Model 6496 Freezing Rain Sensor User`s Manual
Contents
1. claimant Under no circumstances will the Company reimburse claimant for cost incurred in removing and or reinstalling replacement parts c This warranty shall not apply to any Company products which have been subjected to misuse negligence or accident d This warranty and the Company s obligation thereunder is in lieu of all other warranties express or implied including warranties of merchantability and fitness for a particular purpose conse quential damages and all other obligations or liabilities No other person or organization is authorized to give any other warranty or to assume any additional obligation on the Company s behalf unless made in writing and signed by an authorized officer of the Company 19 w allweatherinc All Weather Inc 1165 National Drive Sacramento CA 95818 Fax 916 928 1165 Phone 916 928 1000 Toll Free 800 824 5873 6496 001 Revision A September 20122. frequency too low EEPROM failure RAM failure ROM failure Watchdog Timer failure 3 2 1 Power Interrupt Timer failure 5 7 on time Power On time count in hex in count 10 minute increments 000000 O1F FFF 8 9 cold start Cold Start Power On count 0000 FFFF count 10 11 ice count 0000 FFFF Total failures encountered This number is incremented 00 FF 12 failures count each time the ice detector transitions from OK to fail 13 Failure Detail 1 Oscillator Frequency failure 0 F count F Heater failure count 0 4 3 0 14 i See ERRSTAT1 Last Error 1 i See ERRSTAT2 Last Error 2 17 Second Last Error 1 See ERRSTAT1 See ERRSTAT2 4 18 Second Last Error 2 Model 6496 Freezing Rain Sensor User s Manual Definition Comments Interpretation Range 19 Permanent See ERRSTAT1 Error 1 20 Permanent See ERRSTAT2 Error 2 21 software version Software Version perVDD SC1 00 FF 22 correlation 0 01 ice accretion increments 00 FF count Since power on Summation 1 byte wide of 23 checksum bytes 0 22 00 FF 3 1 3 Poll Command The poll command is summarized below where 00 1s the address lt CR gt and lt LF gt are a carrier return and line feed FRRA00 lt CR gt lt LF gt DCP Poll Command Model 6496 Freezing Rain Sensor User s Manual 4 UNPACKING AND INSTALLATION 4 1 UNPACKING The Model 6496 Freezing Rain Sensor is a precision in
3. the microcontroller to the reset state if the internal 5 V DC power supply falls below 4 65 V DC and holds it there until the power supply returns above 4 65 V DC No output strings are transmitted while the microcontroller is reset 5 2 2 Continuous Built In Test The Continuous BIT verifies the following operations e The internal probe heater is in the correct state The return leg of the heater is monitored e The discrete output for ice is in the correct state This discrete output is fed back to the micro controller through a passive voltage divider and voltage comparator e The probe oscillator is operating correctly Frequencies between 39 00 and 40 15 kHz are valid e The internal probe heater is deicing correctly Once it has turned on the internal probe heater must cause the probe oscillator frequency to return to at least 39 97 kHz within the 25 second timeout otherwise the internal probe heater is considered to have failed 10 Model 6496 Freezing Rain Sensor User s Manual 5 2 3 BIT Failure That Disables Ice Status Output The ice status output is disabled by Continuous and Initiated BIT failures as shown in Table 3 Ice detection is disabled when these failures occur because the integrity of the ice detection capability may be compromised Table 3 BIT Failure Information Ice Detection Disabled Initiated BIT Continuous BIT Failure Type Oscillator Failure Frequency Too High Oscillator Failure Frequency
4. Model 6496 Freezing Rain Sensor 2 weather 6496 FREEZING RAIN SENSOR wee shewatherin lt com User s Manual Rev allweatherinc All Weather Inc 1165 National Drive Sacramento CA 95834 USA 800 824 5873 www allweatherinc com Copyright 2012 All Weather Inc All Rights Reserved The information contained herein is proprietary and is provided solely for the purpose of allowing customers to operate and or service All Weather Inc manufactured equipment and is not to be released reproduced or used for any other purpose without written permission of All Weather Inc Throughout this manual trademarked names might be used Rather than put a trademark symbol in every occurrence of a trademarked name we state herein that we are using the names only in an editorial fashion and to the benefit of the trademark owner and with no intention of infringement All Weather Inc and the All Weather Inc logo are trademarks of All Weather Inc Disclaimer The information and specifications described in this manual are subject to change without notice Latest Manual Version For the latest version of this manual see the Product Manuals page under Reference on our web site at www allweatherinc com allweatherinc All Weather Inc 1165 National Drive Sacramento CA 95834 Tel 916 928 1000 Fax 916 928 1165 Contact Customer Service e Phone support is available from 8 00am 4 30pm PT Monday thro
5. Too Low EEPROM Failure RAM Failure ROM Failure Watchdog Timer Failure Power Interrupt Timer Failure Power Fault Monitor Failure Internal Probe Heater Always ON Internal Probe Heater Always OFF Internal Probe Heater Always ON with 1 Enable Deicing Failure Unknown Reset Failure Note 1 The software no longer reports the ice status once a failure is annunciated Note 2 In Continuous BIT the Internal Probe Heater Always OFF failure is set when the heater is ON and a deicing failure has been detected If the frequency indicates that the ice has been removed within the expected time the software will not annunciate an internal probe heater failure In this case the actual failure is most likely caused by a problem in the heater feedback circuitry rather than the heater control circuitry The failure will be annunciated the next time the Initiated BIT is performed 11 Model 6496 Freezing Rain Sensor User s Manual 5 2 4 Initiated Built In Test BIT The Initiated BIT is performed at initial power up of the Freezing Rain Sensor and following power interruptions that last longer than than 200 ms The Initiated BIT consists of the following tests e The ice and fault status outputs are set in the serial output string so monitoring electronics or test equipment can verify activation e The Freezing Rain Sensor internal probe heater is turned on for a short period of time to verify correct operation of the heater he
6. aker panel is in the ON position Model 6496 Freezing Rain Sensor User s Manual 5 OPERATION The Freezing Rain Sensor operates automatically and sends data packets to the DCP There are no controls or indicators on the sensor itself 5 1 POWER INTERRUPTIONS The Freezing Rain Sensor uses a power fail monitor to verify the supply voltage If a power fault lasting more than 200 ms is detected the Freezing Rain Sensor will report a failure in the STATUS output 5 2 BUILT IN TEST BIT CAPABILITIES The Freezing Rain Sensor has hardware continuous power up and operator initiated tests Whenever a failure is detected and verified the Freezing Rain Sensor stops detecting and annunciating icing conditions and the internal probe heaters are disabled Failures detected in Initiated and Continuous BIT are counted and enunciated once they have been verified Failures are verified by delaying debouncing the failure for a period of time to minimize or eliminate nuisance errors Failures detected in Initiated BIT are latched and power must be cycled off and on to clear a failure If failures detected in Continuous BIT go away the probe returns to normal mode and once again enables all detection functions 5 2 1 Hardware Built In Test The hardware BIT consists of a watchdog timer that forces the microcontroller in the Probe Assembly to re initialize if 1t does not receive a strobe every 1 6 seconds An internal voltage monitor forces
7. all Mini Con X9 7280 5SG 300 Field Connector Data Output In response to poll command 85 265 V AC 47 64 Hz 50 W 55 to 70 Operating Temperature 67 to 1582F 65 to 70 Storage Temperature 85 to 158 F Humidity 0 100 noncondensing Serial Connector Supply Voltage 17 Model 6496 Freezing Rain Sensor User s Manual Parameter Specification Unistrut mounted on single leg pedestal 244 pipe NEMA 4X electo polshed 304 stainless steel Dimensions without mounting tabs teed Her ple be 55h 02 Shipping Weight 7 5 kg 17 Ib 18 Model 6496 Freezing Rain Sensor User s Manual 11 WARRANTY Unless specified otherwise All Weather Inc the Company warrants its products to be free from defects in material and workmanship under normal use and service for one year from date of installation or a maximum of two years from date of shipment subject to the following conditions a The obligation of the Company under this warranty is limited to repairing or replacing items or parts which have been returned to the Company and which upon examination are disclosed to the Company s satisfaction to have been defective in material or workmanship at time of manu facture b The claimant shall pay the cost of shipping any part or instrument to the Company If the Com pany determines the part to be defective in material or workmanship the Company shall prepay the cost of shipping the repaired instrument to the
8. ater control circuit and heater feedback circuit e The correct operation of the watchdog timer is verified by simulating a microcontroller time out and waiting for a reset input e Proper ROM operation is verified by computing a checksum of the ROM contents and comparing against a a checksum stored in the ROM e RAM operation is verified by writing and reading test bytes e The Power Interrupt Timer is checked by verifying its transitions to a warm state after performing a cold start e The power fail input is pulled down to verify a power failure is detected e Fach time the critical data from the EEPROM are read a checksum is read and compared to the checksum computed from the contents Each time critical data are written to the serial EEPROM a checksum 1s computed and stored with the data e Resets for unknown reasons such as reset from the watchdog timer are detected 5 3 OPERATOR INITIATED TESTS The operator can test the freezing rain sensor functionality by squeezing the tip of the probe between the index finger and thumb This simulates icing by decreasing the frequency of the probe CAUTION Be careful if the probe has just been through a deicing cycle since it may f reach temperatures up to 204 C Clean the probe after touching itas oil residue from skin will affect the performance of the probe 5 4 CORRELATION COUNTING The Freezing Rain Sensor tracks the ice accumulation on the probe during an
9. ation for the Freezing Rain Sensor is sent to the AWOS Data Collection Platform DCP when polled The DCP combines information from the Freezing Rain Sensor with data from other AWOS sensors to generate reports describing the nature of the freezing rain ice frost or wet snow that has accreted on the sensor probe 1 1 ACCESSORIES The following accessories are available for the Model 6496 Freezing Rain Sensor Part Number Description M105737 00 Probe Assembly Replacement Gasket M491742 00 Data Cable connects Model 6496 Freezing Rain Sensor to DCP M491745 01 50 ft Power Cable Model 6496 Freezing Rain Sensor power connector to bare wires Model 6496 Freezing Rain Sensor User s Manual 2 FUNCTIONAL DESCRIPTION The Model 6496 Freezing Rain Sensor is mounted on an enclosure containing the power supplies and communication interface see Figure 1 Extensive internal self testing identifies problems and provides diagnostic information to indicate whether the sensor is operating properly PROBE o MN o POWER SWITCH Meet To ojolajolajelajolala ITI AMIA ojolajojajajolojolo 9 Figure 1 Model 6496 Freezing Rain Sensor Enclosure The Probe Assembly M482221 00 contains the actual Freezing Rain Sensor probe and its associated electronics The Power Input Board M404802 01 accepts AC power and provides 24 V DC to the Freezing Rain Sensor probe and its associated electronics A 12 V DC power supply also draws its
10. e in a junction box BLACK wire is hot WHITE wire is common and GREEN wire is ground It is recommended that power to the junction box be shut off at the breaker panel while the wiring connections are made inside the junction box Figure 5 Freezing Rain Sensor Connectors 8 Model 6496 Freezing Rain Sensor User s Manual 4 2 3 l 4 2 4 i 2 ae Data Connection Connect the data cable s circular connector to the DATA connector on the bottom of the Freezing Rain Sensor enclosure see Figure 5 DCP Connect the other unterminated end of the cable to the RS 485 TB4 connections on terminal block T B4 of the Model 1190 DCP 40 Connect the GREEN ground wire to pin 7 of terminal block TB4 Connect the BLACK wire RS 485 from the signal cable to pin 1 or 3 and connect the WHITE wire RS 485 to pin 2 or 4 of terminal block TB4 These pin connections are also used for RS 485 connections from other sensors Wait until all wires from any other sensors have been inserted when connecting more than one wire to a terminal block pin before securing the terminal block screw SENSOR RS 485 Q Q OOOOOODOODOO 9 8 T 6 5 4 3 2 1 Final Steps Check that the ON OFF power switch inside the enclosure Figure 1 is ON Close and fasten the enclosure door Remove the two probe protective covers shown in Figure 2 Ensure that the circuit breaker on the bre
11. gerprints etc If any contaminants are present clean probe using isopropyl alcohol and soft cotton cloth The freezing rain sensor probe assembly will be hot if the sensor recently WARNING completed a deice cycle Ensure that the probe assembly has cooled before cleaning the probe While in the deice mode the probe will radiate a NM significant amount of heat This can be observed by placing a hand close to but not on the sensor probe Always avoid direct contact of the probe with skin to avoid a potential burn hazard CAUTION Do not touch the probe with bare hands as oil residue from skin will affect NM the performance of the sensor 6 1 3 Annual Maintenance No additional maintenance beyond that described above for monthly and triannual maintenance is required 14 Model 6496 Freezing Rain Sensor 7 TROUBLESHOOTING Symptom Freezing rain data missing or F displayed for sensor status Freezing rain data intermittent Freezing Rain data inaccurate Ice fails to melt from probe Possible Causes Loose cable or connector Freezing Rain Sensor has failed Loose cables or connectors Freezing Rain Sensor is faulty Freezing Rain Sensor has operational errors Freezing Rain Sensor software has locked up Freezing Rain Sensor internal probe heater or processor has failed or software has locked up User s Manual Action Check all cables and connectors Repair or re
12. icing event The correlation count helps the Freezing Rain Sensor track the amount of ice that has accumulated on the probe during the icing event Each correlation count corresponds to a frequency decrease of 65 Hz during the icing event and reflects 0 010 0 25 mm of ice buildup The correlation count which ranges from O to 255 does not take into account the change in collection efficiency caused by ice buildup The value is no longer incremented once a correlation count of 255 is reached 12 Model 6496 Freezing Rain Sensor User s Manual The Freezing Rain Sensor compensates for the operation of the internal probe heater by adding a value ranging from 0 to 6 to the correlation count when the ice detection cycle is completed The correlation count is reported in Byte 22 of the serial output string see Error Reference source not found The correlation count is initialized to zero when the Freezing Rain Sensor powers up 13 Model 6496 Freezing Rain Sensor User s Manual 6 MAINTENANCE 6 1 PERIODIC MAINTENANCE Tools and Equipment Required e Soft cotton cloth lint free e Isopropyl alcohol 6 1 1 Monthly Maintenance Inspect all mounting hardware and cable assemblies for wear and damage repair or replace as needed 6 1 2 Triannual Maintenance 1 Inspect all mounting hardware and cable assemblies for wear and damage repair or replace as needed 2 Visually inspect the probe surface for contaminants such as dirt oil fin
13. latches Figure 6 Freezing Rain Sensor Probe Assembly 1 The Probe Assembly part number M482221 00 is mounted at the top of the Freezing Rain Sensor enclosure 2 Disconnect the wire connector at the bottom of the Probe Assembly 3 Remove the four screws securing the Probe Assembly to the top of the Freezing Rain Sensor enclosure 4 Remove the Probe Assembly from the unit 5 When installing the new Probe Assembly replace the gasket part number M105737 00 before installing the new Probe Assembly and securing it in place with the four screws 6 Reconnect the wire connector to the bottom of the Probe Assembly The connector is keyed to facilitate lining up the pins to make the connections correctly 16 Model 6496 Freezing Rain Sensor User s Manual 10 SPECIFICATIONS Parameter Specification Sat Point Ice signal activates when ice thickness on probe exceeds 0 020 0 005 in 0 5 0 1 mm Deicin Operates when ice thickness on probe 3 exceeds the set point Ice signal Discrete Output Signals j sr l e Operating status signal e Performed at initial power up If a failure is detected and verified the sensor stops detecting and annunciating ice presence the probe Built In Test BIT heaters are disabled and a failure is annunciated e Hardware and software BIT verifies that internal electronics are functioning properly during ongoing operation Serial Output Baud Rate Serial Port Parameter Setting Conx
14. ly the Ceilometer must be grounded To install grounding follow the steps below see Figure 3 l Ze Drill and tap a Y4 20 hole in the mast Install a grounding clamp in the hole Connect one end of a length of ground cable 4 AWG multi strand insulated wire available from All Weather Inc as P N T605000 to the grounding clamp on the mast Connect the other end of the ground cable to the ground lug on the underside of the Freezing Finally connect a bare copper ground wire between the ground clamp on the mast and an installed ground rod 56 above ground level qq A KA og des gt 3 above max snow level Freezing Rain Sensor 2 2 Pipe Mast Ground Coupling Clamp Teer to Ground Rod Figure 3 Freezing Rain Sensor Mounting Model 6496 Freezing Rain Sensor User s Manual 2 BO GALVANIZED Es STEEL CAP UPPER MOUNTING RAIL 4X NUT 1 4 20 S S 4X 1 4 S S FLAT WASHER 4X 1 4 S S SPLIT WASHER A LL 4X 1 4 20 x 1 00 SS BOLT N w 2X PIPE CLAMP FOR 2 PIPE 2 875 OUTSIDE DIAMETER 2 63 5 mm GALVANIZED STEEL PIPE 2 8752 73 mm LOWER MOUNTING RAIL OUTSIDE DIAMETER OJ REF Figure 4 Mast Mounting Details 4 2 2 Power Connection 1 Connect the power cord s circular connector to the POWER connector on the bottom of the Freezing Rain Sensor enclosure see Figure 5 2 Connect the other unterminated end of the cable to a suitable AC sourc
15. place if necessary No power to Freezing Rain Check main power to the Sensor sensor is ON Freezing Rain Sensor software locked up Cycle power to sensor If no recovery cycle power to the DCP If no recovery replace sensor Consult the SYSLOG for errors prior to the sensor going missing to confirm faulty operation before failure Replace sensor if necessary Check all cables and connectors Repair or replace if necessary Consult the SYSLOG for errors and examine the freezing rain status word for possible causes of the problem Replace sensor if necessary requires maintenance maintenance Cycle power to sensor If no recovery cycle power to the DCP If no recovery replace sensor Cycle power to sensor If data still inaccurate replace sensor Cycle power to sensor If ice still fails to melt replace sensor 15 Model 6496 Freezing Rain Sensor User s Manual 8 REMOVAL AND REPLACEMENT IMPORTANT Observe ESD grounding procedures when handling modules Do not change modules during weather events never allow precipitation to enter the interior of the Freezing Rain Sensor Whenever a module is being changed the power should be shut off remotely The only time the power should be on with the Freezing Rain Sensor door open is when checking system operation during troubleshooting 3 To gain access to the Probe Assembly open the enclosure door using a screwdriver to release the two
16. power from the Power Input Board to supply power to the the serial converters that output the RS 422 data from to the Freezing Rain Sensor probe to the RS 485 data output connector on the enclosure Model 6496 Freezing Rain Sensor User s Manual 3 DATA COMMUNICATION 3 1 DATA OUTPUT The data is output from the Model 6496 Freezing Rain Sensor over an asynchronous RS 485 interface The data are output in response to a poll command 3 1 1 Communication Parameters Table 1 lists the settings for the communication parameters Table 1 6496 Freezing Rain Sensor Communication Settings Parameter Setting 4800 bps 3 1 2 Data Format The serial string output from the Model 6496 Freezing Rain Sensor has the following format Table 2 Freezing Rain Sensor Serial Output String Data Format Bit Definition Comments Interpretation Range Tims sting 6 Reserved forfutureuse 1 Heater ON 2 Probe Heater State 0 Heater OFF 1 Ice 1 Failure status Output 0 0K no failure 1 2 oscillator Oscillator frequency count in hex Frequency 774060000 Dec oscillator frequency 3 ERRSTAT1 e Oscillator failure frequency too high Model 6496 Freezing Rain Sensor User s Manual Byte 00 Probe Heater OK 01 Probe Heater always On or OPEN i je 10 Probe Heater always OFF 3 ERRSTAT2 11 Probe Heater ON with 1 enable 5 Deicing failure 1 Active Bit Definition Comments Interpretation Range Oscillator failure
17. rdware Built Test a a e e 10 322 Continuous Brilla Letonia caliza 10 5 2 3 BIT Failure That Disables Ice Status Outputsxcccsciei iinwieiteeriedivemiset iea 11 52A Initiated Bull Lest BI eee a a A E E 12 3 0 Operator Ba AE 1 lt 6 BA Tests a is 12 3 4 C Ore ALON C OUMUNEG craneae an auaseeeednaiettexe teens 12 AENA O o 14 6 1 Periodic Maintenance cccccsccesccesccsscesscesccesccesccnscesscesccesccesccescesscesscesecesccesceescesscesscescees 14 old Monthly Manteniendo abet 14 6 2 Tianna Ma o de Lo 14 SUS AMO MA A e ce 14 l lc ea LES HDD TINE e ad e e e a do 15 8 REMOVAL AND REPLACEMENT cccccccecececcececccccceccccccecenecceneaeaceneacscenearsnentasens 16 O SPECTRA MON Se e 17 DD VV ATAU AAI NI jaa idad AA 19 Model 6496 Freezing Rain Sensor User s Manual 1 OVERVIEW The Model 6496 Freezing Rain Sensor uses an ultrasonically vibrating probe to detect the presence of icing conditions The 40 kHz vibrating frequency of the probe decreases as ice frost or wet snow accumulate Once these types of frozen precipitation have accreted on the probe to a thickness of 0 020 0 5 mm the frequency decreases by approximately 130 Hz and an internal heater inside the probe assembly turns on to deice the probe The internal heater draws 35 W during deicing and stays on for 60 seconds The sensing probe cools within a few seconds A 24 byte string reporting whether ice 1s present and status inform
18. strument and should be handled with extreme care at all times When the equipment is received check that all parts listed on the packing slip are accounted for and inspect the equipment for visible transport damage Report any damage or discrepancies to All Weather Inc Customer Service Figure 2 shows the protective covers that are around the probe and the probe assembly at the top of the Model 6496 Freezing Rain Sensor enclosure Do not remove these protective covers until the enclosure installation has been completed Figure 2 Probe and Probe Assembly Protective Covers 4 2 INSTALLATION The Model 6496 Freezing Rain Sensor must be firmly mounted to a vertical 2 2 pipe for proper operation The Model 6496 Freezing Rain Sensor should be installed in an open area away from trees buildings or other obstructions Mount the Freezing Rain Sensor so that the probe assembly is oriented into the prevailing wind 4 2 1 Mechanical Mounting Freezing Rain Sensor The Freezing Rain Sensor mounts on the mast using the M488397 00 Mounting Kit Refer to Figure 3 and Figure 4 during installation Mount the Freezing Rain Sensor on the mast with the top of the enclosure 5 6 167 cm from ground level or at least 3 feet 1 meter above the maximum snow level using Mounting Kit M488261 00 Model 6496 Freezing Rain Sensor Ground Cable User s Manual In order for the Freezing Rain Sensor s built in lightning protection to function proper
19. ugh Friday Call 916 928 1000 and ask for Service e Online support is available by filling out a request at www allweatherinc com customer support html e E mail your support request to support allweatherinc com Model 6496 Freezing Rain Sensor User s Manual Revision History Revision Date Summary of Changes 2012 Sept24 Initial release Model 6496 Freezing Rain Sensor User s Manual TABLE OF CONTENTS TOVE He WV coos sesso sah test ied cachet sac as ce cmert no tesa Go oti ode sod ie das Goce 1 1 1 COS SONG Sats aes str tee tse ease eect dato see te ce aaa ado te vented tele das selene toetoe adem Grad ected eels dee ewe Goad neh 1 2 FUNCTIONAL DESCRIPTION suicida 2 3 DATA COMMUNICATION 2 a o o di 3 1 221 21 119 0 1 mene AAA 3 SM C mmu ncation Parameters ed io dede 3 E Di ck 0 cl as eee neem E cee eee 3 ls POLE Oli a ae teste cece ot he ee pd haere ate he it he hoe ee tae ha hoe 5 4 UNPACKING AND INSTALLATION c ccccccccececcccacecccccceccacaceceaeaceneacsteneaesneceaceneaeas 6 nn UU E RO 6 A A A Re OT COTE ET evens or nT Ese eed OO re ACLs oe HOC ONE oe ORY IN evan ser om 6 42 Mechanical Mounino A E 6 42 2 Power COMM C tl OM noaa A a nee 8 423 Data Come cOn Rd ee 9 E SS sucsasncven oo vans cecnsnaed asec miametoned A sacniaaaed yas ealmeneteneo vane cen 9 ER LL GD As e eae rr a o o TE See 10 Ol POW EF ILE MUONS usos ais 10 5 2 built in Test B11 Capapiitiess ccsrss do do 10 SEL Ha
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