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User Manual SONO-VARIO

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2. 1 2 8 Temperature 1 2 4 Temperature compensation when working at high temperatures 12 5 Analogue EEE EEE 1 2 1 serial RS485 and IMP Bus 1 2 2 The IMP Bus as a user friendly network 1 2 8 Error Reports and Error 2 Configuration of the Measure Mode nnurnnnnnnnnennnnnnnnvennnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnennnnnnnnvennnnn 2 1 Operation Mode CA and CF at non continuous Material Flow 2 1 1 Average Time in the measurement mode CA and 2 1 2 Filtering at material gaps in mode CA 2 1 3 Mode CC automatic summation of a moisture quantity during one longer batch process 11 2 1 4 CH Automatic Moisture Measurement in one Batch 2 1 5 How to use the SONO VARIO with extremely short Batching Times 2 2 Overview of single modes for different 3 SONO Probes for measuring Moisture of Sand and Aggregates 3 1 1 SONO probes in use with different sand grading A CIDAUN 4 1 Creati
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5. Moisture Range r Temperature Range 5 cm et Maximum 100 Set 020 0 50 Minimum 0 Set Minimum 0 set Maximum 125 Simulate Close IMKOV 43 48 7 1 4 Selection of the individual Calibration Curves In the menu Calibration and the window Material Property Calibration the calibration curves CAL1 to Cal15 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 X Calibration Item Set Active Calib Default Calibration Item Please select one calibration from Call to Call5 to operate 00000 Ma Calibration 00000 00000 00000 1 06035 Unitversal S and Mix jeas 06000 gepi 2 06040 Lime Sand Linear 06000 gegi 3 06041 Cement Powder 06041 0 000 Set Default Calib 4 05042 Wood Pellets 05042 06000 gepi z 06043 Wheat 06043 Denn 06000 M 06044 Flour 06044 05000 06000 ad 05045 Suger 05045 06000 6000 Universal Sand Min B 4 Brown coal granulate 4 3 0504 7 0504 7 06000 06000
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7. In case of welding work at the plant all probes must be completely electrically disconnected Any damage caused by faulty installation is not covered by the warranty Abrasive wear of sensor parts is not covered by the warranty 5 1 1 Protection of the Probe 5 Connector against Abrasion If sand and gravel flows above the buffle plate and could touch the probe connector of the SONO probe than it is recommended to mount an extra protection for the probe s connector This is feasible e g with a commercial flexible garden hose with an inner diameter of 27mm The hose can be slotted longitudinally and can be mounted around the connector and the cable It could be fixed with cable ties The following picture shows this solution for protection of the probe s connector IMKO MECROMCOULTECHNII V GVB 30 48 5 2 What could be done if the Material Flow is not optimal There are plants where the material flow is so bright that the material height is too less above the probes surface Following picture shows a funnel chute where guiding plates left and right and also above the probe are bundling the material flow Especially with sticky sand or other sticky materials it is recommended that the guiding plates are coated with PTFE or another plastic Please consider The minimum material height above the probes surface is 30mm For discarding poor measurement values it is also possible to implement filter functions in the S
8. SONO VARIOstandard for general fine Bulk Goods like Sand SONO VARIOxtrem for very high abrasive Goods like Gravel and Grit SONO VARIOLp for low Density Materials like Woodchips IMKO Micromodultechnik GmbH Telefon 49 0 7243 5921 0 Im St ck 2 Fax 49 0 7243 90856 D 76275 Ettlingen e mail info imko de http www imko de I publik TECH_MAN TRIME SONO ENGLISH SONO VARIO SONO VARIO Xtrem LD MAN Vers2_3 english doc MKO y 2 48 User Manual for SONO VARIO As of 02 December 2014 Thank you for buying an IMKO moisture probe Please carefully read these instructions in order to achieve best possible results with your SONO VARIO probe for the in line moisture measurement Should you have any questions or suggestions regarding your new 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 VARIO nerrnnnnnnnnnnnennnnnnnnnnnnnvennnnnnnnnnnnnnnnnnnnnnnnnnnsennennnnnnnnnnr 1 1 1 The patented TRIME TDR Measuring Method nes 1 1 2 TRIME compared to other Measuring Methods 1 1 3 Areas of Application with SONO VARIOStandard SONO VARIOXtrem and SONO VARIO 4 L2 o EEE EE 1 2 1 Measurement value collection with pre check average value and filtering 1 2 2 Determination of the mineral
9. The TRIME TDR technology with the radar method offers high reliability for measuring moisture of sand and aggregates Conventional measurement techniques such as microwave technology show considerable dependencies in different grading ranges The calibration curve Universal Sand Gravel Grit of a SONO probe is suitable for measuring the moisture in sand with a grading size of 0 2mm as well as in gravel and grit Moisture in m c Fine Sand 1 Sand Gravel 2 4mm 222 Gravel 4 6mm __ Gravel 6 12mm Gravel Sand Granulates Gravel 4 6mm Gravel 6 12mm Gravel Sand Granulates 1 Universal Calibration Cali 100 150 200 250 tpAve Radartime in Picoseconds r IMKO 17 48 3 1 1 SONO probes in use with different sand grading ranges The sand densitiy is varying depending on grading ranges but also on mineral type The SONO probe as standard version is calibrated with calibration curve for sand with a grading range of 0 2mm With Cal1 it is also possible to measure gravel and grit Depending on grading ranges the bulk density of sand is varying considerably Therefore for other grading ranges up to 0 8mm there are other calibration curves Cal1 to Cal6 stored inside the SONO probe Following table gives an overview about the calibration curves inside the SONO probe for sand gravel and grit Aggregates Bulk Density in kg dm Recommended and
10. 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 They are not galvanically isolated and therefore raises the danger of mass grindings or interferences which can lead to considerably security problems An 5485 network needs shielded and twisted pair cables especially for long distances Depending on the topology of the network it is necessary to place 100Ohm termination resistors at sensitive locations In practice this means considerable specialist effort and insurmountable problems The robust IMP Bus ensures security SONO probes have in parallel to the standard RS485 interface the robust IMP Bus which is galvanically isolated 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 Error Reports and Error Messages SONO probes are very fault tolerant This enables failure free operation Error messages can be recalled via th
11. Therefore the dry probe head must be free in air When the LED is on continual for 5 seconds the first calibration point is completed in air Now the blue LED starts with a quicker blinking during 10 seconds preparation time for the second point in water During this 10 seconds the probe head must be plunged in water When the LED is on continual for 5 seconds the calibration is completed in water After that the LED is off If the calibration should be failed the blue LED will be blinking continual Unplug the MIL connector and the calibration connector Plug in the blind cap of the calibration connector Plug in the MIL connector again The blue LED should be active continual now SONO VARIO is ready to use With strong pressing of a hand to the probe head the analogue moisture output 4 20mA should be respond If necessary the basic balancing procedure could be repeated several times Probe head must LED is LED is out LED is on ME blinking Unplug the continual Plug in the calibration connector Plug in the Preparation Air MIL connector with for 10s LED is blinking calibration SONO MIX is quicker 10s Water connector ready to use time for calibration Plunge the calibration Unplug MIL Screw blind cap calibration completed probe head completed connector and of calibration power SUPPE successfully into water successfully Plug it again connector mmm 3 seconds 10 seconds 5 seconds 10 second
12. 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 296 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 IMKO 4 11 48 Sufficient material for an accurately moisture measurement value of e g 8 Material gaps over e g 3 seconds which must be bridged for an accurately measurement with a Lower Limit Keep Time of 5 seconds A m M P eL RECEN lt n NE HD 7 y The following parameter setting in mode CA fits high pass filtering for bridging material gaps Average Mode under Mode C CA Cuclic Average Average Parameters Average Time s Filter Upper Limit Offset 20 Filter Lower Limit Offset 20000 Upper Limit Keep Time mo 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
13. 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 the conductivity of the measured material The established moisture content as well as the conductivity respectively the temperature can either be uploaded directly into a PLC via two analogue outputs 0 4 20 mA 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 mineral concentration specified in a recipe has been complied with This means more reliability at the production 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 temperature and the mineral contents of the measured material Microwave measuring systems operate with high frequencies 2GHz At these freque
14. 48 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 Operating Mode Average Time Filter inactiv inactiv m inactiv Upper Limit 100 100 100 100 Offset Filler inactiv inactiv inactiv inactiv Lower Limit 100 100 100 100 Offset e g 20 inactiv 100 e g 10 inactiv 100 inactiv inactiv inactiv inactiv For very difficult applications where it is not certain which mode inside the SONO probe 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 Upper inactiv inactiv inactiv Limit Keep 10 Time Lower bro inactiv inactiv inactiv Limit Keep 10 Time Moisture Threshold No Material Delay X m Weight Invalid Measure Count O O IMKO MERCMCDULTECHNI 16 48 3 SONO Probes for measuring Moisture of Sand and Aggregates
15. Serial Port Audio wideo und Gamecontroller 38 Bildbearbeitungsger ate Bluetooth 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 5 von USB Serial Part COM Lrwetlerie Linsietiungen tier COM Lad Anschiussemdmhungen Teby Dess COMI P ackntorniien CONZ Sekunder er HUE alm nn Se Werte e pereks belegt y Boudeaten zu beheben 9 Sui Werte TG pensis 7 4 Paid Kane Emo argen Bytes COMG belegt COM berets sanden Staten COMLO erets beg COML1 berote belegt COML2 erata balag 2OMLS Coe o FHarteururg hare rue 4 Aerts rere Aitae Coton fuoduserm Se de werte uj OFT berate being lt veram COMIS Gerets besiegt PlugPtary Pr pr Mcr COMIT being gn Erter Wyeded e seder drake COM
16. USB Module from IMKO 39 Quick Guide for the Commissioning Software SONO CONFIG 41 7 1 14 Scan of connected SONO probes on the serial interface 41 7 1 2 Configuration of Measure Mode and serial SONO interface 42 7 1 3 Analogue outputs of the SONO 42 7 1 4 Selection of the individual Calibration Curves 43 7 1 5 Test run in the respective Measurement 44 7 1 6 Measure run in 44 7 1 7 Basic Balancing in Air and 45 Technical Data 46 MKO 4 48 1 Instrument Description SONO V ARIO 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 dielectric constants respectively the moisture content are determined SONO VARIO consists of a high grade steel casing with a wear resistant sensor head with ceramic window An integrated TRIME TDR measuring transducer is installed into the casing A high
17. 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 Nonlinear calibrations are possible with polynomials up to 5th grade coefficients mO m5 IMKO offers more suitable calibration coefficients for different materials These calibration coefficients can be entered and stored in the SONO probe by hand with the help of SONO CONFIG The charts Cal 1 15 in the next two pages show different selectable calibration curves which are stored inside the SONO probe Plotted is on the y axis the gravimetric moisture MoistAve and on the x axis depending on the calibration curve the associated radar time tpAve in picoseconds 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 In air SONO probes measure typically 60 picoseconds radar time in water 1000 picoseconds
18. moisture output 2 for temperature Or 2 Moist Conductivity Analogue output 1 for moisture output 2 for conductivity in a range of 0 20dS m Or 3 Moist Temp Conductivity Analogue output 1 for moisture output 2 for both temperature and conductivity with an automatic current window change 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 Minimum 0 Minimum 0 MKO y 7 48 1 2 1 The serial RS485 and IMP Bus interface SONO probes are equipped with a standard RS485 as well as 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 RS485 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 for the IMP Bus To operate with the RS485 inside the SONO probe it is necessary to switch and activate the RS485 interface with help of the modul SM USB or SONO VIEW In the download area of IMKO s homepage www imko de we publish the transmission protocol of the SONO probes
19. stored in a file Attention for a test run in mode CA CF CS or A it must be ensured that the SONO probe was also set to this mode Measure Mode CA CF CS A If this is not assured the probe returns zero values in Mode CA Cyctic age Dete MostAve TD Ave toe Mosti Moist Most TOAL 1082 TOR 16 04 08 11 03 2014 7 56 26 50 50 00 91 07 4 222 88 7 50 7 50 757 7 50 910 910 9140 16 04 07 1140 2014 7 9 20 90 JAR 91 07 gt 222 65 FM 7 L00 1 0 910 910 11 03 2014 7 26 50 50 00 21 00 4 221 74 8 10 2 5 7 4 757 20 9140 91 0 10 09 05 1140 2014 25 20 52 00 90 93 3 220 98 7 50 SLO 910 310 16 09 09 12 03 2014 7 46 26 20 50 00 1 00 3 221 33 7 7 44 1 00 2 0 91 0 91 0 6 04 03 11 03 2014 25 2 50 00 91 00 221 56 6 32 7 50 31 0 91 0 0 16 04 00 1540 2014 7 52 26 50200 91 07 3 222 30 5 7 7 50 1 00 910 910 16 04 01 11 03 2014 26 5000 91 1 gt 22 62 7 4 7 44 1 00 31 0 920 91 0 16 04 00 11 03 2014 7 52 26 20 50 00 91 14 222 98 7 51 5 7 5 74 910 910 910 16 03 59 11 03 2014 26 20 50 00 91 21 3 2235 7 51 7 44 1 00 910 910 910 10 03 59 11 02 2014 20 20 50 00 91 21 221 44 7 91 7 37 Sl 9 2 910 BO 16 03 57 11 032014 26 00 50 00 91 21 3 223 6 7 5 75 1 00 910 920 9 0 16 03 56 11 03 2014 26 00 50 00 91 1 51 7 5 7 44 100 9 0 910 91 0 16 03 55 11 03 2014 26 00 50 00 91 1 222 9 45 7 494 804 910 910 0 16
20. y 25 0 Coefficient 0 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 24 48 IMKO MEROMCDUTZCHNIE Y GNB 4 2 Connectivity to SONO Probes Uiajs c OJ lU 075 10 58Q050 ONOS 9040 pue ms OtHVA ONOS XIW ONOS OIHVA ONOS Kejdsig q31 Gimme uv Of ayip OG exduiexa 204 20070 sul EJEA UNUO PUB Od Aanb Apsee aq URI eqoid 21 nipe DIINOD ONDS eiemijos 8 SUI ULM uogeuiquoo Ul sgud ONOS VED ve auno seqoid oNOS gt ajqesod si A3IA ONOS BUO E PUBYS eu ULM M3IA ONOS IMKO Y 25 48 4 2 1 Connection Plug and Plug Pinning SONO VARIO is supplied with a 10 pole MIL flange plug Assignment of the 10 pole MIL Plug and sensor cable connections Sensor Connections 7V 24V Power Supply red 0000 1 Analogue Positive Moisture Green 1 Analogue Return Line Moisture yellow RS485 A has to be activated RS485 has to be activated brown 000 2 Analogue Positive Pink Pink 2 Analogue Return Line Screen transparent tr
21. 03 54 11 00 2014 75 26 00 50 00 51 07 3 222 8 04 1 00 910 92 0 16 09 53 14 03 2014 7 4 5 00 90 93 221 23 7 51 7 51 100 900 910 71 0 16 03 52 11 03 2014 7 5 50 00 91 07 22 15 7 45 74 7 51 90 910 91 0 16 03 51 11 03 2014 55 06 41 1 3 222 6 7 5 751 10 210 90 16 03 50 11 03 2014 7 5 50 00 91 14 222 7 46 745 745 910 900 91 6 16 03 49 11 20 2014 re 20 0 91 29 2 t 1 00 920 92 0 16 03 68 11 03 2014 26 00 50 00 91 21 3 23 0 7 98 74 100 920 910 90 10 03 97 11433 2014 5 25 70 502 00 91 1 22 55 73 7 4 41 00 9101 1 0 16 03 46 1108 2014 25 70 50 00 1 14 242 63 2 9 7 52 7 52 920 71 0 16 03 45 11 03 2014 55 00 91 1 3 2225 7 45 7 7 45 1 00 910 91 0 16 03 44 18 03 2014 25 5000 91 14 3 222 52 7 45 8 05 1 00 910 902 0 16 03 43 11 03 2014 25 70 50 00 91 14 2 39 7 45 7 45 7 45 910 910 10 03 42 11 09 2014 7 52 25 3 1 14 922 38 4 00 91 0 91 0 16 03 44 12 03 2014 25 50 50 00 91 07 7 4 7 46 7 46 910 91 16 03 40 11 02 2014 7 46 75 90 50 00 91 07 3 pO 7 94 7 46 1 00 920 91 0 16 03 39 11 03 2014 50 00 91 07 2 7 46 7 46 7 6 1 00 910 1 0 Following measurement values 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 res
22. 35 Do Measurement Calculate Coetts Coetts gt Probe Close MKO 46 48 8 Technical Data SONO VARIO SENSOR DESIGN Casing High Grade Steel V2A 1 4301 SONO VARIOStandard The probe head surface consists of stainless steel with abrasion resistant aluminium oxide ceramic SONO VARIOXtrem The probe head surface consists of hardened steel with highly abrasion resistant Si3O4 ceramic SONO VARIOLD The probe head surface consists of stainless steel with abrasion resistant special ceramic Available are high temperature versions of the SONO VARIO up to 150 C with external measurement transformer SONO ES upon request MOUNTING Sensor Dimensions SONO VARIOStandard 108 x 45mm diameter x length SONO VARIOxXtrem and LD 108 x 71mm diameter x length The mounting flange can be screwed on to the rear side of any container hopper or silo MEASUREMENT RANGE MOISTURE The sensor measures from 0 up to the point of material saturation Measurement ranges up to 10096 moisture pure water are possible with a special calibration MEASUREMENT RANGE CONDUCTIVITY The sensor as a material specific characteristic value delivers the radar based conductance EC TRIME in a range of 0 12dS 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 3mm beneath the wear resistant sensor head inside the sens
23. LO teet s herr Sareko a COMIS Abbrechen der wenn das Gel 77 20 belegt verd Treo Event bei unvorhergesehenis des tr Utt aes Mirinae Anoahle Lese T 2224 Dan Shien der Vertindung RIS aktiv 45 eroti bewy der Modemenseusrung bamn a c oes des Garate r k COM Come COMTS After changing the COMXx port settings SONO CONFIG must be restarted MKO y 41 48 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 SonoConfig E 5 x Serial Port Exik Bus Help LN 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 kli
24. ONO probe with Upper and Lower Limit please take a look under chapter Operation Mode IMKO 3 1 4 8 MECROMOCDUTECHNIE Y GNB 5 3 Assembly Dimensions SONO VARIO can either be installed at the base or the side wall of containers One fact to consider is that the installation into the container base also enables the measurement of smaller material quantities A mounting flange is available for SONO VARIO The flange can both be welded on to the base and the side wall of the container The probe can be adjusted to the correct position respectively correct installation height SONO VARIOsStanaard 108mm Probe Diameter 2 N 3 X Vessel a w wall N Mounting SONO VARIOstandarc Flange SONO VARIOxtrem and VARIOLD 108mm Probe Diameter FR dn 2 I E Vessel SK Wall a Mounting Flange SONO VARIOxtrem 32 48 Vessel Wall SONO VARIO Dimensions of the Mounting Flange IMKO 33 48 MECROMODUTECHNIE 7 5 4 Mounting in curved Surfaces In order to prevent the probe head from projecting and interfering with wipers the centre of the probe head should be flush with the radius of the wall The ceramic must be laterally aligned to the rotational axis as the gap towards the wipers is smallest in this position In order to ensure that the probe head is completely covered with material the probe is best positioned near the base In or
25. Set 10 06043 Expanded clay 06043 06000 06000 11 05049 Lightly sand 05049 Material Temp Coetts 12 06050 Sewage sludge 06050 06000 06000 13 06054 Ceramic Suspension 06054 9 5 14 06058 Aj to Water 06058 06000 Den 0 05 15 06053 15 06053 06000 06000 0 0 0 m5 Set Save Head 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 0 5 Attention Use dot as separator for mO to m5 not comma MKO 44 48 7 1 5 Test run in the respective Measurement Mode In the menu Test and the window Test in Mode CA or 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
26. 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 should be noted that no material sticks on the probes surface Otherwise the moisture zero point of the probe will be shifted up and the probe would not be detect a moisture low value below the Moisture Threshold Time chart for mode CC Moisture 5 3 1 IMKO 1 3 48 The first batch process stops SONO probe recognizes that the measurement value is below the moisture threshold of 1 and the probe stops automatically with the summation yellow curve Short interruptions were bridged bw Start of first batch process The SONO probe recognizes that the adjustable moisture threshold of e g 1 has been exceeded and the probe starts automatically with the continuous accumulation of measurement values yellow curve The last freezed summerized and averaged moisture value is freezed at the analogue output until the No Material Delay time of e g 5 seconds has expired and a new batch process starts Time Start of second batch process After the period of No Material Delay e g 5 seconds the SONO probe recognizes that the threshold of 195 has been exceeded The previously stored measurement value is cleared and the probe s
27. ansparent is grounded at the sensor The plant must be properly grounded IMKO 26 48 4 2 2 Analogue Output 0 10V with Shunt Resistor There 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 2 3 Connection Diagram with the Display Module SONO VIEW The stand alone module SONO VIEW permits the display of moisture values and configuration for advanced process control with SONO probes _ SONO VARIO PL SONO SILO ui 24V DE Power Suppl F a 58 aerma dH 2 2 58 52 29 IMP Hus COM 26 e 5 TT mu GE _IMP Bus RT 58 E Jill Re u 1 Analog Positiv 1 Analog Positiv I E NE 1 Analog Positiv 0 4 20mA PLC 0 4 20mA SONO VIEW Analogue input or Analogue input Installation in the control motsture moisture roam er inside the Distribution Cabinet distribution cabinet IMKO 27 48 MECROMCOUTECHNIE Y 5 Installation of the Probe The installa
28. as well as individual applications
29. be adjusted with the button Set Default Calib Attention Use dot as separator 0 0581 not comma IMKO 23 48 4 1 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 which can be entered into the probe with help of SONO CONFIG The following diagram shows a sample calculation for a linear calibration curve with the coefficients mO and m1 for a specific material e SONO Prbbe New Calibration Curve grav Moisture in oe e 30 HIS ROB 4 20 9 M M 25 0225 10 ee SED ED EE SE ED eee Delta y P 100 200 300 400 500 600 700 ty Ave Radartime in Picoseconds 4 05 The coefficient m is calculated from the slope of the curve Cal14 Delta
30. c 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 1 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 occurs Each of these settings will be preserved after shut down of the probe and is therefore stored on a permanent basis 2 1 Operation Mode CA and CF at non continuous Material Flow For mode CA and CF 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 required 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 th
31. 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 falsify the measurement e With the universal holder deliverable by IMKO the SONO VARIO can be placed above a conveyor belt Particularly with inhomogeneous or loose sand the material can be constantly condensed which leads to higher measurement results Areas with strong turbulences are not ideal for the installation There should be a continuous material flow above the probe head e For special installations inside mixing containers it should be noted that the stirring movement of blades should be conducted without gaps above the probe head e he probe should not be installed in the direct vicinity of electrical disturbing sources such as motors n case of curved installation surfaces in containers the centre of the probe head should be flush with the radius of the container wall without disturbing the radial material flow in the container The probe may not project and come in contact with blades or wipers e The probe connector should be protected against splashing water after installation Attention Risk of Breakage The probe head is made of special steel and a very wear resistant ceramic plate 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
32. cking Exit Config Calibration Test IMKO MECRCMCDUTECDHNHI 42 48 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 5485 or both interfaces Due to very robust behavior it is recommended to select the IMP Bus Measure Mode amp Parameters Default Cycle Mode Cyclic Set Default Mode amp Parameters Actual Cycle Mode Cyclic I Average Mode of Mode C CA Cyclic Average Select Bus Kalman with Boost C No Pa C IMP amp RS485 Offset with Moist ve 10 fe IMP Average Parameters Average Time s RS485 Filter Upper Limit Offset Filter Lower Limit Offset 52 Set Upper Limit Keep Time Lower Limit Keep Time Moisture Threshold No Material Delays iu Boost Offset Weight Invalid Measure Count Set 7 1 3 Analogue outputs of the SONO probe In the menu Config and the window Analog Output the analogue outputs of the SONO probe can be configured see Chapter Analogue outputs Analog Qutput Output Current 0 20m4 C 4 20m 20 0m C 20 4m Dutput Channels Moist Temp C Moist Conduct C Moist Temp Conduct
33. ctor for measured values This parameter otandard Setting 5 influences the reaction response time Setting Range 0 5 Invalid Measure Count This parameter works only in mode CC or CH Number of MKO 10 48 Standard Setting 2 discarded poor measurement values after the start of a Setting Range 0 10 new batch when No Material Delay has triggered The This par meter is de activated in first measurement values e g due to dripping water will be mode CK rejected 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 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 disp
34. der to prevent water from accumulating above the sensor head which could falsify the measurement an installation angle of approximately 30 above the base centre is recommended Fill the crack The centre of the with sand or silicone sensor head should be flush with the radius of sealing compound _ the vessel wall The sensor may not project The ceramic must be Welded on laterally aligned to the Mounting rotational axis Frame s 30 Clamping gt Collar Vessel Wall Probe SONO VARIO 5 5 Funnel shape for higher material depth If a too quick material flow leads to a too low material height above the probes surface than a guided funnel shape plate arrangement under a vibration chute could solve the problem The plates are ideally coated with PTFE for a better adherence behavior 34 48 5 6 Gas and waterproofed Installation For a pressure tight installation in a temperature range of 20 C to 80 C a flange installation is recommended The mounting flange can be welded to the container wall Sealing is possible with a 5 5mm thick O ring which is fixed with a locking ring Vessel Wall Mounting Flange Locking ring SONO VARIO 108mm Probe Diameter Vessel Wall Welded on Mounting Flange Locking Slot for O Ring ring with 5 5mm diameter IMKO 35 48 MCROMCOUTZOHMME T ONE 5 7 Installation in a conveyor pipeline For a pressure tight installation of t
35. disabled for Mode CK Lower Limit Keep Time The maximum duration in seconds of the filter function for Standard Setting 10 Lower Limit failures too low measurement values for Setting Range 1 100 longer lasting material gaps ie the time in which no With the setting of 100 this material is located on the probe can be bridged parameter must be disabled for Mode CK Moisture Threshold The accumulation of moisture values starts above the in moisture Moisture Threshold and the analogue signal is output The Standard Setting 1 accumulation pauses if the moisture level is below the Setting Range 1 20 threshold value No Material Delay The accumulation stopps if the moisture value is below the in seconds moisture threshold The SONO probes starts again in a Standard Setting 5 new batch with a new accumulation after the time span of s the No Material Delay is exceeded Setting Range 1 20 Boost Automatic summation stops if threshold is below No otandard Setting 35 Material Delay After expiration of No Material Delay the Setting Range 1 100 probe is ready to start a new summation in a new batch Offset Non linearities in the process can be compensated E g in otandard Setting 0 5 fluid bed dryers non linearities can occur due to changes in Setting Range 0 5 the material density during the drying process Offset works together with the parameter Average time Weight omoothing fa
36. e 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 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 7 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 point 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 2596 has to be determined with laboratory measurement methods oven drying Step 3 With the two calibration points P1 and P2 the calibration coefficients 0 and m1 can be determined for the specific material see next page Step 4 The coefficients m1 0 0581 and 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
37. e probe 9 48 IMKO 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 Parameters in the Measurement Function Mode CA CF CC CH and CK Average Time The time in seconds for the generation of the average Standard Setting 2 value can be set with this parameter Setting Range 1 20 Filter Upper Limit Offset Too high measurement values generated due to metal Standard Setting 20 wipers or blades are filtered out The offset value in IS Setting Range 1 20 added to the dynamically calculated upper limit With the setting of 20 this parameter must be disabled for Mode CK Filter Lower Limit Offset Too low measurement values generated due to insufficient Standard Setting 20 material at the probe head are filtered out The offset value Setting Range 1 20 in is subtracted from the dynamically calculated lower With the setting of 20 this parameter limit with the negative sign must be disabled for Mode CK Upper Limit Keep Time The maximum duration in seconds of the filter function for otandard Setting 10 Upper Limit failures too high measurement values can be Setting Range 1 100 set with this parameter With the setting of 100 this parameter must be
38. e serial interface MKO 8 48 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 Measurement Mode A On Request only in network operation for the retrieval of measurement values via the serial interface 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 5 20 seconds without floating average 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 and filtering Mode CA Cyclic Average Filter For relative short measuring processes with continual average value filtering and an accuracy of up to 0 1 Mode CF Cycli
39. e 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 probe 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 dependent on screw velocity It is recommended to use measurement mode if the probe is installed in the middle of the screw conveyor without a cut out of the spiral Please take also a look the chapter Overview of single modes for different applications IMKO 37 48 MECRCMCDUTECHNIE Y GNB 5 9 Exchange of the Probe Head of the VARIOxtrem LD At the SONO VARIOxtrem and VARIOLD not only the ceramic plate but the whole metal ceramic wear resistant probe head can be exchanged This is how easy it is to exchange the wear resistant probe head Loosen the 4 fastening screws look for the right sequence of washer and gasket rings Lift off the probe h
40. ead carefully so that the robust spring contacts in the interior are canted as little as possible Clean the surface inside the probe body for the O Ring Place the probe head so that the two spring contacts are inserted in the contact bushings Screw the 4 fastening screws back on It is to consider that the 4 screws find the 4 holes in the green epoxy plate inside the probe Wear resistant Sensor Head Hardened Steel Ceramic Window SC P 4 with Compound Pad O Ring Contact Bushing Probe Body 4 x Fastening Screws for Wear resistant Sensor Head MKO y 38 48 5 9 1 Basic Balancing of a new Probe Head The probe heads are all identical and are manufactured to fit precisely In spite of this fact after an exchange it is necessary to make a basic calibration in air and water that SONO VARIOxtremLD measures precise and accurate with the new probe head Therefore some work steps are required Basic calibration procedure 1 Provide a small container with water in which the probe head can be plunged in For the first calibration point in air the probe head must be completely dry If appropriate dry it with a towel Unplug the blind cap of the calibration connector and plug in the calibration connector Plug in the MIL connector with power supply to the probe The blue LED is on for 3 seconds and start with a slow blinking for the next 10 seconds preparation time for the first calibration point in air
41. grading Please note the bulk Calibration Curve ranges density may vary dependent on type of plant Sand 0 2mm D 1 5 Cal1 Universal sand gravel and grit Gravel and grit D c 1 7 Cal6 gravel and grit 4 to 32mm similar to Cal1 Sand 0 2mm D c 1 6 Cal2 1 6 for bulk density 1 6 Sand Gravel D c 1 7 Cal3 1 7 0 4mm for bulk density 1 7 Sand Gravel D c 1 8 Cal4 1 8 0 5mm for bulk density 1 8 Sand Gravel D c 1 9 Cal5 1 9 0 8mm for bulk density 1 9 For very high demands in recipe accuracies e g 1 liter per m it is recommended to make a fine adjustment ideally inside the PLC If itis necessary to measure only with one SONO probe very different sand grading ranges without an online changing of the calibration curve than a measurement value conversion can be done inside the PLC with the known grading range Furthermore it could be of advantage if a SONO probe must be not adapted selected to a fixed grading range making replacement parts easier to keep in stock Following table gives an overview about sand grading ranges bulk density and the analog output of the SONO probe With a little math it is possible to translate a standard moisture measurement value measured with into the correct measurement value associated to the grading range IMKOV 18 48 4 20mA Current output Measurement conversion for 0 to 20 moisture at different sand grading ranges with standard calibration cur
42. he SONO VARIO in a conveyor pipeline it is important that the material flow inside the pipe will not be disturbed This can be realized with a concavely curved flange which is welded on the pipe in such a way that the radius of the pipe is only disturbed with the flat ceramic plate of the SONO VARIO with a width of 32mm and a length of 86mm Depending on the pipe 5 diameter e g 150mm the ceramic plate reaches about 2mm inside the pipe and disturbes the material flow only slightly A detailed flange construction is further depending on pipe thickness the proposed maximum pressure and other plant parameters The following sketch shows a possible flange construction Special semicircular fange 9 Ring Holder which press the probe to the flange Groove for O ring SONO VARIO Rectangular window with 34mm width and 88mm length for the ceramic plate of the SONO probe 108 2mm IMKO 36 48 5 8 Installation of SONO VARIO inside a Screw Conveyor The installation of SONO VARIO 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 LUE SUA i Cut out SONO probe of the spiral The SONO probe 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 abov
43. ial sticking and therefore measurement errors are be prevented 3 The SONO VARIO can detect clearly the start and the end of a batch process So the SONO VARIO can calculate an automatic summation of the moisture quantity during one batch process in mode CC Even short batches with few material can be precisely measured Further advantage is that the PLC programming can be made more simple without switching signals Unfavourable conditions for moisture probes occur if the probes are installed inside silos or inside outlets The picture shows how sticky and adhere sand can be even at near vertical walls Furthermore a moisture probe can be seen which is installed directly inside the outlet of a silo where sand can stick not only at the wall but also on the moisture probe Such an installation place can lead to measurement failures because it cannot be controlled visually IMKO MECRCMOCDUTECOHNIE 7 CNE 28 48 5 1 Further important Assembly Instructions The following instructions should be followed when installing the probe e The universal holder should be installed direct under a silo flap so that the flowing material covers the moisture probe completely with minimum 30mm material height The direction of the material flow should be bundled against the sensors surface when the flap opens This secures that the sensors surface is covered with material immediately after opening of the flap and not only when the flap has opened complete
44. is below the limit of 296 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 2 1 3 Mode CC automatic summation of a moisture quantity during one longer 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 three 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 to 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 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 pr
45. lay 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 measurement values Filter Upper Limit 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 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
46. ly It improves the measurement when measuring moisture at short batches with short opening speeds of the flap e For sand the angle of attack for the sensor holder should be between 45 55 for gravel and grit the angle must be more steep between 55 70 so that no backwater occurs above the probe s surface 45 55 Sand cox Sand Angle sensor holder 45 to 55 Gravel Angle sensor holder 55 to 70 219 TIME EOE the silo should be lie just below the top edge of the baffle plate of the sensor This ensures that the probe s surface is completely covered during material flow e The installation locations may not be situated beneath the inlets for additives Important for measuring moisture of gravel and grit i Gravel or grit could have so much water that free water can flow above the probes s surface E g the maximum moisture content of a gravel with 2 8mm grain size lies at 3 5 For gravel with 8 32mm grain size the maximum lies at 2 5 The SONO probe can measure the water content in the range of 0 to 3 5 precise But if gravel is completed saturated and free water flows above the SONO probe s surface the probe s measuring could fail with a value of up to 796 moisture Therefore for gravel it is necessary that a PLC calculates with a limit of e g 3 596 or 2 596 The PLC has to reduce a higher moisture value of the probe to a maximum of 3 5 or 2 596 for gravel 29 48 IMKO e n
47. mperature 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 10 to 15 for every calibration curve Cali of Cal15 see chapter Selection of the individual calibration curve Please contact IMKO should you need any assistance in this area 1 2 5 Analogue Outputs The measurement 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 30 For a 0 10V DC voltage output 500 resistor can be installed in order to reach 0 10V output Analogue Output 1 Moisture in 96 0 2096 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 2 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 Output Channel 1 and 2 one of three possible selections 1 Moist Temp Analogue output 1 for
48. n Curve for a specific Material The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with 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 probe 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 CF 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 valu
49. n be variably aligned with the SONO CONFIG software For a 0 10V DC voltage output a 500R resistor can be installed CALIBRATION 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 A zero point correction can be performed easily with the SONO CONFIG software COMMUNICATION The serial interface enables network operation of the probe whereby a data bus protocol for the connection of several SONO probes to the serial interface is implemented by default The connection of the probe to industrial busses such as Profibus Ethernet etc is possible via optional external gateway modules available upon request POWER SUPPLY 7V to max 24V DC 1 5 W max AMBIENT CONDITIONS 0 70 C On request High temperature version with external measurement transformer MEASUREMENT FIELD EXPANSION SONO V ARlOStandard Xtrem Approximately 30 50 mm depending on material and moisture SONO VARIOLD Approximately 70 100 mm depending on material and moisture CONNECTOR PLUG The sensor is equipped with a robust 10 pole MIL flange connector Ready made connection cables with MIL connectors are available in cable lengths of 4m 10m or 25 m MKO 48 48 Precise Moisture Measurement in industry hydrology forestry agriculture environmental and earth science civil engineering
50. ncies 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 modular TRIME technology enables a manifold of special applications without much effort due to the fact that it can be variably adjusted to many applications 1 1 3 Areas of Application with SONO V ARIOStandard SONO VARIOxtrem and SONO VARIO SONO VARIO is suited for moisture measurement of different materials An installation is possible into containers hoppers above conveyor belts or in silos he SONO VARIOStandard is suited for measuring of normal abrasive materials like sand and gravel up to 4mm The probe head consists of stainless steel with a rectangular ceramic window he SONO VARIOxtrem is suited for measuring of very high abrasive materials like gravel 4 32 and grit The probe head consists of oil hardened steel with a rectangular special ceramic window he SONO VARIO Low Density is suited for moisture measurement of materials with low density like corn wood chips and other materials For wood chips and other very loose materials which show a bad flowability an installation inside a screw conveyor is recommended due to bette
51. ng a linear Calibration Curve for a specific 4 1 1 Nonlinear calibration 3 48 4 2 Connectivity to SONO 24 4 2 1 Connection Plug and Plug 0 2 25 4 2 2 Analogue Output 0 10V with a Shunt Resistor 26 4 2 3 Connection Diagram with the Display Module 26 Installation of the Modes e 27 5 1 Further important Assembly 28 5 1 1 Protection of the 5 Connector against 29 5 2 What could be done if the Material Flow is not 30 5 3 ASSembly DIMENSIONS PTT T 31 5 4 Mounting in curved 33 5 5 Funnel shape for higher material 33 5 6 Gas and waterproofed eene 34 5 7 Installation in a conveyor xz ctc ni EGEE ow 35 5 8 Installation of SONO VARIO inside a Screw Conveyor 36 5 9 Exchange of the Probe Head of the VARIOXtrem LD sees 37 5 9 1 Basic Balancing of a new Probe 38 Serial Connection to the SM
52. o averaging and no summation The PLC read out the measurement values from the SONO probe immediately after opening the silo flap in a cycle of 200 milliseconds and in a time range as long as the silo flap is opened e g 3 seconds The PLC has to store the single measurement values and has to build an average value of these e g 10 to 20 single measurement values Solution B If the PLC is not powerful enough to store single measurement values the SONO probe has to be placed into a rapid position for converting single measurement values in a short time range of 3 to 4 seconds Following principle has to be considered SONO probe has to be adjusted into Mode CC cycle cumulated ke The power supply e g 24V DC of aggregate the SONO probe has to be interrupted with relay by the PLC for 0 5 seconds after opening of the silo flap Before closing of the silo flap the PLC has to read in the cumulated measurement value from the SONO probe via the analogue signal PLC switch off power supply 24V DC of SONO VARIO 0 5 Secends By interrupting the power supply of the SONO probe the internal measurement PLC recorda memories of the SONO probe are cleared the cumulated i e the SONO probe can start very quickly with new measurement cycles With Mode CC the SONO probe can build average and a cumulated measurement value in short time ranges Time IMKO 15
53. ocess 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 IMKO ae 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 5 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 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 How can the mode be used if the SONO probe cannot detect the moisture threshold by itself e g above a conveyor belt if there is constantly material above the probe over a longer time In this case a short interrupt of the probe s power supply e g for
54. on of the mineral 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 mineral concentration or the composition of a special material Hereby the attenuation of the radar pulse in the measured volume fraction of the material is determined This novel and innovative measurement delivers a radar based conductance value EC TRIME in dS m as characteristic value which is determined in dependency of the mineral concentration and is issued as an unscaled value The EC TRIME measurement range of the SONO probe is 0 12dS m 1 2 3 Temperature Measurement A temperature sensor is installed into the SONO VAHIO which establishes the casing temperature 3mm beneath the sensor surface The temperature can optionally be issued at the analogue output 2 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 1 2 4 Temperature compensation when working at high temperatures 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
55. or casing and is issued at the analogue output 2 The material temperature can be measured with an external calibration and compensation of the sensor intrinsic heating On request High temperature version with external measurement transformer MEASUREMENT DAT A PREPROCESSING MEASUREMENT MODE CA Cyclic Average For relative short measuring processes with continual average value filtering and an accuracy of up to 0 196 MEASUREMENT CF Cyclic Float Average For very slow measuring processes with floating average value filtering and an accuracy of up to 0 196 MEASUREMENT MODE CS Cyclic Successive For very short measuring processes without floating average with internal up to 100 measurements per second and a cycle time of 200 milliseconds at the analogue output 47 48 IMKO 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 SIGNAL OUTPUT 2 x Analogue Outputs 0 4 20mA Analogue Output 1 Moisture in e g 0 20 variably adjustable Analogue Output 2 Conductivity EC TRIME 0 20dS 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 into an adjustable 5 second cycle between these two current measurement windows The two analogue outputs ca
56. ot 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 first 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 Calculated lt in File in Probe ht 1544 41 bl 1 047
57. pective moisture value By clicking Save the recorded data is saved in a text file in the following path SONO 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 run in Datalogger Operation In the menu Measure 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 IMKOVA 45 48 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 n
58. r and homogenuous densities inside a screw conveyor MKO y 5 48 1 2 Mode of Operation 1 2 1 Measurement value collection with pre check average value and filtering 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 200 milliseconds In the Measurement Mode CA CF CC and CK not the momentarily measured individual values are directly issued but an average value is accumulated via a variable number of measurements 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 SONO probes 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 Determinati
59. s 5 seconds fe 171 1 Calibration Connector MIL Blue LED Connector IMKO 39 48 VETROMODULTSO F t 7 GNB 6 Serial Connection to the SM USB Module from IMKO The SM USB provides the ability to connect a SONO probe either to the standard RS485 interface or to the IMP Bus 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 RS485B Lead Colour brown Pin F RS485A Lead Colour white 12VDC IMP B nn r f one With the option to accomplish download of the firmware for the SONO probe 4 Pin B 0V Power Supply 7 Pin A 12VDC Power Supply 7 Pin C rt Lead Colour Pin J Lead Colour blue red How to start with the SM USB module from IMKO e Install USB Driver from USB Stick e Connect the SM USB to the USB Port of the PC and
60. tarts again automatically with the continuous a of measurement values yellow curve IMKOV 14 48 2 1 4 Mode CH Automatic Moisture Measurement in one Batch Mode CH is 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 Mode CH executes an automatic filtering e g if dripping water occurs It is recommended to use mode CH for standard applications under a silo flap Mode CH Cyclic Hold is identically to Mode CC but without summation If the PLC already accumulates moisture values than an additional automatic summation of a moisture quantity inside the SONO probe during one batch process will produce errors 2 1 5 How to use the SONO VARIO with extremely short Batching Times With batching times i e opening times of the silo flap with greater than 5 seconds the SONO probe can convert a stable measurement value by itself If it is necessary to mix small quantities of concrete than the batching times i e the opening times of the silo flap can be very shortly Here the SONO probe has not enough time and cannot convert by itself a stable measurement value This must be especially taken into consideration with larger gravel aggregates With batching times smaller than 5 seconds there are two possibilities to come to stable measurement values Solution A The SONO probe has to be adjusted to Mode CS i e n
61. temperature compensation A 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 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 TemperatureCompensation MKO y 6 48 B 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 compensation Therefore it is necessary to measure in parallel the material temperature with the te
62. the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick Connection of the SONO probe to the SM USB with 4 wires for power supply and serial interface 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 SONO CONFIG e The SONO probe logs in the window Probe List after max 30 seconds with its serial number IMKO Wee 40 48 Note 1 In the Device Manager passes it as follows Control Panel gt System gt Hardware gt Device Manager Ger te Manager Datei Aktion Ansicht gt Hee E DH WS 50 BB Acronis Devices F Anschl sse COM und LPT E ECP Druckeranschluss LPT1 Under the entry Ports COM amp LPT now the E Intel R Active Management Technology SOL COM20 item USB Serial Port COMx is found Kornmunikationsanschluss COMI E Prolific USB to Serial Bridge COMP E Prolific USB to Serial Bridge COM3 Be E Standardmafigige Seriell Gber Bluetooth verbindung COIMT4 A Standardmafigige Seriell Gber Bluetooth verbindung 017115 F Standardmafigige Seriell Gber Bluetooth verbindung COMITE I Standardm ligige Seriell Gber Bluetooth verbindung COM 7 m Standardm ligige Seriell Gber Bluetooth verbindung 18 58
63. tion conditions are strongly influenced by the constructional circumstances of the installation facility The ideal installation location must be established individually For measuring sand gravel and grit the SONO VARIO should ideally be installed under a silo valve which has many advantages see below Installation of the SONO VARIO for measuring sand gravel and grit under a silo valve or on a conveyor belt Dependent on material it is important to find the suitable angle 55 70 of the mounting plate It should be not too steep but also not too flat and the flowing material should cover the probes surface completely during flowing It should be mentioned that with the innovative features of SONO probes and an extremely rugged design it is possible to install a SONO VARIO directly under valves of silos also for gravel with 32mm size The installation inside a silo could be also possible but it must be observed that during filling and emptying no material e g sand can be stick on the probes surface which could be result in measurement errors The following instructions should be followed when installing the probe The SONO VARIO should be installed ideally under a valve of the silo which has many advantages 1 The material flows constant and therefore the material density is constant which guarantees more precise measurement values 2 Dueto higher material pressure the probe s surface is cleaned continuously Mater
64. ve Cal1 Grading range Moisture A value of 0 moisture Moisture value at 20mA and bulk value at 4mA content thus conforms to output current at the density current at the an output current in mA analog output in kg dm analog output at the analog output of theoretically 0 2mm 1 6 0 29 4 24mA 18 496 0 20mA Current output Measurement conversion for 0 to 2096 moisture at different sand grading ranges with standard calibration curve Cal1 Grading range Moisture A value of 0 moisture Moisture value at 20mA and bulk value at 4mA content thus conforms to output current at the density current at the an output current in mA analog output in kg dm analog output at the analog output of theoretically Please note The guide values only apply for sand For measuring gravel and grit with different gradings it is recommended to use the standard calibration curve Cal1 or Cal6 Here the analog output 0 4 20mA corresponds to 0 2096 moisture IMKO 19 48 4 Calibration Curves SONO probes are supplied with a universal calibration curve for sand Cal1 Universal Sand Gravel Grit A maximum of 15 different calibration curves CAL1 Cal15 are stored inside the SONO probe and can optionally be activated with help of the program SONO CONFIG via the serial interface with the modules SONO VIEW or SM USB A preliminary test of an appropriate calibration curve 15 can be activated in the menu Calibration and

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