before 5 seconds
have elapsed, learning is halted and no program values are altered.

Simultaneously pressing the up and down keys for 2 seconds bypasses the
learning of a new reference speed. This method is used to keep an old reference
speed.

NOTE: Alarms cannot be reset when in the program mode.

4.3.5 Start-Up Delay (A)

The first program step is user selectable time (in seconds) after start-up to reach
normal operational speed. The preset condition is also displayed (10 seconds for
first time programming). The preset value can be changed to any value from 0-
99 seconds using the up or down keys.

CAUTION

SELECTING ZERO DELAY WILL EFFECTIVELY REMOVE ANY START-UP

DELAY. THIS COULD CAUSE AN ALARM CONDITION TO OCCUR AS
SOON AS THE UNIT IS TURNED ON.

REC 3774 4-4

 4.3.6 Alarm Trip (b)

This program step is user selectable from 0-160% of normal speed (100%) that
the alarm will de-energize. It allows the selection of an alarm trip for under or
over speed. The preset value is 40% (under). The preset value can be changed
in 1% increments to any value of 0-160%. Zero disables the alarm and prevents
alarm operation. An over speed alarm point can be established by selecting a
percentage greater than 100%.

For example, a reference speed that has been learned at 100 RPM can be
tripped at 80 RPM if an 80% value has been programmed.

4.3.7 Alarm Delay (C)

This program step is the user selectable amount of time (in seconds) between
the alarm trip step b sense level and when the relay is de-energized (alarm
condition.

To avoid false alarm operation due to irregular speed input pulses, an alarm
delay function is provided. An alarm condition is removed if normal speed is
detected during the alarm delay period.

An alarm delay of 1 to 65 seconds can be selected. The alarm preset value is 10

seconds. The Alarm Delay Time can be thought of as a window and when the
Time Between Pulses (Period) is outside the delay window, the alarm will de-
energize in Alarm Delay Time seconds. Refer to Section 5.2 for RPM and Alarm
Delay Time examples.

4.3.8 Alarm Control d)

The 60-200-1 will always reset when power is interrupted.

WARNING

THE ALARM CONTROL MODE CAN AFFECT THE OPERATORS SAFETY.

The output alarms are operated by removing power from the output relays. The
loss of power will always produce an alarm condition at the outputs. However,
if power is suddenly restored, the 60-200-1 will again enter its Start-Up Delay
mode.

WARNING

PRIOR ALARM CONDITIONS WILL NOT BE RETAINED

The power up reset function can be duplicated without actually removing power
from the 60-200-1. An external pin is provided to allow a relay or switch contact
to cause the 60-200-1 to be reset. This provides a remote reset function. NOTE:
Either power cycle or operating the remote reset (Pin #10 - see Figure 3-4B)
causes a start-up type reset. A start-up reset may cause a momentary alarm
condition until the relays energize.

REC 3774 4-5

 Power up reset and remote reset functions are always available. The preset
value for this program step is d = 1, indicating only these methods of reset are
allowed.
The selection of d = 2 also allows inhibit alrm condition, in addition to power on
or remote reset. The inhibit pin #9 provides this function. (See Figure 3-4B.)

When inhibit pin #9 is connected to signal common (pin #4 or #8), the output
alarm is held energized (no alarm). When inhibit pin #9 is removed from signal
common and is left disconnected, the unit will start as if it had just powered on,
including start-delay.

NOTE: The inhibit pin #9 must be held low (common) for at least
160msec. in order for the unit to see the inhibit alarm signal.

4.3.9 Start-Up Delay Control (E)

The 60-200-1 may be installed to receive power independent of the sensor it is

monitoring. This can create a situation where it could become active and detect
an under speed condition (absent pulses) and cause an undesired alarm
condition. To prevent this confusion at start-up, a value of E = 2 can be
selected. The value of E = 2 instructs the 60-200-1 to wait after a reset
condition until there are pulses detected before going into the Start-Up Delay
mode of operation.

Selecting a value of E = 1 instructs the 60-200-1 to go directly into the Start-Up

Delay after being reset

4.3.10 Alarm Function (F)

The 60-200-1 has two ways of removing an alarm condition. The first is by
selecting F = 1 at this program step. Selecting F = 1 forces the 60-200-1 to
latch (lock-up) its alarm so a remote reset, power interrupt, or toggle of the inhibit
line can cause the removal of an alarm condition.

If a F = 2 is selected at this step, an additional condition is allowed to clear any

alarms. This condition is the return of the signal input to the normal speed range
(indicate). It effectively removes the latch function of the output.

WARNING
INSURE DESIGN AND INSTALLATION ARE PROPERLY PERFORMED SO
THAT A LATCHING APPLICATION DOES NOT HAVE A NON-LATCHING
CONFIGURATION

After installation, conduct a test to insure the desired method of clearing alarms
has been selected.

REC 3774 4-6

 4.3.11 Current Output (J)

The Motion Monitor has as an option 0-20/4-20mA output which replaces the
standard 0-2+VDC output (See Figure 3-4B). The option board arrives calibrated
from the factory. The customer need only select the proper setting in the
program as shown below:

J = 1 for 4-20mA at 0-100%

J = 2 for 4-20mA at 0-199%
J = 3 for 0-20mA at 0-100%
J = 4 for 0-20mA at 0-199%

FIGURE 4-4

4.3.12 Run Mode (=)

The program mode is ended by pressing the select key to enter the value
selected for the Alarm Function program step. The 60-200-1 automatically
records the changes entered into non-volatile memory and enters the run mode.
The display shows the percent of speed and the equals (=) symbol in the left
digit.

REC 3774 4-7

 This page left blank intentionally.

REC 3774 4-8

 Chapter 5
THEORY OF OPERATION
5.1 Theory of Operation

The 60-200-1 is a speed analyzer containing a microprocessor with temporary and

permanent memory. Programming instructions are retrieved when power is applied.

Depending on programming selections, the unit will either wait until signal pulses are
present or automatically begin the start delay when it is powered up or reset.

Start delay prevents the unit from recognizing an error until the source of the speed
pulses has had time to reach a stable speed. At the end of the start delay period, any
speed deviations start the alarm delay process.

Speed pulse rate (pulse frequency) is constantly monitored and compared to the alarm
trip levels and alarm delay time established during the Learn programming steps. When
the pulse rate deviates from the alarm trip levels, the process of alarm delay is begun.

The alarm delay is selected during programming and may have to be determined
experimentally. The alarm delay is a type of filter because only sustained deviations
cause alarms. The alarm delay time can be thought of as a window. When the time (in
seconds) between pulses is longer than the alarm delay time window, the alarm will de-
energize. This means that the RPM and the minimum alarm delay window must be
selected together and the variable is what number of pulse per revolution sensor is used.
See Section 5.2 of this manual for further information.

Once an alarm has been set, the alarm will either continue until power is cycled off and
on, the external remote reset signal is activated, or the inhibit control line has been held
low for more than 160 msec. The inhibit control will only cause an alarm inhibit if
selected during programming. Alarms also can be cleared automatically if selected
during programming.

There is 12VDC supplied to the signal side of the unit by the power supply for remote
and sensor operation.

The signal side of the unit can be wired to accept NPN or dry contact switching. The
contact switch closure can produce electrical noise that may require filtering by an
external capacitor.

5.2 RPM and Minimum Alarm Delay Time

In previous sections, the concept of Alarm Delay Time as a window has been
introduced. In this section of the manual, the window concept will be explained in more
detail.

By choosing an Alarm Delay Time (DT), you create a window (DT) seconds wide. If
the time between pulses in the pulse stream coming into the Motion Monitor is longer
than this Alarm Delay window for length of time equal to the Alarm Delay Time (DT),
than the relay for that channel will de-energize.

REC 3774 5-1

 There are ten basic Motion Monitor systems. (See Chapter 8.) They are:

A. Shaft Driven Systems

60-24H-1 High speed, single channel

60-24L-1 Low speed, single channel
60-24H-2 High speed, dual channel
60-24L-2 Low speed, dual channel
60-24LL-1 Low low speed, single channel
60-24LL-2 Low low speed, dual channel

B. Non-Contacting (Proximity) Systems

60-22H-1 High speed, single channel

60-22L-1 Low speed, single channel
6022H-2 High speed, dual channel
60-22L-2 Low speed, dual channel

Examples of the above systems follow with 20 RPM and 100 RPM used for 100 percent
reference speed, Minimum Alarm Delay Time (in seconds) are shown for different
percent under speed.

EXAMPLE 1 EXAMPLE 2 EXAMPLE 3

Model 60-22H, Normal Model 60-22L, Normal Model 60-24H, Normal
RPM (100), (1 pulse per RPM (20), (30 pulses RPM (100), (12
rev.) per rev.) pulses per rev.)
Alarm Min. Delay Alarm Min. Delay Alarm Min. Delay
Setpoint Time (Sec.) Setpoint Time (Sec.) Setpoint Time (Sec.)
20%* 5 10%* 3 1% 5
30% 5 20% 2 10% 3
40% 3 30% 2 20% 2
50% 2 40% 2 30% 2
60% 2 50% 1 40% 2
70% 2 60% 1 50% 1
80% 1 70% 1 60% 1
90% 1 80% 1 70% 1
100% 1 90% 1 80% 1
100% 1 90% 1
100% 1

* Minimum Setpoint

REC 3774 5-2

 EXAMPLE 4 EXAMPLE 5
Model 60-24L, Normal Model 60-24LL, Normal
RPM (20), (80 pulses per RPM (5), (500 pulses per
rev.) rev.)
Alarm Min. Delay Alarm Min. Delay
Setpoint Time (Sec.) Setpoint Time (Sec.)
1% 5 1% 5
10% 3 10% 3
20% 2 20% 2
30% 2 30% 2
40% 2 40% 2
50% 1 50% 1
60% 1 60% 1
70% 1 70% 1
80% 1 80% 1
90% 1 90% 1
100% 1 100% 1

In the above examples, the lower the setpoint, the wider the Delay Time window
required, because the distance between the pulses in the incoming pulse stream is
increasing. If a one second time delay is required for a lower setpoint for Example 1,
then a higher pulse per revolution sensor is required.

For calculating other RPM ranges and what is the minim delay time allowed, use the
following formulas:

RPM x PPR
A. Hz =
60

Where: PPR = Number of pulses per revolution sensor.

RPM = Revolution per minute at the alarm setpoint.

B. Pulse Period = (1 / Hz) + 1 (seconds)

C. Minimum Delay Time = (Pulse Period + 1 rounded to the nearest whole number
in seconds.

CAUTION

AVOID USING A RPM THAT HAS THE SAME TIME BETWEEN PULSES AS THE
ALARM DELAY TIME WINDOW. USE AN ALARM DELAY TIME WINDOW THAT IS
ONE OR TWO ALARM DELAY SECONDS LONGER.

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REC 3774 5-4

 Chapter 6
TROUBLESHOOTING
6.1 Error Detection

The 60-200-1 has a built-in error detection system. If the operator tries to program the
unit with values that cannot be carried out, the unit will display an error code that informs
the operator of the problem. Some defective hardware conditions also can provide an
error code. If the unit has been in the run mode, a key should be pressed to activate the
display to show the error message.

Error code definitions are:

Err1 = Cannot measure. Signal missing or too slow.

Err2 = Calculated alarm is too low. A very low reference speed with a very low
percent trip point can result in asking the unit to look for pulses longer
than every 5 seconds (system limit).

For example, a sensor producing 10 pulses per revolution and connected

to a shaft turning at 3 RPM will produce a pulse every 2 seconds. The
60-200-1 motion monitor could learn a slow reference speed during
programming. However, when an alarm trip point of 20% of speed is
selected, an Err2 error is detected because the resulting low speed signal
takes longer than 5 seconds to measure.

Err3 = Calculated alarm too high. This is similar to Err2. If the frequency of the
reference signal and the over speed alarm trip point determines a
frequency above 3000 Hz, the error condition will occur.

Err4 = Signal frequency too high. The input signal is greater than 3000 Hz, or a
wrong sensor was selected, or noise or false triggering is occurring in the
sensor.

Err7 = CPU failure. The microprocessor cannot execute its program. The 60-
200-1 will attempt to set both alarms and make the information available
to the display. However, some failures may prevent the 60-200-1 from
setting alarms or sending information to the display.

Err8 = NV memory failure. When the 60-200-1 motion monitor is initially

installed, the only values that will be loaded are those that were
programmed at the factory when the unit was tested. These values are
also kept as part of the microprocessor memory. If an error is detected in
attempting to use the program (NV) memory, these values will be
selected and Err8 will be displayed. This failure occurs when exiting the
program mode or when power is applied because NV memory is used.
The 60-200-1 starts to operate using the default program values.

REC 3774 6-1

6.2 Troubleshooting

The 60-200-1 display is off during normal operation. Error messages are not displayed
until the display is activated by a key momentarily touched. An exception to this is
during programming when the display is on and any error messages are displayed.

The following chart shows some types of problems that could occur and possible
corrective actions.

SYMPTOM POSSIBLE CAUSE CORRECTION

No Display No power. Restore power.

Fuse Blown. Replace fuse.

Defective unit. Replace unit.

Fails to Learn REF No signal (Err1). Provide signal.

Speed
Signal too fast (Err4). Repair sensor.

Defective unit.
Replace unit.

Fails to Go into Defective unit. Replace unit.

Program/Run Mode

Cannot Increase/ Defective unit. Replace unit.

Decrease Program
Values

If the unit cannot be made operational, bypass the unit by moving the jumpers on the
output relays. For example, normally closed contacts could be selected rather than
normally open contacts. NOTE: The output wiring diagram shows normal as energized
relays (normally open contacts).

It is possible to program the 60-200-1 into an awkward or unworkable configuration. To

force the unit to reload the factory preset values, press the select and down keys
during reset.

REC 3774 6-2

 Chapter 7
REPLACEMENT PARTS
7.1 Ordering Information

The Thermo Scientific Motion Sensor is identified by a multiple character model number
that precisely identifies a particular type of unit. An explanation of the alphanumeric
model number is shown below. It will enable the owner to define the model number,
pulse rate, and voltage of the sensor.

60-XXX-XXX-XXX
A B C

A = Motion Monitor Family

B = Channel Designator: 1 = Single Channel

2 = Dual Channel

C = Options I = 0-20/4-20mA Option

Model Numbers Description

60-200-1 Single Channel Monitor

60-200-2 Dual Channel Monitor
60-200-1-I Single Channel Monitor with 0-20/4-20mA Option Board
60-200-2-I Dual Channel Monitor with 0-20/4-20mA Option Board

Parts List - Electronics Enclosure

DESCRIPTION PART NO.

Fuse 042059
Jumper 042248
Cable Assembly 042115
CPU Board 042814
Power Supply Board 046174
Option Board 0-20/4-20mA 046099

When ordering parts, please call 763-783-2695 or fax 763-783-2525.

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REC 3774 7-2

 Chapter 8
OPTIONS
8.1 Shaft Driven (60-24) Systems (Direct Coupled)

Several shaft driven systems are available:

60-24H-1 High speed, single channel

60-24L-1 Low speed, single channel
60-24H-2 High speed, dual channel
60-24L-2 Low speed, dual channel
60-24LL-1 Low low speed, single channel
60-24LL-2 Low low speed, dual channel

Reference the individual components manual for wiring instructions.

These systems include a motion sensor, programmable motion monitor, manuals and
wiring diagrams. Mounting hardware is optional and is shown with other options listed
below.

8.1.1 Options for Shaft Driven Models

Option suffix letters are added to the system model number to specify selections.
For example, 60-24H-1-R is high speed, single channel model with rigid
mounting hardware.

Suffix letters are:

-F = Flexible mounting strap and rigid coupling for shaft speeds of

under 200 RPM.

-R = Rigid mounting brackets for sensor with flexible shaft coupling,

suitable for all shaft speeds.

-X = Intrinsic safety barrier to allow mounting sensor in Class I or II,

Div. 1 hazardous area.

8.2 Non-Contacting (60-22) Systems (Proximity Systems)

The non-contacting systems available are:

60-22H-1 High speed, single channel

60-22L-1 Low speed, single channel
60-22H-2 High speed, dual channel
60-22L-2 Low speed, dual channel

Reference the individual components manual for installation instructions.

These systems include motion sensor with 20 ft. lead wire, programmable motion
monitor, a bracket for mounting the sensor, manuals and wiring diagram. A thirty slot
target disc with mounting kit is also included with the low speed (22L) models.

REC 3774 8-1

 8.2.1 Options for Non-Contact Models

Option suffix letters are added to the system model number to specify selections.
For example 60-22H-1-CH is high speed, single channel with 100 ft. lead wires
and hose clamp style target hardware.

Suffix letters are:

-C = 100 ft. of lead wire cable on sensor instead of standard 20 ft.

-H = Hose clamp hardware with insulator for simple target on rotating

shafts.

-T = Three pulse target with mounting kit for lower speed applications
of 60-22H models (10-1500 RPM).

-X = Intrinsic safety barrier to allow mounting sensor in Class I or II,

Div. 1 hazardous area.

-Z = Conduit connector, metric to English. Note that hazardous area

mounting of sensor requires running the cable in conduit.

REC 3774 8-1

8.3 Parts List - Optional Systems

Non-Contacting System (Proximity Sensors)

BASIC SYSTEM COMPONENTS - 60-22 SERIES
DESCRIPTION MODEL # PART NO.
Monitor, Single Channel 60-200-1 041543
Monitor, Dual Channel 60-200-2 042663
Monitor, Single Channel with 0-20/4-20mA Option 60-200-1-I 046096
Monitor, Dual Channel with 0-20/4-20mA Option 60-200-2-I 046097
Proximity Sensor, 30mm 60-220-30 042615
Proximity Sensor, 12mm 60-220-12 042614
Sensor Mounting Kit 042677
ACCESSORIES - 60-22 SERIES
DESCRIPTION MODEL # PART NO.
Proximity Sensor, 30mm, 100 cable 60-220-30-100 042698
Proximity Sensor, 12mm, 100 cable 60-220-12-100 042697
Sensor Target, 30 holes 041585
Sensor Target, 3 holes 041584
Spacer Kit for Targets 042676
Hose Clamp Kit 041565
Conduit Adapter, 30mm 042605
Conduit Adapter, 12mm 042604
Remote Digital RPM Meter 042768
Intrinsically Safe Barrier, 4 Wire 60-245-4W-12V 042707

Shaft Driven Systems (Direct Coupled Sensors)

BASIC SYSTEM COMPONENTS - 60-24 SERIES

DESCRIPTION MODEL # PART NO.
Monitor, Single Channel 60-200-1 041543
Monitor, Dual Channel 60-200-2 042663
Monitor, Single Channel with 0-20/4-20mA Option 60-200-1-I 046096
Monitor, Dual Channel with 0-20/4-20mA Option 60-200-2-I 046097
Sensor, High RPM, 5-900 RPM FM 60-242-12P-12V 042277
Sensor, Low RPM, 1-20 RPM FM 60-242-80P-12V 042279
Sensor, Low RPM, <1-5 RPM (Non-FM) 60-241-500P- 045056
5/24V
ACCESSORIES - 60-24 SERIES
DESCRIPTION MODEL # PART NO.
Coupling, Rigid Stud 042221
Screw, Stud 005318
Coupling, Flexible 042165
Rigid Sensor Mounting Plates 041579
Flexible Arm for PN 042221 042222
Remote Digital RPM Meter 042768
Intrinsically Safe Barrier, 4 Wire 60-245-4W-12V 042707

REC 3774 8-2