Watchdog Super Elite

Watchdog Super EliteBUCKET ELEVATOR & BELT CONVEYORHAZARD MONITORING SYSTEM COperation Manual SupplementSENSOR WIRING DIAGRAMSPart No.’s - WDC4V4C, WDC4V46Cwww.go4b.com/usaUS

WARNINGRotating parts can crush,cut and entangle.Do NOT operate withguard removed.Lockout power beforeremoving guard orservicing.DANGERExposed moving partswill cause severe injuryor death.Lockout power beforeremoving cover orinspection door.

TABLE OF CONTENTSCUSTOMER SAFETY RESPONSIBILITIESPage 4 - 5ELECTRICAL CONNECTIONPage 6 - 7PRE-SET PROFILESPage 8BUCKET ELEVATOR LEG WIRING DIAGRAMS- Typical Sensor Placement for Bucket ElevatorsPage 91. WDC3 to WDC4 Sensor Wiring DiagramPage 102. Sensor Wiring Diagram Profile with TouchswitchesPage 113. Sensor Wiring Diagram Profile with Rub BlocksPage 124. Sensor Wiring Diagram Profile with Motion Alignment SensorsPage 135. Sensor Wiring Diagram Profile with Knee or Idler PulleysPage 146. Sensor Wiring Diagram with Ambient SensorPage 157. Sensor Wiring Diagram with Touchswitches and Plug SwitchPage 168. Sensor Wiring Diagram with Rub Blocks and Plug SwitchPage 179. Sensor Wiring Diagram with Motion Alignment Sensors and Plug SwitchPage 1810. Sensor Wiring Diagram with Motion Alignments Sensors,Plug Switch and Head Pulley SensorsPage 1911. Sensor Wiring Diagram with Touchswitches and Differential SpeedPage 2011A. Sensor Wiring Diagram Profile With Rub Blocks and Differential SpeedPage 2112. Sensor Wiring Diagram with Touchswitches, DifferentialSpeed and Plug SwitchPage 22ENCLOSED BELT CONVEYOR WIRING DIAGRAMS- Typical Sensor Placement for Enclosed Belt ConveyorsPage 2313. Sensor Wiring Diagram with 6 Rub Blocks, 4 BearingTemperature Sensors and 2 Lug Style Tail Pulley Alignment SensorsPage 2414. Sensor Wiring Diagram with Touchswitches, 4 BearingTemperature Sensors and 2 Lug Style Tail Pulley Alignment SensorsPage 25DRAG CHAIN CONVEYOR WIRING DIAGRAMS- Typical Sensor Placement for Drag Chain ConveyorsPage 2715. Sensor Wiring Diagram for Slack Chain Detection with Plug SwitchPage 2816. Sensor Wiring Diagram for Slack Chain Detection without Plug SwitchPage 29PRODUCT WARRANTYPage 32

Dear 4B Customer:Congratulations on your purchase. 4B appreciates your business and is pleased youhave chosen our products to meet your needs.Please read in its entirety and understand the literature accompanying the product beforeyou place the product into service. Please read the safety precautions carefully beforeoperating the product. With each product you purchase from 4B, there are some basicbut important safety considerations you must follow to be sure your purchase is permittedto perform its design function and operate properly and safely, giving you many yearsof reliable service. Please read and understand the Customer Safety Responsibilitieslisted below. Failure to follow this safety directive and the Operation Manuals and othermaterial furnished or referenced, may result in serious injury or death.SAFETY NOTICE TO OUR CUSTOMERSA. In order to maximize efficiency and safety, selecting the right equipment for eachoperation is vital. The proper installation of the equipment, and regular maintenanceand inspection is equally important in continuing the proper operation and safetyof the product. The proper installation and maintenance of all our products is theresponsibility of the user unless you have asked 4B to perform these tasks.B. All installation and wiring must be in accordance with Local and National ElectricalCodes and other standards applicable to your industry. (Please see the article“Hazard Monitoring Equipment Selection, Installation and Maintenance” at www.go4b.com.) The installation of the wiring should be undertaken by an experiencedand qualified professional electrician. Failure to correctly wire any product and/ormachinery can result in the product or machine failing to operate as intended, and candefeat its design function.C. Periodic inspection by a qualified person will help assure your 4B product isperforming properly. 4B recommends a documented inspection at least annually andmore frequently under high use conditions.D. Please see the last page of this manual for all warranty information regarding thisproduct.CUSTOMER SAFETY RESPONSIBILITIES1. READ ALL LITERATURE PROVIDED WITH YOUR PRODUCTPlease read all user, instruction and safety manuals to ensure that you understand yourproduct operation and are able to safely and effectively use this product.2. YOU BEST UNDERSTAND YOUR NEEDSEvery customer and operation is unique, and only you best know the specific needsand capabilities of your operation. Please call the 24-hour hotline at 309-698-5611 forassistance with any questions about the performance of products purchased from 4B.4B is happy to discuss product performance with you at any time.PAGE 4

3. SELECT A QUALIFIED AND COMPETENT INSTALLERCorrect installation of the product is important for safety and performance. If you havenot asked 4B to perform the installation of the unit on your behalf, it is critical for thesafety of your operation and those who may perform work on your operation that youselect a qualified and competent electrical installer to undertake the installation. Theproduct must be installed properly to perform its designed functions. The installer shouldbe qualified, trained, and competent to perform the installation in accordance with Localand National Electrical Codes, all relevant OSHA Regulations, as well as any of yourown standards and preventive maintenance requirements, and other product installationinformation supplied with the product. You should be prepared to provide the installerwith all necessary installation information to assist in the installation.4. ESTABLISH AND FOLLOW A REGULAR MAINTENANCE AND INSPECTIONSCHEDULE FOR YOUR 4B PRODUCTSYou should develop a proper maintenance and inspection program to confirm that yoursystem is in good working order at all times. You will be in the best position to determinethe appropriate frequency for inspection. Many different factors known to the user willassist you in deciding the frequency of inspection. These factors may include but are notlimited to weather conditions; construction work at the facility; hours of operation; animalor insect infestation; and the real-world experience of knowing how your employeesperform their jobs. The personnel or person you select to install, operate, maintain,inspect or perform any work whatsoever, should be trained and qualified to perform theseimportant functions. Complete and accurate records of the maintenance and inspectionprocess should be created and retained by you at all times.5. RETAIN AND REFER TO THE OPERATION MANUAL FOR 4B’S SUGGESTEDMAINTENANCE AND INSPECTION RECOMMENDATIONSAs all operations are different, please understand that your specific operation may requireadditional adjustments in the maintenance and inspection process essential to permitthe monitoring device to perform its intended function. Retain the Operation Manualand other important maintenance and service documents provided by 4B and havethem readily available for people servicing your 4B equipment. Should you have anyquestions, please call the free 24-hour hotline number (309-698-5611).6. SERVICE REQUESTIf you have questions or comments about the operation of your unit or require the unit tobe serviced please contact the 4B location who supplied the product or send your requestvia fax (309-698-5615) or call us via our 24-hour hotline number in the USA (309-6985611). Please have available product part numbers, serial numbers, and approximatedate of installation.PAGE 5

ELECTRICAL CONNECTIONAll wiring must be in accordance with local and national electrical codes and should be undertaken byan experienced and qualified electrician.Always use dust/liquid tight flexible metal conduit with approved fittings to protect the sensor cables.Use rigid metal conduit to protect the cables from the sensors to the control unit. Conduit systems canchannel water due to ingress and condensation directly to sensors and sensor connections which overtime will adversely affect the performance of the system. As such, the installation of low point conduitdrains is recommended for all sensors.All electrical connections are made via 3 sets of terminals provided as shown in image 1.FUSE RATINGS In order to maintain the product certification, all fuses MUST be replaced with equivalent fuses at thesame rating. Failure to do so will invalidate the certification and any warranties which may exist.Model WDC4V4C F1, F2, F3, F5 200 mA maximum.F1 to F3 are used to limit the current available to the sensor inputs.F5 is used to limit the current available to the internal electronics.F6 is not used.Model WDC4V46C F1 to F3 2 amp maximum, used to limit the current available to the sensor inputs. F5 200 mA, used to limit the current available to the internal electronics. F6 2 amp maximum, used to protect the AC power supply.NOTETo calibrate speed and utilize the Watchdog’s built-in alarm and shut-down capabilities, a motorinterlock (run) signal is required. For typical motor interlock wiring examples, review the wiringdiagrams for terminals 6 & 7 in the WDC4 manual (section 9).NOTERecommended cable type is Belden 5508FE with 10 conductors each 22 AWG, shielded. Overallouter diameter is 0.23 inches. Belden 5508FE wire colors are used in all of the sensor wiringdiagramsPAGE 6

WARNINGThe unit should ONLY be powered with either a main supply (WDC4V46C model) OR a 24 VDC(WDC4V4C and WDC4V46C models) NOT BOTH.FIELD WIRINGCONNECTIONS44 - 0 VDC43 - Speed Sensor42 - Pulley Sensor41 - Plug Sensor40 - Head Rub - Right39 - Head Rub - Left38 - Head Align - Right37 - Head Align - Left36 - 24 VDC (Fuse F1)35 - 0 VDC34 - Tail Rub - Right33 - Tail Rub - Left32 - Tail Align - Right31 - Tail Align - Left30 - 24 VDC (Fuse F2)29 - 0 VDC28 - Bearing Sensor 627 - Bearing Sensor 526 - Bearing Sensor 425 - Bearing Sensor 324 - Bearing Sensor 223 - Bearing Sensor 122 - Ambient Sensor 221 - Ambient Sensor 120 - 24 VDC (Fuse F3)POWER & RELAY CONNECTIONSImage 1 Inside View - Bottom BoardWDC4 Wiring ConnectionsPAGE 706 - Motor Starter Interlock (-)07 - Motor Starter Interlock ( )08 - Alarm Relay Normally Open09 - Alarm Relay Normally Closed10 - Alarm Relay Common11 - Stop Relay Normally Open12 - Stop Relay Normally Closed13 - Stop Relay Common14 - 120 to 240 VAC Connection15 - VAC Neutral Connection16 - Ground or 0 Volt Connection17 - 24 VDC Connection ( )18 - 24 VDC Connection (-)

PRE-SET PROFILESLeg (TS) / 1SP, 4BS, 4TSLeg (RB) / 1SP, 4BS, 4RBLeg (WDA) 4MA, 4BSLeg (TS) / 1SP, 6BS, 6TSBackOKImage 2Profile - Select New ProfileSELECT NEW PROFILE MENU SETUP (PASSWORD) PROFILE SELECT NEW PROFILETo help make the set up process easier for bucket elevator legs, four pre-set program profiles areavailable to choose from (Image 2). All four profiles are highlighted in RED at the top of each wiringdiagram (xxxxx). Refer to section 14 of the WDC4 Watchdog Super Elite product manual for moreinformation regarding sensor settings.1. LEG (TS) / 1 SP, 4BS, 4TS 1 Speed Sensor 4 Bearing Temperature Sensors 4 Touchswitch Sensors (Alignment)2. LEG (RB) / 1SP, 4BS, 4RB 1 Speed Sensor 4 Bearing Temperature Sensors 4 Rub Block Sensors (Alignment)3. LEG (WDA) 4MA, 4BS 4 Motion Alignment Sensors 4 Bearing Temperature Sensors4. LEG (TS) / 1SP, 6BS, 6TS 1 Speed Sensor 6 Bearing Temperature Sensors 6 Touchswitch Sensors (Alignment)NOTEAll pre-set program profiles default to the factory settings. To modify settings from the factorydefaults, go to the EDIT SELECTED PROFILE menu.PAGE 8