INSTALLATION AND INSTRUCTION MANUAL FOR TM-16 EMERGENCY WARNING SYSTEM SPECIAL NOTE BOONE CABLE WORKS & ELECTRONICS, INC. 1773-219 TH LANE P.O. BOX 429 READ THIS ENTIRE BOOKLET BOONE, IOWA 50036 USA BEFORE PROCEEDING WITH PHONE (515) 432-2010 FAX (515) 432-5262 THE INSTALLATION TOLL FREE NUMBER 1 800 265-2010 Web Address: (rolfesatboone.com)
TABEL OF CONTENTS 1. General 2. Instrument (Battery Powered) 3. Instrument (110 VAC Powered) 4. Wiring Runs, Color Coded and Splices 5. Sensors A. Probe B. Belt Alignment C. Surface D. Fire Detection 6. Operating Instructions 1
1. General Boone Cable Works & Electronics, Inc. offers a comprehensive line of temperature monitoring equipment. This complete product range and our extensive systems experience allows us to offer effective solutions for a wide range of solutions for your individual system requirements. Our extensive background in temperature monitoring along with a constant program of innovation and technological development allows us to offer cost-effective and user-orientated solutions. Please read all the instructions for system installation before beginning. 2. TM Instrument (Battery Powered) The instrument is in a Nema 13 enclosure, which offers protection against dust, spraying of water and oil in an indoor environment. It features a hinged clear polycarbonate cover for easy viewing and accessibility. Two locking screws are provided on the cover to secure it in place. Refer to the Hoffman installation instructions included with the unit before mounting the enclosure. To mount, remove the instrument splice compartment cover that is attached by two screws. (See drawing 180095-A) Disconnect the battery pack. Remove the instrument panel, which is secured with four screws. The instrument is mounted with three mounting holes. Fasten the instrument using the top hole. Then level the instrument and secure it with the mounting holes at either end of the splice compartment cover. Reassemble the instrument. Inside on the left side of the splice compartment there are two TM 9 conductor wires, which have a black jacket. (Lead #1 is for sensors 1 through 8 and lead #2 is for sensors 9 through 16). They are spliced color to color with the TM wires from the sensors. The unit is powered by a single 9 volt battery. The Battery compartment is also located behind the splice compartment cover. 2
3. TM Instrument (110 VAC Powered) The instrument is in Nema 13 enclosure, which offers protection against dust, spraying of water and oil in an indoor environment. It features a hinged clear polycarbonate cover for easy viewing and accessibility. Two locking screws are provided on the cover to secure it in place. Refer to the Hoffman installation instructions included with the unit before mounting the enclosure. To mount, remove the instrument splice compartment cover that is attached by two screws. (See drawing 180095-A) Remove the instrument panel, which is secured with four screws. The instrument is mounted with three mounting holes. Fasten the instrument using the top hole. Then level the instrument and secure it with the mounting holes at either end of the splice compartment cover. Reassemble the instrument. Inside on the left side of the splice compartment there are two TM 9 conductor wires, which have a black jacket. (Lead #1 is for sensors 1 through 8 and lead #2 is for sensors 9 through 16). They are spliced color to color with the TM wires from the sensors. Located on the right side of the splice compartment are two terminal blocks. Attach 110 VAC or 220 VAC depending on which input/power voltage was selected when ordering. See serial number decal if unsure. If the instrument is configured for 220 VAC then attach one power line to N and the other power line to L. If the instrument is configured for 110 VAC then attach the neutral line to N and the power line to L. For both 110 VAC and 220 VAC attach earth ground to GND. The second terminal block provides normally open (NO) and normally closed (NC) contacts that change state when the BF enters an alarm condition. Use either the common (C) to NO or C to NC contact. Do not use both the NO and NC contacts. The contacts are rated at 125 VAC at 1 amp, resistive load. At the bottom of the enclosure are conduit knockouts that are removed to run wires to the instrument. 3
4. Wiring Runs, Color Coded and Splices The Instrument, which can monitor 16 sensors, has two TM wires in its splice compartment. The wire marked #1 is for zones 1 through 8. The wire marked #2 is for zones 9 through 16. The wire is run from the instrument to within 5 feet of each sensor. Strap and mount the wire so that it is exposed to the least amount of physical and environmental stress. The most desirable method is to enclose all wires in a dedicated conduit to provide mechanical protection. 4
Below is a table listing the color code for the BF 9-conductor wire. Wire #1 Zone Wire #2 Zone Black Common Black Common Blue 1 Blue 9 Green 2 Green 10 Red 3 Red 11 Yellow 4 Yellow 12 Clear 5 Clear 13 Purple 6 Purple 14 White 7 White 15 Brown 8 Brown 16 A typical TM system is shown in drawing #180096-A. Drawing #180096-A shows one sensor for each zone. Depending on the application you may wish to use multiple sensors on each zone. The TM wire from the sensors is spliced at the instrument in the splice compartment. The 9 wires are spliced color to color using grease crimps. 5
TM Series Thermostat Style - Temperature Sensors TM Series sensors are available in three standard styles: 1. Bearing Probes: consisting of a stainless steel.25 diameter thermowell and hardware for mounting through 1/8 NPT threaded grease zerk hole in the bearing housing. Bearing can still be maintained with the probe in place. 2. Belt alignment sensor: consisting of a 5 x 1 half round brass friction bar, a mounting plate and sensor. Surface mount sensor: consisting of a thermostat imbedded in a plated brass mounting lug with 10 of stainless braided duplex. 3. Surface sensors have a plated copper, mounting lug with hole in it for bolting directly to a piece of equipment. These sensors are designed to be used on equipment that has no grease zerk or where access to the grease zerk is limited. TM Bearing Probes: All TM Probes are available in 1408, 1608, and 1808 standard sizes. All sensors use a single pole NC bimetallic thermostat with a contact rating of 1 amp 24 VAC or DC resistive. All probes come with mounting hardware to mount the probe into the standard 1/8 NPT grease zerk hole in the bearing housing. All probes come with a standard 10 of stainless steel overbraided splicing pigtail attached. Model TMP-140, 160 or 180 Bearing probes (Complete) Description: 140, 160 or 1808 thermostat imbedded in a 4 long by ¼ D stainless Steel thermowell, includes steel T grease zerk fitting, Brass compression connector and 10 of stainless overbraided splicing pigtail. Components available as replacement parts: 1. Probe style sensor with pigtail only. 2. Steel T grease zerk fitting with brass ¼ compression fitting. TM Belt Alignment Sensors: All TM belt alignment sensors are available in 1408, 1608, and 1808 standard sizes. All sensors use a single pole NC bimetallic thermostat with a contact rating of 1 amp 24 VAC or DC resistive. All belt alignment sensors come with brass friction bar and rub mounting plate. All belt alignment sensors come with a standard 10 of stainless steel overbraided splicing pigtail attached. Model TMR-140, 160 or 180 Belt alignment sensor (Complete) Description: 140, 160 or 1808 thermostat imbedded in a plated copper lug with a ¼ mounting hole, 5 x 1 half round brass friction bar and Teflon insulator with mounting plate. Sensors come with a standard 10 of stainless overbraided splicing pigtail attached. Components available as replacement parts: 1. Lug style surface mount sensor with pigtail only. 2. Replacement 5 x 1 half round brass friction bar. 3. Teflon spacer/insulator. 4. 3 x 7 mounting plate. 6
TM Surface Mount Sensors: All TM surface mount sensors are available in 1408, 1608, and 1808 standard sizes. All sensors use a single pole NC bimetallic thermostat with a contact rating of 1 amp 24 VAC or DC resistive. All surface mount sensors come with a standard 10 of stainless steel overbraided splicing pigtail attached. These sensors are designed to be used on bearings that have small grease zerks, where probe style sensors can not be used. Model TMS-140, 160 or 180 Surface mount sensor (Complete) Description: 140, 160 or 1808 thermostat imbedded in a plated copper lug with a ¼ mounting hole. Sensors come with a standard 10 of stainless overbraided splicing pigtail attached. TMS surface sensors are also available with a large washer style lug that can accommodate being placed under the grease zerk. (NOTE: The grease zerk must compress fully against the sensor to provide good heat transfer from the bearing housing to the sensor.) It is also recommended that you reduce the temperature range of the surface sensor by 20 to 40 degrees in order to accommodate the slower transfer of heat with this type of arrangement. Other sized temperature sensors are available as special order only items. Please contact Boone Cable Works & Electronics, Inc. for price, availability, and lead-time on all special orders. 5. Standard Sensors A. Probe Sensor The probe sensor is designed to be inserted into the grease zerk hole of a bearing. (See Drawing #180090) Heat is transferred from the bearing race to the probe sensor. Below are directions for proper probe installation. 1. Clean around bearing and grease zerk to avoid getting any dirt into the bearing. 2. Remove the existing zerk. 3. Install the brass nipple, tee and 1/8 compression connector assembly. 4. Reinstall the zerk into the side of the tee. 5. Insert the stainless steel thermostat housing into the bearing into the compression connector assembly at the top of the steel mounting T. 6. Hold the stainless steel thermostat housing so that it is approximately 1/8 from the bearing race and tighten the compression connector nut. 7. Run the probe sensor wire into a splice fitting and attach the sensor into the system. 7
WARNING IF THE SENSOR IS NOT ATTACHED PROPERLY AND SECURELY TO THE MONITORED PIECE OF EQUIPMENT, HEAT MAY FAIL TO TRANSFER TO THE SENSOR CAUSING IT TO NOT OPERATE PROPERLY. CHECK THE SENSORS REGULARLY TO SEE IF THEY ARE ATTACHED SECURELY. B. Belt Alignment Belt alignment is accomplished by attaching the sensor to a brass heat transfer plate (See Drawing #180091 and 180091-A for conduit ready installations). The brass pad transfers the heat of the belt rubbing against it and activates the sensor. Two style of brass plates are available, as ½ moon and an optional round disk style. The ½ moon offers a greater range of motion on the belt, while the round disk is easier to install. It is important to tighten the sensor securely for a good thermal bond. The sensor has a thermostat attached to the housing with approximately 10 feet of wire. See Drawing #180096-A when wiring the probe into the system. WARNING IF THE SENSOR IS NOT ATTACHED SECURELY TO THE MONITORED PIECE OF EQUIPMENT, HEAT MAY FAIL TO TRANSFER TO THE SENSOR CAUSING IT TO NOT OPERATE PROPERLY. CHECK THE SENOSRS REGULARLY TO SEE IF THEY ARE ATTACHED SECURELY. 8
9
C. Surface Sensors The sensor is a surface mount device with high thermal conductivity. The sensor has a ¼ hole for mounting. This hole may be drilled to the size required. When mounting the sensor on a bearing with a zerk, remove the zerk. Place the zerk through the sensor mounting hole and reinsert the zerk (See Drawing #180090). The bearing may also be drilled and tapped. A bolt would be used to go through the sensor and into the threaded hole. Heat is transferred through the bearing housing to the sensor. It is critical that the sensor and bearing are securely compressed together, so that the bearing heat is transferred directly to the sensor with no air gap. The surface sensor has a thermostat attached to the bolting lug with approximately 10 feet of wire. See Drawing #180096-A when wiring the sensor into the system. WARNING IF THE SENSOR IS NOT ATTACHED SECURELY TO THE MONITORED PIECE OF EQUIPMENT, HEAT MAY FAIL TO TRANSFER TO THE SENSOR CAUSING IT TO NOT APERATE PROPERLY. CHECK THE SENSORS REGULARLY TO SEE IF THEY ARE ATTACHED SECURELY. 10
D. Fire Detection The quantity and location of fire detection sensors for the TM Emergency Warning System are judgement calls and are best determined by the user. Some general recommendations are: 1. One determining factor on how many sensors per room is the cubic volume of air in that room. 2. Always mount the sensor(s) as high as possible in the room. Due to the fact that heat rises, the warmest place in a room is near the ceiling. 3. Mount sensors securely in place. This is to ensure that excessive heat will not cause the sensors to fall, before they activate in an alarm situation. Alarm pull stations should be located at exits or according to code requirements. The normally closed contact of the pull station is used. The pull station appears like any other sensor to the TM System. Which means if the wire is inadvertently broken, the TM System will issue an alarm. Accessories such as remote audible and visual alarms and an auto dialer are available. These accessories use the normally open or normally closed contacts on the TM Instrument. The auto dialer offers one voice/pager message up to four numbers. WARNING THE CUSTOMER IS TOTALLY RESPONSIBLE FOR SENSOR LAYOUT DESIGN. CHECK THE SENSORS REGULARLY TO SEE IF THEY ARE ATTACHED SECURELY. 11
6. Operation Instructions The TM Emergency Warning System Instrument has an on/off switch, test button, alarm horn and 16 monitor zone LED s respectively. To operate the system, place the on/off switch in the on position. Once the instrument is turned on, the test button activates all LED s and alarms. The monitor LED s are for each sensor or zone. They are normally off but light up for an alarm condition. The alarm buzzer supplied with the instrument is an 85 decibel buzzer that activates for an alarm condition. The alarm contacts for a remote alarm are supplied with the 110 VAC unit. They can switch a resistive load of 1A at 125 VAC. These contacts are activated in an alarm condition. When the voltage output drops below 4 volts the audible alarm is turned on, but no monitor LED s will light. This tells the operator that the batteries are low or the 110 VAC power supply needs maintenance. The battery powered unit will run a minimum of 4000 hours with no alarms and 100 hours with 1 alarm condition. To replace the batteries, remove the two screws on the splice compartment. Remove the old 9V battery from the holder and replace with a new one. The sensors are normally closed thermostats that open when the temperature goes above a preset point. The wiring to and from the thermostats is also tested in this manner. If the 9 conductor wiring is broken it will also cause an alarm on the sensor with damaged wire. TM-16 instruments are also available with an optional external alarm shutoff switch. This switch is located below the unit alarm on the left side of the instrument. (See drawing #180093-A) Be sure to correct the problem associated to the alarm condition immediately and restore the alarm to the normal on position. All monitored equipment should be taken out of service until the alarm condition has been corrected and the alarm switch has been returned to the on position. Use the test button on the front of the instrument to confirm that the system is operating properly. 12
13