Application basics/handbook

Transcription

1 Application basics/handbook Inclination sensor / Tiltmeter GKAS2000 series with Modbus output a Dear Customer, thank you for purchasing this product. These Instruments are a results of a cooperation between KELAG and GEOSIG and have been optimised to meet the requirements of the majority of customers out of the box and may have even be delivered tailored to your needs. In any case, to be able to get the most out of our product, please carefully study this manual, its appendices and referenced manuals, as well as any other documents delivered with it. This is a reliable and easy to use device, and at the same time a sophisticated product, which requires care, attention and know-how in configuring, installing, operating and maintenance. GKAS2000_UG_E.doc page 1 of 18

2 Contents: Application basics/handbook... 1 Contents: Applications and Hardware Overview Tilt and levelling applications Inclination and angle measuring Acceleration measuring Vibration measuring Characteristics / Technology Shock resistance of the sensing element Repeatability and long term stability Resolution Reduced sensitivity to vibrations thanks to gas attenuation Structure of the sensing element Functional principle Mechanical mounting Alignment for inclination measuring Output signal in dependency of inclination or acceleration Mounting for acceleration and vibration measuring Offset-Alignment Temperature compensation Configuration and Calibration Electrical Connection Jumper Settings Entering the Configuration Mode Leaving the Configuration Mode Software Configuration Software Start Program Setup Device Parameter Setup Device Calibration Checking Data after the Configuration Read Data from The Device Software cfg File (tmon Configuration File) agn File (tmon the Measurement Agenda File) koo File ( tmon Sensors Coordinates File) RS-485 Network: Converters and Terminal Resistor RS-232 to RS-485 converters I-7520 series RS-232 to RS-485 converters R-8520 series USB to RS-485 converter K Terminal Resistor GKAS2000_UG_E.doc page 2 of 18

3 It is necessary to configure and calibrate the Tilmeter device via the GS_Tiltmeter_Config, before the device can be used. This document describes the preparation and handling of the Tiltmeter device. 1. Applications and Hardware 1. Overview Typical applications for the SCA series sensors are: - inclination limiter (tilt sensor) - levelling - inclination - acceleration - vibration Depending on the intended use the best suitable type must be selected. Please contact our product specialists for information. Phone: Tilt and levelling applications Typical applications can be tilt limiters, levelling of machinery, apparatuses or measuring equipment, automatic levelling of jibs / booms, excavator shovels, platforms etc. 1.2 Inclination and angle measuring Examples: inclination measuring in measuring equipment like lasers, in vehicles, robots, surgical operation tables, building and production machinery 1.3 Acceleration measuring Low speed acceleration with high resolution can also be measured. Other measuring range (eg. 4g or 12g) is possible on request. For higher speed measuring please ask the factory. 1.4 Vibration measuring Low frequency Vibration (>18Hz) with high resolution can also be measured. Other measuring range (eg. 4g or 12g) is possible on request. For higher speed measuring please ask the factory. GKAS2000_UG_E.doc page 3 of 18

4 2. Characteristics / Technology 2.1 Shock resistance of the sensing element The sensing elements based on capacitive measuring principle feature high precision and high shock resistance, resulting from the particular 3D micromechanics technology made of high purity silicon. Thanks to the optimized structure, no drifts caused by deformation must be expected, even after severe shocks. For the +/- 15 and +/- 30 range they are used two sensing element for one channel with a special Differential measuring method which increase performance by factor 2. Also lot of other ESD and noise effect are reduced very much. 2.2 Repeatability and long term stability For the +/- 15 and +/- 30 range for instance repeatability up to <0,01 and long term stabilities of the same order can be achieved. The hysteresis is in the range of arc seconds caused by quick temperature changes degenerates to zero within a short time. 2.3 Resolution The sensing elements formed by a dual capacitor produce extremely low noise levels and a high output signal. The major part of the noise is caused by the signal conditioning circuitry. Resolutions in the order of <0,001 with averaging are possible (7µ Hz Noise give resolutions down to 0,0006 ) 2.4 Reduced sensitivity to vibrations thanks to gas attenuation Influences by vibrations may interfere with inclination measuring. The gas attenuation in the sensing element filters a good part of such interferences and in addition helps avoid overshooting of the sensing pendulum. For inclination sensors the influence of vibrations is reduced, for vibration sensors the sensor s natural resonance is damped. This means that the appropriate sensor type must be selected for each application. 2.5 Structure of the sensing element Silicon wafer with metal film (capacitor) Pendulum with measuring mass Silicon wafer with metal film (capacitor) Measuring direction 2,9mm 1.95mm GKAS2000_UG_E.doc page 4 of 18

5 2.6 Functional principle The pendulum with the measuring mass is moved in the measuring direction by a force (acceleration, inclination, vibration) acting in this direction. The movement of the measuring mass causes a change of capacitance which is registered as primary measuring signal. The output signal (4 20mA) is proportional to the deflection, thus to the acceleration. For inclination measuring the conversion from g = 9.81 m/s 2 into angular degrees is a sine function. A sensor with small measuring range (+/-0,5g = +/- 30 ) has a higher resolution than a sensor with large (+/-12g) measuring range. Measuring principle and alignment (e.g. for acceleration / shocks) 3. Mechanical mounting The housings are marked with a symbol indicating the measuring direction. 3.1 Alignment for inclination measuring Principle: X-axis of rotation Y-axis of rotation (two axis SCA124- Version only) The position of the axis shown is only indicative for illustration and does not show the exact position 0 Position 90 Position GKAS2000_UG_E.doc page 5 of 18

6 3.2 Output signal in dependency of inclination or acceleration The orginal sinus function of the Sensor Element is linearized by the modbus sensor. So the output signal is lienar. 3.3 Mounting for acceleration and vibration measuring The sensor can be used as acceleration and vibration measuring Please contact for this application the factory. The sensing direction is indicated by a symbol on the back of the housing 3.4 Offset-Alignment Caused by the integration into the application a mechanical offset between the sensor and the application may occur. For precise measuring we recommend an offset alignment at the position 0g as described below. The alignment will be done in the application device by matching the offset voltage. Thus the absolute precision increases considerably. (See also chapter 3.5 Temperature compensation) 3.5 Temperature compensation Due to shrinking / dilatation of the sensing element at temperature variations the geometry of the element slightly varies. This will have an effect on the result of the measurement. Due to the symmetrical shape of the sensing element, most of this effect is automatically compensated. The remaining drift caused by temperature variation is very low, but should be compensated additionally for high precision applications. Methods: - External temperature-measurement with polynomial calculation (available on request). - External temperature measurement with defined calibration-points - Customized sensor with stored temperature coefficients For information please contact our technical consultants by phoning: GKAS2000_UG_E.doc page 6 of 18

7 4. Configuration and Calibration In this section the configuration procedure is described step by step. Details for each step of the procedure are described in the subsection mentioned in brackets after the description. The following steps are required to configure and calibrate the device: Power the device and connect it to the serial port IBMPC via RS485 adapter (2.1. Electrical Connection) Set the Jumper to enter the default network parameter mode (0. Jumper Settings) Use the software GS_GTM_config.exe for the device configuration (2.3 Software Configuration) Remove the Jumper to exit the configuration mode (0. Jumper Settings 5. Electrical Connection The device has a 10-pin connector. The connector pin assignment is as follows : Pin SIGNAL Comment 1 RS485A For RS-485 network 2 RS485B For RS-485 network 3 U+ Power input, +10 to +30 VDC range 4 GND Ground 5 R_TERM Pins 5 and 6 are used for RS-485 network termination resistor 6 R_TERM Pins 5 and 6 are used for RS-485 network termination resistor 7 RS485A For RS-485 network 8 RS485B For RS-485 network 9 U+ Power input, +10 to +30 VDC range 10 GND Ground 6. Jumper Settings 6.1 Entering the Configuration Mode To enter the configuration mode, insert the jumper SETUP on the board. This jumper is located close to the LEDs. After that, the device is set to the following default network parameters: Network address: 1 Network speed: 9600 baud. 6.2 Leaving the Configuration Mode To exit from the configuration mode, remove the jumper SETUP on the board again. GKAS2000_UG_E.doc page 7 of 18

8 7. Software Configuration 7.1 Software Start The software does not require an installation. Just launch the executable GS_GTM_config.exe. 7.2 Program Setup Set the program parameters on the Setup Page (See Figure 1) as follows: Baudrate: 9600 (Default during configuration mode, might be different if already configured) Net Address: 1 (Default during configuration mode, might be different if already configured) Com Port: Select the serial port to which the device is connected Figure 1. Program Setup Page 7.3 Device Parameter Setup Set the parameters on the Device Setup page (See Figure 2) according to the list below: Sensor#1 type: Select the sensor type according to the device specification. Sensor#2 type: Select the sensor type according to the device specification. If it is an uniaxial tilt meter and no second sensor is assembled, select SCA100T- 01 Baudrate: Select the used network speed for the device. This speed will be used once the configuration is finished.(after removing the jumper) Net Address: Set the used network address for the device. This address will be used once the configuration procedure is finished.(after removing the jumper) GKAS2000_UG_E.doc page 8 of 18

9 To upload the settings to the tilt meter push the button Write to device. Data will be written to device s setup registers. To read the data from the device push the button Read from device a After Device Parameter Setup the power must be turned off and on before next steps This parameters are only in the production software. (Has not to be changed) Has to be checked if more the one sensor is running into one line (bus). The addresses has to be different. Figure 2. Device Setup Page GKAS2000_UG_E.doc page 9 of 18

10 7.4 Device Calibration Temperature Sensor Calibration Set the current air temperature value in the field Current temperature. The measurement of temperature has to take place close to the angle sensor. Push the button Make Calibration! to calibrate the device accordingly. a After the Temperature Sensor Calibration the power must be turned off and on before next steps Angle Sensor Calibration Set the device horizontally for both axes Wait for at least 10 seconds. Push the button Make calibration! (Sensors are horizontal more than 5. a After the Angle Sensor Calibration the power must be turned off and on before next steps Figure 3. Device Calibration Page GKAS2000_UG_E.doc page 10 of 18

11 8. Checking Data after the Configuration To check the functionality of the device the same software can be used as for the configuration and calibration. To start and setup the software follow the instructions in Section 0 and Section Read Data from The Device The page Read Current Data from Device (see Figure 4) shows the real time measured data from the device. The data refresh interval can be set in the field Scan Rate (ms). Figure 4. Read current data Page GKAS2000_UG_E.doc page 11 of 18

12 2. Software The tmon software uses the following configuration files: ini file: cfg - file: agn file: koo file: The tmon project file The configuration file of the tilt sensor that is attached to the project The measurement agenda. The points (sensors) are listed in the order how they are measured. There is also the information about the channels, addresses, gain and offset. Contains the coordinates of the points (tilt sensors) 1. cfg File (tmon Configuration File) A valid cfg-file is presented below. It is necessary to adjust all values accordingly to the used network. [General] Coordinates=MB.koo MeasureAgenda=MB.agn ChainId=MB Strategy=0 [Sampling] Interval=0.2 TimeWindow=5 [Com] PortNum=1 BaudRate=38400 PortDelay=0 Echo=0 2. agn File (tmon the Measurement Agenda File) Each line in the file contains data about a single requested value. If the first symbol on a line is a #, the rest of the line is commented out. # poliynomial coeff for sensor # 1(X) poliynomial coeff for sensor # 2(Y) poliynomial coeff for T sensor # name Slave ID Channel ID (MODBUS register number - 1) a0 a1 a2 a3 b0 b1 b2 b3 T0 Tgain GTM-01-A E GTM-01-A E GTM-01-T GTM-02-A E GTM-02-A E GTM-02-T GKAS2000_UG_E.doc page 12 of 18

13 Table 1 Number in line Description Value for angle Value for temperature Notes 1 Value ID (unique name) It is recommended.-a 2 Device network address From 1 up to 127 It is recommended.- T From 1 up to Physical register s number (device s MODBUS data model) See Table 2 See Table 2 4 Polynomial coefficient a0x Polynomial coefficient a1x Polynomial coefficient a2x Polynomial coefficient a3x Polynomial coefficient b0y Not used 9 Polynomial coefficient b1y Not used 10 Polynomial coefficient b2y Not used 11 Polynomial coefficient b3y Not used 12 Polynomial coefficient T0 Not used 13 Polynomial coefficient TGain Not used Table 2 Register s number Description Notes 0 Sensor # 1 ADC code Ch#1 (last measure sample) 1 Sensor # 1 ADC code Ch#2 (last measure sample) 2 Sensor # 2 ADC code Ch#1 (last measure sample) 3 Sensor # 2 ADC code Ch#2 (last measure sample) 6 Sensor # 1 Temperature register code (last measure sample) 9 Sensor # 1 Temperature register code (last measure sample) 11 Sensor # 1 Angle Ch#2 (last measure sample) (for SCA100T only) 10 Sensor # 1 Angle Ch#1 (last measure sample) 11 Sensor # 1 Angle Ch#2 (last measure sample) (for SCA100T only) 12 Sensor # 1 Temperature (last measure sample) 13 Sensor # 2 Angle Ch#1 (last measure sample) 14 Sensor # 2 Angle Ch#2 (last measure sample) (for SCA100T only) 15 Sensor # 2 Temperature (last measure sample) GKAS2000_UG_E.doc page 13 of 18

14 100 Sensor # 1 ADC code Ch#1 (average for last 1 second) 101 Sensor # 1 ADC code Ch#2 (average for last 1 second) 102 Sensor # 2 ADC code Ch#1 (average for last 1 second) 103 Sensor # 2 ADC code Ch#2 (average for last 1 second) 106 Sensor # 1 Temperature register code (average for last 1 second) 109 Sensor # 1 Temperature register code (average for last 1 second) 110 Sensor # 1 Angle Ch#1 (average for last 1 second) 111 Sensor # 1 Angle Ch#2 (average for last 1 second) (for SCA100T only) 112 Sensor # 1 Temperature (average for last 1 second) 113 Sensor # 2 Angle Ch#1 (average for last 1 second) 114 Sensor # 2 Angle Ch#2 (average for last 1 second) (for SCA100T only) 115 Sensor # 2 Temperature (average for last 1 second) 200 Sensor # 1 ADC code Ch#1 (average for last Sensor # 1 ADC code Ch#2 (average for last Sensor # 2 ADC code Ch#1 (average for last Sensor # 2 ADC code Ch#2 (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Angle Ch#1 (average for last Sensor # 1 Angle Ch#2 (average for last 2 (for SCA100T only) 212 Sensor # 1 Temperature (average for last Sensor # 2 Angle Ch#1 (average for last Sensor # 2 Angle Ch#2 (average for last 2 (for SCA100T only) 215 Sensor # 2 Temperature (average for last Sensor # 1 ADC code Ch#1 (average for last Sensor # 1 ADC code Ch#2 (average for last Sensor # 2 ADC code Ch#1 (average for last 5 GKAS2000_UG_E.doc page 14 of 18

15 303 Sensor # 2 ADC code Ch#2 (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Angle Ch#1 (average for last Sensor # 1 Angle Ch#2 (average for last 5 (for SCA100T only) 312 Sensor # 1 Temperature (average for last Sensor # 2 Angle Ch#1 (average for last Sensor # 2 Angle Ch#2 (average for last 5 (for SCA100T only) 315 Sensor # 2 Temperature (average for last Sensor # 1 ADC code Ch#1 (average for last Sensor # 1 ADC code Ch#2 (average for last Sensor # 2 ADC code Ch#1 (average for last Sensor # 2 ADC code Ch#2 (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Temperature register code (average for last Sensor # 1 Angle Ch#1 (average for last Sensor # 1 Angle Ch#2 (average for last 10 (for SCA100T only) 412 Sensor # 1 Temperature (average for last Sensor # 2 Angle Ch#1 (average for last Sensor # 2 Angle Ch#2 (average for last 10 (for SCA100T only) 415 Sensor # 2 Temperature (average for last 10 GKAS2000_UG_E.doc page 15 of 18

16 1. koo File ( tmon Sensors Coordinates File) Each line of the file contains data about coordinates for a single requested value (sensor). GTM-01-A F GTM-01-T F GTM-02-A F GTM-02-T F GTM-03-A F GTM-03-T F GTM-04-A F GTM-04-T F GTM-05-A F GTM-05-T F GKAS2000_UG_E.doc page 16 of 18

17 3. RS-485 Network: Converters and Terminal Resistor A standard IBM PC normally doesn t have a RS485 interface. A converter from standard PC interfaces USB or RS-232 to RS- 485 is needed. 3.1 RS-232 to RS-485 converters I-7520 series Converter I-7520 or I-7520A can be used, If single power supply for converter and devices is used. These converters have galvanic isolation between RS-232 interface and power supply input (see Figure 5) Figure 5. Block Diagram of I-7520 Converters I-7520R and I-7520AR can be used when galvanic isolation between RS-232 interface and power supply isn t needed. Figure 6. Block Diagram of I-7520R GKAS2000_UG_E.doc page 17 of 18

18 It is not recommended to use I-7520 converters. They have non-standard RS-485 output signal (non-differential output), it reduces a communication s reliability for large networks with long lines and for lines with high level noises. A converters R-8520 series is recommended, they have a standard RS-485 output s signal. R-8520 series is similar I-7520 (it is consist of R-8520, R-8520A, R-8520R, R-8520AR converters), but has standard RS-485 differential output signal. 3.2 RS-232 to RS-485 converters R-8520 series R-8520 series converters are recommend for using. They have a standard RS-485 differential output signal. A difference between R-8520/R-8520A and R-8520R/8520AR the same as for I-7520 series. 3.4 USB to RS-485 converter K-104 Converter K-104 can be used for connecting to the computer with USB interface. Please read manufacture s documentation for details ( 3.5 Terminal Resistor Termination is used to match the impedance of a node to the impedance of the transmission line being used. When impedance are mismatched, the transmitted signal is not completely absorbed by the load and a portion is reflected back into the transmission line. If the source, transmission line and load impedance are equal these reflections are eliminated. A resistor is added in parallel with the receiver s A and B lines in order to match the data line characteristic impedance specified by the cable manufacture (120 Ω is a common value). This value describes the intrinsic impedance of the transmission line and is not a function of the line length. A terminating resistor of less than 90 Ω should not be used. Termination resistors should be placed only at the extreme ends of the data line, and no more than two terminations should be placed in any system that does not use repeaters. The terminal resistor is set betw GKAS2000_UG_E.doc page 18 of 18