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User Manual SONO-MIX MINI

1. 15 show different selectable calibration curves which are stored inside the SONO probe On the y axis the gravimetric moisture MoistAve is shown On the x axis depending on the calibration curve the associated radar time tpAve in picoseconds is shown With the software SONO CONFIG the radar time tpAve is shown on the screen parallel to the moisture value MoistAve see Quick Guide for the Software SONO CONFIG 21 45 oO e num num gt K WEINE at E te 29 EE Hu eee o 9 00 20 e gt EE MN UL EE Eu EK BINE E HEHE SEIN SER ast E ENSE BIEN UN 001 EAEE LL WEIL T1 YI LL li ALI IH Li IL Bobb fs eee Hu uu snl spuo2soo9 d ul aw yepey say 0 ja i i i i 1 i i 1 n i i i i i i i 4 4 4 4 4 nc zaca Jii LJ i v a A 1 x F gt d n seni women FI LE LEJ nd C WwW ul 94njSIO N ed IMKOy 2 3 45 MCROMCDUUECHNIE 3 1 1 SONO MIX MINI for measuring Moisture of Sand and Aggregates The TRIME TDR technology with the radar method offers high reliability for measuring moisture of sand and aggregates as different grain sizes unlike other measurement techniques such as microwave technology do not cause any distortion of the measure
2. Invalid Measure Count 2 O oO _ _ O O C1 IMKO A 16 45 vrbes Rec ARE 2 3 Calibration of SONO MIX MINI in a mixing plant SONO MIX MINI is delivered with a raw calibration function which is far higher than the real moisture values kiln dried values of a sand gravel or fresh concrete mixture The reason is that SONO MIX use a powerful modified filter algorithm which would work incorrect at Zero values division by zero results in infinite Therefore it is necessary with SONO MIX as well as with all other moisture probes to make a recipe specific calibration with the PLC in the mixing plant Another reason for this calibration is that every mixer type has another behaviour concerning the raw density of the mixed material Determination of water content in a PC or in a PLC Measurement values in a PC without unit A D Converter PLC Measurement values without SONO MIX unit e g from 0 Measurement values to 32768 without unit in the range of Oto 25 or 0 4 20mA current output signal In practice a mixer moisture probe has to be calibrated with two points in the mixing plant The first calibration point should be relatively dry e g at 2 to 3 gravimetric moisture The second point should be in a range which matches the maximum moisture value in practice e g 5 The closely together these both moisture values1 and 2 are the higher could be the measurement error due to the reference
3. a JA new basic balancing of the SONO probe is necessary MKO 41 45 8 TECHNICAL DATA SONO MIX MINI SENSOR DESIGN Casing High Grade Steel V2A 1 4301 Sensor head with highly wear resistant ceramic window MOUNTING Sensor Dimensions 135 x 60 x 40 Diameter x Length x Height MEASUREMENT RANGE MOISTURE SONO MIX MINI measures from 0 up to the point of material saturation Measurement ranges up to 90 moisture are possible with a special calibration MEASUREMENT RANGE CONDUCTIVITY The sensor as a material specific characteristic value delivers the radar based conductance EC TRIME Radar based Conductance in a range of 0 50dS m The conductivity range is reduced in moisture measurement ranges gt 50 MEASUREMENT RANGE TEMPERATURE Measurement Range 0 C 70 C The temperature is measured at the sensor casing beneath the wear resistant sensor head and can optionally be issued at the analogue output 2 The material temperature can be measured with an external calibration and compensation of the sensor intrinsic heating MEASUREMENT FIELD EXPANSION Approximately 50 80 mm depending on material and moisture POWER SUPPLY V to 24V DC 1 5 VV max Attention Do not use unstabilized power supplies AMBIENT CONDITIONS 0 70 C MKO 42 45 MEASUREMENT MODE WITH DATA PREPROCESSING SONO MIX MINI can be set to different measurement modes MEASUREMENT MODE CS Cyclic Successive For very short measuring p
4. and filtering Mode CA Cyclic Average Filter For relative short measuring processes with continual average value filtering and an accuracy of up to 0 196 Mode CF Cyclic Float Average for continual average value with filtering and an accuracy of up to 0 1 for very slowly measuring processes e g in fluidized bed dryers conveyor belts etc Mode CK Cyclic Kalman Filter with Boost Standard setting for SONO MIX for use in fresh concrete mixer with continual average value with special dynamic Kalman filtering and an accuracy of up to 0 196 Mode CC Cyclic Cumulated with automatic summation of a moisture quantity during one batch process Mode CH Cyclic Hold similar to Mode CC but without summation Mode CH is recommended for applications in the construction industry If the SONO probe is installed under a silo flap Mode CH can measure moisture when batch cycles are very short down to 2 seconds Mode CH executes an automatic filtering e g if dripping water OCCUTS Each of these settings will be preserved after shut down of the probe and is therefore stored on a permanent basis 2 1 Cyclic operation modes CA CF CH CC and CK For the cyclic modes the SONO probes are supplied ex factory with suited parameters for the averaging time and with a universally deployable filter function suited for most currently applications The setting options and special functions of SONO probes depicted in this chapter are only rarely requir
5. for the IMP Bus In the Support area of IMKO s homepage www imko de we publish the transmission protocol of the SONO probes 1 2 2 The IMP Bus as a user friendly network system With external power supply on site for the SONO probes a simple 2 wire cable can be used for the networking By use of 4 wire cables several probes can be also supplied with power Standard RS485 interfaces cause very often problems The RS485 is usually not galvanically isolated and therefore raises the danger of mass grindings or interferences which can lead to considerably security problems An RS485 network needs shielded and twisted pair cables especially for long distances Depending on the topology of the network it is necessary to place 1000hm termination resistors at sensitive locations In practice this means considerable specialist effort and insurmountable problems ans MKO The robust IMP Bus ensures security SONO probes have in parallel to the standard RS485 interface the robust galvanically isolated IMP Bus which means increased safety The serial data line is isolated from the probe s power supply and the complete sensor network is therefore independent from single ground potentials and different grid phases Furthermore the IMP Bus transmit its data packets not as voltage signals but rather as current signals which also works at already existing longer cables A special shielded cable is not necessary and also stub lines are no problem 1 2 3 E
6. generation of the average value can be set with this parameter CC CH CK Setting of the time for calculation of the trend or expectation value for the Boost amp Offset function CA CC CF CH CK Too high measurement values generated due to metal wipers or blades are filtered out The offset value in is added to the dynamically calculated upper limit CA CC CF CH CK Too low measurement values generated due to insufficient material at the probe head are filtered out The offset value in is subtracted from the dynamically calculated lower limit with the negative sign CA CC CF CH CK The maximum duration in seconds of the filter function for Upper Limit failures too high measurement values can be set with this parameter CA CC CF CH CK The maximum duration in seconds of the filter function for Lower Limit failures too low measurement values for longer lasting material gaps ie the time where no material is located on the probe s surface can be bridged CA CF CK inactive CC CH The accumulation of moisture values starts above the Moisture Threshold and from here the analogue signal is outputted The accumulation pauses and will be frozen if the moisture level is below the threshold value The No Material Delay time starts and material gaps disturbance can be eliminated CA CF CK inactive CC CH The accumulation stopps if the moisture value is below the Moisture Threshold The accumulation pauses for the period
7. inside the SONO probe In this example a temperature deviation of 5 C is produced by inside self warming of the SONO probe The correction value 5 can be setted in the CoeffO window Temp CoeffixMeasured Temp Coeff0 Coeffi Coeff Material Temp Offset an The example shows the parameters for displaying the temperature in the unit Degree Fahrenheit Temp CoeffixMeasured Temp CoeffO Coeffi Coeff Now 1 0 New 1 8 32 E 7 1 9 Compensation of the electronic temperature ise With this method of temperature compensation a possible temperature drift of the SONO electronic can be compensated Temperature Compensation Now TempComp Because the SONO electronic shows a generally low temperature n2 TT drift SONO probes are presetted at delivery for standard ambient conditions with the parameter TempComp 0 2 Dependent on New TempComp SONO probe type this parameter TempComp can be adjusted for on TT higher temperature ranges up to 120 C for special high temperature version to values up to TempComp 0 75 But it is to consider that it is necessary to make a Basic Balancing of the Set TempComp SONO probe in air and water if the parameter TempComp is changed to another value as TempComp 0 2 The parameter TempComp can be changed with the software tool SONO CONFIG in the menu Calibration and the window Electronic Temperature Compensation a Attention When changing the TempComp parameter
8. mS or 50dS m Analogue output 1 for moisture output 2 for 3 Moist a both temperature and conductivity EC Temp Conductivity TRIME with an automatic current window change in cycles of 5 seconds 4 Moist Analogue output 1 for moisture output 2 for the standard deviation based on the single MoistSTdDev moisture values This function is useful in e g fluid bed drier for air volume control Adjustment for the Measurement Ranges For analogue output 1 and 2 the moisture dynamic range and temperature dynamic range can be variably adjusted The moisture dynamic range should not exceed 10096 Moisture Range Temp Range Maximum e g 20 for sand Set in 96 Maximum 70 C Minimum 0 Minimum 0 C Conductivity Range 0 20dS m or 0 50dS m Dependent on probe type and moisture range SONO probes can measure pore water conductivities EC TRIME in ranges of 5dS m up to 50dS m 1 2 1 The serial IMP Bus interface SONO MIX MINI is equipped with the IMP Bus interface to set and readout individual parameters or measurement values An easy to implement data transfer protocol enables the connection of several sensors probes at the serial interface In addition SONO probes can be directly connected via the module SM USB or the display module SONO VIEW to the USB port of a PC in order to adjust individual measuring parameters or conduct calibrations Please consider The initial default setting of the serial interface is pre setted
9. measurement especially at moisture values which are beyond of these two points or not between these two points Following process can be recommended 1 Record measurement values in the PLC for a dry mixture of one cubic meter i e the mixture has a relative low water content It is recommended to average the values of the PLC over the last 5 seconds of the dry mixing time In this example a measurement value of 8126 has been recorded with the PLC SONO MIX Measurement Digit Value of Water Measurement value in a PC A D Converter content values PLC current signal in 96 moisture without unit from from 4 20mA 0 to max 32768 digits Measurement 5 968 mA 8126 values with dry This is the mixture Dry value A D IMKOy 17 45 2 Add water manually into the dryer mixture e g 20 0 liter water The added and measured water content is later used for the calculation of the c1 Sensitivity of the SONO MIX for this recipe When the mixture has a stable consistency than record the measurement values with the PLC in the more wet mixture It is recommended to average the values over the last 5 seconds of the mixing time In this example a measurement value of 10811 has been recorded with the PLC SONO MIX Measurement Digit Value of Measurement value in a PC A D Converter values without unit PLC Current signal without unit from O from 4 20mA to max 32768 digits Measurement 7 968 mA 6 2 8126 values of dry Thi
10. more inert is the reaction rate if differently moist material passes the probe A longer averaging time results in a more stable measurement value This should in particular be taken into consideration if the SONO probe is deployed in different applications in order to compensate measurement value variations due to differently moist materials At the point of time of delivery the Average Time is set to 4 seconds This value has proven itself to be useful for many types of applications At applications which require a faster reaction rate a smaller value can be set Should the display be too unstable it is recommended to select a higher value 2 1 2 Filtering at material gaps in mode CA and CF A SONO probe is able to identify if temporarily no or less material is at the probe head and can filter out such inaccurate measurement values Filter Lower Limit Particular attention should be directed at those time periods in which the measurement area of the probe is only partially filled with material for a longer time i e the material sand temporarily no longer completely covers the probe head During these periods Lower Limit Keep Time the probe would establish a value that is too low The Lower Limit Keep Time sets the maximum possible time where the probe could determine inaccurate too low measurement values Furthermore the passing or wiping of the probe head with metal blades or wipers can lead to the establishment of too high measur
11. of hardened steel and ceramic An integrated TRIME TDR measuring transducer is installed into the casing A high frequency TDR pulse 1GHz passes along wave guides and generates an electro magnetic field around these guides and herewith also in the material surrounding the probe Using a new patented measuring method IMKO has achieved to measure the transit time of this pulse with a resolution of 1 picosecond 1x10 consequently determine the moisture and to provide information in regard to the concrete composition The established moisture content as well as the concrete composition respectively the temperature can either be uploaded directly into a SPC via two analogue outputs 0 4 20mA or recalled via a serial interface 1 1 2 TRIME compared to other Measuring Methods In contrary to conventional capacitive or microwave measuring methods the TRIME technology Time Domain Reflectometry with Intelligent Micromodule Elements does not only enable the measuring of the moisture but also to verify if the cement content specified in a recipe has been complied with This means more reliability at the mixing fresh concrete TRIME TDR technology operates in the ideal frequency range between 600MHz and 1 2 GHz Capacitive measuring methods also referred to as Frequency Domain Technology depending on the device operate within a frequency range between 5MHz and 40MHz and are therefore prone to interference due to disturbance such as the tem
12. of the setted delay time and will be frozen if the moisture level is below the threshold value The SONO probes starts again in a new batch with a new accumulation after the setted time span of the No Material Delay is completely exceeded CA CF inactive CC CH CK Defines how strong single measurement values are weighted dependent on deviation to the current expected average value With e g Boost 35 a single measurement value is weighted with only 6596 100 35 for a new average value CA CF inactive CC CH CK Non linearities in the process can be compensated by higher weighting of higher values Can be used e g in fluid bed dryers or under silo flaps where non linearities can occur due to changes in the material density during process Offset works together with the parameter Average time CA CF CK inactive CH Smoothing factor for analog output setting This parameter 11 45 Setting Range 0 50 Unit Measurement Values Invalid Measure Count otandard Setting 2 values Setting Range 0 10 Unit Measurement Values with 3 single values per second Moisture Std Deviation Count Standard Setting 5 values Setting Range 0 20 Unit Measurement Values with 3 single values per second MKO influences the reaction response time with factor 3 E g 15 values responds to a reaction time of 15 3 5 seconds CK The reaction response time works nearly 1 1 E g 15 values responds to a reactio
13. 5 10 34 29 435 2014 4 31 Ka 6 1 6 45 4 Lo 1 00 sa 6 af 10 54 5 Me mic 14 10 34 28 2506 2015 4 93 233 79 C 18 g4 52 3 j I 4 85 5 04 0 54 5 4t Bis 84 5 E 10 54 27 06 2013 4a 44 44 791 84 so 4 Q 4 84 1 00 A4 6 d 84 84 9 l 10 34 26 25 06 2015 431 23 70 Q 17 B4 54 2 92 05 4 4 85 1 00 34 5 4 84 5 ww 10 34 25 08 313 46 w ka Sa i 732 M a 4 94 4 08 a 5 u bat 84 5 10 34 24 25 06 2015 438 75 B4 5 3 t91 39 436 4 96 4 85 0 84 5 46 84 5 84 5 0 33 25 25 06 2015 ahs 23 70 0 16 Ba SA 190 85 A j 4 87 1 00 1 00 k 5 Z t 4 5 a 34 22 25 06 2015 4 3 443 70 Q 17 B4 54 3 91 45 487 485 4 82 4 95 34 6 45 84 4 4 Following measurement values are displayed on the screen MoistAve Moisture Value in Average MatTemp Temperature EC TRIME Radar based Conductivity EC TRIME in dS m or mS cm TDRAve TDR Signal Level for special applications DeltaCount Number of single measurements which are used for the averaging tpAve Radar time average which corresponds to the respective moisture value By clicking Save the recorded data is saved in a text file in the following path XSSONO CONFIG exe Pfad MD Dateiname The name of the text file Statis SN yyyymmddHHMMSS sts is assigned automatically with the serial number of the probe SN and date and time The data in the text file can be evaluated with Windows EXCEL 7 1 6 Measure Run in Datalogging Operation In the menu Datalogging
14. 5 1 2 4 Material Temperature MeaSUreMENt sssesssrrssrrrresrrrrerrrrenrrrrer renen rr rr kk rr RR nnn nnns 5 1 2 5 Temperature compensation of the internal SONO electroniC EEE 6 I EN AVOUT Pm 6 12 1 TheseraliMr BISIUJIe Ta D gjygj ran edu han rak ka EE e gud wen 7 1 2 2 The IMP Bus as a user friendly network system msmsssssrssssrresrrrrsrrsrrerrrrrnrrrrerrrrrnr rr ren rr rann 7 1 2 8 Error Reports and Error Messages ssssmessssrssssrresssreorsrrerrrreorsrrerrrrrrrrrrerrrrrnr nennen rn rr rr nnns 8 2 Configuration of the Measure Mode 11 nana ns ansnn some nese e nn e sene rrene esse eren nes see ken RARE RAR nn KA AA KAKA KAKA KA WWW AA WAA 9 2 1 Cyclic operation modes CA CF CH CC and CK yss nssessressresssressrrsrrrrrrrrnrrrrrr rene ren r rr KEK KAKA KA 9 2 1 1 Average Time in the measurement mode CA and CF aaa aaa nenen eee 11 2 1 2 Filtering at material gaps in mode CA and OF aaa aaa piken 11 2 1 3 Mode CC automatic summation of a moisture quantity during one batch process 13 2 1 4 Mode CH Automatic Moisture Measurement in one Batch 14 2 2 Overview of single modes for different applications sssresssrrerrrresrrrrerrrrrnrrrrnrrrrrnrrrrn emer 15 2 3 Calibration of SONO MIX MINI in a mixing plan tana aaa ane eea ende eee ene ee eee ee de nnn 16 2 3 1 Shortest expecting mixing time
15. CDUUECHNK Y CNE 18 45 T NS Following draft shows the parameters at different mixer volumes with 0 8 cubic meter and 1 0 cubic meter Moisture 40 Digit Kl Digit Digit BT Digit 4000 2000 4000 3000 a Delta Delta 64 Liter 1000 Digit 80 Liter 80 Liter 1000 Digit 100 Liter Water 16 Liter Water Water 20 Liter Water To come to the standard parameter liter per one cubic meter the result with liter per 0 8 cubic meter can be calculated to one cubic meter l e 64 Liter 0 8 80 Liter m If a volume of e g 1 5 cubic meter was used following calculation will result 120 Liter 1 5 80 Liter m To come and compare the exact water content values per cubic meter inside the mixture it is possible to take a representative sample out of the mixer for kiln drying weight of water The moisture is calculated by Moisture in 96 10096 weight complete Whereby the weight of water results in the difference of the weight complete before and after the kiln drying The exact water content in liter per cubic meter of the mixture can be calculated with the moisture value and the raw density of the mixture This results with e g 396 moisture and 1700kg m raw density in Water content in liter m moisture in raw density 100 3 0 1700 100 51 Literim Typical ravv densities for sand gravel and concrete mixtures are Pure sand approx 1500 kg m Sand gravel mixture appr
16. COMIS Abbrechen der komer atie wenn das Gert p COMDS peres beiegr anbgeschaltet vnd Part U Mei Event be uritur qeveris Entfernung des gt tr Gar ae Mine Ancahle der Lese T peng Beer cilek kar der Verbindung RTS aktiv unten 1 lend COMES erate belegt Abechalben det Modernansbmummung bam m Nin nisis Grose der Sd coms rock abren des Gerate dysh coe come core Al sechen After changing the COMX port settings SONO CONFIG must be restarted IMKO 34 45 WCROMCDUTECHNK P caver 7 Quick Guide for the Commissioning Software SONO CONFIG With SONO CONFIG it is possible to make process related adjustments of individual parameters of the SONO probe Furthermore the measurement values of the SONO probe can be read from the probe via the serial interface and displayed on the screen In the menu Bus and the window Configuration the PC can be configured to an available COMx port with the Baudrate of 9600 Baud Bus Configuration General Serial Port COMO MI X C Use the selected port Automatically search the port 7 1 1 Scan of connected SONO probes on the serial interface In the menu Bus and the window Scan Probes the serial bus can be scanned for attached SONO probes takes max 30 seconds SONO CONFIG reports one or more connected and founded SONO probes with its serial number in the window Probe List One SONO probe can be selected by klicking Probe List Ext Config Cal
17. Commissioning Software SONO CONFIG esse eren nese kk KAK RA A 34 7 1 1 Scan of connected SONO probes on the serial interf Ce EE 34 7 1 2 Configuration of Measure Mode and serial SONO interface 35 7 1 3 Set analogue outputs of the SONO probe sssvmrmarrreeesrsssrrrrerssrrsrrrnrnnrrrrrrrrrrnrrrrrrrrnrn anne 35 7 1 4 Selection of the individual Calibration Curves lll 36 7 1 5 Test run in the respective Measurement Mode i u k 38 7 1 6 Measure Run in Datalogging Operation s sssmsrrssssrresssrrssrsrresrrrrnrrrrerrrrrrrrrrrnrrrr ee eee eee ee enet 38 7 1 7 Basic Balancing in Air and Water kk rr rr eee rr rar KK KAK KK 39 7 1 8 Offsetting the material temperature sensor aaa aaa nana nen need enen ere ee eee eee ee reze eee ee eee na 40 7 1 9 Compensation of the electronic temperature L Eli eee na ner eee ee eee eee ee eee eee eee na 40 TECHNICAL DATA SONO MIX MING ua uv ah r ea 41 MKO 4 45 1 Instrument Description SONO MIX MINI 1 1 1 The patented TRIME TDR Measuring Method The TDR technology Time Domain Reflectometry is a radar based dielectric measuring procedure at which the transit times of electromagnetic pulses for the measurement of dielectricity constants respectively the moisture content are determined The SONO MIX MINI Mixer Probe consists of a high grade steel casing with a wear resistant sensor head made
18. N The sensor is provided with a universal calibration for sand A maximum of 15 different calibrations can be stored For special materials variable calibrations with polynomials up to the 5 order are possible and can be downloaded into the sensor with the SONO CONFIG software Download per Internet A zero point correction can be performed easily with the SONO CONFIG software COMMUNICATION A RS485 interface and the IMP Bus enables network operation of the probe whereby a data bus protocol for the connection of several SONO probes to the serial bus is implemented by default The connection of the probe to industrial busses such as Profibus Ethernet etc is possible via optional external modules available upon request PROBE CONNECTION The sensor is equipped with a PG fitting and a 6 pole cable with 5 meter length MKO 43 45 MKO 44 45 IMKO 45 45 Precise Moisture Measurement in hydrology forestry agriculture environmental and earth science civil engineering as well as individual applications
19. OM17 x J Standardma tfigige Seriell ber Bluetooth Yerbindung LOS P A 5B Serial Port COM e Audio video und Gamecontroller 8 Bildbearbeitungsger ate Eluetooth Funkger te COMx set must be between COM1 COM9 and it should be ensured that there is no double occupancy of the interfaces If it comes to conflicts among the serial port or the USB SM has been found in a higher COM port the COM port number can be adjusted manually By double clicking on USB Serial Port you can go into the properties menu where you see connection settings with Advanced button the COM port number can be switched to a free number timerechelion von USB Serial Port COM4 ren Amchamende ngen Tiber Dena COM usc hlusenunmme com m COMI berets beta Bis pro Sekunde 9600 USE Nackstzrtifien COMZ Abecen Reduce Se de Werte n bereits belegt Bautan zu beheben mm Dalers O i eres beje sanidad Esther Si de Werte Tur Lasse Ddeg gen kon Enofangen Bytes COME bereits belegt COM berets belegti Stoppt Serjan n tun COMLO horats beg Thasteuenug Kara rwetieric Linsioflungen tier CUMI DM E ut n ruar COMHLZ2 bereda bele COML2 Gerate belegt COMLS barut bokt COMI Gerais halvt Ayre t otay 5 COMLS beretts beer i Verear ee a CMS borets belegt Plugetay f r swede Schnittstelle 2 F paster COMLT herots beled g Werbenat vu COM L beretts belegt Sereler Drucker a
20. ONO probe can be configured see Chapter Analogue outputs IMKO 36 45 WOSCMCDUUECHNIN Analog Output Output Current C 0 20mA C 20 0m C 20 4mA Dutput Channels Moist Temp C Moist Conduct C Moist Temp Conduct C Moist MoistStdDev m Moisture Range r EC Trime mS cm r Moist Std Deviation Max 20 Set Min 0 Set r Temperature Range Max 100 Set 0 20 C 0 50 Max o Set Min 0 Set Min 0 Set Simulate Close 7 1 4 Selection of the individual Calibration Curves In the menu Calibration and the window Material Property Calibration the calibration curves CAL1 to Call5 which are stored in the SONO probe are loaded and displayed on the screen takes max 1 minute With the mouse pointer individual calibration curves can be activated and tested with the SONO probe by activating the button Set Active Calib Furthermore the individual calibration curves CAL1 to Cal15 can be adapted or modified with the calibration coefficients see Chapter Creating a linear calibration curve Material Property Calibration Calibration Item Set Active Calib Default Calibration Item Please select one calibration from Call to Call5 to operate CallD P CalName in Probe MatlD P TemlD P DeniD P No Calibration Universal S and Mix Sand bulk density 1 6 Sand bulk density 1 7 Sand bulk density 1 8 Sand bulk density 1 3 Gravel Grit Wood Shavings Brown coal gra
21. User Manual SONO MIX MINI IMKO Micromodultechnik GmbH Telefon 49 0 7243 5921 0 Im St ck 2 Fax 49 0 7243 90856 D 76275 Ettlingen e mail info oimko de http Wwww imko de publik TECH_MAN TRIME SONO ENGLISH SONO MIX MINI Manual SONO MIX MINI Vers2 5 english docx IMKOJA 2145 User Manual for SONO MIX MINI As of 15 October 2015 Thank you for buying an IMKO moisture probe Please carefully read these instructions in order to achieve best possible results with your mixer probe SONO MIX MINI for the in line moisture measurement in sand gravel fresh concrete or any other material Should you have any questions or suggestions regarding your new mixer probe after reading please do not hesitate to contact our authorised dealers or IMKO directly We will gladly help you List of Content 1 Instrument Description SONO MIX MINI nes serre enes see e eee nese sere enes nnn nnn 4 1 1 4 The patented TRIME TDR Measuring Method nnns 4 1 1 2 TRIME compared to other Measuring Methods 4 11 3 ATeas OlADPICEHON i bensen mmm 4 1 2 Mode of Operation FR 5 1 2 1 Measurement Values with physically Pre check Average Value and Filtering 5 1 2 2 Auto Correction at Abrasion seeeesssssssssseseeeene nennen nnne eee nnn ee eee nnn KK nan nnns 5 1 2 3 Determination of the Cement Concentration z
22. ad Colour blue red e How to start with the USB Module SM USB from IMKO e Install USB Driver from USB Stick e Connect the SM USB to the USB Port of the PC and the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick e Connection of the SONO probe to the SM USB via the serial interface and power supply e Check the setting of the COM Ports in the Device Manager und setup the specific COM Port with the Baudrate of 9600 Baud in SONO CONFIG with the button Bus and Configuration COM1 COM15 is possible e Start Scan probes in SONOConfig e he SONO probe logs in the window Probe List after max 30 seconds with its serial number Note 1 In the Device Manager passes it as follows Control Panel gt System gt Hardware gt Device Manager IMKO 33 45 WMCROMCDUTECHNI Bele E Ger te Manager Datei Aktion Ansicht 7 alis E amp E PB ma cd wsso 0 Under the entry Ports COM amp LPT now the 3 an f Anschl sse COM und LPT A E Intel R Active Management Technology SOL COMO E Kommunik atiansanschluss COMI E Prolific LISB En Serial Bridge COM h v Prolific USB to Serial Bridge COM3 E Standardmafigige Seriell ber Bluetooth Yerbindung COMI in E Standardmatfigige Seriell ber Bluetooth Yerbindung LOS E Standardmafigige Seriell ber Bluetooth Yerbindung COM165 2 J Skandardm ligige Seriell ber Bluetaeth verbindung C
23. asurement values are issued as a current signal via the analogue output With the help of the service program SONO CONFIG the SONO probe can be set to the two versions for 0 20mA or 4 20mA Furthermore it is also possible to variably adjust the moisture dynamic range e g to 0 10 0 20 or 0 309e For a 0 10V DC voltage output a 500R resistor can be installed in order to reach a 0 10V output Analogue Output 1 Moisture in 0 20 variable adjustable Analogue Output 2 Conductivity EC TRIME or optionally the temperature In addition there is also the option to split the analogue output 2 into two ranges into 4 11mA for the temperature and 12 20mA for the conductivity The analogue output two hereby changes over into an adjustable one second cycle between these two current measurement windows For the analogue outputs 1 and 2 there are thus two adjustable options Analog Output two possible selections 0 20mA 4 20mA For very special PLC applications the current output can be also inverted into 20mA 0mA or 20m 4mA Analogue Output Channel 1 SONO MIX MINI offers only analogue output Analogue output2 is not connected The analogue outputs of the SONO probe can be adjusted into one to four possible selections MKO 7 45 1 Moist Temp Analogue output 1 for moisture output 2 for material temperature Analogue output 1 for moisture output 2 for 2 Moist Conduct li conductivity in ranges of 0 20dS
24. batch process Are there short material gaps during a batch process which are shorter than the No Material Delay with no material at the probes surface then the SONO probe pauses shortly with the summation Is the pause greater as the No Material Delay then the probe is ready to start a new batch process Please note If the PLC already accumulates single moisture values in higher cycle rates than an additional automatic summation of a moisture quantity inside the SONO probe during one batch process will produce errors Here mode CS is recommended How can the mode CC be used if the SONO probe cannot detect the moisture threshold by itself e g above a conveyor belt if there is constant material covering above the probe head over a longer time In this case a short interrupt of the probe s power supply e g for about 0 5 seconds with the help of a relay contact of the PLC can restart the SONO probe at the beginning of the material transport After this short interrupt the SONO probe starts immediately with the summarizing and averaging Please note It should be noted that no material sticks on the probes surface Otherwise the moisture zero point detection of the probe will be shifted up and the probe would not be detect a moisture low value below the Moisture Threshold IMKO MCROMCDUUECHNIE 14 45 Time chart for mode CC The first batch process stops The The last freezed summerized and SONO probe recognizes that the av
25. ctive mixer types The ideal installation location must be established individually The following guidelines should hereby be observed 5 1 Assembly Instructions The following instructions should be followed when installing the probe e The installation locations may not be situated beneath the inlets for additives water and cement e n case of an uneven base the probe must be installed at the highest point of the base No water may accumulate at the probe head as this could falsity the measurement e Areas with strong turbulences are not ideal for the installation There should be a continuous material flow above the probe head e The stirring movement of the mixer blades should be conducted without gap above the probe head e The probe should not be installed in the direct vicinity of electrical disturbing sources such as motors e he probe may not project into the mixer The installation height of the probe may possibly have to re adjusted due to wear of the mixer blades arms and the mixer base No material may deposit on the probe head as this could falsify the measurement e n case of curved installation surfaces in the mixer the centre of the probe head should be flush with the radius of the mixer wall without disturbing the radial material flow in the mixer The probe may not project and come in contact with blades or wipers Attention Risk of Breakage The probe head is made of special steel and a very wear resistant cera
26. e Positive Moisture 1 Analogue Return Line Moisture RS485 A RS485 B com IMP Bus 2 Analogue Positive 2 Analogue Return Line Screen is grounded at the sensor The plant must be properly grounded MP Bus Rosa Rem IMKO 28 45 MCROMCDUUECHNIE Y CNE 4 1 2 Analogue Output 0 10V with a Shunt Resistor There are PLC s which have no current inputs 0 20mA but voltage inputs 0 10V With the help of a shunt resistor with 500 ohm in the delivery included it is possible to generate a 0 10V signal from the current signal 0 20mA The 500 ohm shunt resistor should be placed at the end of the line resp at the input of the PLC Following drawing shows the circuit principle PLC SONO Probe Current signal 0 20mA Analog Positive Analog Return Line 4 1 3 Connection diagram with SONO VIEW SONO SILO SONO VARIO 24V DE Power Suppl 1 Analog Pesitiv IMP Bus RIT Connection to further SONO probes Connection to further SONO probes 1 Analog Positiv 1 Analog Positiv mr i j 0 4 20mA SONO VIEW Analogue input Analogue input Installation in the control moisture or moisture ream or inside the Distribution Cabinet distribution cabinet MKO 29 45 5 Installation of the Probe The installation conditions are strongly influenced by the constructional circumstances of the respe
27. ed It is necessary to take into consideration that the modification of the settings or the realisation of these special functions may lead to faulty operation of the probe For applications with non continuous material flow there is the option to optimise the control of the measurement process via the adjustable filter values Filter Lower Limit Filter Upper Limit and the time constant No Material Keep Time The continual floating averaging can be set with the parameter Average Time 10 45 Parameters in the Measurement Mode CA CF CC CH and CK Average Time Standard Setting 2s Setting Range 1 20 Unit Seconds Filter Upper Limit Offset Standard Setting 2596 Setting Range 1 20 Unit Absolut Filter Lower Limit Offset Standard Setting 2596 Setting Range 1 20 Unit Absolut Upper Limit Keep Time Standard Setting 10 Setting Range 1 100 Unit Absolut Lower Limit Keep Time otandard Setting 10 Setting Range 1 100s Unit Seconds Moisture Threshold start threshold in moisture otandard Setting 0 196 Setting Range 0 100 Unit Absolut No Material Delay period time Standard Setting 10s Setting Range 1 100s Unit Seconds Boost otandard Setting 35nn Setting Range 1 100nn Unit without unit Offset otandard Setting 0 596 Setting Range 0 596 Unit Absolut Weight otandard Setting 5 values MKO Function CA CF Time in seconds for the
28. ement values Filter Upper Limit The Upper Limit Keep Time sets the maximum possible time where the probe would determine inaccurate too high measurement values Using a complex algorithm SONO probes are able to filter out such faulty individual measurement values The standard settings in the Measurement Mode CA and CF for the filter functions depicted 2145 IMKOy in the following have proven themselves to be useful for many applications and should only be altered for special applications It is appropriate to bridge material gaps in mode CA with Upper and Lower Limit Offsets and Keep Time For example the Lower Limit Offset could be adjusted with 296 with a Lower Limit Keep Time of 5 seconds If the SONO probe determines a moisture value which is 2 below the average moisture value with e g 8 than the average moisture value will be frozen at this value during the Lower Limit Keep Time of 5 seconds In this way the material gap can be bridged This powerful function inside the SONO probe works here as a highpass filter where the higher moisture values are used for building an average value and the lower or zero values are filtered out In the following this function is described with SONO parameters oufficient material for an accurately moisture measurement value of e g 896 Material gaps over e g 3 seconds which must be bridged for an accurately measurement with a Lower Limit Keep Time of 5 seconds os T ul pr E pre te on ue
29. ent on screw velocity It is recommended to use measurement mode CK if the probe is installed in the middle of the screw conveyor without a cut out of the spiral 5 1 1 Installation of the SONO MIX MINI in a mobile Mixer Truck When installed the SONO MIX MINI in a screw conveyor inside a mobile mixer truck it is possible to measure sand moisture very precise So a reliable recipe accuracy is guaranteed IMKOJA 32145 MCROMCDUUECHNK T CNE 6 Connection of the Probe to the SM USB Module from IMKO In fact that the IMP Bus is more robust and enables the download of a new firmware to the SONO probe the SONO probes are presetted ex factory to the IMP Bus So it is recommended to use the IMP Bus for a serial communication Both connector ports are shown in the drawing below The SM USB is signalling the status of power supply and the transmission signals with 4 LED s When using a dual USB connector on the PC it is possible to use the power supply for the SONO probe directly from the USB port of the PC without the use of the external AC adapter Connection to the Probe RS485 Connector Pin B 0V Power Supply Pin A 12VDC Power Supply Pin G R8485B Lead Colour brown Pin F RS485A Lead Colour white 12VDC IMP Bus Connector With the option to accomplish a download of the firmware for the SONO probe Pin B 0V Power Supply Pin A 12VDC Power Supply Pin C rt Lead Colour grey pink H Pin J com Le
30. eraged moisture value is freezed measurement value is below the at the analogue output until the No moisture threshold of 1 and the Material Delay time of e g 5 probe stops automatically with the seconds has expired and a new summation yellow curve batch process starts Short interruptions a were bridged pu a a G 5 f Characteristic of in sand i adjustable No Material Detay e g 5 seconds i 1 i Adjustable Moisture fhreshotd 9 Time Start of first batch process The Start of second batch process After the period SONO probe recognizes that the of No Material Delay e g 5 seconds the adjustable moisture threshold of e g SONO probe recognizes that the threshold of 196 has been exceeded and the 1 has been exceeded The previously stored probe starts automatically with the measurement value is cleared and the probe continuous accumulation of starts again automatically with the continuous measurement values yellow curve accumulation of measurement values yellow curve 2 1 4 Mode CH Automatic Moisture Measurement in one Batch Mode CH can be used for applications in the construction industry If the SONO probe is installed under a silo flap Mode CH can measure moisture when batch cycles are very short down to 5 seconds and perhaps shorter Mode CH executes an automatic filtering with Invalid Measure Count e g if dripping water occurs or for filtering out
31. f close to the wall you will see at least a slight effect of the filling amount 2 3 2 SONO MIX to control the water cement ratio SONO MIX can be also used to control the w c ratio by determination of the moisture respectively the water content at the end of the mixing process Similar as described in the previous chapter a recipe specific calibration with the PLC in the mixing plant can be made at the end of the mixing process with the final fresh concrete Depending to the concrete recipe the probe has to be calibrated with two points in the mixing plant however this two points shall lie in a closer and higher moisture range e g between 7 to 8 due to the concrete type With the determined moisture or water content and the known cement content the w c ratio can be calculated It should be considered that the PLC should calculate the moisture content with several single values over 3 to 5 seconds shortly before the discharge of the mixture IMKOJA 20145 3 Calibration Curves SONO MIX MINI is supplied with the calibration curve Cal9 MIX for the mixer operation with sand and gravel Cal9 MIX is slightly increased in the dry measurement range to ensure that in dry sand and gravel the readings do not move to 096 values because values around 096 can be disadvantageous for the filter arithmetic So in dry sand gravel the readings of the SONO MIX MINI show higher measurement values For an absolute value calculation for the water addition in
32. g SONO probes measure internally at very high cycle rates of 10 kHz and update the measurement value at a cycle time of 250 milliseconds at the analogue output In these 250 milliseconds a probe internal pre check of the moisture values is already carried out i e only plausible and physically checked and pre averaged single measurement values are be used for the further data processing This increases the reliability for the recording of the measured values to a downstream control system significantly In the Measurement Mode CS Cyclic Successive an average value is not accumulated and the cycle time here is 250 milliseconds In the Measurement Mode CA CF or CK not the momentarily measured individual values are directly issued but the average value is accumulated via a variable number of measurements Average in order to filter out temporary variations These variations can be caused by inhomogeneous moisture distribution in the material surrounding the sensor head The delivery scope of the SONO MIX MINI includes suited parameters for the averaging period and a universally applicable filter function deployable for currently usual applications The time for the average value accumulation as well as various filter functions can be adjusted for special applications 1 2 2 Auto Correction at Abrasion Even in the event of abrasion at the probe head of a SONO probe the automatic measurement compensation enables significantly longer operating pe
33. ibration Test Measure No SeraNo ResetBaudite ProbeName HwVersin FwVersion SOND YARIO 2 06 2 200603 IMKO A 35 45 t FE 7 1 2 Configuration of Measure Mode and serial SONO interface In Probe List with Config and Measure Mode amp Parameters the SONO probe can be adjusted to the desired measure mode CA CF CS CK CC or CH see Chapter Configuration Measure Mode Furthermore the serial interface inside the SONO probe can be selected to IMP Bus RS485 or both interfaces Due to very robust behavior it is recommended to select the IMP Bus Measure Mode amp Parameters Default Cycle Mode C Cyclic Set Default Measure Mode amp Parameters Actual Cycle Mode C Cyclic tt Average Mode of Mode C CH Cyclic AverageHc ve Kalman with Boost ON e Offset with Moist ve 10 G C C RS485 Average Parameters Average Timels Ia o Set Filter Upper Limit Offset abs ps Filter Lower Limit Offset abs 25 0 Upper Limit Keep Timels ln Lower Limit Keep Timels TEN Moisture Threshold abs 01 0 No Material Delavis 10 Boost nn 35 Offset abs 10 5 W eight no values Invalid Measure Count no values 12 Moist Std Deviation Count no values 5 Algorithmus Parameters Quick Quick Precision Meas Timesino values 2 Set Close 7 1 3 Set analogue outputs of the SONO probe In the menu Config and the window Analog Output the two analogue outputs of the S
34. int P2 with X2 Y2 e g 500 25 l e tpAve of 500ps corresponds to 25 moisture content The gravimetric moisture content of the material e g 25 has to be determined with laboratory measurement methods oven drying Step 3 With the two calibration points P1 and P2 the calibration coefficients m0 and m1 can be determined for the specific material see next page Step 4 The coefficients ml 0 0581 and mo 4 05 see next page for the calibration curve Cal14 can be entered directly by hand and are stored in the probe by pressing the button Set The name of the calibration curve can also be entered by hand The selected calibration curve e g Cal14 which is activated after switching on the probes power supply will be adjusted with the button Set Default Calib Attention Use dot as separator 0 0581 not comma 3 2 1 Nonlinear calibration curves SONO probes can also work with non linear calibration curves with polynomials up to 5th grade Therefore it is necessary to calibrate with 4 8 different calibration points To calculate nonlinear coefficients for polynomials up to 5th grade an EXCEL software tool from IMKO can be used on request It is also possible to use any mathematical program like MATLAB for finding a best possible nonlinear calibration curve with suitable coefficient parameters mO to m5 The following diagram shows a sample calculation for a linear calibration curve with the coefficients mO and m1 for a
35. it is possible to aquire and store measurement data from several SONO probes with variable and longer cycle rates in a datalogger operation e g to store measurement data during a long term drying cycle IMKOy 39 45 7 1 7 Basic Balancing in Air and Water SONO probe heads are identical and manufactured precisely After an exchange of a probe head it is nevertheless advisable to verify the calibration and to check the basic calibration and if necessary to correct it with a Basic Balancing With a Basic Balancing two reference calibration measurements are to be carried out with known set points RefValues For the reference media different calibration materials are used dependent on the SONO probe type For SONO probes with a ceramic measurement window air and water tap water is used For other SONO probes like SONO GS1 glass beads are used for basic calibrations on request Attention Before performing a Basic Balancing it must be ensured that the SONO probe was set to Measure Mode A If this is not assured the probe returns zero values After a Basic Balancing the SONO probe has to be set to Measure Mode C again because otherwise the probe would not measure continuously In the menu Calibration and the window Basic Balancing the two set point values of the radar time tp are displayed with 60ps and 1000ps 1 Reference set point A tp 60ps in air the surface of the probe head must be dry The firs
36. ment result The calibration curve Call Universal Sand Mix is suitable for measuring the moisture in bulk sand gravel and gravel sand granulates The deviations for the below listed gravel sand types to the universal calibration curve Cal1 are so low that only one single calibration curve may be used Moisture in da pq co E 3 Fine Sand Sand 2 Gravel 2 4mm Gravel 4 6mm Li Gravel 6 12mm Gravel Sand Granulates Universal Calibration Call Tr N i HH i ES NI N NR N d SEEN d 100 150 N e e 250 tpAve Radartime in Picoseconds Gravel 4 6mm Gravel 6 12 mm Gravel Sand Granulates 24 45 IMKO 3 2 Creating a linear Calibration Curve for a specific Material The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with the help of SONO CONFIG Therefore two measurement points need to be identified with the probe Point P1 at dried material and point P2 at moist material where the points P1 and P2 should be far enough apart to get a best possible calibration curve The moisture content of the material at point P1 and P2 can be determined with laboratory measurement methods oven drying It is to consider that sufficient material is measured to get a representative value Under the menu Calibration and the window Material Property Calibration the calibration curves CAL1 to Cal15 which are stored in the SONO pr
37. mic in order to warrant for a long life span of the probe In spite of the robust and wear resistant construction the ceramic plate may not be exposed to any blows as ceramic is prone to breakage Attention Risk of Overvoltage In case of welding work at the plant all probes must be completely electrically disconnected SONO probes need a stabilized power supply with 7V DC to max 24 V DC With unstabilzed power supply there is the risk of overvoltage We strongly suggest not to use unstabilized power supplies Attention Risk of Malfunction In larger concrete plants it could be possible that there are used different mass potentials for different power lines especially if the PLC is installed in larger distance to the moisture probe Here it could come to problems that the analogue moisture signal 0 4 20mA could not be measured correctly in the PLC With such a problem we recommend to use an isolated powerbox for the SONO probe Available upon request by IMKO Any damage caused by faulty installation is not covered by the warranty Abrasive wear of sensor parts is not covered by the warranty IMKOJA WOSCMCDUUECHNK Y CNE 30 45 5 2 Assembly Dimensions SONO MIX MINI can either be installed at the base or the side wall of a mixer One fact to consider is that the installation into the mixer base also enables the measurement of smaller material quantities A cut out must be performed in the mixer base before welding on the moun
38. n time of 15 seconds CA CF CK inactive CC CH Number of discarded poor measurement values after the start of a new batch when No Material Delay has triggered The first measurement values will be rejected e g due to dripping water CA CC CF CH CK If the parameters Temperature or EC TRIME RbC are not needed the analogue output 2 can be setted tot he mode Moist Moist Std Deviation In this mode the standard deviation of all single moisture values can be outputted With this function the homogeneity of the single measurement values can be determined and it is possible to control a regulating process e g pressure regulation CA CC CF CH CK CS Recommended is Quick Precision with Meas Timez2 where the TDR pulse is detected precisely For still a little better accuracies Meas Time can be increased however the single measurement cycle is increased by 60 milliseconds per step e g from 280ms to 340ms Older SONO probe versions do not have this Quick Precision function Quick und Quick Precision With Meas Time no values Unit without unit 2 1 1 Average Time in the measurement mode CA and CF SONO probes establishes every 200 milliseconds a new single measurement value which is incorporated into the continual averaging and issues the respective average value in this timing cycle at the analogue output The averaging time therefore accords to the memory of the SONO probe The longer this time is selected the
39. nsation Therefore it is necessary to measure in parallel the material temperature with the temperature sensor which is placed inside the SONO probe Normally this is related with high efforts in laboratory works SONO probes offer the possibility to set special temperature compensation parameters tO to t5 for every calibration curve Cal1 of Cal15 see chapter Selection of the individual calibration curve Please contact IMKO should you need any assistance in this area 1 2 5 Temperature compensation of the internal SONO electronic With this method of temperature compensation a possible temperature drift of the SONO electronic can be compensated Because the SONO electronic shows a generally low temperature drift SONO probes are presetted at delivery for standard ambient conditions with the parameter TempComp 0 2 Dependent on SONO probe type this parameter TempComp can be adjusted for higher temperature ranges up to 120 C for special version to values up to TempComp 0 75 But it is to consider that it is necessary to make a Basic Balancing of the SONO probe in air and water if the parameter TempComp is changed to another value as TempComp 0 2 The parameter TempComp can be changed with the software tool SONO CONFIG in the menu Calibration and the window Electronic Temperature Compensation p Attention When changing the TempComp parameter a new basic balancing of the v SONO probe is necessaryl 1 2 6 Analogue Outputs The me
40. nulate SONO MIX Salz Lightly sand Sewage sludge oo ti MON e GJ n2 a W Linear Air to Water 1 10tp Material Coeffs Rn Set Default Calib Calibration Name Universal and Mix Set Temp Coeffs 5 6 20 0 06 0 3 45 IM Kos The desired and possibly altered calibration curve Cal1 15 which is activated after switching on the probes power supply can be adjusted with the button Set Default Calib The calibration name can be entered in the window Calibration Name The coefficients mO to m1 for linear curves and mO to m5 for non linear curves can be entered and adjusted directly by hand with the buttons Set and Save Possible are non linear calibration curves with polynomials up to fifth order mO m5 Attention Use dot as separator not comma for coefficients mO to m5 IMKOy 38 45 7 1 5 Test run in the respective Measurement Mode In the menu Test and the window Test in Mode CA to CF the measured moisture values MoistAve Average of the SONO probe are displayed on the screen and can be parallel saved in a file In the menu Test and the window Test in Mode CS the measured single measurement values Moist 5 values per second of the SONO probe are displayed on the screen and parallel stored in a file In Test in Mode A single measurement values without average are displayed on the screen and can also be stored in a file Attention fo
41. o zero measurement values which falsify the accumulated measurement value considerably recipe errors can occur Unlike current microwave probes SONO probes work in mode CC with automatic summation where it is really ensured that the measured material has contact with the probe This increases the reliability for the moisture measurement during one complete batch process The summation is only working if material fits at the probe Due to precise moisture measurement also in the lower moisture range SONO probes can record accumulate and store moisture values during a complete batch process without an external switching or trigger signal The SONO probe freezes the analogue signal as long as a new batch process starts So the PLC has time enough to read in the freezed moisture value of the batch For applications without a PLC the freezed signal of the SONO probe can be used for displaying the moisture value to a simple 7 segment unit as long as a new batch process will start With the parameter Moisture Threshold the SONO probe can be configured to the start moisture level where the summation starts automatically Due to an automatic recalibration of SONO probes it is ensured that the zero point will be precisely controlled The start level could be variably set dependent to the plant Recommended is a level with e g 0 596 to 1 With the parameter No Material Delay a time range can be set where the SONO probe is again ready to start a new
42. obe are loaded and displayed on the screen takes max 1 minute With the mouse pointer individual calibration curves can be tested with the SONO probe by activating the button Set Active Calib The measurement of the moisture value MoistAve with the associated radar time tpAve at point P1 and P2 is started using the program SONO CONFIG in the sub menu Test and Test in Mode CA see Quick Guide for the Software SONO CONFIG Step 1 The radar pulse time tpAve of the probe is measured with dried material Ideally this takes place during operation of a mixer dryer in order to take into account possible density fluctuations of the material It is recommended to detect multiple measurement values for finding a best average value for tpAve The result is the first calibration point P1 e g 70 0 l e 70ps picoseconds of the radar pulse time tpAve corresponds to 096 moisture content of the material But it would be also possible to use a higher point P1 e g 190 7 where a tpAve of 190ps corresponds to a moisture content of 7 The gravimetric moisture content of the material e g has to be determined with laboratory measurement methods oven drying Step 2 The radar pulse time tpAve of the probe is measured with moist material Ideally this also takes place during operation of a mixer dryer Again it is recommended to detect multiple measurement values of tpAve for finding a best average value The result is the second calibration po
43. ox 1700 kg m Sand gravel cement mixture dependent on water content between 2000kg m und 2400kg m A precise measurement of the raw density of the sand gravel mixture can be done with standard sample cubes 19 45 IM KO 2 3 1 Shortest expecting mixing times and density effects at partial loads Time to evaluate signal at dry mix stage The sensor can be configured depending on the requirements of the applications but in the pre setting it requires 15 20s till the value is stable after filling the mixer with aggregates and cement Time to evaluate signal at wet mix stage The sensor will immediately detect the incoming water but commonly it lasts a little till the water is distributed homogeneous thus we suggest not to have shorter wet mixing time than 45s Does density have an effect on accuracy If the mixer load varies from 20 to 100 of total mixer capacity it needs to calibrate for different loads At 2096 load the sensor could experience no material or less material Different density does always have an effect and on any sensor operating with an electrical field but how strong this effect is depends on the installation place in the mixer as closer to the wall of the mixer as less this effect is as due to the mixing energy with smaller batches more material is located at the outside of the mixer But it always has to be ensured that at least one mixing tool cleans the sensor per turn to ensure the sensor stays clean Even i
44. perature and the mineral contents of the measured material Microwave measuring systems operate with high frequencies 2GHz At these frequencies nonlinearities are generated which require very complex compensation For this reason microwave measuring methods are more sensitive in regard to temperature variation SONO probes calibrate themselves in the event of abrasion due to a novel and innovative probe design This consequently means longer maintenance intervals and at the same time more precise measurement values The quality of fresh concrete is the decisive factor for the stability and the durability of concrete constructions Hereby the two parameters moisture and cement content assume a central role as these determine the consistency and the desired mechanical stability of concrete The measurement of these two basic parameters therefore warrant for ideal quality and durability SONO MIX MINI accurately measures both in the dry mixture and in the wet mixture A dry mixture can e g be mixed with residual water varying solids content so that the water content to 7 096 target is met The remaining 3096 clean water content can then be dosed with SONO MIX MINI precisely 1 1 3 Areas of Application The SONO MIX MINI mixer probe is suited for installation into intensive mixers and chutes and other plant technologies MKO 5 45 1 2 Mode of Operation 1 2 1 Measurement Values with physically Pre check Average Value and Filterin
45. r a test run in mode CA CH CC CF CS or A it must be ensured that the SO probe was also set to this mode Measure Mode CA CF CS A If this is not assured the probe returns zero values r a Test in Mode CH Cyclic Average Hold m tn Ten Date MostAve MatTeno EC T ne TDRAve Getta tove Masti i Mast Maui Monti TORI TDAJ1I TDR3 ToR4 l 10 34 41 2906 2015 5 00 3 79 0 18 84 57 r 233 406 4 p 4 99 00 1 00 3 4 L 34 2 t0 34 40 2506 2015 1 23 70 Q 18 84 52 293 30 5 09 5 0 4 89 1 00 24 5 34 E 84 5 84 5 3 10 24 39 25 06 2013 49 a 29 0 17 54 3 193 20 493 4 94 4 54 1 00 st gs 5 64 5 94 5 Haz Graph T me s 4 10 34 38 25 06 2015 5 3 BA 2 133 63 196 5 11 1 00 1 00 54 6 546 LO 84 5 s r J gt 10 34 37 22 26 2013 5 06 21 79 C 15 03 58 3 133 48 5 14 3 4 57 1 00 n n 54 Bab 84 5 E 5 10 34 36 2506 2015 a PJ 0 16 64 55 3 192 35 455 4 e 3 09 1 00 54 6 54 84 5 84 5 10 34 35 15 06 2015 asi 24 2p 0 17 44 54 2 233 17 a i 2 1 09 1 00 f 4 LO na 5 JOTE 10 34 34 2506 201 4 94 PO 8 84 52 3 t 2 47 494 4 96 4 81 1 00 24 B t 54 84 vi P ti 1 34 33 2606 2015 4 9 23 9 6 17 Ha SA 1 v9 00 a 49 1 05 EN s Na a4 Li 10 34 32 2506 2015 4 97 23 70 Q 17 B4 5 2 122 33 5 AS 1 00 0 34 5 B46 1 34 i tata rer wa t1 10 94 31 25 06 2014 3 9 n 8a 452 i 192 s b 1 08 j D4 1 4 44 a4 Li 10 34 30 2506 2015 4 83 23 70 Q 17 B4 56 3 231 60 4s 4 54 4 95 24 6 4t 54 5 84
46. riods without the necessity of recalibration Many other probes deployed for the material moisture measurement are equipped with a dielectric screen ceramic or plastic plate If this screen is exposed to wear and a regular recalibration is not conducted these probes will provide faulty measurement values as the intensity of the measuring field subsequently increases due to the wear At the SONO series with the TRIME TDR radar based method the innovative probe design ensures for the automatic correction of the sensor in case of changes to the dielectric screen caused by abrasion This consequently means continuous reliability and longer maintenance intervals at the SONO probes 1 2 3 Determination of the Cement Concentration With the radar based TRIME measurement method it is now possible for the first time not only to measure the moisture but also to provide information regarding the conductivity respectively the cement content the expansion rate or the composition of a special material Hereby the attenuation of the radar pulse in the measured volume fraction of the material e g fresh concrete is determined This novel and innovative technology measures the same amount of material as with the moisture measurement and delivers a radar based conductance value EC TRIME Radar based Conductivity in dS m EC TRIME is a characteristic value which is determined in dependency of the cement concentration respectively the water cement ratio and is i
47. rocesses without floating average with internal up to 100 measurements per second and a cycle time of 200 milliseconds at the analogue output Measurement mode CS can also be used for getting raw data from the SONO probe without averaging and filtering MEASUREMENT MODE CA Cyclic Average Filter For relative short measuring processes with continual average value filtering and an accuracy of up to 0 1 MEASUREMENT MODE CF Cyclic Float Average for continual average value with filtering and an accuracy of up to 0 1 for very slowly measuring processes e g in fluidized bed dryers conveyor belts etc MEASUREMENT MODE CK Cyclic Kalman Filter Standard setting for SONO MIX MINI for use in fresh concrete mixer with continual average value special dynamic Kalman filtering and an accuracy of up to 0 1 SIGNAL OUTPUT 2 x Analogue Outputs 0 4 20mA Analogue Output 1 Moisture in 0 2096 variably adjustable Analogue Output 2 Wires are not occupied at the cable Conductivity RbC 0 50dS m or optionally the temperature In addition there is the option to split the analogue output 2 into two ranges into 4 11mA for the temperature and 12 20mA for the conductivity The analogue output 2 hereby changes over in 5 second cycles between these two current measurement windows The two analogue outputs can be variably aligned with the SONO CONFIG software For a 0 10V DC voltage output a 500R resistor can be installed CALIBRATIO
48. rror Reports and Error Messages SONO probes are very fault tolerant This enables failure free operation Error messages can be recalled via the serial interface IMKOJA 9 45 2 Configuration of the Measure Mode The configuration of SONO probe is preset in the factory before delivery A process related later optimisation of this device internal setting is possible with the help of the service program SONO CONFIG For all activities regarding parameter setting and calibration the probe can be directly connected via the serial interface to the PC with SM USB Module or the SONO VIEW display module which are available from IMKO The following settings of SONO probes can be amended with the service program SONO CONFIG Measurement Mode and Parameters e Measurement Mode A On Request only in network operation for the retrieval of measurement values via the serial interface e Measurement Mode C Cyclic SONO VARIO is supplied ex factory with suited parameters in Mode CH for measuring moisture of sand and gravel For other applications mode CA could be usable Up to 6 different modes can be adjusted Mode CS Cyclic Successive For very short measuring processes e g 2 10 seconds without floating average and without filter functions with internal up to 100 measurements per second and a cycle time of 250 milliseconds at the analogue output Measurement mode CS can also be used for getting raw data from the SONO probe without averaging
49. s T ets in t ES Le ARS T a Pi The follovving parameter setting in mode CA fits a high pass filtering for bridging material gaps Average Mode under Mode C CA Cuclic Average Average Parameters Average Times o o Filter Upper Limit Offset 200 0 Filter Lower Limit Offset 20 Upper Limit Keep Time h n Lower Limit Keep Time Bo The Filter Upper Limit is here deactivated with a value of 20 the Filter Lower Limit is set to 296 With a Lower Limit Keep Time of 5 seconds the average value will be frozen for 5 seconds if a single measurement value is below the limit of 2 of the average value After 5 seconds the average value is deleted and a new average value building starts The Keep Time function stops if a single measurement value lies within the Limit values MKO 13 45 2 1 3 Mode CC automatic summation of a moisture quantity during one batch process Simple PLCs are often unable to record moisture measurement values during one longer batch process with averaging and data storage Furthermore there are applications without a PLC where accumulated moisture values of one batch process should be displayed to the operating staff for a longer time Previously available microwave moisture probes on the market show two disadvantages 1 Such microwave probes need a switching signal from a PLC for starting the averaging of the probe This increases the cabling effort 2 Material gaps during one batch process will lead t
50. s and density effects at partial loads 19 2 3 2 SONO MIX to control the water cement ratio L keke 19 3 Gali Di allO DEBRIS cT m 20 3 1 1 SONO MIX MINI for measuring Moisture of Sand and Aggregates 23 3 2 Creating a linear Calibration Curve for a specific Material eseeesssseessss 24 3 2 1 Nonlinear calibration curves uuesnennneenennnnennennnnnnennnnnnnnnnnnnnennnn nennen nennen nnns 24 4 Connectivity to SONO PROD S i rome v Lus doe uni vnu Evans ud Rd ue Vaid nm ee nee 26 4 1 1 Connection Plug and Plug PINNING kk KK kK 27 4 1 2 Analogue Output 0 10V with a Shunt Resistor susmmssssrssssssrresessrreosrsrrnnnrrrrronrrrrrnnnrr kek 28 4 1 3 Connection diagram with SONO VIEW aaa aaa eee eee nene nene eee ee eee eee ente tete rep eee eee eee 28 5 Installation of the PTODE nunmehr aaa na ann rain 29 5 1 Assembly Instructions E ner eper eee eee nnne RKA RR RR RR nnne RAR KKR snas nnn nnns 29 3 45 5 2 Assembly DimenSsiorS E ii kk rens nennen nennen nnne KAK pere KRK RR KRKA KKR RR RR nnns 30 5 1 Installation of the SONO MIX MINI inside a Screw Conveyor aaa nanen nenen 31 5 1 1 Installation of the SONO MIX MINI in a mobile Mixer Truck esses 31 Connection of the Probe to the SM USB Module from IM KO 32 Quick Guide for the
51. s is the mixture Dry value A D Measurement 7 232mA 4 396 10811 This is the values of This is the more PLC value more wet wet value A D where the mixture concrete mixture has exactly 20 0 liter more water inside Note For prefab concrete with higher flow spread it is recommended to record the wet measurement values without concrete plasticizer in the mixture The reason is that the plasticizer modifies the density of the fresh concrete considerably which leads to deviations in the measurement values 3 Determination of the Sensitivity of the SONO MIX for this recipe For calibration and calculation of the mixing water for further mixtures the coefficient c1 Sensitivity of the SONO MIX can be calculated easily in the following way c1 Sensitivity 10811 8126 20 0 liter 2 134 25 digits PLC per liter water Attention This sensitivity is a value for the concrete volume which is used in this procedure for e g 1 0 cubic meter concrete For higher or partial volumes it is necessary to calculate the added water content up or down dependent on the volume Because the SONO MIX measures moisture precise also with different grain size distribution it is possible to calculate with a standard c1 Sensitivity for similar recipes For very different recipes e g recipes with coloring agents or other added special materials it is recommended to check the c1 Sensitivity and if necessary determine a new c1 Sensitivity IMKO OICMO
52. specific material 25 45 excom acm ies grav Moisture in t Ave Radartime 4 05 in Picoseconds The coefficient m is calculated from the slope of the curve Cal14 Delta y 25 0 Coefficient mq mee 0581 Delta x 500 70 The coefficient mg is the offset on the y axis at x 0 Coefficient mg Y2 m4 X2 25 0 0581 500 4 05 v MCROMCDUUECHNH Y GER IMKO 26 45 4 Connectivity to SONO Probes Appin pur Asea epeus eq ue agod eui O Sua 4snipe i 4NOO ONOS 97eMjos eei eu ul uongwurquoo al UJ pou Duige ado ajeudosdde ue o auiuo sqoud ONOS siwnbgyuos U3 s G lOnuo IOLA SEPSH AOL oO JO vues seqoud ONOS Jao eu IB pue Y yugg 0 J ld Sup win AN Aot 0 a yuo t vuo2 0 qi OlHvA ONOS a as fejdsig a31 d P T S Uo yS EE wie amp WAX OlHVA ONOS N Y XIW ONOS x Oll VA ONOS d uoquiqie punpiwout ug SHEL Of JO ejep suydeo 0j ejydurgxe 304 eqoud ay umm SPESIUNLUJOI pug Od v ule eqoud ONOS NDA j29uuco uva Of ajq ssod s y AA3IA ONOS END euojg punss equi UPM M3IA ONOS 27 45 wecnowcoureceae V CNB 4 1 1 Connection Plug and Plug Pinning SONO MIX MINI is supplied with a 6 pole cable with 5 meter length Assignment of the 6 pole sensor cable connections Sensor Connections Lead Colour Lead Colour 7V 24V Power Supply Wei OV Power Supply 1 Analogu
53. ssued as an unscaled value The EG TRIME measurement range of the SONO MIX MINI is 0 50dS m 1 2 4 Material Temperature Measurement A temperature sensor is installed into the SONO probe which establishes the casing temperature 3mm beneath the sensor surface The temperature can optionally be issued at the analogue output2 As the TRIME electronics operates with a power of approximately 1 5 W the probe casing does slightly heat up A measurement of the material temperature is therefore only possible to a certain degree The material temperature can be determined after an external calibration and compensation of the sensor self heating The offset of the measured temperature value can be adjusted with help of the program SONO CONFIG Despite SONO probes show a generally low temperature drift it could be necessary to compensate a temperature drift in special applications SONO probes offer two possibilities for temperature compensation MKO 6 45 Temperature compensation for the measured material Water and special materials like oil fruits and others can show a dependency of the dielectric permittivity when using SONO probes at high temperature ranges The dielectric permittivity is the raw parameter for measuring water content with SONO probes If special materials show a very special temperature drift e g in lower temperatures a higher drift than in higher temperatures than it could be necessary to make a more elaborate temperature compe
54. t set point can be activated with the mouse pointer by clicking to No 1 By activating the button Do Measurement the SONO probe determines the first reference set point in air In the column MeasValues the measured raw value of the radar time t is displayed e g 1532 05 picoseconds 2 Reference set point B tp 1000ps in water The SONO probe head has to be covered with water in a height of about 50mm The second set point can be activated with the mouse pointer by clicking to No 2 By activating the button Do Measurement the SONO probe determines the second reference set point in water In the column MeasValues the measured raw value of the radar time t is displayed 3 By activating the button Calculate Coeffs and Coeffs gt Probe the alignment data is calculated automatically and is stored in the SONO probe non volatile With a Test run in Mode A the radar time tp of the SONO probe should be now 60ps in air and 1000ps in water Basic Balancing Refvaluesitp ps Moisty alues Measvaluesitii ps Comments Coefficients lt Calculated gt lt in File gt lt in Probe gt b 1889 74 b1 1 24275 Do Measurement Calculate Coeffs Coeffs gt Probe Close IMKO 40 45 7 1 8 Offsetting the material temperature sensor Material Temp Offset In the menu Calibration and the window Material Temp Offset a zero point offset can be adjusted for the material temperatur sensor which is installed
55. the first false measurements after opening the silo flap The measurement cycle starts if the probe detects the Moisture Threshold value and freeze the analogue output value until the next cycle MKO 15 45 2 2 Overview of single modes for different applications The following table gives an overview about possible parameter settings in different modes Application Sand Above a Inside a Inside a Gene ina screw At the Installation Gravel conveyor mixer fluid bed rally conveyor end of a and specific under a belt dryer simple with screw Parameters silo flap appli filtering conveyor cations options due to Long metal term process Operating Mode Average Time Filter inactiv inactiv uM inactiv e g 20 inactiv Upper Limit 100 100 100 100 100 Offset Filter inactiv inactiv inactiv inactiv e g 10 inactiv Lower Limit 100 100 100 Offset u mr inactiv inactiv inactiv For very difficult applications where it is not certain which mode is the best we recommend to select mode CA with averaging time 1 second With help of the software SONO CONFIG a data record can be stored directly during process conditions After forwarding this data set to IMKO we would be pleased to be at your disposal for finding the best suitable working mode m Upper o inactiv inactiv inactiv Limit Keep 10 Time Lower bru inactiv inactiv inactiv Limit Keep 10 Time Moisture Threshold No Material Delay te Weight D
56. ting frame and it is necessary to verify the fit of the frame and the probe at the base respectively the wall IMKOy 31 45 5 1 Installation of the SONO MIX MINI inside a Screw Conveyor The installation of the SONO MIX MINI inside a screw conveyor ensures optimum conditions concerning material flow and material density because the measured material is not loose but is condensed by the screw Cut out SONO MIX MINI of the spiral The SONO MIX MINI can be installed along the screw conveyor It is recommended to attain a mounting angle with a limit value of 30 to ensure that enough material lies above the probe s surface Optionally the spiral conveyor can be cutted so that a plug formation ensures that enough materials lies above the probes s surface It is also possible to install the probe at the end of the screw conveyor where it is also ensured that enough material in a backlog with a relative constant density lies above the probe s surface It is recommended to use measurement mode CF if the spiral is cutted out of if the probe is installed at the end of the screw conveyor Furthermore it is possible to install the SONO MIX MINI in the middle of the screw conveyor without a cut out of the spiral Here it is necessary to set appropriate filter algorithms because the metal of the spiral has an influence of the measurement The appropriate parameters have to be found depend
57. to the mixer it is important to take this into account In general the calibration of the probe for the water addition by a PLC has to be determined with laboratory measurement methods oven drying A maximum of 15 different calibration curves Call Cal15 are stored inside the SONO probe and can optionally be activated via the program SONO CONFIG If SONO MIX MINI is used without mixer operation only for measuring the moisture content of aggregates like sand and gravel then the calibration curve Cal 1 Universal Sand Mix must be set If SONO MIX MINI isn t used inside a mixer but e g beneath a flap the operation mode must be changed from CK to CA A preliminary test of an appropriate calibration curve Call 15 can be activated in the menu Calibration and in the window Material Property Calibration by selecting the desired calibration curve Cal1 Cal15 and with using the button Set Active Calib The finally desired and possibly altered calibration curve Call 15 which is activated after switching on the probes power supply will be adjusted with the button Set Default Calib Nonlinear calibrations are possible with polynomials up to 5th grade coefficients mO to m5 IMKO publish on its website more suitable calibration coefficients for different materials These calibration coefficients can be entered and stored in the SONO probe by hand Cal14 and Cal15 with the help of SONO CONFIG The following charts Cal 1

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