Eaton Electrical Trs 3064 Users Manual

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TRS 3064

Installation,

Operation and

Maintenance of

the

Airflex@

Timing Rotorseal

and Cam

Limit Switch

Revised: Feb. 1, 1982

1.0

Operation

Throughout this manual, there are a number of

Hazard Warnings that must be read and understood

in order to prevent possible personal injury and/or

damage to the equipment. Carefully read these warn-

ings. They are included to protect you!

1.1

Description:

This manual describes two

Airflex@

timing

control devices, namely, the

Airflex@

Cam

Limit Switch and the

Airflex@

Timing

Rotorseal. The cam limit switch is a rotary

cam timing switch device. The timing

rotorseal combines the features of a rotary

cam timing switch with those of a rotary air

seal in one compact unit. Both of these

devices are primarily designed to control the

operating functions of mechanical power

presses. Both devices are also referred to as

timers in this manual, since the timing opera-

tion for both devices is the same.

bullgear of an

Airflex@

standard press ap-

plication clutch and brake package (see

Figure 2).

1.2

How It Works:

When these devices are properly wired into

the appropriate

Airflex@

press control system

(refer to Manual CP 3080), these devices can

provide the following functions:

l Inch

l Single stroke

l Continuous

l Semicontinuous

l Monitor the stopping effective-

ness of the braking system

The

Airflex@

press control system requires

two of the timers, in any combination, to con-

trol the above functions and to monitor each

other for failure and shaft breakage.

These devices can be furnished for either

clockwise or counterclockwise rotation. The

direction of rotation of the device is identified

by a decal on the cap and is determined by

viewing the device from the cap end. Timing

rotorseals supplied with

Airflex”

FSPA clutch

and brake packages are assembled for

counterclockwise rotation unless otherwise

specified on the order.

The cam limit switch can be furnished for

either shaft mounting or for foot mounting

with a chain drive (see the illustrated Parts

List in Section 4.0). The timing rotorseal is

designed to be assembled to the flywheel or

The operation of the timing section of the

timing rotorseal is the same as that of the

cam limit switch. In this respect, both devices

are referred to as timers in this manual. There

are five shaft mounted cams which, when

rotated, open and close four automotive type

breaker points (see Figure 1) as LS1, LS2, LS3

and LS4.

LS1 and LS2 are controlled by cams No. 1 (24)

and No. 2 (26) respectively (see Section 4.0 for

item numbers in brackets). LS3, when used for

brake monitoring, is controlled by a two piece

cam No. 3 consisting of an insert (28) and an

outer cam (28A). An optional one piece cam

No. 3 is supplied with both devices that

replaces the two piece cam for applications

that do not require brake monitoring. LS4 is

controlled by split cams No. 4 (33) and No. 5

(33A). Cam functions are discussed in Section

1.2.1.

The timing rotorseal, besides providing the

same timing functions as does the cam limit

switch, also provides a means of air delivery

from a stationary source to operate a rotating

component such as the

Airflex”

clutch. The

seal between the stationary center section

(11) and the rotating adapter (1) is provided by

the inner and outer carbon seals (16 and 19).

The lapped surfaces of these seals are held

against the rotating adapter (1) by inner and

outer springs (12 and 13). Air enters the

stationary center section (11) and passes

through the seals into the rotating adapter (1).

Cam Functions:

The

Airflex”

press control system requires

two timing devices. To differentiate between

the timers both the cam limit switch and the

timing rotorseal have a decal, affixed to the

end cap, with tabs labeled “A” and “B”.

Therefore, one timer should be labeled “A’

and the other “B”; the unused tabs are re-

moved. To be consistent with the

Airflex@

press control wiring diagram the timer that

monitors the brake should be labeled “A”.

The control functions of the cams are:

Cam No. “A” Timer “B” Timer

1

Nonrepeat Nonrepeat

2

Top Stop (Continuous)

3

Brake Monitor

Nonrepeat

Semicontinuous Brake Monitor

or Special Function

4&5 Top Stop (Single Stroke) Top Stop (Single Stroke)

2

Figure 1 illustrates the cams assembled in

the timing section of both devices and their

relationships.

1 Cam No. 2 Cam Insert No. 3 Cam No. 4 Cam insert

No.

Cams for Clockwise Rotation

Cams for Counterclockwise Rotation

Figure 1. Cam profiles and their relationships

3

Cam No. 3 (28 and 28A) monitors the effective-

ness of the press braking system at the top of

the stroke. When cam No. 3 is positioned

according to Paragraph 2.3, deviations in

stopping position greater than

+

15” from top

dead center will be detected.

2.0 Installation

n

!

Danger:

Prior to installation of the

Airflex’“’

Timing

Rotorseal and Cam Limit Switch, make sure

that the machinery is secured in a safe

manner. Failure to do so could result in

serious injury or possibly death.

n

!

Warning:

Only qualified maintenance personnel should

install, adjust or repair these devices. Faulty

workmanship will result in unreasonable

exposure to hazardous conditions, injury or

severe damage to the equipment.

n

!

Caution:

Before you begin any work, study this manual

so that you completely understand what is

required. Do not risk injury. Follow the

instructions.

2.1

Mounting

Instructions for mounting the

Airflex’)

timing

rotorseal, foot and shaft mounted cam limit

switches are given below. Any combination of

these times may be used in the control

system. Follow those instructions that pertain

to the timers being used.

2.1 .1 Timing Rotorseal:

The

Airflex@

timing rotorseal is custom

designed to fit the flywheel or bullgear of an

Airflex@

FSPA clutch and brake package as

shown in Figure 2. The flywheel or bullgear

All control systems, except those capable of

inch and continuous functions only, require

two timers. When two timers are used, except

on control panels with semicontinuous func-

tion, only the two piece cam No. 3 of the “A”

timer is required for brake monitoring. The

cam No. 3 of the “B” timer, is available for a

user’s special function such as a counter. The

optional one piece cam No. 3 profile is the

same as cam No. 4 shown in Figure 1.

LS4 is controlled by split cams 4 (33) and 5

(33A). This set of cams determines the top

stop setting and the amount of time the run

buttons must be depressed before the operator

can remove his hands from them. If the run

buttons are released before this predetermin-

ed setting, the press will stop.

The minimum dwell setting of these cams is

135”,

and they are fannable up to 255” in in-

crements of 40

‘.

For the proper setting of

these cams, refer to Paragraph 2.3.

Grease Hole

\

\

/-

Grease Fitting

Figure 2. Timing rotorseal mounting configuration

and Lockwasher

The timing rotorseal end plate (36) is used to

assemble the device to the crankshaft. The end

plate also provides the necessary bearing run-

ning clearance and must be properly shimmed.

Follow instructions given in Form PP3000.

Before mounting the timing rotorseal, check

to be sure its direction of rotation corresponds

with that of the flywheel or bullgear.

4

2.1.2.

To

a)

b)

c)

d)

e)

f)

g)

h)

i)

j)

mount the timing rotorseal:

Make sure that the air tube “O” rings (2)

are in place.

Install the plastic insert (37A) in the head

of the drive screw (37).

Install drive screw. Tighten the screw, being

careful not to distort the end plate (36).

Tie-wire the drive screw to the end plate

mounting screws.

Align the tang of shaft (6) with the slot in

the drive screw insert, and align the

grease holes in the adapter (1) with those

in the hub of the flywheel or bullgear.

Install the lockwashers and mounting

bolts. Tighten the mounting bolts uniform-

ly SO the adapter flange fits squarely

against the register face.

Inspect all air connection tubes and

remove all burrs.

Lightly grease or oil the ends of the air

tubes and insert them into the mating

adapter holes.

Attach the opposite ends of the tubes to

their connections.

Connect flexible air hose (35) to the

center section and air supply line.

A

!

Caution:

Do not use a rigid pipe air line in place of the

flexible air hose (35). Rigid pipe does not

allow compensation for any eccentricity be-

tween the device and the shaft and will cause

a preload condition that will shorten the bear-

ing life of the device.

k)

Apply air pressure and check for air leaks.

Repair as required.

l)

Remove air pressure.

m)

Refer to appropriate paragraph and mount

second timer.

Wiring instructions are given in Paragraph 2.2.

Foot Mounted Cam Limit Switch:

The foot mounted cam limit switch must be

chain driven by the crankshaft. The sprocket

ratio between the shaft and switch must be

1:1. Sprockets furnished by

Airflex”

are 3/8

in. pitch. Chain of proper length, determined

by the placement of the timer, and the chain

guard must be furnished by customer.

Mount the timer as follows:

a)

Select a convenient mounting area for the

timer so that there is no interference with

the chain drive. Locate the timer as close

as possible to the driving shaft so that

the chain length is held to a minimum.

b)

c)

d)

e)

f)

g)

h)

Rigidly attach a sprocket to the drivi

/i

g

shaft.

Key the other sprocket to the cam limit

switch shaft and lock it in position with

set screws and jam screws. The cam limit

switch shaft diameter is .6250/.6245

inches, has a 3/16 inch square keyway

and has a one inch long mounting length.

Fabricate a sturdy bracket or prepare the

machine surface for mounting. Bear in

mind that the bracket design or positioning

of the switch will be influenced by the

direction of rotation of the switch.

Position the switch so that the driving

and driven sprockets are in alignment.

Fasten the switch to its support with four

3/8 inch cap screws and lockwashers.

Attach and tension the drive chain

following chain manufacturer’s

recommendations.

Fabricate a guard to cover sprockets and

chain.

Refer to appropriate paragraph and mount

second timer.

Wiring instructions are given in Paragraph 2.2.

2.1.3 Shaft Mounted Cam Limit Switch:

The shaft mounted cam limit switch is design-

ed for attaching directly to a shaft end. The

shaft end must be machined as shown in

Figure 3 to accept the shaft pilot and bolt

circle.

3. 250

Dia B. C.

Cam Limit

Swtch

@ A

.OlO

Dia.

“i

3’5

PI/Of

Da.

Y

,376

1.25 Deep

56

I-

318-16

NC-2

4 Bolts

Eq.

Spaced

Figure 3. Shaft machining details

Before mounting the timer, check to be sure

its direction of rotation corresponds to that of

the shaft. Fasten the flange to the shaft with

lockwashers and cap screws.

Refer to appropriate paragraph and mount

second timer.

Wiring instructions are given in Paragraph 2.2.

2.2 Wiring:

Two rotary timers are required in the

Airflex@

press control system. The timers must be

appropriately labeled to identify them and the

functions they control. The timer that

monitors the brake’ should be labeled “A” to

agree with the

Airflex@

wiring diagrams.

Label the other timer “B”. “A” and “B” decals

are furnished on each timer end cap. Remove

the letter that is not used.

The timer is internally wired at the factory. All

leads have the breaker point number to which

they are wired printed on the insulation. Label

each lead with the corresponding schematic

wire number and “A” or “B” to identify the

timer to which the lead is connected.

An insulated straight connector fitting for 3/4

inch flexible conduit is furnished with the timer.

n

!

Caution:

A length of flexible conduit must be used be-

tween the timer and rigid conduit. This flexible

connection allows compensation for any

eccentricity between shafts for shaft mounted

timers and will permit chain tension ad-

justments

for the

foot mounted timers.

Use 16 gauge stranded machine tool wire,

U.L. listed,

105OC

temperature rating, voltage

rating 600 volts, minimum insulation thick-

ness 0.031”, oil resistant, for wiring the timers

to the control panel.

n

!

Caution:

No strain relief is provided internal to the

timer. Therefore, when wiring the timer into

the application, provide enough slack wire to

prevent wire breakage at the contact points.

2.3

Timer Adjustment:

Reread and follow the Hazard Warnings

stated under Paragraph 2.0.

Cams No. 1, 2, 3 insert, 4 and 5 (24, 26, 28, 33

and 33A, respectively) are dowelled together

and are adjusted as a unit. The outer part of

cam No. 3 (28A) in timer “A” is adjusted

separately. All the cams, once adjusted, are

clamped together by tightening of the two jam

nuts (30). See the illustrated parts list in

Section 4.0 for the relationship of these parts

and when making adjustments.

2.3.1. Top Stop and Brake Monitoring

For existing installations: proceed to Step “g”.

a)

Position the crankshaft at top dead center.

Make sure, it will remain in a safe position.

b)

Turn electrical power off to main control

panel.

c)

Remove end cap (31) from timer by remov-

ing the two socket head cap screws.

d)

Loosen jam nuts (30). Hold adjusting

knob (29) and align indicator groove on

cam No. 3 (28A) in timer “A” with fiber

cam follower of LS3 as shown in Figure 4.

No. 3 Breaker Point

Fiber Cam Follower

Indicator Groove

Figure 4. Brake monitoring cam alignment

e)

f)

g)

h)

i)

j)

k)

l)

Retighten the jam nuts (30).

Position felt seal (34), replace end cap

(31), install and tighten the two socket

head cap screws. Turn electrical power on.

Stroke press to check the stopping position.

Note the relationship between the desired

stopping position and the actual stopping

position.

If the stop is unsatisfactory, inch to the

top of the stroke. Secure the machine in a

safe manner to avoid possible injury.

Turn electrical power off and remove end

cap (31).

Loosen jam nuts (30) and rotate adjusting

knob (29) in opposite direction of cam

arrow to advance the stopping position,

or in same direction of cam arrow to retard

the stopping position.

Hold adjusting knob (29) from rotating

and align indicator groove on brake

monitoring cam No. 3 with fiber cam

follower of LS3 as shown in Figure 4.

6

m) Retighten the jam nuts (30) and repeat

Steps “f”,

“g”

and

“h”.

n)

Repeat this procedure as necessary to ob-

tain the desired stopping position.

2.3.2 Long Operation:

This feature is provided so an adjustment can

be made to extend the LS4 open time and

accommodate presses with long strokes and/or

slow crankshaft speeds.

a)

b)

c)

d)

e)

f)

g)

Turn electrical power off to main control

panel.

Remove end cap (31) from timer by remov-

ing the two socket head cap screws.

Remove jam nuts (30) and washer (40).

Remove adjusting knob (29).

Note that cam No. 5 (33A) has four dowel

holes for adjustment. Cams are factory

adjusted to a minimum setting of

135”.

Rotate cam No. 5 (33A) to increase or

decrease cam dwell.

Insert the dowel of the adjusting knob

through cam No. 5 (33A), cam No. 4 (33)

and spacer (41) to engage cam No. 3 insert

(28). Proper engagement can be determined

by rotating the cam adjusting knob. All

cams, except cam No. 3 (28A), will turn as

a unit when the knob is rotated.

Adjust top stop position and brake monitor-

ing cam as outlined in Paragraph 2.3.1.

2.3.3 Timer Synchronizing Instructions:

a)

First, refer to Paragraph 2.3, Timer Ad-

justments. Where two

Airflex@

timers

exist, this section applies to both units.

b)

Set stroking selector on control panel to

“inch”, turn power “ON”, and inch press

3.0 Maintenance

n

!

Danger:

Prior to performing any maintenance, repair or

adjustment on the

Airflex@

Timing Rotorseal

and Cam Limit Switch, make sure that the ma-

chinery will remain secured in a safe manner.

Failure to do so could result in serious injury

or possibly death.

n

!

Warning:

Only qualified maintenance personnel should

install, adjust or repair these devices. Faulty

workmanship will result in unreasonable ex-

posure to hazardous conditions, injury or

severe damage to the equipment.

3.1

7

c)

d)

e)

f)

g)

h)

i)

j)

to top of stoke. With electrical power

“OFF”, remove both timer end caps.

Make

sure

the machinery is secured in a safe

manner.

On each timer, loosen the locknuts

(30)

and rotate the cam assemblies,, so that

the leading edge of the lobe on both cam

No. 4 and 5 (33 and 33A) just start to open

the LS4 breaker points. Tighten locknuts

(30). Also, refer to brake monitoring cam

adjustment at this point, when applicable

(see Paragraph 2.3.1 and Figure 4).

Set the control panel stroking selector to.

‘Single Stroke”, operate the press, and

observe the stopping position. Retard or

advance both cam assemblies, as required,

to establish desired top stop position.

Tighten locknuts.

With “top stop” established, it is likely at

this stage of adjustment that one cam’

No. 4 of one timer may slightly lead the

cam No. 4 of the second timer.

Inch the press through the stroke just far

enough for the lobe of the

leading cam

to

barely contact the fiber cam follower on

the breaker point.

With power “OFF”,

adjust the second

cam assembly to an identical setting.

Tighten locknuts.

Run the press again on “Single Stroke” a

few times to verify proper operation and

stopping position.

With power “OFF”,

replace the felt seal

(34), the timer end caps and socket

screws.

The two timers should now be properly

synchronized, and the press ready for

operation.

n

!

Caution:

Before you begin any work, study this manual

so that you completely understand what is

required. Do not risk injury. Follow the

instructions.

Breaker Point Assemblies:

The breaker points furnished with the

Airflex@

timers have silver alloy contacts.

Standard automotive breaker points have

tungsten contacts and

must not

be used as a

substitute. The breaker points should be

checked periodically for wear.

Refer to Figure 6 when making any adjustments.

Breaker Point Opening Gap:

This gap is preset at the factory on new units

at time of assembly. A gap setting of .040” to

.050” must be maintained at all times. The

opening gap must be checked regularly and

reset when required. To inspect for proper

opening gap:

a)

b)

c)

d)

e)

h)

i)

j)

k)

Position the crankshaft at top dead center.

Use die safety blocks or otherwise secure

to hold the ram in this position.

Turn electrical power

off

to main control

panel.

Remove end cap (31) from timer by remov-

ing the two socket head cap screws.

Mark the location of the fiber follower of

the LS4 (42) breaker point with respect to

the cam No. 5 (33A). This will prevent the

need for several timer adjustments to

locate the top stop position. See Figure 5.

To inspect LS1, refer to Figure 6 and

remove the two socket head cap screws

(43) and mounting bridge sub-assembly (32).

Loosen jam nuts (30).

Rotate cam adjusting knob (29) so that

breaker point gap being measured is at

its maximum opening.

Measure gap as indicated in Figure 6.

If gap must be adjusted, follow instruc-

tions given in Paragraph 3.1.2.

Lubricate the cam follower with a multi-

purpose lithium soap grease.

Measure gap of LS2 by repeating Steps

“g”

to

“j”.

Opening Gap

Adjust To .040 - .050 inches

Mounting bridge removed

T

Cam No. 5 (33A)

Fiber Follower

LS4

\

Mark As Shown

Figure 5

Marking top stop position

1)

Rotate No. 3 cam (28A) so that breaker

point gap of LS3 is at its maximum opening.

m) Repeat Steps “h” through “j”.

n) Replace mounting

brid.ge

sub-assembly

(32) and cap screws (43).

Lubricate

r

Here

\

Fiber Cam Follower

Figure 6

Breaker point maintenance

8

o)

P)

q)

r)

s)

t)

u)

v)

w)

Align No. 5 cam with previously establish-

ed top stop mark by rotating cam

adjusting knob.

Maintain No. 5 cam alignment by holding

adjusting knob. Rotate No. 3 cam so that

indicator groove lines up with the fiber

cam follower on LS3 breaker point. Refer

to Figure 4. This alignment must be done

with the crankshaft at top dead center.

Tighten inner jam nut and lock in place

with outer jam nut. Do not back inner jam

nut off to meet outer jam nut.

Reinspect cam positions.

Make sure that the ground connection is

tight, (see Figure 6).

Position felt seal (34) and replace end

cap (31).

Turn electrical power on when press is

ready to run.

If top stop position must be readjusted,

follow instructions given in Paragraph 2.3.

Breaker Point Adjustment:

When making the following adjustment, exer-

cise caution with the wire leads to make sure

they are secure and not shorted out.

n

!

Caution:

Make sure the electrical power is turned off

before proceeding to avoid possible injury.

a)

Refer to Figure 6 and loosen the two

breaker point mounting screws (44).

b)

Shift the breaker point assembly (23) to

establish the correct gap.

c)

With the opening gap properly set,

retighten the mounting screws (44).

Measure gap of LS4 by repeating. Steps

“g” through “j”.

d)

Make sure that the ground connection is

tight (see Figure 6)

e)

If points cannot be adjusted to proper gap

or are pitted, they must be replaced.

Follow instructions given in Paragraph 3.1.3.

f)

After all breaker point adjustments have

been made, refer to Paragraph 3.1.1 and

complete Steps “p” through “v”.

3.1.3 Breaker Point Replacement:

a)

Identify all wire leads before detaching

them from breaker point terminals.

b)

Disconnect the wire leads from the

breaker point being replaced.

c)

Remove the two breaker point mounting

screws (44) and discard the old breaker

point.

d)

Coat the fiber cam follower with the

grease lubricant furnished with the new

breaker point.

e)

Install the new breaker point.

f) Attach the wire leads to the breaker point.

g)

Adjust the breaker point gap as outlined

in Paragraph 3.1.2.

3.2

Bearings and Seals Replacement:

3.2.1

The bearings in both types of timers and the

rotating seals (16 and 19) in the timing

rotorseal are not considered to be field’

replaceable items and it is recommended that

the units be returned to the factory.

For dimensional information, request

Form PP3000.

For additional information, contact Eaton

Corporation, Industrial Drives Operations,

Airflex Division, 9919 Clinton Road, Cleveland,

Ohio 44144, telephone (216) 281-2211.

9

Item

No.

-

6.

20.

22.

23.

24.

25.

26.

27.

28.

28A

29.

30.

31.

32.

33.

33A

34

38.

40.

41.

42.

45.

46.

47.

Part No. Description

302276

159 x 41

139 x 12

See table C

See table C

201854

See table C

201869

See table C

306030

203003

61 x 22

412230

409346

See table C

See table C

119 x 23

507137

153 x 530

203107

404583

411367

405330

203351

Shaft

Bearing

Snap ring

Breaker points

No. 1 cam

Washer

No. 2 cam

Cam adjusting sleeve

No. 3 cam insert

No. 3 cam

Cam adjusting knob

Jam nut

End cap

Bridge

No. 4 cam

No. 5 cam

Felt seal

Mounting plate

Flat washer

Spacer

Housing

Shaft

Housing

Spacer

iii-

Req.

1

2

1

4

1

1

1

1

1

:

1

1

1

1

1

1

1

1

1

1

1

-

The part no. for the complete assembly is stamped on

the timer decal. Identify the timer with this number

when specifying component parts.

ise

~AL~AQ

ii/lwise

_

145748 AP 145748

AT

C’Clockwise

30°

Dwell

o-

22

-

1 Req’d. I

SHAFT MOUNTED

CAM LIMIT SWITCH

TABLE C

FOOT MOUNTED

CAM LIMIT SWITCH

Part No. for Optional Cam No. 3 (Item No. 28A), is as follows:

203002

(For clockwise and clockwise 30” dwell)

203087

(for c’clockwise and c’clockwise 30” dwell)

Eaton Corporation

Airflex Division

Cleveland, Ohio 44144

PWNTED

IN

u.

5.

A.

PDF format

Form ML-318

Revised September 3, 1997

Eaton Corporation

Airflex Division

9919 Clinton Road

Cleveland, Ohio 44144

Printed in U.S.A.

EATON PRODUCT WARRANTY

Subject to the conditions stated

herein, Eaton Corporation warrants to

the Purchaser that each new Airflex

Product manufactured by Eaton will be

free from failures caused by defects in

material and workmanship, and will

deliver its rated capacity, for a period

of twelve (12) months from the date of

shipment to Purchaser, provided such

Product is properly installed, properly

maintained, operated under normal

conditions and with competent

supervision. Warranty claims shall be

made in writing and the part or parts

shall, if requested by Airflex Division,

be returned prepaid to the Airflex

Division for inspection. Upon a

determination that a defect exists,

Eaton shall thereupon correct any

defect, at its option either by repairing

any defective part or parts or by

making available at Eaton’s plant a

repaired or replacement part. This

warranty does not extend to normal

wear parts or components of the

Product, such as friction material and

friction surfaces.

LIMITATION OF WARRANTY

THE FOREGOING WARRANTY IS

EXCLUSIVE AND IN LIEU OF ALL

OTHER WARRANTIES WHETHER

WRITTEN, ORAL OR IMPLIED. ANY

IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE ARE

SPECIFICALLY EXCLUDED.

In no event shall Eaton be liable for

special, incidental or consequential

damages. Eaton’s liability arising out

of the supplying of such Product, or its

use, whether in warranty, contract or

otherwise, shall in no case exceed the

cost of correcting defects in the

Products as herein provided. Upon

expiration of the twelve (12) month

period, all such liability shall

terminate. THE FOREGOING SHALL

CONSTITUTE THE SOLE REMEDY

OF PURCHASER AND THE SOLE

LIABILITY OF EATON.