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Torquetrak Tpm2: Torque and Power Monitoring System

The document provides instructions for installing and operating a TorqueTrak TPM2 system for monitoring torque and power on a rotating shaft. It describes the system components, including the rotating collar assembly, stationary interface and strain gage sensor. It provides details on installing the rotating collar, stationary ring and interface. It also describes the operation and LED statuses of the stationary interface.

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0% found this document useful (0 votes)
37 views52 pages

Torquetrak Tpm2: Torque and Power Monitoring System

The document provides instructions for installing and operating a TorqueTrak TPM2 system for monitoring torque and power on a rotating shaft. It describes the system components, including the rotating collar assembly, stationary interface and strain gage sensor. It provides details on installing the rotating collar, stationary ring and interface. It also describes the operation and LED statuses of the stationary interface.

Uploaded by

anson.zhou1992
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 52

TorqueTrak TPM2

Torque and Power Monitoring System

User’s Guide
866600-9_E
Contents
1 System Overview....................................................3
1.1 System Components .......................................4
1.1.1 Rotating Collar Assembly ......................................... 4
1.1.2 Stationary Interface .................................................. 5
2 Installation ..............................................................5
2.1 Rotating Collar Installation...............................7
2.2 Stationary Ring and Stationary Interface
Installation.................................................................9
2.2.1 Stationary Interface Connections.............................10
2.2.2 Stationary Ring Installation......................................12
3 System Operation and LED Descriptions .............13
3.1 Stationary Interface .......................................13
3.1.1 Startup Operation....................................................13
3.1.2 Normal Operation....................................................14
3.1.3 Stator LED ..............................................................14
3.1.4 Rotor LED ...............................................................15
3.1.5 Torque LED ............................................................16
3.1.6 Speed LED .............................................................16
3.2 Transmitter LED Operation............................16
4 Communications Protocol .....................................17
4.1 Data Byte Format ..........................................17
5 TPM2 Stationary Interface Transmitted Data .......17
5.1 Message Format ...........................................17
5.1.1 Strain Gage Value...................................................18
5.1.2 Shaft Speed Value ..................................................19
5.1.3 Status Information ...................................................19
5.1.4 Checksum...............................................................23
6 TPM2 Stationary Interface Commands (Received
Data)...........................................................................23
6.1 Command Format .........................................23
6.1.1 Command bytes......................................................24
6.1.2 Checksum...............................................................24
Appendix A: TPM2 Specifications .............................29
Appendix B: Troubleshooting ....................................34
Appendix C: Strain Gage Installation .........................36
Appendix D: Dimensions ...........................................41
Appendix E: Maximum Shaft Speeds ........................50
This document is subject to change without prior notification.
Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.1
Warranty and Service Information.............................. 51

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.2
1 System Overview

The TorqueTrak Torque and Power Monitoring System Generation


2 (TPM2) is a rugged precision instrument designed for
applications where ongoing measurement of torque and/or power
on a rotating shaft is required.
System Features include:
➢ Digital design inherently immune to electrical noise.
➢ Non-contact inductive power and data transfer eliminates
wear surfaces for long life without signal degradation.
➢ Installation does not require shaft modification or machine
disassembly.
➢ Built-in shunt system calibration.

New features:
➢ Single turn transmitter and stationary ring with a minimum
number of connections and high reliability.
➢ Fully encapsulated electronics for high reliability.
➢ Eight user selectable input ranges from 0.25 to 32 mV/V
(125 to 16000 microstrain with gage factor of 2.0).
➢ RS-422 serial communications from stationary interface
for long distance error free data transmission to system
monitoring and display equipment.
➢ 15 bit signed strain value, 16 bit signed speed value, and
24 bits of status information contained in every data
sample.
➢ Four dual color LEDs on stationary interface for system
status and error indication in addition to status information
contained in the RS-422 serial communications data.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.3
1.1 System Components
Mounting Flange
Stationary Ring
Sends power to the Rotating
Collar and receives data
signal from the Rotating
Collar.

Strain Gage Sensor


(Glued to shaft; not
included but ordered as
an accessory)
Converts mechanical
torque to electrical Shaft
signal which is
transmitted from the
Rotating Collar to the
Stationary Ring.

Rotating Collar
& Transmitter Module
Clamps to shaft with bolts Lead wires to
provided. Houses transmitter
Transmitter Module which
converts strain gage
signal to digital code. Stationary
Interface

Mounting Flange

Communications
Power Connector
Connector

Fuse (2A)

Figure 1 - System Components

Refer to TPM2 Specifications in Appendix A: TPM2 Specifications

1.1.1 Rotating Collar Assembly

The transmitter is part of the rotating collar assembly mounted on


the shaft near the strain gage. The transmitter supplies power to
the gage, measures and digitizes the gage signals, and transmits
the digitized signals to the stationary interface. The transmitter is
powered inductively from the stationary ring.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.4
1.1.2 Stationary Interface

The stationary interface generates power for, and receives data


from the transmitter. The stationary interface then communicates
the data to a connected host device through a dedicated bi-
directional RS-422 interface.

2 Installation

WARNING!

PERSONAL INJURY
DO NOT USE this product as a safety or
emergency stop device or in any
application where failure of the product
could result in personal injury.
Failure to comply with these
instructions could result in
death or serious injury.
*
The end user is responsible for the proper installation and
operation of this device. Improper installation or operation could
result in damage, injury or death.
Certain environments could cause damage or degradation to the
components of the system resulting in mechanical failure.
The TPM2 system must be sealed by the installer for operation in
wet/harsh environments.
Mechanical failure could cause parts to detach from the shaft and
fly off at high speeds. These flying parts could cause equipment
damage, bodily injury and possibly death. Keep equipment and
personnel away from areas where parts flung from the shaft could
enter.
A shield or guard is recommended in applications where
something or someone could come in contact with the rotating
parts of the system.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.5
All metal should be kept clear
of the ring and collar, with the
exception of the TPM2, shaft,
and mounting bracket(s).
(Distances shown below.)

Mounting
Bracket

1.20
(30)
1.00
(25)

Figure 2 - Metal Interference Area

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.6
Make sure there is proper rotor-stator spacing before rotating the
shaft.
Make sure the TPM2 is properly installed and clear of all
obstructions before rotating the shaft.
Keep clear of the machinery while the shaft is rotating.
Each TPM2 is custom made to fit a certain shaft size range.
Therefore the shaft diameter must be specified at time of order.
Do not try to adapt the TPM2 to a shaft size outside its intended
range of operation.

2.1 Rotating Collar Installation

If there is any damage to the rotating collar (gouges, chips, cuts,


cracks, etc.) IMMEDIATELY DISCONTINUE USE, remove from
the shaft and contact BEI for a replacement.
The Rotating Collar must be installed on a smooth, clean area of
the shaft.
DO NOT operate the rotating collar at rotational speeds exceeding
specifications listed in Appendix “F”.
DO NOT mount the rotating collar directly over the strain gage.
DO NOT substitute mounting hardware. Use only the supplied
mounting hardware for installation. Contact BEI for replacement
mounting hardware.
DO NOT remove the Counter-Weight/Magnet or loosen its screws.
Use the supplied thread lubricant as indicated.
Use Threadlocker (Loctite 242) supplied as indicated.
Should removal of the transmitter be necessary, reinstall with #242
Loctite applied to the threads of M-6 screws.
Install the rotating collar assembly with the ring surface on which
the transmitter is mounted, nearest to the stationary ring.
Apply anti-seize compound to the threads of all M-10 collar bolts
prior to assembly.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.7
Collar bolt

Counter-
weight /
magnet

Transmitter

Transmitter
mounted ring

Figure 3 - Rotating Collar Installation

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.8
Alternately tighten the collar bolts, keeping the gaps between the
rotating collar sections equal, until specified bolt torque is reached.
Table 1: Torque Specifications
Description Type N-m ft- in-
lbs lbs
Collar bolts M10 -1.5 class 10.9 20 15 180
Transmitter M5-0.8 class 10.9 6.2 4.6 55
screws
Stator Coil PCB M6 3.6 2.7 32
Make sure the rotating collar is mounted squarely on the shaft and
does not wobble.
The rotating collar bolts and transmitter mounting screws must be
tightened for proper system operation since power for the
Transmitter is conducted through these fasteners.
Make sure there is proper rotor-stator spacing before rotating the
shaft.

2.2 Stationary Ring and Stationary Interface Installation

The TPM2 enclosure is only sealed when the mating


connectors/cables are attached.
In other words: Do not expose to adverse conditions (liquids)
if connectors/cables are disconnected.
The TPM2 stationary interface requires a custom fabricated mount
to hold it securely in place. Refer to Appendix D: Dimensions, for
mounting flange dimensions necessary to create a custom
mounting bracket. Figure 2 provides information about rotor-to-
stator spacing guidelines and a metal interference area that should
be kept clear of all other metal.
Generally it is a good idea to mount the stationary interface with
the cable connections pointing down to minimize the exposure of
the connectors to contaminants, but axially rotated orientations are
acceptable as dictated by available space and other application
specific considerations. The mounting should secure the
stationary interface and power ring as rigidly as possible.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.9
2.2.1 Stationary Interface Connections

2.2.1.1 Power Connection

The TPM2 comes with a standard 10ft (3m)1 power cable


terminated at one end with a rugged metal sealed circular 3 pin
connector. The other end is un-terminated and must be
connected by the end user to a 24VDC regulated power supply (a
range from 10 to 30VDC is acceptable) with a maximum current of
2 amps and typical operating current of 0.5 amps. Actual
operating current depends on the power supply voltage (lower
voltages require more current), and the efficiency of the inductive
power transfer to the rotating collar.
The power is fused at the TPM2 Stationary interface with a
5_x_20mm 2 amp fast blow fuse. The standard supplied power
cable is 16awg shielded twisted pair with a resistance of 4.2mΩ/ft.
Be sure to take into account the resistance and added voltage
drop of any additional wire connected between the power supply
and the TPM2 (for instance between an intermediate junction box
and a control cabinet).
The three pin TPM2 power connector has the following pinout and
color code:
Table 2: Stationary Interface Power Cable
Pin# Wire Signal Description
Color
1 RED +24VDC (10 to 30VDC is acceptable),
15 watt max, 10 watt typical
2 BLK Power Supply common
3 CLR TPM2 chassis (connected to aluminum
enclosure)

The internal power supply of the TPM2 is isolated from its


aluminum enclosure so for safety and to reduce electrical noise,
the CLR conductor in the power cable should be terminated to
chassis ground (cabinet, frame or earth ground) at the user
terminated end.

1
Contact Binsfeld Engineering for other cable lengths.
This document is subject to change without prior notification.
Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.10
2.2.1.2 Communications Connection

The TPM2 comes with a standard 10ft (3m) communications cable


terminated at one end with a rugged metal sealed circular 7 pin
connector. The other end must be field terminated by the end
user.
Communication distances of over 1000ft (300m) are possible with
proper cabling and installation. Slower baud rates generally allow
for the longest possible cable lengths. When long cable lengths
are required, use the lowest baud rate possible for the desired
sampling rate.
The recommended RS-422 interface for connecting a PC USB
port to the TPM2 communications connector is the model
USOPTL4-LS isolated, locked S/N converter from B&B
Electronics; http://www.bb-elec.com.
Any RS-422 interface should work but may not work with the
standard BEI TPM2 Configuration and Monitoring software. Be
aware that the baud rate must be set high enough to support the
desired output sample rate. Please see the TPM2
Communications Specification document for detailed information.
DIP switch settings for the USOPTL4-LS (back side):
1 - RS-422
2 - Echo ON or OFF, does not matter
3 - 4 Wire
4 - 4 Wire

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.11
The 7 pin TPM2 communications connector has the following
pinout and color code:
Table 3: Stationary Interface Communications Cable
Pin# Wire Color Signal Description
1 BLU/WHT RX+, connect to USOPTL4-LS TDB+
2 WHT/BLU RX-, connect to USOPTL4-LS TDA-
3 common
4 CLR common, connect to USOPTL4-LS
GND
5 common
6 WHT/ORN TX-, connect to USOPTL4-LS RDA-
7 ORN/WHT TX+, connect to USOPTL4-LS RDB+
NOTE: Wire colors specified in the format XXX/ZZZ have a
primary color of XXX and a stripe color of ZZZ.

2.2.2 Stationary Ring Installation

After securely mounting the stationary interface to its bracket,


assemble and mount the stationary ring around the shaft. Mount
the ring on top of the surface of the stationary interface mounting
flange labeled “FRONT” with the surface of the ring that is labeled
“FRONT” also facing to the front. Mount the ring splice tabs in the
same plane as the mounting flange (on the back side of the ring).
When the “FRONT” label on the mounting flange and the “FRONT”
label on all the ring pieces and splice tabs can be read from the
same side, it is mounted correctly. Tighten all ring assembly
screws as specified in Table 1.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.12
3 System Operation and LED Descriptions

3.1 Stationary Interface

Figure 4 - Stationary Interface Faceplate

3.1.1 Startup Operation

Immediately after power-up, internal operation is tested. If the test


fails, only the red Torque LED is turned ON solid and remains so
until power is removed.
If the test passes, the red Torque LED flashes at a rate of 5Hz for
1/2 second. The green Rotor LED flashes opposite the red
Torque LED. The internal firmware of the Stationary Interface can
be updated if special programming messages are received during
this time period.
If no programming messages are detected, normal operation
continues starting with a test of the indicator LEDs. First, all red
LEDs are turned ON for 1 second then turned OFF. Next, all
green LEDs are turned ON for 1 second and then turned OFF.
After the LED test, normal LED operation commences.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.13
3.1.2 Normal Operation

Following Startup, the Inductive Interface varies inductive power


from high to low seeking to establish communications with the
rotor. The green Stator LED flashes with a frequency of 2.34Hz
and a duty cycle (ON time relative to OFF time) that is proportional
to the power level. The greater the ratio of the ON to OFF
duration of the green Stator LED, the higher the inductive power.
The Rotor LED becomes solid green to indicate that the rotor
power supply voltage is within its target range. At that point the
Stator LED stops indicating the inductive power level and begins
indicating stator power and connected device communications
status.

3.1.3 Stator LED

The Stator LED has two modes during normal operation. Typically
it operates as an indicator for the status of Stator main regulated
voltage, main regulator over current, power amplifier over
temperature, and connected device communications. It also
indicates the output power level while it varies to produce the
required transmitter voltage level. When the Rotor LED is
flashing, the stator is adjusting and indicating the output power
level.
The Stator LED is solid green when stator power supply voltage is
in range, the power supply current is under the over current
threshold, the power amplifier is below the over temperature
threshold, and no communications errors exist with the connected
device. The acceptable stator power supply range is 10 to 30
volts DC.
Auto baud rate detection of the RS-422 connection is a feature of
the TPM2. Requirements are defined in the TPM2
Communications Specification that allow the TPM2 to properly and
accurately determine the baud rate being used. While operating in
Auto Baud Rate Detection mode, the Stator LED flashes green
with a 50% duty cycle at 5Hz.
The Stator LED will change to red while power supply voltage,
power supply over current, power amplifier over temperature, or
communications errors exist. Communications errors are UART
errors like framing, parity, checksum, and buffer overrun. As soon
as the error condition clears, the LED returns to solid green.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.14
Power supply over current errors begin to appear when an over
current condition is sensed for more than 2 seconds. When over
current errors are detected the Stator LED is red. If the error
condition lasts for more than 3 seconds, an over current fault is
triggered and inductive power for the transmitter is shut OFF for 7
seconds, during which the Stator LED remains red. After the 7
second OFF period expires, inductive power is re-enabled and
adjusted. If over current is detected again, the cycle repeats.
Power amplifier over temperature errors begin to appear whenever
the sensed amplifier section temperature exceeds the over
temperature threshold. While over temperature errors exist, the
Stator LED is red. If the condition remains for more than 1
second, an over temperature fault is triggered and the inductive
power is shut OFF. The inductive power is held OFF and the
Stator LED remains red until the temperature is sensed to cool
below a lower threshold temperature. Cooling could take several
seconds or minutes depending on the ambient temperature
around the instrument. When the power amplifier section has
cooled, it is re-enabled.

3.1.4 Rotor LED

The function of the Rotor LED is to indicate the health of the


inductive link between the rotor and the stator regarding power
transfer and communications. It does not indicate the status of
rotor measurement problems. Rotor measurement problems like
signal over range are indicated in the status bits of the RS-422
data from the stator to a connected device or host.
The Rotor LED is solid green when rotor power supply voltage and
communications are OK.
The Rotor LED flashes (red or green) when rotor power supply
voltage is not within the normal operating window.
The Rotor LED is red when rotor communication errors are
detected.
The Rotor LED is off when rotor communications are lost for 16
consecutive 4800Hz sample times.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.15
3.1.5 Torque LED

The Torque LED is solid green when the rotor is communicating


and the differential and common mode inputs are within range.
The Torque LED is red when the differential or common mode
inputs are not within range.
The Torque LED is off when rotor communications are lost.

3.1.6 Speed LED

The Speed LED flashes green for 200msec for every magnet
pulse detected when the pulse frequency is low. The Speed LED
flashes green for 20msec for every magnet pulse detected when
the pulse frequency is high. The low pulse frequency threshold is
approximately 1.75Hz when frequency is increasing from below
0.88Hz. The low frequency threshold is approximately 0.88Hz
when frequency is decreasing from above 1.75Hz.
If the duration of speed pulses becomes too short or pulse
frequency is erratic, the Speed LED flashes red (not green).

3.2 Transmitter LED Operation

When the single green Transmitter LED is ON solid, all is OK with


the transmitter.
One quick Transmitter LED pulse (about 0.1 second every 1.7
seconds) indicates transmitter voltage is detected to be outside of
the normal operating range.
Two quick Transmitter LED pulses (each pulse 0.1 second
duration, separated by 0.3 seconds of OFF time, repeated every
1.7 seconds) indicates the transmitter is having problems saving
configuration values in memory.
A 50% duty cycle 1.2Hz flashing rate indicates that the transmitter
input signal is out of range, either common mode or differential
mode.
A 50% duty cycle 4.7Hz flashing rate indicates that the transmitter
input reference signal is out of range.
If the Transmitter LED is OFF, the transmitter voltage is very low.

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.16
4 Communications Protocol

Bi-directional RS-422 communications are supported with the


connected device but are not required. The TPM2 does not
expect any data to be received from the connected device so no
communications errors are declared if there is nothing connected
to the RS-422 connector. In simple systems the connected device
could just monitor the data sent from the TPM2 but bi-directional
communications are required to configure parameters such as
gain, baud rate and sample rate.

4.1 Data Byte Format

Each transmitted or received byte consists of: 1 start bit, 8 data


bits, 1 parity bit (optional), 1 stop bit (minimum). The 8 data bits
are transmitted least significant bit first.

5 TPM2 Stationary Interface Transmitted Data

5.1 Message Format

The TPM2 streams out samples at the selected sample rate.


Each sample consists of 8 bytes as follows:

Table 4: TPM2 Stationary Interface sample transmit data


Byte Description
0 Strain Gage Value (low byte)
1 Strain Gage Value (high byte)
2 Shaft Speed Value (low byte)
3 Shaft Speed Value (high byte)
4 Status Info (byte 0)
5 Status Info (byte 1)
6 Status Info (byte 2)
7 Checksum byte

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.17
5.1.1 Strain Gage Value

The combined low byte and high byte of the Strain Gage Value
form a 16 bit signed integer that is used to calculate the torque
strain using the equation:
є = (Valout * 15729) / (Gxmtr * GF * 7864.32)
є = strain (in units of µstrain)
Valout = TPM2 output Strain Gage Value
Gxmtr = user selectable transmitter gain (see Table 3)
GF = gauge factor
(15729 / 7864.32) is a system derived constant
The Torque Strain value, along with the shaft parameters, allow
the monitoring device to calculate the actual shaft torque in force
times distance units (Newton-meters, ft-lbs, etc.) using the
equation:
T = (є * π * E * (OD4 - ID4)) / (KT * OD * (1 + v))
T = torque (N-m or ft-lbs)
є = strain, (in units of µstrain)
E = modulus of elasticity of the shaft material (N/mm2 or Mpsi)
OD = outside diameter (mm or inches)
ID = inside diameter (mm or inches)
v = Poisson’s ratio of the shaft material
KT = torque units dependent constant (for N-m, KT = 1.6 x 1010:
for ft-lbs, KT = 192)
The sign of the Strain Gage Value indicates the relative torque
force direction.
From the torque, the power can be calculated using the equation:
P = (T * 2π * ω) / Kp
P = power
T= torque
2π is radians/revolution
ω = rotational speed (RPM)
Kp = torque units dependent power constant

Table 5: Power Constant values (Kp)


Power units Torque units Kp
watts N-M 60

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.18
hp ft-lbs 33000
hp in-lbs 2750

5.1.2 Shaft Speed Value

The combined low byte and high byte of the Shaft Speed Value
forms a 16 bit signed integer. This binary integer value is in either
revolutions per minute (RPM) or hundredths of revolutions per
minute (RPM x 100). The resolution of the Shaft Speed Value is
indicated by the RPM_RES bit in status byte 0.
The sign of the Shaft Speed value indicates the relative direction
of rotation. When looking at the front of the TPM2 Stator, a
positive value indicates clockwise rotation and negative indicates
counter-clockwise rotation. A zero Shaft Speed Value indicates
that the shaft is turning slower than the minimum shaft speed
value or has stopped.
The Shaft Speed Value is measured once per shaft revolution.
This new value is transmitted with the next sample and the
RPM_NEW status flag is set to indicate a new shaft speed
measurement. This same value is transmitted on subsequent
samples, until the shaft completes another rotation and a new
speed is measured.

5.1.2.1 Shaft Power Calculation

The actual shaft power can be calculated using the measured


Strain Gage Value, the shaft parameters and the measured Shaft
Speed Value.

5.1.3 Status Information

The status information bytes are grouped bit flags that indicate the
operating status of the TPM2. The flags are active high; bits set to
‘1’ indicate the condition exists and bits cleared to ‘0’ indicate the
condition does not exist. Below is a description of each bit (flag).

This document is subject to change without prior notification.


Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.19
5.1.3.1 Status Info byte 0 (Stator Status and Error flags)

Bit Name/Description
0 RPM_NEW
1 = Shaft Speed value in this sample was just measured
0 = Shaft Speed value in this sample is old, a hold from the last
sample measured
1 RPM_ERR
1 = An error was detected in the RPM measurement. Check
rotor-stator alignment and spacing
0 = No RPM measurement errors detected.
2 RPM_RES
1 = The Shaft Speed value’s resolution is 1/100 RPM, set when
the shaft speed falls below approximately 53 RPM.
0 = The Shaft Speed value’s resolution is 1 RPM, cleared when
the shaft speed rises above approximately 105 RPM.
3 ECOM_ACK
1 = A command has been received OK. This is an
acknowledgment that the TPM2 received one or more
commands since the last sample was sent. It is set in the
sample following reception of the command(s), after which it is
cleared.
0 = No command received since last sample sent.
4 ECOM_ERR
1 = An error was detected in external communication link from
the Connected Device. Possible errors: Transmit buffer overrun,
received data parity error, received data framing error, incorrect
received message checksum detected.
0 = No external communication errors detected
5 STAT_PWR_ERR
1 = The Stator main regulated power supply voltage is too high
or low, or an over current error exists.
0 = No Stator main regulated power supply problems are
detected.
6 II_AMP_TEMP_WRN
This document is subject to change without prior notification.
Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.20
1 = The II power amplifier temperature is at or nearing thermal
shutdown.
0 = The II power amplifier temperature is OK.
7 STAT_TEST_MODE
1 = Stator in test mode.
0 = Stator in normal mode.

5.1.3.2 Status Info byte 1 (Rotor Error Flags)

0 TRQ_HLD_ERR
1 = The Torque value in this sample is a hold from the last good
sample received from the Transmitter
0 = The Torque value is new
1 TRQ_RNG_ERR
1 = The Torque value in this sample is out of range
0 = The Torque value is not out of range
2 GAGE_DIFF_ERR
1 = Gage differential mode input of the transmitter is out of
range. This error will also give a TRQ_RNG_ERR
0 = Gage differential mode input of the transmitter is in range
3 GAGE_COM_ERR
1 = Gage common mode input of the transmitter is out of range.
This error will also give a TRQ_RNG_ERR
0 = Gage common mode input of the transmitter is in range
4 ROT_PWR_LO_ERR
1 = The Rotor power supply voltage is too low.
0 = The Rotor power supply voltage is not low.
5 ROT_DATA_ERR
1 = An error has been detected receiving data from the Rotor
(Transmitter)
0 = Rotor data is being received OK
6 ROT_DATA_GONE
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1 = There is no Rotor (Transmitter) Data being received without
error
0 = Rotor data is being received
7 RFU
Not currently used

5.1.3.3 Status Info byte 2 (Rotor Status)

0 GAIN0
1 GAIN1
2 GAIN2

Table 6: TPM2 Transmitter Gain settings


1
GAIN2 GAIN1 GAIN0 GAIN Strain Input Strain
Factor Range Voltage Gage
Full Range Value
Scale Full Full
(µϵ) Scale Scale
(mV/V)
0 0 0 1 ±16000 ±32.000 ±16000
0 0 1 2 ±8000 ±16.000 ±16000
0 1 0 4 ±4000 ±8.000 ±16000
0 1 1 8 ±2000 ±4.000 ±16000
1 0 0 16 ±1000 ±2.000 ±16000
1 0 1 32 ±500 ±1.000 ±16000
1 1 0 64 ±250 ±0.500 ±16000
1 1 1 128 ±125 ±0.250 ±16000
1
Gage Factor = 2.0

3 Shunt 1 is ON
1 = Shunt 1 (200uV/V) is ON.
0 = Shunt 1 is OFF
4 Shunt 2 is ON
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1 = Shunt 2 (1000uV/V) is ON.
0 = Shunt 2 is OFF
5 RFU
Not currently used
6 RFU
Not currently used
7 RFU
Not currently used

5.1.4 Checksum

The checksum byte is simply the low byte of the sum of the 7 other
bytes in the sample.

6 TPM2 Stationary Interface Commands (Received Data)

Commands are sent to the TPM2 for set up and control of TPM2
operation.

6.1 Command Format

Commands consist of 4 byte blocks.

Table 7: Stationary Interface command message format


Byte Description
0 Command code
1 Command data byte1
2 Command data byte2
3 Checksum byte

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6.1.1 Command bytes

Command code, Command data byte1, Command data byte2


The first byte is the command byte. It is a single byte value The
first three bytes identify the command and command data.

6.1.2 Checksum

The checksum (chksum) byte is simply the low byte of the sum of
the three command bytes.

Table 8: Stationary Interface commands


Command Description byte0 byte1 byte2 byte3
cmd chksum
code
Establish communications 0x55 0x08 0xef chksum
(auto baud detect)
Send the entire message at
the desired baud rate
repeatedly. If possible,
insert a byte of dead time
between messages to allow
the TPM2 to properly frame
the message. If it is not
possible to create this
transmission timing, send
the message repeatedly with
zero or no more than a few
bits of dead time between
messages for a minimum of
10msec (at least two
messages at low baud rates,
whichever is longer). Then
stop transmitting for at least
8 byte times. Keep
repeating the sequence until
an auto baud response data
(55 01 02 03 FE E8 C4 05)
is received back from the
TPM2 indicating success.
Dead time greater than
120msec terminates auto
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Command Description byte0 byte1 byte2 byte3
cmd chksum
code
baud detection whether it is
successful or not. If auto
baud detection is
unsuccessful, the TPM2 will
revert to its last known good
settings. When auto baud
detection is successful, the
TPM2 will continue to
transmit the auto baud
response data once every
90msec until it detects
receive dead time of more
than 120msec. After
detecting sufficient receive
dead time, normal data
transmission is resumed.
Configure communications 0x8a chksum
byte1 bits
b7, b6 – parity
00 = none (default)
01 = even
10 = odd
b5 – stop bits
0 = 1 stop bit
(default)
1 = 2 stop bits
b4 downto b0 - baud
rate code value
0 = 460.8K
1 = 230.4K
2 = 115.2K
(default)
3 = 57.6K
4 = 28.8K
5 = 14.4K
6 = 9600
7 = 4800
8 = 2400
9 = 1200

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Command Description byte0 byte1 byte2 byte3
cmd chksum
code
byte2, TX sample rate value:
0 = 4800 samples/sec
1 = 2400
2 = 1200 (default)
3 = 600
4 = 300
5 = 150
6 = 75
7 = 37.5
8 = 18.75
9 = 9.375

Note: the baud rate code


value in byte1must be <=
the sample rate value in
byte2 because the baud
rate limits the possible
sample rates.

System control: 0x90 0x00 chksum


byte1 - RFU
byte2
1 = Reset TPM2
Transmitter
2 = Reset TPM2
System
0x80 = Disable
Auto Baud
detection.
Auto Baud
detection is active
by default at
power-up or
system reset.

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Command Description byte0 byte1 byte2 byte3
cmd chksum
code
Transmitter control 0xa0 chksum
byte1 bits, shunt control
b7 downto b2,
RFU
b1 – shunt 2, 0 =
OFF, 1 = ON
b0 – shunt 1, 0 =
OFF, 1 = ON
byte2, transmitter gain
value
0 = gain of 1
(default)
1 = gain of 2
2 = gain of 4
3 = gain of 8
4 = gain of 16
5 = gain of 32
6 = gain of 64
7 = gain of 128

Speed input configuration 0x60 chksum


byte1 – zero speed
RPM threshold value (0
to 250).
Value of 0 sets the
threshold to its
minimum which is
approximately =
0.4RPM / PPR.
Default value is
60RPM.
byte2 – pulses per
revolution (PPR) value (1
to 254).
Value of 0 means
speed input not
used.
Default value is 1.

Notes:
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The ECOM_ACK bit in sample data status byte 0 serves as an
acknowledgement to messages sent to the TPM2.
The baud rate, parity, stop bits, sample rate and transmitter gain
parameters are saved in non-volatile memory and retained
through power loss.
The effects of Transmitter Control Commands are delayed due to
internal communications between the Transmitter and the TPM2.
Transmitter control commands that modify either the gain or
shunts require approximately 2.5 seconds to take effect. A
command that modifies both gain and shunts at the same time
requires 4 seconds.

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Appendix A: TPM2 Specifications

Transmitter (mounted inside rotating collar)


Sensor Input: Full Bridge strain gage
(4 active arms, 350Ω standard; up
to 1000 Ω acceptable.)
Bridge Excitation: 3.0 VDC, Regulated
25mA max.
Linearity: 0.05% Full Scale
DC Specifications:
Table 9: Transmitter Input Range Specifications
Nominal 32 16 8 4 2 1 0.5 0.25
Input
Range
(mV/V)
Strain1 16000 8000 4000 2000 1000 500 250 125
max PFS
(µЄ)
Offset 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10
Error
max
(%FS)
Gain 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
Error
max (%)
Offset 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.010
TC max
(%FS/°C)
Gain TC 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.010
max
(%/°C)
FS - Full Scale, PFS – Positive Full Scale,
TC – Temperature Coefficient
1
Strain using gage factor = 2.0

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AC Specifications:
Table 10: Typical Signal Bandwidth and Delay
Sample Rate Bandwidth1 (Hz) Delay2 (ms)
(samples/second)
9.375 3 1700
18.75 6 850
37.5 12 420
75 25 210
150 50 104
300 100 50
600 200 25
1200 380 11
2400 740 4.3
4800 1000 1
1
Bandwidth is the frequency at which the signal is -3dB (70.8%)
relative to the DC (0Hz) level.
2
Signal delay is measured from analog (gage) input of the
transmitter to the end of the sample transmission out of the
communication link.
These values are valid for all input range (gain) settings.

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Table 11: Typical Signal To Noise Ratio (dB)
Input Range
Sampling 1 2 3 4 5 6 7 8
Rate
(SPS)
9.375 >100 >100 >100 >100 >100 94 81 73
18.75 >100 >100 >100 >100 >100 88 79 70
37.5 >100 >100 >100 >100 94 84 76 68
75 >100 >100 >100 >100 88 82 73 66
150 >100 >100 >100 98 85 79 71 64
300 96 96 96 92 82 76 69 62
600 89 89 89 84 79 74 66 60
1200 82 82 81 80 76 71 64 58
2400 76 76 76 76 73 68 62 56
4800 73 73 73 72 70 66 60 54
Signal to Noise Ratio (in dB) is calculated as follows:
S/N = 20 * log10 (Nominal Signal Range / Residual Noise Level)

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Transmitter Connections:
Power Connection: Through Collar mounting bolts and
Transmitter mounting screws
Sensor Input: Full (Wheatstone) bridge (120Ωmin)
Sensor Excitation: 3.0Vdc (25mA max)
Sensor Connection: Solder pads or included cable
+Exc: positive excitation voltage to the sensor (red)
+Sen: positive sense voltage from the sensor (green)
-Sen: negative sense voltage from the sensor (white)
-Exc: negative excitation voltage to the sensor (black)

Table 12: Stationary Interface General Specifications


Input Power 10-30Vdc; 15W max, 10W nom
Communication RS-422 full duplex, point-to-point serial
interface
External Harsh environment sealed circular
Connections connectors with 10ft (3m) cables and
(included) discrete wire termination at the user end
(standard). Contact BEI for other lengths
or custom end terminations.
PC software For device configuration and simple
(included) monitoring of output data. Not intended
to replace data acquisition system.

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Table 13: TPM2 General System Specifications
Torque signal resolution 15 bits, 1 unit in 32,768
Torque signal sampling rate 4800Hz (max)
Shaft speed signal resolution 33.91nsec
Shaft speed signal sampling 1 per revolution
rate
Operating temperature -40° to +70°C, 0 to 90% non-
condensing humidity
Specifications are subject to change without notice.

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Appendix B: Troubleshooting

There are multiple features built into the TPM2 system to aid in
troubleshooting. There are four bi-color status LED’s on the
Stationary Interface. There are also 24 status bits in the serial
data transmitted from the Stationary Interface.
Generally the first step in troubleshooting is to observe (if possible)
all LED's on the Stationary Interface.
There should always be at least one LED ON or flashing in
some way. If all Stationary Interface LED's are OFF, it may not
be receiving power:
1. Check the power source and wiring to the TPM2.
2. Check the TPM2 power fuse (5 x 20mm 2 amp fast blow).

If at least one Stationary Interface LED is ON or flashing,


observe (if possible) the transmitter LED on the rotating collar.
The transmitter LED operation is detailed in paragraph 3.2 of
this document.
If the transmitter LED is always OFF, then the transmitter
power is too low for operation:
3. Check that the stationary ring is mounted correctly with
the proper surface facing the rotating collar as specified in
the installation instructions.
4. Check that the rotating collar is mounted with the proper
surface facing the stationary ring as specified in the
installation instructions.
5. Check that the spacing between the stationary ring and
the rotating collar is as specified in the installation
instructions.
6. Check that all bolts in the rotating collar are tight, including
the bolts that secure the transmitter.
7. Check that all bolts holding the stationary ring together are
tight.

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If the Transmitter and/or Stationary Interface LED's are flashing
in some manner, refer to section 3 of this manual to determine
the operational status.
In addition to the status LED's, the TPM2 RS-422 data contains
status information. Please refer to the TPM2 Communications
Specification document for detailed information.

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Binsfeld Engineering Inc. | 231-334-4383 www.binsfeld.com 866600-9_E Pg.35
Appendix C: Strain Gage Installation

View BEI’s online Strain Gage Installation Training videos at:


Training Videos

(Also refer to instruction bulletin B-127-12 provided with GAK-2-


200 Strain Gage Application Kit from Vishay Measurements
Group, Inc., Raleigh, NC, 919-365-3800,
www.measurementsgroup.com.)

PREPARING THE SURFACE


1. A 3-inch square area will be used for gaging. Scrape off
any paint or other coatings and inspect shaft for oil
residue. If necessary, use a degreasing solution or
isopropyl alcohol to remove.
2. Rough sand the gaging area with 220 grit paper. Finish
the sanding procedure by wetting the gaging area with M-
Prep Conditioner A and the wetted surface with 400 grit
paper provided. Rinse by squirting with M-Prep
Conditioner A. Wipe the area dry with tissue taking care
to wipe in only one direction. Each time you wipe use a
clean area of the tissue to eliminate contamination.
3. Rinse shaft this time by squirting with M-Prep Neutralizer
5A. Wipe the gaging area dry with a clean tissue, wiping in
only one direction and using clean area of tissue with each
wipe. Do not allow any solution to dry on the surface as
this may leave a contaminating film which can reduce
bonding. Surface is now prepared for bonding.

MARKING THE SHAFT FOR GAGE ALIGNMENT


4. The gage needs to be perpendicular to the shaft axis. In
general, this can be accomplished by eye since
misalignment of less than 4 degrees will not generate
significant errors. For higher precision, we recommend
two methods for marking the shaft:
a. Use a machinist square and permanent marker or
scribe for perpendicular and parallel lines; or

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b. Cut a strip of graph paper greater than the
circumference of the shaft. Tape it to the shaft while
lining up the edges. Mark desired gage position with a
scribe or permanent marker.

PREPARING THE GAGE FOR MOUNTING


5. Using tweezers, remove one gage from its package. Using
the plastic gage box as a clean surface, place the gage on
it, bonding side down. Take a 6” piece of PCT-2M Mylar
Tape and place it on the gage and terminal, centered.
Slowly lift the tape at a shallow angle. You should now
have the gage attached to the tape.

POSITIONING THE GAGE


6. Using the small triangles located on the four sides of the
gage, place the taped gage on the shaft, perpendicular
with the shaft axis, aligned with your guide marks. If it
appears to be misaligned, lift one end of tape at a shallow
angle until the assembly is free to realign. Keep one end
of the tape firmly anchored. Repositioning can be done as
the PCT-2M tape will retain its mastic when removed and
therefore not contaminate the gaging area.

Figure 5 - Strain Gage Mounting

POSITIONING THE GAGE ON THE SHAFT


7. Gage should now be positioned. Once again, lift the gage
end of the tape at a shallow angle to the surface until the
gage is free of the surface. Continue pulling the tape until
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you are approximately 1/8” – 1/4” beyond gage. Turn the
leading edge of the tape under and press it down, leaving
the bonding surface of the gage exposed.
8. Apply a very thin, uniform coat of M-Bond 200-Catalyst to
the bonding surface of the gage. This will accelerate the
bonding when glue is applied. Very little catalyst is
needed. Lift the brush cap out and wipe excess on lip of
bottle. Use just enough catalyst to wet gage surface.
Before proceeding, allow catalyst to dry at least one
minute under normal ambient conditions of + 75F and 30-
65% relative humidity.

NOTE: The next three steps must be completed in


sequence within 3 – 5 seconds. Read through instructions
before proceeding so there will be no delays.

Have Ready:
M-Bond (Cyanoacrylate) Adhesive
2” – 5” piece of Teflon tape
Tissues

MOUNTING THE GAGE


9. Lift the leading edge of the tape and apply a thin bead of
adhesive at the gage end where the tape meets the shaft.
Adhesive should be of thin consistency to allow even
spreading. Extend the line of glue outside the gage
installation area.
10. Holding the tape taut, slowly and firmly press with a single
wiping stroke over the tape using a Teflon strip (to protect
your thumb from the adhesive) and a tissue (to absorb
excess adhesive that squeezes out from under the tape).
This will bring the gage back down over the alignment
marks on the gaging area. This forces the glue line to
move up and across the gage area. A very thin, uniform
layer of adhesive is desired for optimum bond
performance.
11. Immediately, using your thumb, apply firm pressure to the
taped gage by rolling your thumb over the gage area. Hold
the pressure for at least one minute. In low humidity
conditions (below 30%) or if ambient temperature is below

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+ 70 F, pressure application time may have to be
extended to several minutes.
12. Leave the Mylar tape on an additional five minutes to
allow total drying then slowly peel the tape back directly
over itself, holding it close to the shaft while peeling. This
will prevent damage to the gages. It is not necessary to
remove the tape immediately after installation. It offers
some protection for the gaged surface and may be left
until wiring the gage.

WIRING THE GAGE


13. Tin each solder pad with a solder dot. (It is helpful to
polish the solder tabs, e.g. with a fiberglass scratch brush
or mild abrasive, before soldering.) Trim and tin the ends
of the 4-conductor ribbon wire. Solder the lead wires to the
gage by placing the tinned lead onto the solder dot and
pressing it down with the hot soldering iron. Note: For
single-stamp torque gages, a short jumper is required
between solder pads 2 and 4 as shown in the diagram on
the next page
14. Use the rosin solvent to clean excess solder rosin from
the gage after wiring. Brush the gage pads with the
solvent and dab with a clean tissue.
15. Paint the gage area (including the solder pads) with M-
Coat A polyurethane and allow to air dry 15 minutes.
This protects the gage from moisture and dirt. To further
protect the gage, apply M-Coat J protective coating for
protection against moisture, fluids and mechanical
damage.

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Figure 6 - Strain Gage Wiring

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Appendix D: Dimensions

Figure 7 - General Dimensions

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Figure 8 - Stationary Interface Mounting Dimensions

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Figure 9 - Stationary Interface Bottom Dimensions

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Rotor to stator spacing is
accomplished by aligning
the non-transmitter side of
the rotor collar with the
front of the stationary
interface.

Figure 10 - Collar Spacing

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Figure 11 - 0.75" to 6" Shaft Diameter Dimensions

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Figure 12 - 6" to 24" Shaft Diameter Dimensions

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Figure 13 - 24" to 40" Shaft Diameter Dimensions

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Figure 14 - 40" to 48" Shaft Diameter Dimensions

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Figure 15 - Stationary Ring Mounting Tab Dimensions

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Appendix E: Maximum Shaft Speeds
Table 9: Rotating Collar OD and Max Recommended RPM
1
Collar Outside Diameter Maximum safe
RPM
(inches) (mm)
5 127 9100
5.5 139 8500
7.5 190 6900
9.5 241 5900
11.5 292 4300
13.5 342 3800
15.5 393 3400
17.5 444 3100
19.5 495 2800
21.5 546 2300
23.5 596 2200
25.5 647 2100
27.5 698 1900
31.5 800 1500
35.5 901 1400
39.5 1003 1300
43.5 1104 1200
47.5 1206 1000
51.5 1308 1000
1
Valid only if rotating collar is properly installed with
mounting bolts tightened to specified torque values.

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Warranty and Service Information

Limited Warranty
Binsfeld Engineering Inc. warrants that its products will be free
from defective material and workmanship for a period of one year
from the date of delivery to the original purchaser and that its
products will conform to specifications and standards published by
Binsfeld Engineering Inc. Upon evaluation by Binsfeld
Engineering Inc., any product found to be defective will be
replaced or repaired at the sole discretion of Binsfeld Engineering
Inc. Our warranty is limited to the foregoing, and does not apply to
fuses, paint, or any equipment, which in Binsfeld Engineering’s
sole opinion has been subject to misuse, alteration, or abnormal
conditions of operation or handling.

This warranty is exclusive and in lieu of all other warranties,


expressed or implied, including but not limited to any implied
warranty of merchantability or fitness for a particular purpose
or use. Binsfeld Engineering Inc. will not be liable for any
special, indirect, incidental or consequential damages or loss,
whether in contract, tort, or otherwise.

NOTE (USA only): Some states do not allow limitation of implied


warranties, or the exclusion of incidental or consequential
damages so the above limitations or exclusions may not apply to
you. This warranty gives you specific legal rights and you may
have other rights which vary from state to state.

For service please contact Binsfeld Engineering Inc.:


4571 W. MacFarlane Road
Maple City, MI 49664
Phone: (+1) 231-334-4383
Fax: (+1) 231-334-4903
Internet: www.binsfeld.com
Email: sales@binsfeld.com

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