Part Number 20-22

Revision A

™
M/D TOTCO
I N S T RU M E N TAT I O N

INSTALLATION, CALIBRATION, AND OPERATION

Line Tension Transducer

with EMI Filter

TCE-100K

Manufacturers of Precision Instruments

Printed in U.S.A. December 22, 1997

 Manual 20-22 contains 26 pages, divided as follows:

Cover. . . . . . . . . . . . . . . . . . . . . . . . December 1997

iii through iv . . . . . . . . . . . . . . . . . . December 1997
1 through 12 . . . . . . . . . . . . . . . . . . December 1997
Appendix A. . . . . . . . . . . . . . . . . . . December 1997
Appendix B . . . . . . . . . . . . . . . . . . . December 1997

All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.

Information in this manual is subject to change without notice.

 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

December 22, 1997 iii

M/D TOTCO
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv December 22, 1997

M/D TOTCO
 Table of Contents

Table of Contents
1. Introduction ...................................................................................................................... 1
2. Description........................................................................................................................ 2
3. Principle of Operation...................................................................................................... 2
4. Installation ........................................................................................................................ 3
4-1 General............................................................................................................................... 3
4-2 Selecting the Correct Power Supply................................................................................... 3
4-3 Installation Procedure......................................................................................................... 4
4-4 Installation in Hazardous Locations.................................................................................... 5
5. Periodic Inspection .......................................................................................................... 5
5-1 General............................................................................................................................... 5
5-2 Periodic Inspection Procedure ........................................................................................... 6
6. Field Maintenance ............................................................................................................ 6
6-1 General............................................................................................................................... 6
6-2 Deflecting Block Removal and Replacement Procedure.................................................... 6
6-3 Clamping Mechanism Removal and Replacement Procedure ........................................... 7
7. Calibration......................................................................................................................... 8
7-1 Physical Calibration Procedure .......................................................................................... 8
7-2 Application Notes ............................................................................................................... 8
7-3 Routine Calibration ............................................................................................................. 9
8. Shop Maintenance............................................................................................................ 9
9. Parts List of Recommended Spares............................................................................... 9
10. Illustrated Parts Breakdown.......................................................................................... 10
10-1 Part Number and Description Reference ......................................................................... 11
A-1 International Installation...............................................................................................A-1
A-2 List Of Drawings............................................................................................................A-1
A-3 Declaration of Conformity ............................................................................................A-1
B-1 North American Installation .........................................................................................B-1
B-2 List Of Drawings............................................................................................................B-1

December 22, 1997 Table of Contents - 1

M/D TOTCO
Table of Contents TCE-100K
Manual 20-22

Table of Contents - 2 December 22, 1997

M/D TOTCO
 TCE-100K LINE-TENSION TRANSDUCER
Installation, Operation, and Maintenance

1. Introduction
This manual contains installation and operation instructions relative to the M/D TOTCO
TCE-100K Line-Tension Transducer (Figure 1). Read the appropriate section of this
manual before installing or operating this equipment. Make sure that personnel operating
the wire rope system and TCE-100K are familiar with the procedures in this manual.

Crank
Yoke
Wire
Rope

Top

Wire Deflection
Yoke Crank
Rope Block

Signal Output
Connector

Figure 1. TCE-100K Line-Tension Transducer, Top and Side Views

December 22, 1997 Page 1

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

2. Description
The TCE-100K Line-Tension Transducer provides a 4-20 mA loop powered electrical
signal output proportional to a wire rope’s single-line load up to 100,000 lbs. (45360 kg),
maximum. The system consists of:
• An aluminum block with internally sealed strain gages and electronic signal-
conditioning circuitry
• Deflection plates
• A center clamping mechanism

Features of the TCE-100K are:

• Accepts wire-rope diameters from 7/8 to 2 inches (22.2 to 50.8 mm) without
requiring modification.
• Light weight: 17 pounds (7.7 kg)
• Low maintenance
• High accuracy with better than .2% repeatability
• Certified intrinsically safe EEx ia IIB T6 to EN50 020
(ISSeP certificate number 94.101.199X)
• Certification pending, intrinsically safe for use in Class I, Division 1,
Groups C & D hazardous locations, temperature code T4 (UL file E139543)
• “CE” marked for compliance with European Union EMC Directive
(see declaration of conformaity in Appendix A)

3. Principle of Operation
When the TCE-100K is installed, the transducer is clamped to the anchored wire rope
(deadline). Because of the transducer’s geometry, the wire line is bent or deflected by
1/4 inch (6.35 mm) at the center of the transducer body when properly installed.
When additional load is applied to the wire rope, the wire rope tends to straighten at the
deflection point; it therefore exerts an outward force on the yoke. This force is transmitted
through the clamping mechanism, with reaction forces at the deflection blocks to the
transducer body.
These combined forces create a strain on the transducer body, which the strain gages
detect. The strain-gage bridge and the signal conditioner combine to produce a 4-20 mA
output signal proportional to the tension in the wire rope.

Page 2 December 22, 1997

M/D TOTCO
TCE-100K
Manual 20-22 Installation, Operation, and Maintenance

4. Installation
4-1 General

This section contains procedures for installing the TCE-100K system. The system
is factory calibrated to output 4 to 20 mA, representing 0 to 100,000 lbs (0 to
45360 kg) line tension when loop powered by 13 to 28 Volts DC.
No special tools or electric power are required for installation. The only special
part necessary for installation is the mating signal cable of suitable length for the
particular application.
Each TCE-100K Line Tension Transducer is delivered fully operational for the
wire line load range of 0 to 100,000 lbs (0 to 45360 kg).

CAUTION
The TCE-100K directly measures single-line load only. Be sure the
equipment displaying the load value accommodates the correct
number of lines strung.

CAUTION
The TCE-100K is often installed where high vibration is present.
While vibration does not damage the TCE-100K, be sure to route the
signal wire so vibration does not cut or damage the wire.

4-2 Selecting the Correct Power Supply

Inside the transducer body are load-sensing strain gages and an electronic signal
conditioner that provide a 4-20 mA, loop-powered signal output representing 0 to
100,000 lb of line pull. The signal conditioner within the TCE transducer requires
a minimum 13 Volt drop to operate (and a maximum of 28 Volts). Make sure the
power supply is capable of supplying adequate voltage to the signal conditioner
(min 13 VDC) and all other devices in the loop.
To select the correct Power Supply, insure both below formulas are met.
Loop Power Supply > 13V + (.02 X Total Loop Resistance)

Loop Power Supply < 28V - (.004 X Total Loop Resistance)

NOTE
M/D TOTCO recommends a 24VDC Power Supply be used with the
TCE transducer.

December 22, 1997 Page 3

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

4-3 Installation Procedure

Install the TCE-100K Line Tension Transducer as follows:

1. Find an acceptable site to install the TCE-100K, keeping in mind the
following:
a. The best place to install the device is close to the anchor; this reduces cable
sway and vibration.The shortest distance from the anchor to the TCE-100K
is 3 feet (0.914 m).
b. Reduce cable-routing effort by considering the location of the data-acquisi-
tion unit to which the TCE-100K is attached.
c. Because it is not a hydraulic device, the elevation of the TCE-100K relative
to other devices is not important.

NOTE
To simplify installation, perform these steps when the wire line is not
under load.

2. Make sure that the crank retaining screw (Figure 2) is in place and
tight.
3. Loosen the yoke (Figure 2) by rotating the crank counterclockwise.
Rotate the crank until there is enough gap to allow installation.
4. Open the clamp by lowering the clamping mechanism and rotating it
180 degrees.
This allows the installation of the wire rope.
5. Close the clamp by rotating 180 degrees.
Make sure that the holes in the clamping block line up with the guide posts.
6. Tighten the clamp by rotating the crank clockwise one full turn after the
wire rope contacts the transducer body.
7. When installing signal cable, PIN A is (-) signal and PIN C is (+)
source. Secure the cable near the sensor, providing strain relief and pre-
venting accelerated cable wear.
8. Attach RF ground lead (minimum 1 inch ground braid) to one of the
four socket head cap screws next to the signal connector.

NOTE
The ground wire must be attached to the steel structure and as short
as possible- 25 feet maximum.

Page 4 December 22, 1997

M/D TOTCO
TCE-100K
Manual 20-22 Installation, Operation, and Maintenance

4.56

Crank

Retaining Wire
Screw Rope Yoke

Clamping
Shoe

Signal Output End

Connector Deflector

3.20

Body

RF Ground
Attachment
Point

4.00

Figure 2. TCE-100K System Assembly

4-4 Installation in Hazardous Locations

When the TCE-100K, Line Tension Transducer, is installed in a hazardous area,

the transducer must be connected with an intrinsic safety barrier. Appendix A
details International installations and Appendix B North American installations.

5. Periodic Inspection
5-1 General

This section contains procedures for periodic inspection and field maintenance.
Periodic inspection includes preventative maintenance and service for equipment
safety, security, and cleanliness.

December 22, 1997 Page 5

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

5-2 Periodic Inspection Procedure

Perform the following steps every two weeks:

1. Wipe off and inspect equipment for excessive wear, gouging, and cable
fraying.
2. Replace defective parts or assemblies to reduce downtime.
3. Return defective item to the nearest M/D TOTCO facility for shop
maintenance or repair.

6. Field Maintenance
6-1 General

Field maintenance is limited to removal and replacement of system components or

the assembly itself. Detailed shop maintenance includes component disassembly,
cleaning, inspection, and reassembly.
Field-repairable components include:
• Deflecting blocks
• Clamping mechanism assembly
6-2 Deflecting Block Removal and Replacement Procedure

If deflecting blocks become worn, output from the device will decrease. If signal
output loss can be attributed to deflecting block wear, replacement is necessary.
Remove and replace deflecting blocks as follows:
1. Perform the installation procedure in Section 4-3 in reverse order.
When a step instructs to tighten by rotating clockwise, perform the opposite to
loosen (rotate counterclockwise), etc.
2. Using a 5/32-inch hex wrench, remove the two screws holding the
deflecting block in place (Figure 2).
3. Apply Loctite thread-locking adhesive to each of the screws removed
in Step 2 above.
4. Install new deflecting block using the Loctite-treated screws.
5. Perform the installation procedure in Section 4-3.

Page 6 December 22, 1997

M/D TOTCO
TCE-100K
Manual 20-22 Installation, Operation, and Maintenance

6-3 Clamping Mechanism Removal and Replacement Procedure

If the clamping shoe of the clamping mechanism becomes worn, output from the
transducer will decrease. If signal output loss can be attributed to clamping shoe
wear, replacement is necessary.
Remove and replace the clamping shoe as follows:
1. Perform the installation procedure in Section 4-3 in reverse order.
When a step instructs to tighten by rotating clockwise, perform the opposite to
loosen (rotate counterclockwise), etc.
2. Remove the retaining screw and lock washer from the clamping shoe.
(Figure 2).
3. Rotate the clamping shoe 90 degrees and slide the shoe off.
4. Install a new clamping shoe and lock by installing the retaining screw
and washer removed in Step 2 above.
5. Perform the installation procedure in Section 4-3.

December 22, 1997 Page 7

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

7. Calibration
Physical calibration is the most desirable technique because it takes into account all
possible parts of an installation by directly loading the sensor. The physical calibration
procedure assumes the sensor reacts in a linear fashion to increasing load. This means that
the calibration techniques are all of a 2-point variety, with the two points defining the lin-
ear response of the sensor.
As with any 2-point calibration, the farther apart the data points are, the more accurate the
calibration. As a general rule, try to take one data point from somewhere less than 25% of
total capacity, and a data point from somewhere above 75% capacity.
Calibration is done by applying an accurately known load to the system, and adjusting the
display to match the known load value. It is recommended that every installation get a
physical calibration at least once, preferably at commissioning.
7-1 Physical Calibration Procedure

1. Remove all load from the system so that the system is in a condition
where the measured value on the display should read zero. Although
the low cal point doesn’t need to be zero, zero is often the easiest data
point to obtain.
2. Adjust the display to read zero.(Refer to your display user’s manual)
3. Apply a known physical load.
4. Adjust the display to read the actual value of the known load. (Refer to
your display user’s manual)
5. Remove the load and verify that the display reads zero again.
6. Activate each calibration circuit in the system (shuntcal, voltage substi-
tution, bridge substitution) and record the values of each for future ref-
erence.
7-2 Application Notes

When a system is defined, the decision of what kind of electrical calibration to use
should be settled during system definition prior to sale. As a rule of thumb:
• If the load can be removed routinely, such as a simple crane
application, then choose shunt calibration.

• If the load cannot be removed easily, then choose voltage sub-

stitution.

At this time, one should also start planning for a physical calibration at the com-
missioning of the system. This physical calibration must be performed at least
once so that accurate cal constants can be acquired. These values become the cali-
bration constants for future maintenance and routine calibrations.

Page 8 December 22, 1997

M/D TOTCO
TCE-100K
Manual 20-22 Installation, Operation, and Maintenance

7-3 Routine Calibration

Provided you have calibration constants from a good physical calibration, frequent
checks of system calibration can be accomplished by closing a switch and making
sure the displayed value matches the recorded value.
This means that in most applications, daily calibration checks can be performed by
the operator. Maintenance personnel are not needed except to resolve situations
where the displayed value does NOT match the recorded value.

8. Shop Maintenance
Detailed shop maintenance of the sensor assembly includes:
• Disassembly
• Cleaning
• Inspection
• Reassembly
Do not separate permanently bonded parts such as the expansion plug; instead, replace the
next higher assembly. Lubricate crank screw threads.
If the sensor does not operate or does not hold calibration, return the transducer body to a
M/D TOTCO designated repair facility.

9. Parts List of Recommended Spares

Units Per
Part Number Description Assy

TCE-100K-01 LINE TENSION TRANSDUCER, 100K 1

TCL-100K-102 SHOE 1

TCL-100K-103 END DEFLECTOR 2

TCL-100K-104 POST 2

TCL-100K-107 YOKE, LINE TENSION XDCER 1

221700-001 GASKET, CONNECTOR, EMI 1

J811-14XS SCREW, 1/4-20 X 1.75, CSK, SKT 4

261028 CRANK, SHOE 1

221691 CONNECTOR, 3 PIN, BOX M 1

December 22, 1997 Page 9

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

10. Illustrated Parts Breakdown

Figure 3. TCE-100K Parts Diagram

Page 10 December 22, 1997

M/D TOTCO
TCE-100K
Manual 20-22 Installation, Operation, and Maintenance

10-1 Part Number and Description Reference

Units
Figure &
Part Number Description per
Index No.
Assy

Fig 3 TCE-100K-01 Line Tension Transducer Assembly 1

1 221663 Body 1

2 TCL-100K-103 Deflection Block 1

3 TCL-100K-107 Yoke 1
4 999449-670 Screw, 10-32 X .50 1

5 221691 Connector, MS Box, 3-Pin 1

6 999449-528 Pan Head, X-Rec, .312 4

7 999291-005 Washer, Flat 4

8 221700-001 Gasket 1

9 J811-14XS Screw, 1/4-20 X 1.75 4

10 261028 Crank Shoe 1

11 999268-009 Washer, Lock, Hel, .190 1

12 991702-007 Lubricant 1

13 991201-012 Loctite #242 1

14 TCL-100K-102 Shoe 1

15 TCL-100K-104 Post 2

December 22, 1997 Page 11

M/D TOTCO
 TCE-100K
Installation, Operation, and Maintenance Manual 20-22

Page 12 December 22, 1997

M/D TOTCO
 APPENDIX A
INTERNATIONAL INSTALLATION DOCUMENTATION

A-1 International Installation

This appendix contains two drawings which detail information applicable to International
installations. You must reference these drawings while completing many of the procedures pro-
vided in this manual.

A-2 List Of Drawings

The following TCE-100K drawings are located in this appendix:

Table A-1. Drawings List

Drawing # Description # of Pages

221594 Intrinsically Safe, EMC, Loop Powered

2
Transducer

A-3 Declaration of Conformity

Included within this Appendix is a copy of the Declaration of Conformity for the TCE-100K. Please
refer to this document as required.

December 22, 1997 Page A-1

M/D TOTCO
Appendix A TCE-100K
INTERNATIONAL INSTALLATION DOCUMENTATION Manual 20-22

Page A-2 December 22, 1997

M/D TOTCO
 APPENDIX B
N AMERICAN INSTALLATION DOCUMENTATION

B-1 North American Installation

This appendix contains two drawings which detail information applicable to North American
installations. You must reference these drawings while completing many of the procedures pro-
vided in this manual.

B-2 List Of Drawings

The following TCE-100K drawings are located in this appendix:

Table B-1. Drawings List

Drawing # Description # of Pages

221635 Intrinsically Safe, EMC, Loop Powered

2
Transducer, UL

December 22, 1997 Page B-1

M/D TOTCO
Appendix B TCE-100K
INTERNATIONAL INSTALLATION DOCUMENTATION Manual 20-22

Page B-2 December 22, 1997

M/D TOTCO