Views: 222 Author: Leah Publish Time: 2025-02-16 Origin: Site
Content Menu
● Understanding the Components
● Tools and Materials Required
● Step-by-Step Installation Guide
>> 1. Preparing the Mounting Location
>> 2. Assembling the Tension Clamp
>> 3. Securing the Banding Temporarily
>> 4. Preparing for Tensioning
>> 5. Tensioning the Banding and Clamp
>> 7. Removing the Tension Tool
>> 9. Finalizing Installation Location and Tension
>> 10. Installing the 18mm Barrel Sensor
● Common Issues and Troubleshooting
● Best Practices for Long-Term Reliability
● Advantages of Using a Tension Clamp Mount
● Alternative Mounting Methods
● FAQ
>> 1. What is the correct tension for the banding?
>> 2. Can I reuse the banding?
>> 3. What type of banding should I use?
>> 4. How often should I inspect the clamp and banding?
>> 5. What do I do if the sensor is not aligned correctly?
The 18mm barrel sensor is a versatile and widely used component in various automation and sensing applications. Its robust design, often featuring a stainless steel housing, makes it suitable for harsh environments[2]. To ensure optimal performance and longevity of the sensor, proper installation using a tension clamp mount is crucial. This guide provides a detailed, step-by-step approach to correctly installing an 18mm barrel sensor with a tension clamp mount. This process involves mechanically securing the sensor to a pipe or structure using a clamp and banding system, ensuring proper alignment and tension for reliable operation[1]. This article will cover everything related to 18mm barrel sensor tension clamp mount.
Before starting the installation, it's important to familiarize yourself with the components involved:
- 18mm Barrel Sensor: The sensor itself, typically housed in an 18mm diameter cylindrical metal barrel[2].
- Tension Clamp: A clamp designed to secure the sensor to a pipe or mounting surface, often using a tensioning mechanism to ensure a firm grip[1].
- Banding Material: Usually stainless steel, used to wrap around the pipe and secure the clamp[1].
- Tensioner Tool: A tool used to apply the correct amount of tension to the banding[1].
- Buckle: A fastener that locks the banding in place after tensioning[1].
- Fasteners: Bolts, nuts, and screws required for assembly[4].
18mm Barrel Sensor
- Tension Clamp Mount Kit: Includes the clamp, banding, buckle, and any necessary hardware.
- Tensioner Tool: Specifically designed for the banding being used[1].
- Wrench Set: Including a 15/16-inch or 24 mm open-ended wrench[1].
- Allen Wrench Set: Including a 4 mm Allen wrench[1].
- Screwdriver Set: As needed for any specific fasteners.
- Pliers: For handling and bending banding[1].
- Safety Glasses: To protect your eyes during installation.
- Gloves: To protect your hands.
- Measuring Tape or Calipers: To ensure accurate positioning.
- Optional: Anti-seize lubricant for stainless steel nuts and bolts[4].
- Clean the Pipe Surface: Ensure the pipe surface is clean and free from dirt, rust, or any other debris that could interfere with the clamp's grip.
- Inspect the Pipe: Check for any damage or irregularities on the pipe surface. The mounting location should be smooth and uniform.
- Loosely Install Banding: Bend the banding down around the rods of the tensioner plate. The end of the band with the buckle attached should be bent at a length that allows the buckle to sit near the bottom side of the pipe, opposite to the clamp assembly. The acceptable location for the buckle is anywhere on the lower half of the pipe, opposite to the clamp[1].
- Wrap and Fold: Wrap the free end of the band around the pipe and through the buckle. Fold back the loose end at least 90° to temporarily secure the band in place[1].
- Insert Banding into Tensioner Tool: Place the banding within the tensioner tool. Place the nose of the tensioner tool against the buckle and slide the banding into the tool[1].
Note: The position of the clamp assembly may be moved after the banding has been tensioned, so the clamp does not need to be in the final position during this step. Emerson recommends that the clamp be positioned to allow for the most ergonomic use of the tensioner tool for this step[1].
- Apply Tension: Turn the crank on the tensioner tool to tighten the banding. This will slowly compress the tensioner plate and spring. The banding should be tightened until the entire black indicator mark is visible on the threaded stem[1].
- Check Indicator Mark: If the environment makes it difficult to see this indicator mark, the proper installation distance between the tension plate and the top of the tension nut should be set at 0.32 inches, or 8.1 mm[1].
- Tighten Set Screw: Using a 4 mm Allen wrench, tighten the set screw on the buckle to lock the banding in place[1].
- Reduce Tension: Once the banding is secured, reduce the tension on the tensioner tool by spinning the crank counter-clockwise, and remove the tool. Then bend the loose end of the banding over the top of the buckle[1].
Note: Emerson recommends leaving enough length of banding to allow for re-tensioning of the banding if ever necessary. If you choose to trim any excess banding, be sure to remove any sharp edges or burs[1].
- Adjust Clamp: With the banding tensioned, the clamp assembly may now be moved to its desired location. Using a 15/16-in or 24 mm open-ended wrench, turn the tension nut clockwise on the threaded stem until it contacts the tensioner plate. Continue to tighten the tension nut to compress the springs until the banding loses tension and the clamp may be freely moved around the pipe[1].
- Loosen Tension Nut: Once the Universal Pipe Mount is in its desired position, loosen the tension nut to decompress the spring to return tension to the banding. When loosening, return the tension nut to the top of the threaded stem[1].
- Mount the Sensor: Mount the 18mm barrel sensor on the pipe clamp. Ensure the sensor passes through the hole of the pipe clamp and has direct contact between the sensor tip and the pipe[1].
- Tighten Bolts: Tighten the bolts to secure the pipe clamp sensor to the pipe[1].
- Wiring: Connect the sensor to the appropriate transmitter or control system, following the manufacturer's instructions. Ensure all connections are secure and properly insulated.
- Testing: Test the sensor to ensure it is functioning correctly. Verify that the sensor is detecting the target object or condition as expected.
- Banding Slippage: Ensure the banding is properly tensioned and the buckle is securely locked. If slippage occurs, re-tension the banding and check the buckle.
- Sensor Misalignment: Verify that the sensor is properly aligned with the target object. Adjust the clamp position as needed.
- Clamp Loosening: Periodically check the tension of the clamp and re-tighten if necessary.
- Corrosion: Use stainless steel components in corrosive environments to prevent rust and degradation[2].
- Regular Inspection: Periodically inspect the clamp, banding, and sensor for any signs of wear or damage.
- Proper Tensioning: Ensure the clamp is properly tensioned to maintain a secure grip on the pipe.
- Environmental Protection: Protect the sensor from harsh environmental conditions such as extreme temperatures, moisture, and chemicals[2].
- Use Quality Components: Use high-quality clamps, banding, and sensors to ensure long-term reliability[3].
- Secure Mounting: Provides a firm and stable mounting platform for the sensor.
- Adjustability: Allows for easy adjustment of the sensor position.
- Versatility: Can be used on a variety of pipe sizes and materials.
- Durability: Resistant to vibration, shock, and environmental factors.
- Ease of Installation: Relatively simple to install with the right tools and instructions.
While the tension clamp mount is effective, other mounting methods may be suitable depending on the application:
- Direct Mounting: Mounting the sensor directly to a solid surface using screws or bolts.
- Magnetic Mounting: Using a magnetic base to attach the sensor to a metal surface.
- Adjustable Brackets: Using brackets that can be adjusted to accommodate different sensor positions.
- Wear Safety Glasses: Always wear safety glasses to protect your eyes from debris.
- Wear Gloves: Wear gloves to protect your hands from sharp edges and chemicals.
- Use the Right Tools: Use the correct tools for the job to prevent injury and damage.
- Follow Manufacturer's Instructions: Always follow the manufacturer's instructions for the sensor, clamp, and tensioner tool.
- Ensure Proper Grounding: Ensure the sensor and mounting structure are properly grounded to prevent electrical hazards.
Proper installation of an 18mm barrel sensor using a tension clamp mount is essential for ensuring reliable performance and longevity. By following this step-by-step guide, you can securely mount the sensor, achieve proper alignment, and maintain consistent tension. Regular inspection and maintenance will further enhance the reliability of the installation. The 18mm barrel sensor tension clamp mount is a reliable way to ensure your sensor is properly installed and functions correctly for years to come. Remember to always prioritize safety and use high-quality components for optimal results.
The banding should be tightened until the entire black indicator mark is visible on the threaded stem of the tensioner tool. If the indicator mark is not visible, the distance between the tension plate and the top of the tension nut should be 0.32 inches, or 8.1 mm[1].
It is generally recommended to use new banding for each installation to ensure optimal tension and grip. However, if the banding is in good condition, it may be reused. Inspect the banding for any signs of wear or damage before reusing it.
Stainless steel banding is recommended for most applications due to its corrosion resistance and durability[2]. The specific grade of stainless steel may vary depending on the environmental conditions.
The clamp and banding should be inspected at least once a year, or more frequently in harsh environments. Check for any signs of corrosion, loosening, or damage.
Loosen the tension nut on the clamp and adjust the position of the sensor until it is properly aligned. Then, re-tighten the tension nut to secure the sensor in the new position[1].
[1] https://www.emerson.com/documents/automation/quick-start-guide-rosemount-0085-pipe-clamp-sensor-assembly-en-89764.pdf
[2] https://www.bannerengineering.com/us/en/products/sensors/photoelectric-sensors/m18-series.html
[3] https://www.breezehoseclamps.com/content/breezecatalog.pdf
[4] https://www.emerson.com/documents/automation/quick-start-guide-rosemount-sensor-clamps-200-series-en-8731548.pdf
[5] https://eriks.co.uk/content/dam/uk/download-images-and-pdfs/pdfs/tech-direct.pdf
[6] https://www.hbjinyong.com/power-fitting/tension-clamp/
[7] https://www.bannerengineering.com/us/en/products/part.58433.html
[8] https://www.wexphotovideo.com/clamps-and-mounts/
[9] https://www.murraycorp.com/bolt-barrel-clamps
