Technical Manual - MESA Systems Co.
Contents
1. BINJSIOW Aeb IMKO MICROMODULTECHNIK GMBH 12 34 1 5 1 SONO VARIO for measuring Moisture of Sand and Aggregates The TRIME TDR technology with the radar method offers high reliability for measuring moisture of sand and aggregates as different grain sizes unlike other measurement techniques such as microwave technology do not cause any distortion of the measurement result The calibration curve Cal1 Universal Sand is suitable for measuring the moisture in bulk sand gravel and gravel sand granulates The deviations to the universal calibration curve Cal1 are approximately 0 5 depending on the moisture range for the below listed gravel sand types Moisture in 96 Fine Sand Sand Gravel 2 4mm Gravel 4 6mm Gravel 6 12mm Gravel Sand Granulates Universal Calibration Cal1 100 150 200 2502. tpAve Radartime in Picoseconds Gravel 4 6mm Gravel 6 12mm Giavel Sand Granulates IMKO 1 3 34 MICROMODULTECHNIK 1 5 2 SONO VARIO for measuring Moisture of Expanded Clay and Lightly Sand Concerning the material density expanded clay and lightly sand differ significantly in comparison to sand and gravel Therefore a separate calibration for each material is necessary It is to consider that expanded clay below a moisture level of 1295 still can absorb more water ie here it must be calculated with more addition of water into a mixture At moisture levels above 1296 the maximum core moisture of expanded clay the surface water of the expanded clay would act as a free addition of water and the addition of water into a mixture should be reduced For measuring these two materials the probe calibration Cal10 or Cal11 can be selected If you want to use a single SONO probe with the calibration Cal1 for both normal sand gravel as well as these two materials then there is the possibility with a simple mathematical conversion inside a PLC Requirement would be that the PLC knows when and what material is to be measured You may convert the following MoistureLightlySand MeasurementValueCal1 Factor of 4 MoistureExpandedClay MeasurementValueCal1 Factor of 4 8 3 2 Offset It is to consider that this correction calculation for expanded clay can only be measured above 3 2 which in practice would be acceptable as it
3. MICROMODULTECHNIK GMBH SONO VARIO User Manual SONO VARI Ostandard for General Bulk Goods SONO VARIOxtrem for very high abrasive Goods like Gravel 4 32 and Grit IMKO Micromodultechnik GmbH Telefon 49 0 7248 5921 0 Im St ck 2 Fax 49 0 7243 90856 D 76275 Ettlingen e mail info imko de http Iwww imko de I publik TECH_MAN TRIME SONO ENGLISH SONO VARIO SONO VARIO Xtrem MAN Vers1_8 english doc MICROMCODULTECHNIK GMBH 2 34 User Manual for SONO VARIO As of 1 August 2011 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 4 1 1 1 The patented TRIME TDR Measuring Method enn 4 1 1 2 TRIME compared to other Measuring Methods 4 1 1 3 Areas of Application with SONO VARIOStandard and SONO VAHlIOXtrem 4 1 2 00 1 12000000 000 5 1 2 1 Measurement value collection with pre check average value and filtering 5 1 2 2
4. Analogue Output 1 Moisture in 95 0 2096 variable adjustable Analogue Output 2 Conductivity RbC 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 MICROMODULTECHNIK GMBH 6 3 4 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 three possible selections 1 Moist Temp Analogue output 1 for 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 100 Minimum 0 Minimum 0 1 2 5 serial RS485 interface SONO VARIO is equipped with a standard RS485 interface to serially readout individual parameters or measurement values An easy to implement data transfer prot
5. C D 20m 4 20 Output Channels Analog Output Moist Temp C Moist Conduct Moist Temp Conduct Temperature Range L onductivite m5 cr 00 binum Moisture Range bl asiman 20 jo 0 20 0 50 EE Set Set MICROMODULTECHNIK GMBH 23 34 2 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 ET l x Cal CalD P CalD F CalNameinProbe CalNameinFile MatiD P TemiD F DeniD P DeniD F 0 00000 00000 No Calibration 00000 00000 00000 00000 00000 00000 1 06035 00000 Universal 06035 00000 06000 00000 06000 00000 2 06040 00000 Lime Sand Linear 06040 00000 06000 00000 06000 00000 3 06041 00000 Cement Powder 06041 00000 06000 00000 06000 00000 4 06042 00000 Wood Pellets 06042 00000 06000 00000 06000 00000 5 06043 00000 Wheat
6. Determination of the mineral 5 1 2 8 Temperature 5 nor GUS OOS RR EE E cm 5 1 2 5 serial RS485 6 1 2 6 Error Reports and Error 6 1 3 Configuration of the Measure 7 1 4 Operation Mode CA and at non continuous Material 7 1 4 1 Average Time in the measurement mode CA and 9 1 5 Calibration Curves 9 1 5 1 SONO VARIO for measuring Moisture of Sand and Aggregates 12 1 5 2 SONO VARIO for measuring Moisture of Expanded Clay and Lightly Sand 13 1 6 Creating a linear Calibration Curve for a specific 14 1 6 1 Nonlinear calibration 14 1 7 Connectivity to SONO nnne na enint nans 16 1 7 1 Connection Plug and Plug aai a 17 1 8 Connection of the RS485 to the USB Module EXPERT 18 1 9 Connection of the RS485 to the SM USB Module from 19 2 Quick guide for the Softwa
7. 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 42VDC Powar Supply Pin R8485B Lead Colour brown Pin R8485A Lead Colour white IMP Bus Connt r With the option to accomplish a download of the firmware far the SONO probe Pin B Power Supply Pin 12VDC Power Supply Pin C rt Lead Colour gray pink Pin com Lead Colour blue red How to start with the USB Module SM USB from IMKO e Install USB Driver from USB Stick Connect the SM USB to the USB Port of the PC and the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick Connection of the SONO probe to the EX9531 via RS485A RS485B and OV Checkthe 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 1 COM15 is possible e Start Scan probes in SONOConfig e he SONO probe logs in the window Probe List after max 30 seconds with its serial number MICROMODULTECHNIK GMBH 20 34 Note 1 In the Device Manager passes it as follows Control Panel gt System gt Hardware gt Device Manager Gerdte Manager Datei Aktion A
8. 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 of the SONO VAHIO 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 VARIO is deployed in different applications in order to compensate measurement value variations due to differently moist materials At the point of time of delivery the Average Time is set to 4 seconds This value has proven itself to be useful for many types of applications At applications which require a faster reaction rate a smaller value can be set Should the display be too unstable it is recommended to select a higher value 1 5 Calibration Curves SONO VARIO is supplied with a universal calibration curve for sand Universal Sand Mix maximum of 15 different calibration curves CAL1 Cal15 are stored inside the SONO probe and can optionally be activated via the program SONO CONFIG A preliminary test of an appropriate calibration curve Cal1 15 can be activated in the menu Calibration and in the window Material Property Calibration by selecting the desired calibration curve Cal1 Cal15 and with using the button Set Active Calib The finally desired and poss
9. 06043 00000 06000 00000 06000 00000 06044 00000 Flour 06044 00000 06000 00000 06000 00000 7 06045 00000 Suger 06045 00000 06000 00000 06000 00000 8 06045 00000 Vario8 06045 00000 06000 00000 06000 00000 06047 00000 Vario 06047 00000 06000 00000 06000 00000 10 06048 00000 10 06048 00000 06000 00000 06000 00000 Calibration Item 11 06049 00000 11 06049 00000 06000 00000 06000 00000 12 05050 00000 Vario12 06050 00000 06000 00000 06000 00000 Set Active Calib 13 06054 00000 Suspension 06054 00000 06000 00000 06000 00000 14 06052 00000 FineSand 06052 00000 06000 00000 06000 00000 Default Calibration Item 15 06053 00000 Vario15 06053 00000 06000 00000 06000 00000 1 Set Default Calib Coefficient Correction 91 m2 t2 d2 m3 t3 d3 4 14 94 45 95 5 000000 002 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 0 000000 00 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 1 000000e 002 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 1 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000 000 0 000000e 000 0 000000 000 0 000000 000 CalN ame Universal m m5 575 t0 5 20 Set Close The desired and possibly altered calibration curve Ca
10. OOM nes LP Fa ban pas i pra xm Werner tan ides erat EE ini 47 ended Dade cy an bereits keksy PERD bereki Dele ie Labo cernis bregi tipp 1 m birmi i rad a herr ese one Ecc bun m E 414 hedaz etme B Verts Di Iber ets beer l al i P banaki kamai pamit tan p Abbrecher der hermits eurgtic E temo b vard Comm reves der or 4L TM scher res ate eee 17 TOHI eser iden 5 Mirame Arraia Ger XOT _ m Ceo con After changing the port settings SONO CONFIG must be restarted IMKO 21 34 MICROMODULTECHNIK GMBH 2 Quick guide for the Software SONO CONFIG With SONO CONFIG it is possible to make process related adjustments
11. between 5MHz and 40 2 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 gt 2GHz At these frequencies nonlinearities are generated which require very complex compensation For this reason microwave measuring methods are more sensitive in regard to temperature variation SONO probes calibrate themselves in the event of abrasion due to a novel and innovative probe design This consequently means longer maintenance intervals and at the same time more precise measurement values The 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 VARIOstandard and SONO VARIOxtrem SONO VARIO is suited for installation into containers hoppers and silos SONO VARIOStandard is suited for measuring of normal abrasive materials The probe head consists of stainless steel with a rectangular ceramic window The SONO VARIOxXtrem is suited for measuring of very high abrasive materials like gravel 4 32 and grit The probe head consists of hardened steel with a rectangular special ceramic window 34 MICROMODULTECHNIK GMBH 1 2 Mode of Operation 1 2 1 Measurement value collection with pre check average value and filtering SONO VARIO measures inte
12. is unlikely that in plant operation the moisture in expanded clay is below 3 296 20 18 Moisture in Lightly Sand Expanded Clay Universal Calibration for Sand and Graval 100 150 200 250 Radartime Picosecoands Lightly Sand MICROMODULTECHNIK T GMBH 1 4 34 1 6 Creating a linear Calibration Curve for a specific Material The calibration curves Call to Cal15 can be easily created or adapted for specific materials with the help of SONO CONFIG Therefore two measurement points need to be identified with the probe Point P1 at dried material and point P2 at moist material where the points P1 and P2 should be far enough apart to get a best possible calibration curve The moisture content of the material at point P1 and P2 can be determined with laboratory measurement methods oven drying It is to consider that sufficient material is measured to get a representative value Under the menu Calibration and the window Material Property Calibration the calibration curves CAL1 to Cal15 which are stored in the SONO 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
13. 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 Detection of malfunctions at the probe head SONO VARIO 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 MICROMODULTECHNIK GMBH 8 34 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 VARIO is able to filter out such faulty individual measurement values The standard settings in the Measurement Mode CA and CF for the f
14. 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 0 196 Mode CF Cyclic Float Average for continual average value with filtering and an accuracy of up to 0 196 for very slowly measuring processes e g in fluidized bed dryers conveyor belts etc Mode CK Cyclic Kalman Filter Standard setting for SONO MIX for use in fresh concrete mixer with continual average value with special dynamic Kalman filtering and an accuracy of up to 0 196 e Calibration if completely different materials are deployed Each of these settings will be preserved after shut down of the probe and is therefore stored on a permanent basis 1 4 Operation Mode CA and CF at non continuous Material Flow For mode Ca and CF the SONO VARIO is 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 the SONO VAHIO 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 the probe For applications with non continuous
15. 0 Coefficient mg Y2 m4 2 25 0 0581 500 4 05 IMKO MICROMODULTECHNIK 16 34 1 7 Connectivity to SONO Probes SONO SILO LED Display 0 20 4 20m ec 9 ase aS i S 0 20mA ye 4 20mA SONO MIX 22 0 10V PLC Water Control System w SONO MOVE With the SM USB module you can connect your SONO probe with a PC and communicate with the probe For example to capture data or to make an individual calibration In the combination with the free software SONO CONFIG adjust ments to the probe can be made easily and quickly IMKO 1 7 34 MICROMODULTECHNIK F GMBH 1 7 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 Lead Colour 7V 28V Power Supply red rt IMP Bus grey pink com IMP Bus blue red Screen transparent is grounded at the sensor The plant must be properly grounded IMKO MICROMODULTECHNIK GMBH 1 8 34 1 8 Connection of the RS485 to the USB Module EXPERT SONO VARIO is equipped with a standard RS485 interface to serially readout individual parameters or measurement values An easy to implement data transfer protocol enables the connection of several sensors probes on the RS485 Interface In addition the SONO VARIO can be directly connected to the US
16. 11 42 42 25 03 2010 11 42 40 25 03 2010 11 42 39 25 03 2010 Measure 11 42 37 25 03 2010 XD co och cn E Following measurement values are displayed on the screen MoistAve Moisture Value Average MatTemp Temperature Conduct Radar based Conductivity RbC TDRAve TDR Level for special applications DeltaCount Number of single measurements which are used for the averaging tpAve Radar time average which corresponds to the respective moisture value By clicking Save the recorded data is saved in a text file in the following path 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 IMKO 25 34 MICROMODULTECHNIK GK 2 1 6 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 air and water tap water can be used Attention Before performing a Basic Balancing it must be ensured that the SONO probe was set to Measure Mode A If this is not assured the p
17. B port of a PC in order to adjust individual measuring parameters or conduct calibrations via the RS485 to USB Module EXPERT which can be provided by IMKO us B Con nector Connection to the Probe Pin F R8485A Lead Colour white Pin RS485B Lead Colour brown Pin B 0V Power Supply RS485 to USB Interface How to start with the USB Module EXPERT EX9531 e Install USB Driver CDM 2 04 06 exe from USB Stick Connect the EX9531 to the USB Port of the PC and the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick Connection of the SONO probe to the EX9531 via RS485A RS485B and OV 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 COM 15 is possible e Start Scan probes in SONOConfig SONO probe logs in the window Probe List after max 30 seconds with its serial number IMKO 1 9 34 MICROMODULTECHNIK F GMBH 1 9 Connection of the RS485 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 optionally to the IMP Bus from IMKO which enables the download of a new firmware to the SONO probe 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
18. E TEMPERATURE Measurement Range 0 C 100 C The temperature is measured 3mm beneath the wear resistant sensor head inside the sensor 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 MEASUREMENT DATA PREPROCESSING MEASUREMENT MODE CA Cyclic Average For relative short measuring processes with continual average value filtering and an accuracy of up to 0 195 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 MICROMODULTECHNIK GMBH 34 34 SIGNAL OUTPUT 2 x Analogue Outputs 0 4 20 Analogue Output 1 Moisture in 95 0 20 variably adjustable Analogue Output 2 Conductivity RbC 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 can be variably aligned with the SONO CONFIG software For a 0 10V DC voltage output
19. 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 be adjusted with the button Set Default Calib Attention Use dot as separator 0 0581 not comma 1 6 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 the software tool TRIME WinCal 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 IMKO 1 5 34 MICROMODULTECHNIK GMBH The following diagram shows a sample calculation for a linear calibration curve with the coefficients mO and m1 for a specific material grav Moisture in 96 in Picoseconds The coefficient m4 is calculated from the slope of the curve Cal14 Delta y 25 0 Coefficient 0 0581 Deltax 500 70 The coefficient mg is the offset on the y axis at x
20. 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 A 5485 interface enables network operation of the probe whereby a data bus protocol for the connection of several SONO probes to the RS485 is implemented by default The connection of the probe to industrial busses such as Profibus Ethernet etc is possible via optional external modules available upon request POWER SUPPLY 7V to 28V DC 1 5 W AMBIENT CONDITIONS 0 70 A higher temperature range is available upon request MEASUREMENT FIELD EXPANSION Approximately 50 80 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 cable lengths of 4m 10m or 25 m
21. ation 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 point in air Therefore the dry probe head must be free in air When the LED is on continual for 5 seconds the calibration 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 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 on continual now SONO MIX 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 be completely dry Plug in the calibration connector Plug in the MIL connector with power supply blinking Unplug the continual for 10s LED is blinking calibration SONO MIX is Preparation Air quicker 10s Water connector ready to use time for calibration Plunge the calibratio
22. ctively 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 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 SPC via two analogue outputs 0 4 20 mA or recalled via a serial RS485 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
23. e 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 order 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 with sand or silicone sealing compound 4 The centre of the sensor head should be flush with the radius of the vessel wall The sensor may not project The ceramic must be Welded on laterally aligned to the Mounting rotational axis Frame 7 30 Clamping Collar i Vessel Wall Probe SONO VARIO MICROMODULTECHNIK GMBH 30 34 3 4 Gas and waterproofed Installation For pressure tight installation in a temperature range from 20 C to 80 C a flange kit is available on request The mounting flange can be welded to the container wall Sealing is done with 5 5mm thick O ring which is fixed with a locking ring Vessel Wall Mounting Flange Locking ring SONO VARIO Vessel JA Wall 108mm Probe Diameter Welded on Mounting Flange A Locking Slot for O Ring ring with 5 5mm diameter IMKO 31 34 MICROMODULTECHN 3 5 Exchange of the Probe Head of the VARIOxtrem At the SONO VARIOxtrem not only the ceramic plate but the who
24. he robust and wear resistant construction the ceramic plate may not be exposed to any blows as ceramic is prone to breakage 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 27 34 MICROMODULTECHNIK GMBH 3 2 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 VARI OsStandard 108mm Probe Diameter E Vessel Wall Probe Height 45mm Mounting SONO VARIOstanaarc Flange SONO VARIOxtrem 108mm Probe Diameter Probe Height Timm Mounting Flange SONO VARIOxtrem 28 34 Vessel Wall Mounting Flange SONO VARIO Dimensions of the Mounting Flange screw M6 2 0 34 MICROMODULTECHNIK GMBH 3 3 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 Th
25. ibly altered calibration curve Cal1 15 which is activated after switching on the probes power supply will be adjusted with the button Set Default Calib Nonlinear calibrations are possible with polynomials up to 5th grade coefficients mO m5 IMKO publish on its website more suitable calibration coefficients for different materials These calibration coefficients can be entered and stored in the SONO probe by hand Cal14 and 5 with the help of SONO CONFIG The following charts Cal 1 15 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 MICROMODULTECHNIK GMBH NENNEN R NNI 400 Mim i VARIO4 Calibratio rm HE Di A H C 10 e CX Ul 9Jn SIO N IMKO MICROMODULTECHNIK 11 34 spuo285s02l4
26. ilter functions depicted in the following have proven themselves to be useful for many applications and should only be altered for special applications Parameters in the Measurement Function Mode CA CF and CK Average Time otandard Setting 10 Setting Range 1 20 Filter Upper Limit Offset Standard Setting 5 Setting Range 1 20 With the setting of 20 this parameter must be disabled for Mode CK Filter Lower Limit Standard Setting 2 Setting Range 1 With the setting of 20 this parameter must be disabled for Mode CK Upper Limit Keep Time Standard Setting 5 Setting Range 1 100 With the setting of 100 this parameter must be disabled for Mode CK Lower Limit Keep Time Standard Setting 30 Setting Range 1 100 With the setting of 100 this parameter must be disabled for Mode CK The time in seconds for the generation of the average value can be set with this parameter Too high measurement values generated due to metal wipers or blades are filtered out The offset value in is added to the dynamically calculated upper limit Too low measurement values generated due to insufficient material at the probe head are filtered out The offset value in is subtracted from the dynamically calculated lower limit with the negative sign The maximum duration in seconds of the filter function for Upper Limit failures too high measurement values can be set with this parameter The maximum d
27. l1 15 which is activated after switching on the probes power supply can be adjusted with the button Set Default Calib The coefficients m1 0 0581 and 4 05 for individual calibration curves can be entered and adjusted directly by hand and are stored in the probe by pressing the Set button Attention Use dot as separator 0 0581 not comma MICROMODULTECHNIK GMBH 24 34 2 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 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 Test in CF Cyclic Float No Time Date MatTemp Cenduct TDRAve DekaCount _ tp we 11 42 52 25 03 2010 12 90 30 00 0 00 90 54 11 373 14 11 42 50 25 03 2010 11 42 48 25 03 2010 11 42 47 25 03 2010 11 42 45 25 03 2010 11 42 44 25 03 2010
28. le metal ceramic wear resistant probe head can be exchanged This is how easy it is to exchange the wear resistant probe head of the SONO VARIO Loosen the 4 fastening screws look for the right sequence of washer and gasket rings Lift off the probe head 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 on 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 N Hardened Steel Ceramic Window with Compound Pad O Ring Contact Bushing Probe Body 4 x Fastening Screws for Wear resistant Sensor Head IMKO MICROMODULTECHN 32 34 3 5 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 MIX 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 air the probe head must be completely dry If appropriate dry it with a towel Unplug the blind cap of the calibr
29. lose MICROMODULTECHNIK T GMBH 26 34 3 Installation of the Probe The installation conditions are strongly influenced by the constructional circumstances of the installation facility The ideal installation location must be established individually The following guidelines should hereby be observed 3 1 Assembly Instructions The following instructions should be followed when installing the probe The installation locations may not be situated beneath the inlets for additives e n case of an uneven base the probe must be installed at the highest point of the base No water may accumulate at the probe head as this could falsify the measurement Areas with strong turbulences are not ideal for the installation There should be a continuous material flow above the probe head e The stirring movement of blades should be conducted without gap above the probe head e he probe should not be installed in the direct vicinity of electrical disturbing sources such as motors e 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 Attention Risk of Breakage The probe head is made of hardened special steel and a very wear resistant ceramic in order to warrant for a long life span of the probe In spite of t
30. n Unplug MIL Screw blind cap calibration completed probe head completed connector and of calibration in air successfully into water successfully plug it again connector 3 seconds 10 seconds 5 seconds 10 seconds 5 seconds Calibration Connector MIL _ Blue LED Connector IMKO 33 34 MICROMCODULTECHNIK GMBH 4 Technical Data SONO VARIO SENSOR DESIGN Casing High Grade Steel V2A 1 4301 SONO VARlIOsStandard 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 special ceramic High temperature versions up to 150 C with external measurement transformer SONO ES are available upon request MOUNTING Sensor Dimensions SONO VARIOsStandard 108 x 45mm Diameter x Length SONO VARIOXtrem 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 096 up to the point of material saturation Measurement ranges up to 9096 moisture are possible with a special calibration MEASUREMENT RANGE CONDUCTIVITY The sensor as a material specific characteristic value delivers the radar based conductance RoC Radar based Conductance in a range of 0 12dS m The conductivity range is reduced in measurement ranges gt 50 MEASUREMENT RANG
31. nsicht E 95 5 BR Acronis Devices a Anschl sse COM und LPT oo ECP Druckeranschluss LPT 1 Be on F Intel R Active Management Technology SOL 30420 E Kommunikationsanschluss COM d E 1 Prolific USB to Serial Bridge COM Under the entry Ports COM amp LPT now the item USB Serial Port is found m Prolific USB to Serial Bridge 1 E Standardmafgige Seriell Ober Bluetooth Verbindung COM14 E Standardmafigige Seriell Gber Bluetooth verbindung 15 Be E Standardmafigige Seriell Gber Bluetooth verbindung COMITES 2 Sbtandardmatfigige Seriell ber Bluetaath verbindung 17 ber Bluetaoth verbindung 18 e Audio Video 358 Bildbearbeitungsgerate Bluetaaeth Funkger te 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 z n von Serial Port IER alb RE Hir zi e finders idera r
32. ocol enables the connection of several sensors probes at the RS485 Interface In addition the SONO VARIO can be directly connected to the USB port of a PC in order to adjust individual measuring parameters or conduct calibrations via the RS485 USB Module which can be provided by 1 2 6 Error Reports and Error Messages SONO VARIO is very fault tolerant This enables failure free operation Error messages can be recalled via the serial RS485 interface 7 34 MICROMODULTECHNIK T GMBH 1 3 Configuration of the Measure Mode The configuration of SONO VARIO 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 RS485 interface to the PC via RS485 USB Module which is available from IMKO The following settings of 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 RS485 interface Measurement Mode C Cyclic SONO VARIO is supplied ex factory with suited parameters in Mode CS for bulk goods Mode CS Cyclic Successive For very short measuring processes e g 5 20 seconds without floating average with internal up to 100 measurements
33. of individual parameters of the SONO probe Furthermore the measurement values of the SONO probe can be read from the probe via the RS485 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 Exil Bus Help E n x Serial Port Ge 2 1 1 Scan of connected SONO probes on the RS485 interface In the menu Bus and the window Scan Probes the 5485 bus can be scanned for attached SONO probes takes max 30 seconds SONO CONFIG reports founded SONO probes with its serial number in the window Probe List IMKO MICROMODULTECHN 22 34 2 1 2 Configuration of Measure Mode In Probe List with Config and Measure Mode amp Parameters the SONO probe can be adjusted to the desired mode CA CF or CS see Chapter Configuration Measure Mode Measure Mode amp Parameters Default Cycle Cyclic Set Default Measure Mode amp Parameters Actual Cycle Mode L Cyclic Average under C Average Time s Filter Upper Limit Upper Limit Keep Time Filter Lower Limit Lower Limit Keep Time 2 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 Output Current
34. re 04242 21 2 1 1 Scan of connected SONO probes on the RS485 21 2 1 2 Configuration of Measure 22 2000000000 nennen nnn nnne nnn 22 2 1 3 Analogue outputs of the SONO probe 22 IMKO 3 34 2 1 4 Selection of the individual Calibration 23 2 1 5 Testrun in the respective Measurement 24 2 1 6 Basic Balancing in Air and 25 3 Mstallation ofthe 26 SEE nel T OO UE 26 CZ EEE LC are DIMENSIONS TT 27 o M n ng in curved SUITaIOOS duis 29 3 4 Gas and waterproofed Installation 30 3 5 Exchange of the Probe Head of the VARIOXtrem 31 3 5 1 Basic Balancing of a new Probe 32 4 Technical Data SONO VAMHMIQ 33 MICROMODULTECHNIK GMBH 4 3 4 1 Instrument Description SONO VARIO 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 respe
35. rnally at a rate of 100 measurements per seconds and issues the measurement value at a cycle time of up to 200 milliseconds at the analogue output In these 200 milliseconds a probe internal pre check of the moisture values is already carried out i e only plausible and physically pre averaged 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 and CF Average 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 VARIO 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 Determination 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 conductivi
36. robe returns zero values After a Basic Balancing the SONO probe has to be set to Measure Mode C again 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 5 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 Lalculated in File zin Probe gt 1544 41 1 04735 Measurement Calculate Coetts Coetts gt Probe C
37. see Quick Guide for the Software SONO CONFIG Step 1 The radar pulse time tpAve of the probe is measured with dried material Ideally this takes place during operation of a mixer dryer in order to take into account possible density fluctuations of the material It is recommended to detect multiple measurement values for finding a best average value for tpAve The result is the first calibration point P1 e g 70 0 l e 70 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 25 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
38. ty 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 RbC Radar based Conductivity in 5 as characteristic value which is determined in dependency of the mineral concentration and is issued as an unscaled value The RbC measurement range of the SONO VARIO is 0 12dS m 1 2 3 Temperature Measurement A temperature sensor is installed into the SONO VARIO 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 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 VARIO 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 109756 0 20 or 0 30 Fora 0 10V DC voltage output a 500R resistor can be installed in order to reach a 0 10V output
39. uration in seconds of the filter function for Lower Limit failures too low measurement values for longer lasting material gaps ie the time in which no material is located on the probe can be bridged Kalman Filter Parameter in Measurement Mode CK Q Parameter Standard Setting 1x10 Setting Range 0 01 1x10 R Parameter standard Setting 0 033 Setting Range 0 01 0 1 This Kalman filter parameter Q is used to characterize the systemic measurement error It is recommended to leave this parameter to the default setting This Kalman filter parameter R is used for smoothing the measurement error The lower this parameter the faster is the response to smaller changes in the moisture readings The 0 34 MICROMODULTECHNIK T GMBH higher this parameter is the more smoothed the measured value but with a delayed reaction time It is recommended to leave this parameter to the default setting K Parameter This Kalman filter parameter K is used for a pre otandard Setting 0 01 dynamic behaviour of the Kalman Filter for Setting Range 0 01 higher changes in the moisture reading i e the reaction rate of the measurement signal can be affected hereby The K parameter is related to the Average Time It is recommended to leave this parameter to the default setting 1 4 1 Average Time in the measurement mode CA and CF SONO VARIO establishes every 200 milliseconds a new single measurement value which is
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