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TECHNICAL DATA SHEET /// TORNADO INTEGRATION MODULE Release 1.1 /// February 2013 INTRODUCTION This datasheet provides key technical parameters for BDT’s Tornado Drive Module (TDM) and Tornado Slave Module (TSM) assemblies. The external dimensions of both modules are identical; the Drive (or Primary) Module includes the Tornado suction generator, an integrated (belt) transport motor, drive electronics and optional additional features, while the Slave (or Secondary) Module includes only the Tornado suction generator and the associated transport belts. Tornado Slave (TSM) and Drive (TDM) modules BASE PRODUCT DIMENSIONS Tornado Drive / Slave Module Length in transport direction: 144 mm Width (without encoder): 118 mm Width (with encoder): 128 mm Height (without adapter plate): 100 mm Distance between the belts: 16 mm Width of belt: 14 mm Diameter of the “active Tornado area”: 54 mm Adapter Plate Length: 107 mm Width: 60 mm Height: 8 mm MASS Tornado Drive Module: 1280 g (1310 g with encoder) Tornado Slave Module: 690 g Adapter Plate: 125 g TRANSPORT SPEED In current applications (TDM module standalone): up to 5,0 m/s Speed is adjustable in a range from: 0,1 – 5,0 m/s Max. acceleration / deceleration of the belt: up to 2 m/s² TRANSPORT POSITION RESOLUTION Standard TDM module: ~3 mm / step (1/24 revolution/step) TDM Module with Encoder: ~28 steps / mm. (1/2000 revolution/step) NOISE LEVEL Depending on the required speed of the impeller, from approx. 50 dB (A) to 75 dB (A) SUCTION FORCE CHARACTERISTIC Max. Suction Force [N] 1,4 1,2 1 0,8 Max. Suction Force [N] 0,6 0,4 0,2 Distance of media to 0 0 5 10 15 20 25 the belt [mm] OPERATING CONDITIONS Temperature range: 10°C – 40°C Humidity range: 20% - 70% R.H. (no condensation) The time to attract a media at a distance depends on the media weight and the distance. System is designed for low dust environments. Special applications / environmental conditions should be tested and proven by the customer. MEDIA Media sheets should be dry and should not stick together. Media weight, from 65g/m² up to 500 g/m² (depending on sheet size and speed) Lower and higher density media can be handled in specific configurations; we recommend a detailed technical review with the BDT experts. LIFE TIME Design Lifetime: Module is designed for one year (24/7/365) of nonstop production, or approx. 8700 operating hours under specified environment (21°C / 50% R.H.) without maintenance. MAINTENANCE After one year of 24/7/365 duty cycle we recommend replacement of the whole unit. Depending on the transported media and the operating environment, it may be necessary to clean the transport belts in case of a build-up of dust or dirt on the belts, as this may affect the maximum transport speed / acceleration. CERTIFICATES No standalone certificates at module level. RoHS – compliant materials CE compliant materials and design UL listed and compliant materials Information about materials safety certificates can be supplied on request. MECHANICAL INTERFACES Mounting of the module: Snap-fit locking plate with locking screw. Screw Holes / Threads for M4 Screws, see drawings. Drive Master Module: Integrated Brushless DC Motor with Belt Drive. Drive Slave Module: Drive from Master module - connected by hexagonal rod. Connection Master/ Slave: drawn hexagon steel rod, EN10278 – 8h11 / EN10088-3 - X5CrNi18-10. ADAPTER PLATE: With the “Quick snap” mounting adapter plate an angular tolerance of +/- 0.3° vertical and +/0,4° horizontal is possible. To fix the Module with the “Quick snap,” a total lateral movement of 10 mm is necessary. The mounting plate includes a spring-loaded “snap” mechanism which can be tightened with a flat-blade screwdriver. DRAWING ADAPTER PLATE Both TDM and TSM Modules can be mounted onto identical “adapter plates” which use a snap-fit release mechanism to lock the modules, allowing for easy release and replacement of individual modules during maintenance. Fix the adapter plate to your chassis using M4 screws. SAFETY CONSIDERATIONS A running TDM or TSM module can cause injuries for operators because of the free running belt and the impeller. Because of this, safety requirements must be taken into account during the design phase with these modules. Make sure that user access to spinning components is limited by design, or use additional safety mechanisms such as interlocking doors and covers. MECHANICAL INTEGRATION GUIDELINE FOR TDM OR TSM Each TDM is able to drive up to four TSM modules, axially coupled. When using two or more TSM modules, we recommend to place the TDM module centrally and to connect the TSM modules symmetrically on both sides. The modules shall be coupled with a hexagonal steel rod, cut to length to suit your layout. The minimum center to center distance is: 120 mm across media transport direction. 165 mm in media transport direction. The optimum distance between modules is related to media format and stiffness / weight. The “active Tornado area” should be fully covered by the media sheet across the media stream direction; if the media edge falls inside the suction area (between the belts), the media can be damaged if the Tornado is running at very high power and/or the media is very thin. Media edge safe Media edge may be damaged CROSS-SECTION of a Tornado module with approximate suction force distribution: Ambient pressure The force of the low-pressure zone is related primarily to impeller speed. The “down-winds” of the Tornado create a small “high pressure” zone at the edges of the Tornado. This can cause some side-effects with very light media; for such critical applications we recommend a detailed technical review with the BDT experts. MECHANICAL INFORMATION – BELT DRIVE Gear ratio: 1:1 Belt travel per revolution of the motor: nominal 72.9 mm, +/- 1.5mm. Depending on the suction force, on the characteristic of the attracted medium (friction coefficient) and the acceleration / deceleration applied to the belt, you may encounter, and need to compensate for, slippage between the transport belt versus the transported medium, and of transport belt versus transport motor. Therefore you will need to experiment empirically with the distance travelled by the transport motor and belts, compared to the resulting distance travelled by the paper / transported media. ELECTRICAL INTERFACES TORNADO DRIVE MODULE (TDM) Connector on module (male): Connector on cable (female): Connector manufacturer: ODU Mini-Snap 22p male G53L0C-P22PFG0-0000 (Series L) ODU Mini-Snap 22p female Series L 90° connector: W23L0C-P22NFG0-120S ODU (www.odu.de) Pin 1 2 3 Signal +48V BLDC +48V BLDC GND BLDC ODU Mini-Snap 22p connector layout Codification Supply voltage for Belt Motor 2A max. 14 1 GND for Belt Motor. 4 5 GND BLDC +24V Tornado 6 7 8 9 10 11 12 GND Tornado +24V miControl GND miControl +24V Sensor GND Sensor Sensor Out Speed In Tornado 13 14 15 CAN Low in CAN High in DIR IN Tornado Supply Voltage Tornado. +24 V 1.3A max GND for Tornado. Supply for motor controller. GND for motor controller. Supply for optional sensor GND for optional sensor. Optical Sensor output Fan speed control (input) (0…10V) CAN bus low signal input CAN bus high signal input Fan direction control (input) 16 17 DI1 miControl DI0 miControl Digital input 1 Digital input 0 Low: <3.5V High: 4-36V 18 AI0 miControl Analog input 0 0…10V 19 20 21 22 Tornado Error CAN High out CAN Low out CAN GND Error output CAN bus high signal output CAN bus low signal output CAN Bus ground return 15 22 ML100 Sensor available as retrofit option – fitted at leading edge or trailing edge. 0V min. speed 10V max. speed CCW: <3,8V. CW: >9,9V. Belt Motor Control Mode DI0 DI1 CW 1 0 CCW 0 1 STOP 1 1 OFF 0 0 Belt Speed control 0V min. speed 10V max. speed Error = low level ELECTRICAL INTERFACES TORNADO SLAVE MODULE (TSM) Connector on module (male): ODU Mini-Snap 8p male G51L0C-P08PFG0-0000 (Series L) Connector on cable (female): ODU Mini-Snap 8p female Series L 90° connector: W21L0CP08NFG0-720S Connector manufacturer: ODU (www.odu.de) Pin Signal ODU Mini-Snap 8p Connector Layout 1 +24V Tornado Supply Voltage +24 V (1.3A max) 2 Speed In Tornado Fan speed control (0-10V) 0V = min, 10V = max. speed 3 Tornado Error Error output Error = low level 4 DIR IN Tornado Fan direction control (input) CCW: <3,8V. CW: >9,9V. 5 GND Tornado Supply ground 6 NC Not used 7 NC Not used 8 NC Not used Codification 1 8 7 BDT PART NUMBERS TIM Modules: Part Nr. Description Comment 950 015 002-02 KIT, TORNADO MASTER PACKED Integrated belt drive motor 950 015 003-02 KIT, TORNADO SLAVE PACKED 950 015 004-02 KIT, TORNADO MASTER ENCODER PACKED No drive motor Integrated belt drive motor + encoder Accessories: Part Nr. Description Comment 376 099 303-01 KIT, SENSOR, ML100 Photosensor for TDM module 258 139 323-03 CABLE TORNADO DRIVE MODULE 5m cable for TDM module (22p) 258 139 343-03 CABLE TORNADO SLAVE MODULE 5m cable for TSM module (8p) BDT MEDIA AUTOMATION GMBH Saline 29 /// 78628 Rottweil /// Germany Phone: +49 (0) 741 / 248-01 /// Fax: +49 (0) 741 / 248 224 www.bdt.de /// eMail: [email protected] The information contained herein is subject to change without notice. BDT shall not be liable for technical or editorial errors or omissions contained herein. As of: February 2013.