Eaton Electrical TRS 3064 User Manual

TRS 3064

Installation,
Operation and

Maintenance of

the

Airflex@

Timing Rotorseal
and Cam

Limit Switch

Revised: Feb. 1, 1982

1.0

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 warn­ings. They are included to protect you!

1.1

Operation

Description:

This manual describes two
control devices, namely, the

Limit Switch and the

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 opera­tion for both devices is the same.

When these devices are properly wired into
the appropriate
(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@

two of the timers, in any combination, to con­trol 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
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

Airflex@

press control system requires

Airflex@

Airflex@

press control system

Airflex”

timing

Airflex@

Cam

Timing

FSPA clutch

bullgear of an
plication clutch and brake package (see
Figure 2).

1.2

How It Works:

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
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”

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 re­moved. To be consistent with the
press control wiring diagram the timer that
monitors the brake should be labeled “A”.

The control functions of the cams are:

Airflex@

press control system requires

standard press ap-

Airflex”

clutch. The

Airflex@

Cam No.

1

2
3

4&5

“A” Timer

Nonrepeat
Top Stop (Continuous)
Brake Monitor

Top Stop (Single Stroke)

“B” Timer

Nonrepeat
Nonrepeat
Semicontinuous Brake Monitor

or Special Function
Top Stop (Single Stroke)

2

Figure 1 illustrates the cams assembled in
the timing section of both devices and their
relationships.

No.

1 Cam

No. 2 Cam

Insert

No. 3 Cam

Cams for Clockwise Rotation

Cams for Counterclockwise Rotation

No. 4 Cam

insert

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.

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 func­tion, 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 in­crements of 40 ‘. For the proper setting of
these cams, refer to Paragraph 2.3.

2.0 Installation

!

n

Danger:

Prior to installation of the

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.

!

Caution:

n

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

2.1 .1 Timing Rotorseal:

Mounting

Instructions for mounting the
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.

The

Airflex@

designed to fit the flywheel or bullgear of an

Airflex@

shown in Figure 2. The flywheel or bullgear

timing rotorseal is custom

FSPA clutch and brake package as

Airflex’“’

Airflex’)

Timing

timing

Grease Hole

Figure

\

\

2. Timing rotorseal mounting configuration

The timing rotorseal end plate (36) is used to
assemble the device to the crankshaft. The end
plate also provides the necessary bearing run­ning 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.

/-

Grease Fitting

and Lockwasher

4

To

mount the timing rotorseal:

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

a)

are in place.
Install the plastic insert (37A) in the head

b)

of the drive screw (37).

Install drive screw. Tighten the screw, being

c)

careful not to distort the end plate (36).
Tie-wire the drive screw to the end plate

d)

mounting screws.
Align the tang of shaft (6) with the slot in

e)

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

f)

bolts. Tighten the mounting bolts uniform­ly SO the adapter flange fits squarely
against the register face.

Inspect all air connection tubes and

g)

remove all burrs.

Lightly grease or oil the ends of the air

h)

tubes and insert them into the mating
adapter holes.

Attach the opposite ends of the tubes to

i)

their connections.
Connect flexible air hose (35) to the

j)

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 be­tween the device and the shaft and will cause
a preload condition that will shorten the bear­ing life of the device.

Rigidly attach a sprocket to the drivi

b)

shaft.
Key the other sprocket to the cam limit

c)

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

d)

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

e)

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

f)

following chain manufacturer’s
recommendations.

Fabricate a guard to cover sprockets and

g)

chain.
Refer to appropriate paragraph and mount

h)

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 design­ed 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.

g

/i

k)

Apply air pressure and check for air leaks.
Repair as required.

Remove air pressure.

l)

m)

Refer to appropriate paragraph and mount
second timer.

Wiring instructions are given in Paragraph 2.2.

2.1.2.

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
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.

Airflex”

are 3/8

3. 250

Dia B. C.

@ A

.OlO

Dia.

“i

3’5 PI/Of Da. Y

,376

1.25 Deep

Figure 3. Shaft machining details

56

I-

318-16

4 Bolts

Cam Limit

Swtch

NC-2

Eq.

Spaced

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
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

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.

Airflex@

wiring diagrams.

Airflex@

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

!

n

Caution:

A length of flexible conduit must be used be­tween 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

Use 16 gauge stranded machine tool wire,

U.L. listed,
rating 600 volts, minimum insulation thick­ness 0.031”, oil resistant, for wiring the timers
to the control panel.

!

n

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.

for the

105OC

Caution:

foot mounted timers.

temperature rating, voltage

Indicator Groove

Figure 4. Brake monitoring cam alignment

Retighten the jam nuts (30).

e)

Position felt seal (34), replace end cap

f)

(31), install and tighten the two socket
head cap screws. Turn electrical power on.

Stroke press to check the stopping position.

g)

Note the relationship between the desired

h)

stopping position and the actual stopping
position.

If the stop is unsatisfactory, inch to the

i)

top of the stroke. Secure the machine in a
safe manner to avoid possible injury.

Turn electrical power off and remove end

j)

cap (31).

Loosen jam nuts (30) and rotate adjusting

k)

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

l)

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”,

n)

Repeat this procedure as necessary to ob-

tain the desired stopping position.

“g” and “h”.

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.

Turn electrical power off to main control

a)

panel.

Remove end cap (31) from timer by remov-

b)

ing the two socket head cap screws.

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

c)

Remove adjusting knob (29).

d)

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

e)

holes for adjustment. Cams are factory
adjusted to a minimum setting of

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

decrease cam dwell.
Insert the dowel of the adjusting knob

f)

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-

g)

ing cam as outlined in Paragraph 2.3.1.

135”.

2.3.3 Timer Synchronizing Instructions:

a)

First, refer to Paragraph 2.3, Timer Ad­justments. Where two
exist, this section applies to both units.

b)

Set stroking selector on control panel to

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

Airflex@

timers

to top of stoke. With electrical power

“OFF”, remove both timer end caps.

sure

the machinery is secured in a safe

manner.

On each timer, loosen the locknuts

c)

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.

d)

‘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

e)

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

f)

enough for the lobe of the
barely contact the fiber cam follower on
the breaker point.

With power “OFF”,

g)

cam assembly to an identical setting.
Tighten locknuts.

Run the press again on “Single Stroke” a

h)

few times to verify proper operation and
stopping position.

With power “OFF”,

i)

(34), the timer end caps and socket
screws.
The two timers should now be properly

j)

synchronized, and the press ready for
operation.

leading cam

adjust the second

replace the felt seal

(30)

Make

to

3.0 Maintenance

!

n

Danger:

Prior to performing any maintenance, repair or
adjustment on the
and Cam Limit Switch, make sure that the ma­chinery will remain secured in a safe manner.

Failure to do so could result in serious injury
or possibly death.

!

Warning:

n

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.

Airflex@

Timing Rotorseal

!

Caution:

n

Before you begin any work, study this manual
so that you completely understand what is
required. Do not risk injury. Follow the
instructions.

3.1

Breaker Point Assemblies:

The breaker points furnished with the

Airflex@

Standard automotive breaker points have
tungsten contacts and
substitute. The breaker points should be
checked periodically for wear.

Refer to Figure 6 when making any adjustments.

7

timers have silver alloy contacts.

must not

be used as a

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:

Position the crankshaft at top dead center.

a)

Use die safety blocks or otherwise secure

to hold the ram in this position.

Turn electrical power

b)

off

to main control

panel.
Remove end cap (31) from timer by remov-

c)

ing the two socket head cap screws.
Mark the location of the fiber follower of

d)

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

e)

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.

h)

If gap must be adjusted, follow instruc-

i)

tions given in Paragraph 3.1.2.

Lubricate the cam follower with a multi-

j)

purpose lithium soap grease.
Measure gap of LS2 by repeating Steps

k)

“g”

to

“j”.

Opening Gap
Adjust To .040 - .050 inches

Cam No. 5 (33A)

T

Fiber Follower

LS4

Figure 5

Marking top stop position

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

1)

point gap of LS3 is at its maximum opening.
m) Repeat Steps “h” through “j”.
n) Replace mounting

(32) and cap screws (43).

Fiber Cam Follower

\

\

brid.ge

sub-assembly

Mark As Shown

Lubricate

r

Here

Mounting bridge removed

Figure 6

Breaker point maintenance

8

Measure gap of LS4 by repeating. Steps

o)

“g” through “j”.

Align No. 5 cam with previously establish-

P)

ed top stop mark by rotating cam
adjusting knob.

Maintain No. 5 cam alignment by holding

q)

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

r)

with outer jam nut. Do not back inner jam
nut off to meet outer jam nut.
Reinspect cam positions.

s)

Make sure that the ground connection is

t)

tight, (see Figure 6).
Position felt seal (34) and replace end

u)

cap (31).
Turn electrical power on when press is

v)

ready to run.
If top stop position must be readjusted,

w)

follow instructions given in Paragraph 2.3.

Breaker Point Adjustment:

When making the following adjustment, exer­cise 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).

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

3.2.1

Bearings and Seals Replacement:

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 [phone].

9

o-

22

-

1 Req’d.

I

Item

No.

-

20.

22.

23.

24.

25.

26.

27.

28.
28A

29.

30.

31.

32.

33.
33A

34

38.

40.

41.

42.

45.

46.

47.

6.

Part No.

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

Description

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.

~AL~AQ

_

ise

145748 AP 145748ATC’Clockwise

ii/lwise

30°

Dwell

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

203087

(For clockwise and clockwise 30” dwell)

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

Eaton Corporation
Airflex Division
Cleveland, Ohio 44144

PWNTED

IN u. 5.

A.

Form ML-318

Revised September 3, 1997
PDF format

EATON PRODUCT WARRANTY

Subject to the conditions stated
herein, Ea ton Corpo rati on w arran ts 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, prop erly
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 surf ace s.

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 E ATON.

Eaton Corporation
Airflex Division
9919 Clinton Road
Cleveland, Ohio 44144

Printed in U.S.A.