User Manual SONO-MIX MINI
Contents
1. 5 1 2 5 Analogue Outputs for Measurement 6 1 2 1 serial RS485 and IMP Bus 6 1 2 8 IMP Bus as a user friendly network system 7 1 2 3 Error Reports and Error 7 2 Configuration of the Measure 8 2 1 Operation Mode CA and CF at non continuous Material 1 8 2 1 1 Average Time in the measurement mode and 10 2 1 2 Filtering at material gaps in mode 10 2 1 3 Mode CC automatic summation of a moisture quantity during one batch process 18 2 1 4 Mode CH Automatic Moisture Measurement in one 19 2 2 Overview of single modes for different 13 2 2 1 Calibration of SONO MIX MINI in a mixing 4 14 2 2 2 Shortest expecting mixing times and density effects at partial loads 14 2 2 3 Howto perform a calibration with SONO MIX MINI for determination of water content 11 83 gasy 15 2 2 4 lt MINI to control the water cement ratio 17 2 2 5 Mode CC aut2. 27 46 4 Connectivity to SONO Probes nb pue Aisea aq ue aqoid o 4snlpe 5 3NO2 ONOS 21605 aui uoneulquio eq ul uone4qije jenpiiput 3AOW ONOS axeu 01 jo seunjde o ajdurexa J04 99024 aneoiunuuoo pue e 24024 ONOS JNOA 3224403 ue nof 8504 5 942 una MBs 10M 10 OIHVA ONOS 3 2 Ta ing gt AOL O 7 9 Rees XIW ONOS 15 NP 2 oy puto Keidsiq a31 4 2 7 Sunesedo sjeudojdde ue 7S C o auguo saqoud ONOS eyeinbuuo 2 9 ajqissod srl M3IA ONOS 2 auoje puEeS YUM agit 2 2 OTIS ONOS 5 28 46 4 1 1 Connection Plug and Plug Pinning SONO MIX MINI is supplied with a 10 pole cable with 5 meter length Assignment of the 10 pole sensor cable connections Sensor Connections Lead Colour Lead Colour 7V 24V Power Supply Wein Wei OV Power Supply Braun Braun 1 Analogue Positive Moisture Gr n Gr n 1 Analogue Return Line Moisture Gelb Gelb RS485 A n c n c RS485 B n c n c rt IMP Bus os Rosa com IMP Bus Grau Grau 2 Analogue Positive n c n c 2 Analogue Return Line n c n c Screen n c n c is grounded at
3. 6 5 Exchange of the Probe Head At the SONO MIX MINI 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 of the SONO MIX MINI 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 Hardened Steel Ceramic Window with Compound Pad O Ring _ Contact Bushing 4 x Fastening Screws for Wear resistant Sensor Head IMKO y 43 46 6 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 MINI 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
4. MEASUREMENT RANGE TEMPERATURE Measurement Range 0 70 The temperature is measured at the sensor casing beneath the wear resistant sensor head and can optionally be issued at the analogue output 2 The material temperature can be measured with an external calibration and compensation of the sensor intrinsic heating MEASUREMENT FIELD EXPANSION Approximately 50 80 mm depending on material and moisture POWER SUPPLY 7V to 24V DC 1 5 W AMBIENT CONDITIONS 0 70 A higher temperature range is available upon request 45 46 MEASUREMENT MODE WITH DATA PREPROCESSING SONO MIX MINI can be set to different measurement modes 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 Measurement mode CS can also be used for getting raw data from the SONO probe without averaging and filtering MEASUREMENT MODE Cyclic Average Filter For relative short measuring processes with continual average value filtering and an accuracy of up to 0 196 MEASUREMENT 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 MEASUREMENT MODE CK Cyclic Kalman Filter Standard setting for SONO MIX MINI for use in fresh concret
5. 20 0m 20 4m Output Channels Moist Temp C Moist Conduct Moisture Range Temperature Range EC Trime mS em Maximum 25 Set Maximum 100 Set C 0 20 0 50 o Set Minimum Minimum Simulate Close 35 46 MECROMCOULTECHNIE Y 5 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 k m Calibration Item Please select one calibration from to Cal15 to operate Set Active Calib Act CalDP in Probe MatlD P DeniD P Default Calibration 0 00000 Calibration 00000 00000 00000 1 06035 Universal Sand Mix 06035 06000 06000 1 2 06040 Lime Sand Linear 06040 06000 06000 3 06041 CementPowder 06041 06000 06000 Set Default Calib 4 06042 wood Pellets 06
6. 2 1 kg dm the result could be 2 296 2 1 kg dm 10 46 2 Liter water per m 3 Add an exact amount of water per manual batching into the mixture to achieve the target moisture e g add exact 112 0 Liter water per cubic meter of the mixture 4 Record again with SONO MIX MINI the second value at the wet mixture e g 8 7 probe value2 5 Calculation of the moisture value difference of SONO MIX MINI into the difference of water content in Liter m 8 7 probe value2 4 5 probe value1 4 2 that means a probe difference of 4 2 corresponds to a water difference of 112 0 liter m in the mixture This represents 112 Liter 4 2 26 67 Liter m per one point difference of SONO MIX MINI or 2 67 Liter m per 0 1 points difference of SONO MIX MINI 2 2 2 Shortest expecting mixing times and density effects at partial loads Time to evaluate signal at dry mix stage The sensor can be configured depending on the requirements of the applications but in the pre setting it requires 15 205 till the value is stable after filling the mixer with aggregates and cement Time to evaluate signal at wet mix stage The sensor will immediately detect the incoming water but commonly it lasts a little till the water is distributed homogeneous thus we suggest not to have shorter wet mixing time than 45s Does density have an effect on accuracy If the mixer load varies from 20 to 100 of total mixer capacity it needs to calibrate for different
7. Filter inactiv inactiv inactiv inactiv e g 20 inactiv e g 20 Upper Limit 100 100 100 100 100 Offset Filter inactiv inactiv inactiv inactiv e g 10 inactiv e g 5 Lower Limit 100 100 100 100 100 Offset Upper inactiv inactiv inactiv inactiv e g 10 inactiv e g 10 Limit Keep 10 10 10 10 10 Time Lower inactiv inactiv inactiv inactiv e g 10 inactiv e g 10 Limit Keep 10 10 10 10 10 Time Moisture 0 1 0 1 0 1 0 1 0 1 Threshold No Material 10 10 10 10 inactiv Boost 35 35 20 20 20 Offset 0 5 0 5 1 1 1 Weight 5 5 25 25 50 Invalid 2 2 inactiv inactiv inactiv Count For very difficult applications where it is not certain which mode is the best we recommend to select mode 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 21 46 3 Calibration Curves SONO MIX MINI is supplied with the calibration curve Cal9 MIX for the mixer operation with sand and gravel Cal9 MIX is slightly increased in the dry measurement range to ensure that in dry sand and gravel the readings do not move to 0 values because values around 0 can be disadvantageous for the filter arithmetic So in dry sand gravel the readings of the SONO MIX MINI show higher measure
8. Probe List One SONO probe can be selected by klicking Probe List E xj Exit Config Calibration Test SenaNo ResetBaudrate 1 120613 IMKO 34 46 MEROMCOUTECHNI E 5 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 be selected to IMP Bus RS485 or both interfaces Due to very robust behavior it is recommended to select the IMP Bus Measure Mode amp Parameters Default Cycle Mode x Set Defaut Measure Mode amp Parameters Actual Cycle Mode gt Average Mode of Mode C Average Select Bus Kalman with Boost No Yes IMP amp 25485 Offset with Moist4ve 10 f IMP Average Parameters Average Time s C 85485 Filter Upper Limit Offset Filter Lower Limit Offset e Set Upper Limit Keep Time Lower Limit Keep Time Moisture Threshold No Material Delay s Boost Offset Weight Invalid Measure Count 5 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 Output Output Current 0 20 4 20m
9. 034 7 5 26 00 16 03 51 143 2 7 5 26 00 16 03 50 11 022 7 5 26 00 16 03 49 11 002 7 6 26 00 16 03 48 1032 7 57 26 00 16 03 47 1103 201 7 5 25 70 16 03 46 1146 2 7 5 25 70 160245 11 032 7 5 25 79 16 03 44 16 03 43 16 03 42 16 03 41 16 03 40 15 03 99 Following measurement values are displayed on the screen MoistAve Moisture Value in 96 Average MatTemp Temperature EC TRIME Radar based Conductivity EC TRIME in dS m or mS cm TDRAve TDR Signal Level for special applications DeltaCount Number of single measurements which are used for the averaging tpAve Radar time average which corresponds to the respective moisture value By clicking Save the recorded data is saved in a text file in the following path XSONO 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 5 1 6 Measure 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 37 46 5 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 calib
10. 12mm Gravel Sand Granulates Universal Calibration 100 150 200 250 tpAve Radartime in Picoseconds Gravel 4 6mm 6 12 Gravel Sand Granulates IMKO 25 46 3 2 Creating a linear Calibration Curve for a specific Material The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with the help of SONO CONFIG Therefore two measurement points need to be identified with the probe Point P1 at dried material and point P2 at moist material where the points P1 and P2 should be far enough apart to get a best possible calibration curve The moisture content of the material at point P1 and P2 can be determined with laboratory measurement methods oven drying It is to consider that sufficient material is measured to get a representative value Under the menu Calibration and the window Material Property Calibration the calibration curves CAL1 to Cal15 which are stored in the SONO 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 CA see Quick Guide for the Software SONO CONFIG Step 1 The radar pulse time tpAve of the probe is measu
11. 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 tipenechefion von USE Serial COM4 rwetteric Einstellungen f Traber Agran ingen Tiber Detak UN Bis pro Sekunde 9600 Reduseren Se de Werte Darbar 8 Se Werte T r Pot Swppbis t 32 4 der RTS aktiv setzen bam Abachalter der des Gerate After changing the port settings SONO CONFIG must be restarted IMKO yt 33 46 5 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 bi x Exit Bus Help Dec 5 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
12. after the Setting Range 1 20 time span of the No Material Delay is exceeded 2 2 6 Mode CC automatic summation of a moisture quantity during one batch process Simple PLCs are often unable to record moisture measurement values during one 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 4 Such microwave probes need a switching signal from a PLC for starting the averaging of the probe This increases the cabling effort 5 Time delays can occur during the summation time with a trigger signal which leads to measurement errors This is particularly disadvantageous for small batches recipe errors can 6 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
13. 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 250 milliseconds In the Measurement Mode CA CF or CK not the momentarily measured individual values are directly issued but the average value is accumulated via a variable number of measurements Average in order to filter out temporary variations These variations can be caused by inhomogeneous moisture distribution in the material surrounding the sensor head The delivery scope of the SONO MIX MINI includes suited parameters for the averaging period and a universally applicable filter function deployable for currently usual applications The time for the average value accumulation as well as various filter functions can be adjusted for special applications 1 2 2 Auto Correction at Abrasion Even in the event of abrasion at the probe head of a SONO probe the automatic measurement compensation enables significantly longer
14. 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 IMKO y In the download area of IMKO s homepage www imko de we publish the transmission protocol of the SONO probes 1 2 2 The IMP Bus as a user friendly network system With external power supply on site for the SONO probes a simple 2 wire cable can be used for the networking By use of 4 wire cables several probes can be also supplied with power Standard RS485 interfaces cause very often problems They are not galvanically isolated and therefore raises the danger of mass grindings or interferences which can lead to considerably security problems An RS485 network needs shielded and twisted pair cables especially for long distances Depending on the topology of the network it is necessary to place 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 85485 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 th
15. dynamically calculated lower limit with the negative sign Upper Limit Keep Time Standard Setting 10 Setting Range 1 100 With the setting of 100 this parameter must be disabled for Mode The maximum duration in seconds of the filter function for Upper Limit failures too high measurement values can be set with this parameter Lower Limit Keep Time Standard Setting 10 Setting Range 1 100 With the setting of 100 this parameter must be disabled for Mode The maximum duration in seconds of the filter function for Lower Limit failures too low measurement values for longer lasting material gaps ie the time in which no material is located on the probe can be bridged Moisture Threshold in moisture Standard Setting 1 Setting Range 1 20 The accumulation of moisture values starts above the Moisture Threshold and the analogue signal is output The accumulation pauses if the moisture level is below the threshold value No Material Delay in seconds Standard Setting 5 Setting Range 1 20 The accumulation stopps if the moisture value is below the moisture threshold The SONO probes starts again in a new batch with a new accumulation after the time span of the No Material Delay is exceeded Boost Standard Setting 35 Setting Range 1 100 Automatic summation stops if threshold is below No Material Delay After expiration of No Material Dela
16. loads At 20 load the sensor could experience no material or less material Different density does always have an effect and on any sensor operating with an electrical field but how strong this effect is depends on the installation place in the mixer as closer to the wall of the mixer as less this effect is as due to the mixing energy with smaller batches more material is located at the outside of the mixer But it always has to be ensured that at least one mixing tool cleans the sensor per turn to ensure the sensor stays clean Even if close to the wall you will see at least a slight effect of the filling amount 15 46 2 2 3 How to perform a calibration with SONO MIX MINI for determination of water content 3 easy steps The mixer probe SONO MIX MINI can measure water content precise also in wet mixtures with higher cement contents Therefore it opens up completely new possibilities for the calibration of the SONO MIX MINI in a mixer control system In this example we show a new method where kiln drying of concrete samples is not necessary for a calibration of SONO MIX MINI Furthermore the creation of different recipes should be easier The calculation of water content can be done with a PC or with a PLC In the following example both options are shown however only the PLC option is calculated with numbers A D Converter PLC Determination of water content in a PC or in a PLC Measurement values in a PC withou
17. 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 process without an external Switching or trigger signal The SONO probe freezes the analogue signal as long as a new batch process starts So the PLC has time enough to read in the freezed moisture value of the batch For applications without a PLC the freezed signal of the SONO probe can be used for displaying the moisture value to a simple 7 segment unit as long as a new batch process starts 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 su
18. of second batch process After the period of No Material Delay e g 5 seconds the SONO probe recognizes that the threshold of 1 has been exceeded The previously stored measurement value is cleared and the probe starts again automatically with the continuous accumulation of measurement values yellow curve 2 2 7 Mode CH Automatic Moisture Measurement in one Batch 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 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 2 seconds Mode CH executes an automatic filtering e g if dripping water occurs IMKO 20 46 2 3 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 a 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 spiral process Operating CH CH CK CK CA CK CF Mode Average 2 2 5 5 10 10 30 Time
19. operating periods without the necessity of recalibration Many other probes deployed for the material moisture measurement are equipped with a dielectric Screen ceramic or plastic plate If this screen is exposed to wear and a regular recalibration is not conducted these probes will provide faulty measurement values as the intensity of the measuring field subsequently increases due to the wear At the SONO series with the TRIME TDR radar based method the innovative probe design ensures for the automatic correction of the sensor in case of changes to the dielectric screen caused by abrasion This consequently means continuous reliability and longer maintenance intervals at the SONO probes 1 2 3 Determination of the Cement Concentration With the radar based TRIME measurement method it is now possible for the first time not only to measure the moisture but also to provide information regarding the conductivity respectively the cement content the expansion rate or the composition of a special material Hereby the attenuation of the radar pulse in the measured volume fraction of the material e g fresh concrete is determined This novel and innovative technology measures the same amount of material as with the moisture measurement and delivers a radar based conductance value EC TRIME Radar based Conductivity in dS m EC TRIME is a characteristic value which is determined in dependency of the cement concentration respectively the water cement r
20. the sensor The plant must be properly grounded IMKO y IMKO 29 46 V 4 1 2 Analogue Output 0 10V with a Shunt Resistor There are PLC s which have no current inputs 0 20 but voltage inputs 0 10V With the help of a shunt resistor with 500 ohm in the delivery included it is possible to generate a 0 10V signal from the current signal 0 20mA The 500 ohm shunt resistor should be placed at the end of the line resp at the input of the PLC Following drawing shows the circuit principle PLC SONO Probe Current signal 0 20mA Analog Positive Analog Return Line 4 1 3 Connection diagram with SONO VIEW Y d SONO SILO SONO VARIO 24V DC Power Suppl IMP Bus COM i M mesu 1 Positiv m 1 Analog Positiv Connection to further SONO probes Connection to further SONO probes 1 Analog Positiv 1 Analog Positiv 0 4 20 PLC SONO VIEW Analogue input or instalation the control EE Distribution Cabinet distribution cabinet 30 46 IMKO 31 46 wecrowoourTecean 4 2 Connection of the Probe to the SM USB Module from IMKO The SM USB provides the ability to connect a SONO probe either to the standard 5485 interface or to the IMP Bus from IMKO In fact that the IMP Bus is more robust and enables the download of a new firmwar
21. 042 06000 06000 5 05043 Wheat 05043 05000 06000 5 06044 06044 06000 05000 7 06045 Suger 06045 06000 06000 niversal S and Mix 8 06046 Brown coal granulate 06046 06000 06000 3 05047 SONO MIX 06047 06000 06000 Set 10 06048 Expanded clay 06048 06000 06000 11 06049 Lightly sand 06043 06000 06000 Material Coeffs 3 Temp Coeffs 12 06050 Sewage sludge 06050 06000 06000 13 06054 Ceramic Suspension 06054 _ 06000 06000 m 5 5 20 14 06058 to Water 06058 0650001 06000 m1 0 05 0 15 06053 15 06053 06000 06000 m2 0 0 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 m0 to m5 not 36 46 MECRCMCOLLTECHNIE 7 5 1 5 Test run in the respective Measurement Mode In the menu Test and the window Test in Mode 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
22. 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 spiral process Operating CH CH CK CK CA CK CF Mode Average 2 2 5 5 10 10 30 Time Filter inactiv inactiv inactiv inactiv e g 20 inactiv e g 20 Upper Limit 100 100 100 100 100 Offset Filter inactiv inactiv inactiv inactiv e g 10 inactiv e g 5 Lower Limit 100 100 100 100 100 Offset Upper inactiv inactiv inactiv inactiv e g 10 inactiv e g 10 Limit Keep 10 10 10 10 10 Time Lower inactiv inactiv inactiv inactiv e g 10 inactiv e g 10 Limit Keep 10 10 10 10 10 Time Moisture 0 1 0 1 0 1 0 1 0 1 Threshold No Material 10 10 10 10 inactiv Boost 35 35 20 20 20 Offset 0 5 0 5 1 1 1 Weight 5 5 25 25 50 Invalid 2 2 inactiv inactiv inactiv Count For very difficult applications where it is not certain which mode is the best we recommend to select mode 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 14 46 2 2 1 Calibration of SONO MIX MINI in a mixing plant SONO MIX MINI is delivered with a raw calibration function w
23. Cal15 with the help of SONO CONFIG The following charts Cal 1 15 show different selectable calibration curves which are stored inside the SONO probe On the y axis the gravimetric moisture MoistAve is shown On the x axis depending on the calibration curve the associated radar time tpAve in picoseconds is shown With the software SONO CONFIG the radar time tpAve is shown on the screen parallel to the moisture value MoistAve see Quick Guide for the Software SONO CONFIG NNI E ep p s QUNM SONO VARIO1 Calibration Curves e aanysioy Ae16 E tpAve Radartime in Picoseconds IMKO 24 46 MECRCMCOULTECHNI A 3 1 1 SONO MIX MINI for measuring Moisture of Sand and Aggregates The TRIME TDR technology with the radar method offers high reliability for measuring moisture of sand and aggregates as different grain sizes unlike other measurement techniques such as microwave technology do not cause any distortion of the measurement result The calibration curve Cal1 Universal Sand Mix is suitable for measuring the moisture in bulk sand gravel and gravel sand granulates The deviations for the below listed gravel sand types to the universal calibration curve Cal1 are so low that only one single calibration curve may be used Moisture in Fine Sand Sand Gravel 2 4mm Gravel 4 6mm Gravel 6
24. PLUG The sensor is equipped with a robust 10 pole MIL flange connector Ready made connection cables with MIL connectors are available in the lengths 4m 10m or 25 m 46 46 Precise Moisture Measurement in hydrology forestry agriculture environmental and earth science civil engineering as well as individual applications
25. User Manual SONO MIX MINI IMKO Micromodultechnik GmbH Telefon 49 0 7243 5921 0 Im Stock 2 Fax 49 0 7243 90856 D 76275 Ettlingen e mail X info Qimko de http www imko de I publik TECH_MAN TRIME SONO ENGLISH SONO MIX MINI SONO MIX MINI_MAN Vers2_3 english doc 2 46 User Manual for SONO MIX MINI As of 10 September 2014 Thank you for buying an IMKO moisture probe Please carefully read these instructions in order to achieve best possible results with your mixer probe SONO MIX MINI for the in line moisture measurement in sand gravel fresh concrete or any other material Should you have any questions or suggestions regarding your new mixer probe after reading please do not hesitate to contact our authorised dealers or IMKO directly We will gladly help you List of Content IMKO y 1 Instrument Description SONO MIX MINI 4 1 1 1 The patented TRIME TDR Measuring Method seen 4 1 1 2 TRIME compared to other Measuring 0 4 1 13 Areas ot AppliCatlOni dte tette tt 4 12 Mode of Operation e aere re o e a e Pe Cha de ede ae 5 1 2 1 Measurement Values with physically Pre check Average Value and Filtering 5 1 2 2 Auto Correction at 5 1 2 8 Determination of the Cement Concentration 2 5 1 2 4 Temperature
26. and store moisture values during a complete batch process without an external switching or trigger signal The SONO probe freezes the analogue signal as long as a new batch process starts So the PLC has time enough to read in the freezed moisture value of the batch For applications without a PLC the freezed signal of the SONO probe can be used for displaying the moisture value to a simple 7 segment unit as long as a new batch process starts With the parameter Moisture Threshold the SONO probe can be configured to the start moisture level where the summation starts automatically Due to an automatic recalibration of SONO probes it is ensured that the zero point will be precisely controlled The start level could be variably set dependent to the plant Recommended is a level with e g 0 596 to 196 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 19 46 MECROMCOUTECHNIE We How can the mode CC be used if the SONO probe cannot detect the moisture threshold by itself e g above a conveyor belt if there is constantly material above the probe over a longer t
27. 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 quality of fresh concrete is the decisive factor for the stability and the durability of concrete constructions Hereby the two parameters moisture and cement content assume a central role as these determine the consistency and the desired mechanical stability of concrete The measurement of these two basic parameters therefore warrant for ideal quality and durability SONO MIX MINI accurately measures both in the dry mixture and in the wet mixture A dry mixture can e g be mixed with residual water varying solids content so that the water content to 70 target is met The remaining 3096 clean water content can then be dosed with SONO MIX MINI precisely 1 1 3 Areas of Application The SONO MIX MINI mixer probe is suited for installation into intensive mixers and chutes and other plant technologies 5 46 1 2 Mode of Operation 1 2 1 Measurement Values with physically Pre check Average Value
28. atio and is issued as an unscaled value The EC TRIME measurement range of the SONO MIX MINI is 0 50dS m 1 2 4 Temperature Measurement A temperature sensor is installed into the SONO MIX MINI which establishes the casing temperature 5mm beneath the sensor head The temperature can optionally be issued at the analogue output 2 As the TRIME electronics operate with a low 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 6 46 1 2 5 Analogue Outputs for Measurement Values The measurement values are issued as a current signal via the analogue output With the help of the service program SONO CONFIG the SONO MIX MINI can be set to the two versions for either 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 or any other range For a 0 10V DC voltage output a 500R resistor can be installed in order to reach a 0 10V output Analogue Output 1 Moisture in variable adjustable Analogue Output 2 Wires are not occupied in the cable 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 con
29. ations 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 the probe For applications with non continuous material flow there is the option to optimise the control of the measurement process via the adjustable filter values Filter Lower Limit Filter Upper Limit and the time constant No Material Keep Time The continual floating averaging can be set with the parameter Average Time Parameters in the Measurement Mode Average Time Standard Setting 2 Setting Range 1 20 MKO y 9 46 Function The time in seconds for the generation of the average value can be set with this parameter Filter Upper Limit Offset Standard Setting 20 Setting Range 1 20 With the setting of 20 this parameter must be disabled for Mode CK Too high measurement values generated due to metal wipers or blades are filtered out The offset value in is added to the dynamically calculated upper limit Filter Lower Limit Offset Standard Setting 20 Setting Range 1 20 With the setting of 20 this parameter must be disabled for Mode CK Too low measurement values generated due to insufficient material at the probe head are filtered out The offset value in is subtracted from the
30. ccumulating above the sensor head which could falsify the measurement an installation angle of approximately 30 above the base centre is recommended The centre of the sensor head should be flush with the radius of the mixer wall The sensor may not project The ceramic must be laterally aligned to the rotational axis Fill the crack with sand or silicone sealing compound Mixer Base or Vessel Wall Mixer Probe SONO MIX 41 46 6 4 Probe Adjustment SONO MIX MINI can either be installed at the base or the side wall of a mixer It may not project into the mixer and should have the same height position as the wear plates in the mixer Welded on Mixer Base Mounting or Frame Vesell Wall Clamping Collar Mixer Probe SONO MIX Moving the Probe out of the Mixer Moving the Probe into the Mixer 1 Remove the compressed sand in 1 Remove the compressed sand in the crack the crack Screw out the green screws as far as required Tighten the red nuts until the using an Allen key desired position is reached 2 to the desired position 3 4 Fasten the red nuts 4 Fasten the three green screws 5 6 2 Loosen the 3 red nuts 3 Fasten the green screws 5 Compress the sand in the crack Tighten all nuts Compress the sand in the crack It may be necessary to newly position the clamping collar It may be necessary to newly position the clamping collar IMKO 42 46
31. cord the measurement values with the PLC in the wet mixture It is recommended to average the values over the last 5 seconds of the wet mixing time In this example a measurement value of 14811 has been recorded with the PLC SONO MIX MINI Measurement values without unit from 4 20mA current output signal Measurement value in a PC without unit A D Converter PLC without unit from 0 to max 32768 Water content for this concrete recipe for an optimal consistency of the recipe Measurement 7 968 mA 6 2 8126 After completion of values dry This is the step 2 this value mixture Dry value A D can be calculated in the following way 62 1 1 38 2441 Measurement 11 232mA 11 3 14811 62 1 values wet This is the this water content mixture Target value A D value corresponds to the calculated w c setpoint for the recipe at the beginning Note For prefab concrete with higher flow spread it is recommended to record the wet measurement values without concrete plasticizer in the mixture The reason is that the plasticizer modifies the density of the fresh concrete considerably which leads to deviations in the measurement values 3 Determination of the sensitivity of the SONO MIX MINI for this recipe For calibration and calculation of the mixing water for further mixtures the coefficient c1 Sensitivity of the SONO MIX MINI can be calculated easily in the following way c1 Sensi
32. ds at the analogue output Measurement mode CS can also be used for getting raw data from the SONO probe without averaging and filtering Mode 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 with Boost Standard setting for SONO MIX MINI for use in fresh concrete mixer with continual average value with special dynamic Kalman filtering and an accuracy of up to 0 196 Mode CC Cyclic Cumulated with automatic summation of a moisture quantity during one batch process Mode CH Cyclic Hold similar to Mode CC but without summation 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 applic
33. ductivity 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 several 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 2 Moist Conductivity Analogue output 1 for moisture output 2 for conductivity in a range of 0 50dS m 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 100 Moisture Range Temp Range Maximum e g 20 for sand Set in 96 Maximum 70 C Minimum 0 Minimum 0 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
34. e 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 the serial interface IMKO y 8 46 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 the SM USB Module or the display module SONO VIEW which are available from IMKO The following settings of SONO probes can be amended with the service program SONO CONFIG Measurement Mode and Parameters e Measurement Mode A On Request only in network operation for the retrieval of measurement values via RS485 interface Measurement Mode C Cyclic The SONO probe is supplied ex factory with suited parameters in Mode C 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 millisecon
35. e 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 Sufficient material for an accurately moisture measurement value of 0 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 The following parameter setting in mode fits a high pass filtering for bridging material gaps Average Mode under Mode C CA Cyclic Average Average Parameters Average Time s n Fiter Upper Limit Offset 20 5 Fiter Lower Limit Offset f2 Upper Limit Keep Time TEN Lower Limit Keep Time NN The Filter Upper Limit is here deactivated with a value of 20 the Filter Lower Limit is set to 296 With a Lower Limit Keep Time of 5 seconds the average value will be frozen for 5 seconds if a single measurement value is below the limit of 2 of the average value After 5 seconds the average value is deleted and a new average value building starts The Keep Time function stops if a single measurement value lies within the Limit values IMKO yt 12 46 IMKO 13 46 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 a screw
36. e mixer with continual average value special dynamic Kalman filtering and an accuracy of up to 0 1 SIGNAL OUTPUT 2 x Analogue Outputs 0 4 20mA Analogue Output 1 Moisture in 96 0 2096 variably adjustable Analogue Output 2 Conductivity RbC 0 50dS m or optionally the temperature In addition there is the option to split the analogue output 2 into two ranges into 4 11mA for the temperature and 12 20mA for the conductivity The analogue output 2 hereby changes over in 5 second cycles between these two current measurement windows The two analogue outputs can be variably aligned with the SONO CONFIG software For a 0 10V DC voltage output a 5008 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 possible and can be downloaded into the sensor with the SONO CONFIG software Download per Internet A zero point correction can be performed easily with the SONO CONFIG software COMMUNICATION A RS485 interface and the IMP Bus enables network operation of the probe whereby a data bus protocol for the connection of several SONO probes to the serial bus is implemented by default The connection of the probe to industrial busses such as Profibus Ethernet etc is possible via optional external modules available upon request CONNECTOR
37. e 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 Bus Conn 5 With the option to accomplish 4 download of the firmware if for the SONO probe if 27 4 Pin B 0V Power Supply Pin A 12VDC Power Supply As Pin C rt Lead Colour grey pink Pin J com Lead Colour blue red How to start with the USB Module SM USB from IMKO e Install USB Driver from USB Stick e Connect the SM USB to the USB Port of the PC and the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick Connection of the SONO probe to the SM USB via the serial interface and power supply 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 15 is possible Sta
38. election of the individual Calibration Curves see 35 5 1 5 Test run in the respective Measurement 36 5 1 6 Measure run in 36 5 1 7 Basic Balancing in Air and 37 6 Installation of the 38 6 1 Assembly Instructions 38 6 2 Assembly DIMENSIONS ive LA Pep Ee eee nanan 39 6 3 Mounting in curved 40 6 4 Probe 2 2 dei ensues 41 6 5 Exchange of the Probe e 42 6 5 1 Basic Balancing of a new Probe 43 7 TECHNICAL DATA SONO MIX 24 nnn tnn nn anena 44 4 46 1 Instrument Description SONO MIX MINI 1 1 1 The patented TRIME TDR Measuring Method The TDR technology Time Domain Reflectometry is a radar based dielectric measuring procedure at which the transit times of electromagnetic pulses for the measurement of dielectricity constants respectively the moisture content are determined The SONO MIX MINI Mixer Probe consists of a high grade steel casing with a wear resistant sensor
39. er be installed at the base or the side wall of a mixer One fact to consider is that the installation into the mixer base also enables the measurement of smaller material quantities A pre assembled mounting frame is available for the SONO MIX MINI The frame can both be welded on to the base and the side wall of the mixer The probe can be adjusted to the correct position respectively correct installation height with adjusting screws and nuts at the clamping collar A cut out must be performed in the mixer base before welding on the mounting frame and it is necessary to verify the fit of the frame and the probe at the base respectively the wall Cut Out for Mounting Frame 127mm Fill the crack with sand or silicone sealing compound Probe Diameter 108mm N Mixer Base E or Vessel Wall 5 5 2 3 Mounting e Frame E 5 Clamping Collar Mixer Probe SONO MIX IMKO 40 46 MEROMCOUTEC HK P 6 3 Mounting in curved Surfaces In order to prevent the probe head from projecting and interfering with the mixer blades the centre of the probe head should be flush with the radius of the mixer wall The ceramic must be laterally aligned to the rotational axis as the gap towards the mixer blade 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 a
40. head made of hardened steel and ceramic An integrated TRIME TDR measuring transducer is installed into the casing A high frequency TDR pulse 1GHz passes along wave guides and generates an electro magnetic field around these guides and herewith also in the material surrounding the probe Using a new patented measuring method IMKO has achieved to measure the transit time of this pulse with a resolution of 1 picosecond 1x10 consequently determine the moisture and to provide information in regard to the concrete composition The established moisture content as well as the concrete composition respectively the temperature can either be uploaded directly into a SPC via two analogue outputs 0 4 20 or recalled via a serial interface 1 1 2 TRIME compared to other Measuring Methods In contrary to conventional capacitive or microwave measuring methods the TRIME technology Time Domain Reflectometry with Intelligent Micromodule Elements does not only enable the measuring of the moisture but also to verify if the cement content specified in a recipe has been complied with This means more reliability at the mixing fresh concrete TRIME TDR technology operates in the ideal frequency range between 600MHz and 1 2 GHz Capacitive measuring methods also referred to as Frequency Domain Technology depending on the device operate within a frequency range between 5MHz and 40MHz and are therefore prone to interference due to disturbance such
41. hich is far higher than the real moisture values kiln dried values of a sand gravel or fresh concrete mixture The reason is that SONO MIX MINI use a powerful modified Kalman filter algorithm which would work incorrect at NULL values division by zero results in infinite Therefore it is necessary with SONO MIX MINI as well as with all other moisture probes to make a recipe specific calibration with the PLC in the mixing plant Another reason for this calibration is that every mixer type has another behaviour concerning the raw density of the mixed material In practice a mixer moisture probe has to be calibrated with two points in the mixing plant The first calibration point should be relatively dry e g at 2 to 396 gravimetric moisture The second point should be in a range which matches the maximum moisture value in practice e g 7 The closely together these both moisture values1 and 2 are the higher could be the measurement error due to the reference measurement especially at moisture values which are beyond of these two points or not between these two points Following process can be recommended 1 Record the SONO MIX MINI moisture value at a dry mixture e g 4 5 probe value1 2 Take a sample of about 2 3kg and determine with kiln drying in the laboratory the correct gravimetric moisture of the sample e g 2 2 This moisture value can be optionally calculated into liter water per m With a raw density of the mixture of e g
42. ime In this case a short interrupt of the probe s power supply e g for about 0 5 seconds with the help of a relay contact of the PLC can restart the SONO probe at the beginning of the material transport After this short interrupt the SONO probe starts immediately with the summarizing and averaging Please note It should be noted that no material sticks on the probes surface Otherwise the moisture zero point 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 The first batch process stops The 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 5 were bridged Ew n gt 5 Characteristic of moisture curve in sand weshold Adjustable Moisture ds 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 Material Delay time of e g 5 seconds has expired and a new batch process starts lt gt D adjustable No Material Delay e g 5 seconds Time Start
43. ment values For an absolute value calculation for the water addition into the mixer it is important to take this into account In general the calibration of the probe for the water addition by a PLC has to be determined with laboratory measurement methods oven drying A maximum of 15 different calibration curves Cal1 Cal15 are stored inside the SONO probe and can optionally be activated via the program SONO CONFIG If SONO MIX MINI is used without mixer operation only for measuring the moisture content of aggregates like sand and gravel then the calibration curve Cal 1 Universal Sand Mix must be set If SONO MIX MINI isn t used inside a mixer but e g beneath a flap the operation mode must be changed from CK to CA A preliminary test of an appropriate calibration curve 15 be activated in the menu Calibration and in the window Material Property Calibration by selecting the desired calibration curve Cal1 Cal15 and with using the button Set Active Calib The finally desired and possibly altered calibration curve 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 to m5 IMKO publish on its website more suitable calibration coefficients for different materials These calibration coefficients can be entered and stored in the SONO probe by hand Cal14 and
44. 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 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 4 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 MINI 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 blinking Unplug the continual Plug in the for 10s LED is blinking calibration SONO MIX is calibration connector Preparation Air quicker 10s Water connector ready to
45. nger 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 11 46 IMKO y 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 The Upper Limit Keep Time sets the maximum possible time where the probe would determine inaccurate too high measurement values Using a complex algorithm SONO probes are able to filter out such faulty individual measurement values The standard settings in the Measurement Mode CA and CF for the filter functions depicted in the following have proven themselves to be useful for many applications and should only be altered for special applications It is appropriate to bridge material gaps in mode CA with Upper and Lower Limit Offsets and Keep Time For example the Lower Limit Offset could be adjusted with 296 with a Lower Limit Keep Time of 5 seconds If the SONO probe determines a moisture value which is 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 her
46. omatic summation of a moisture quantity during one batch process 17 2 3 Overview of single modes for different 20 Le Lo DRESS UTR DEUS 21 3 46 3 1 1 lt MINI for measuring Moisture of Sand and Aggregates 24 3 2 Creating a linear Calibration Curve for a specific 25 3 2 1 Nonlinear calibration mener erinnere 25 4 Connectivity to SONO annes nn na sas nasa tnn usan 27 411 Connection Plug and Plug 28 4 1 2 Analogue Output 0 10V with a 29 4 1 8 Connection diagram with 29 4 2 Connection of the Probe to the SM USB Module from 31 5 Quick Guide for the Commissioning Software SONO CONFIG se 33 5 1 1 Scan of connected SONO probes on the serial 33 5 1 2 Configuration of Measure Mode and serial 34 5 1 3 Analogue outputs of the SONO 34 5 1 4 S
47. out 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 2 1000 0 100 0 1 0 Coefficients Calculated lt File lt Probe b0 1544 41 b1 1 04735 Do Measurement Calculate Coeffs Coeffs gt Probe Close 38 46 6 Installation of the Probe The installation conditions are strongly influenced by the constructional circumstances of the respective mixer types The ideal installation location must be established individually The following guidelines should hereby be observed 6 1 Assembly Instructions The following instructions should be followed when installing the probe e The installation locations may not be situated beneath the inlets for additives water and cement e Incase 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
48. ration 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 used for basic calibrations on request Attention Before performing a Basic Balancing it must be ensured that the SONO probe was set to Measure Mode A If this is not assured the probe returns zero values After a Basic Balancing the SONO probe has to be set to Measure Mode C again because otherwise the probe would not measure continuously In the menu Calibration and the window Basic Balancing the two set point values of the radar time tp are displayed with 60ps and 1000ps 1 Reference set point A tp 60ps in air the surface of the probe head must 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 1000 water The SONO probe head has to be covered with water in a height of ab
49. red directly by hand and are stored in the probe by pressing the button Set The name of the calibration curve can also be entered by hand The selected calibration curve e g Cal14 which is activated after switching on the probes power supply will be adjusted with the button Set Default Calib Attention Use dot as separator 0 0581 not comma 3 2 1 Nonlinear calibration curves SONO probes can also work with non linear calibration curves with polynomials up to 5th grade Therefore it is necessary to calibrate with 4 8 different calibration points To calculate nonlinear coefficients for polynomials up to 5th grade an EXCEL software tool from IMKO can be used on request It is also possible to use any mathematical program like MATLAB for finding a best possible nonlinear calibration curve with suitable coefficient parameters 0 to m5 26 46 V The following diagram shows sample calculation for a linear calibration curve with the coefficients 0 and m1 for a specific material grav Moisture 2 tp Ave Radartime 4 05 in Picoseconds The coefficient m4 is calculated from the slope of the curve Cal14 Delta y 25 0 Coefficient m 0 0581 Delta x 500 70 The coefficient is the offset on the y axis at x 0 Coefficient mg Y2 m4 X2 25 0 0581 500 4 05 9 MOOULTEO RE 7
50. red 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 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 tp Ave 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 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 ente
51. rface 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 CC be used if the SONO probe cannot detect the moisture threshold by itself e g 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 about 0 5 seconds with the help of a relay contact of the PLC can restart the SONO probe at the beginning of the material transport After this short interrupt the SONO probe starts immediately with the summarizing and averaging Please note It should be noted that no material sticks on the probes surface Otherwise the moisture zero point of the probe will be shifted up and the probe would not be detect a moisture low value below the Moisture Threshold 18 46 Following possible parameter settings in mode CC inside the SONO probe can be set Parameter mode Function Moisture Threshold The accumulation of moisture values starts above the in moisture Moisture Threshold and the analogue signal is Standard Setting 1 output The accumulation pauses if the moisture level Setting Range 1 20 is below the threshold value No Material Delay The accumulation stopps if the moisture value is below in seconds the moisture threshold The SONO probes starts Standard Setting 5 again in a new batch with a new accumulation
52. rt Scan probes in SONOConfig The SONO probe logs in the window Probe List after max 30 seconds with its serial number IMKO 32 46 MEROCMCOUTECHNI Y Note 1 In the Device Manager passes it as follows Control Panel gt System gt Hardware gt Device Manager Datei Aktion Ansicht gt 25 B Acronis Devices E Anschl sse COM und LPT 7 ECP Druckeranschluss LPT1 Under the entry Ports COM amp LPT now the 7 Intel R Active Management Technology SOL COM20 item USB Serial Port COMXx is found 2 Kommunikationsanschluss COMI 7 Prolific USB to Serial Bridge 2 7 Prolific USB to Serial Bridge COM3 7 Standardmafigige Seriell ber Bluetooth Verbindung COM14 7 Standardmafigige Seriell ber Bluetooth Verbindung 15 7 StandardmaBgige Seriell ber Bluetooth verbindung 16 E Standardm figige Seriell ber Bluetooth Verbindung 17 7 Standardmafigige Seriell ber Bluetooth Verbindung 18 7 Serial Port COM4 Audio Video und Gamecontroller Bildbearbeitungsgerate 6 Bluetooth Funkgerate 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
53. t can be made at the end of the mixing process with the final fresh concrete Depending to the concrete recipe the probe has to be calibrated with two points in the mixing plant however this two points must lie in a closer and higher moisture range e g between 7 to 8 due to the concrete type With the determined moisture or water content and the known cement content the w c ratio can be calculated It should be considered that the PLC should calculate the moisture content with several single values over 3 to 5 seconds shortly before the discharge of the mixture 2 2 5 Mode CC automatic summation of a moisture quantity during one batch process Simple PLCs are often unable to record moisture measurement values during one 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 for a longer time to the operating staff Previously available microwave moisture probes on the market show three disadvantages 1 Such microwave probes need a switching signal from a PLC This increases the cabling effort 2 Time delays can occur during the summation time with a trigger signal This is particularly disadvantageous for small batches Recipe errors can occur 3 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
54. t unit A D Converter PLC Measurement values without SONO MIX unit e g from 0 Measurement values to 32768 without unit in the range of to 25 or 0 4 2 current output signal Recommended way In this example the SONO MIX MINI has to be calibrated with a PLC for a concrete recipe with a specification of a setpoint wc value of 0 385 water cement With a binder content of 180kg the setpoint for the water content for the concrete results in 62 1 liter 1 Record measurement values in the PLC for the dry mixture i e the mixture has a relative low water content It is recommended to average the values of the PLC over the last 5 seconds of the dry mixing time In this example a measurement value of 8126 has been recorded SONO MIX Measurement A D Converter Water content MINI value in a PC PLC Measurement without unit without unit from values without 0 to max 32768 unit from 4 20mA current output signal Measurement 7 968 mA 6 2 8126 values dry This is the not yet mixture Dry value A D known Measurement values wet mixture 16 46 2 Add water manually into the mixture e g 38 liter mixing water Add manually as much water as the concrete recipe has the desired consistency The added and measured water content is later used for the calculation of the c1 Sensitivity of the SONO MIX MINI for this recipe When the mixture has the optimal consistency re
55. ters C Quick Quick Precision Meas Times 5 Set 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 display be too unstable it is recommended to select a higher value 2 1 2 Filtering at material gaps in mode CA and CF A SONO probe is able to identify if temporarily no or less material is at the probe head and can filter out such inaccurate measurement values Filter Lower Limit Particular attention should be directed at those time periods in which the measurement area of the probe is only partially filled with material for a lo
56. 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 Mode Cyclic Date Motive Merten EC Trime TORAve Nosti Most Moers 15 04 08 11 03 2014 7 56 26 50 50 00 91 07 22 7 50 7 50 757 7 50 160407 11 03 2014 7 54 26 50 0 00 91 02 3 7 57 2 50 7 5 16 04 05 11 022 7 26 50 50 00 9 7 8 0 750 7 4 16 04 05 1 93 20 26 20 55 00 90 9 3 2209 7 50 ne 72 16 04 04 1140 2 2 26 20 50 00 9t 3 750 74 74 16 04 03 11 052 7 26 20 50 00 9 5 74 74 16 04 02 7 52 26 20 50 00 91 07 3 3 7 51 7 44 7 50 16 04 01 11 7 5 26 20 50 00 st 3 74 7 4 16 04 00 1 93 20 7 5 26 20 50 00 9 757 7 51 51 16 03 59 11 032 7 6 26 20 50 00 91 2 7 51 7 51 10 03 59 11 022 7 5 26 20 50 00 91 2 3 7 51 7 44 16 03 57 11 032 7 6 26 00 50 00 2 3 75 8 04 16 03 7 57 26 00 50 00 91 3 1 751 16 03 55 11 03 2014 7 5 26 00 50 00 91 2 745 751 16 03 54 1103 2 26 00 91 07 3 75 751 16 03 53 1143 2 7 26 00 90 93 3 23 75 7 51 16 03 52 11
57. tivity 62 1 24 1 14811 8126 0 005685 With help of the coefficient c1 Sensitivity the amount of mixing water for future mixtures of this recipe can be calculated with the PLC after finishing of the dry mixing times Mixing water Target value A D Dry value A D c1 14811 8126 0 005685 38 Liter Because the SONO MIX MINI measures moisture precise also with different grain size distribution it is possible to calculate with a standard c1 Sensitivity for similar recipes For very different recipes e g recipes with colouring agents or other added special materials it is recommended to check the c1 Sensitivity and if necessary determine a new c1 Sensitivity For partial quantities you have only to multiply the calculated mixing water value with the partial percentage value e g for an 80 partial quantity multiply 38 liter 0 8 30 4 liter for the mixing water subject to a correction for partial quantities The efforts and expenses for preparation additional parameters for different recipes inside a PLC should be easy and manageable when using this method 17 46 2 2 4 SONO MIX MINI to control the water cement ratio SONO MIX MINI can be also used to control the w c ratio by determination of the moisture respectively the water content at the end of the mixing process Similar as described in the previous chapter Calibration a recipe specific calibration with the PLC in the mixing plan
58. turbulences are not ideal for the installation There should be a continuous material flow above the probe head e The stirring movement of the mixer blades should be conducted without gap above the probe head e The probe should not be installed in the direct vicinity of electrical disturbing sources such as motors e The probe may not project into the mixer The installation height of the probe may possibly have to re adjusted due to wear of the mixer blades arms and the mixer base No material may deposit on the probe head as this could falsify the measurement e Incase of curved installation surfaces in the mixer the centre of the probe head should be flush with the radius of the mixer wall without disturbing the radial material flow in the mixer The probe may not project and come in contact with blades or wipers Attention Risk of Breakage The probe head is made of hardened special steel and a very wear resistant ceramic 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 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 IMKO 39 46 MECROMCOUTECHNIE Y 6 2 Assembly Dimensions SONO MIX MINI can eith
59. use mm n m time tor calibration Plunge the calibration Unplug MIL Screw blind cap calibration completed probe head completed connector and of calibration power supply in successfully into water successfully plug it again connector ITY 4 q 1 mm 3seconds 10 seconds 5 seconds 10 seconds 5 seconds Calibration Connector MIL m as Blue LED Connector 44 46 7 TECHNICAL DATA SONO MIX MINI SENSOR DESIGN Casing High Grade Steel V2A 1 4301 Exchangeable especially wear resistant sensor head Tungsten carbide plate with highly wear resistant ceramic window MOUNTING Sensor Dimensions 108 x 132mm Diameter x Length The mounting and fastening frame can be mounted to the rear side of the mixer base or the outer wall of the mixer For this purpose it is adjusted with the help of the additional welded on mounting frame This enables the easy mounting and dismounting as well as the adjustment of the sensor position in case of wear at the mixer base MEASUREMENT RANGE MOISTURE SONO MIX MINI 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 RbC Radar based Conductance in a range of 0 50dS m The conductivity range is reduced in moisture measurement ranges gt 50
60. y the probe is ready to start a new summation in a new batch Offset Standard Setting 0 5 Setting Range 0 5 Non linearities in the process can be compensated E g in fluid bed dryers non linearities can occur due to changes in the material density during the drying process Offset works together with the parameter Average time Weight Standard Setting 5 Setting Range 0 5 Smoothing factor for measured values This parameter influences the reaction response time Invalid Measure Count Standard Setting 2 Setting Range 0 10 This par meter is de activated in mode CK This parameter works only in mode CC or CH Number of discarded poor measurement values after the start of a new batch when No Material Delay has triggered The first measurement values e g due to dripping water will be rejected 10 46 Measure Mode amp Parameters Default Cycle Mode C Cyclic Set Default Measure Mode amp Parameters Actual Cycle Mode Cyclic Average Mode of Mode Kalman Kalman with Boost C No Yes Offset with Moistave 10 No C Yes Average Parameters Average Time s 2000 Filter Upper Limit Offset Filter Lower Limit Offset 25 Upper Limit Keep Time Lower Limit Keep Time ho Moisture Threshold for No Material Delay s 10 Boost 20 Offset 0 Weight 25 Invalid Measure Count 2 Algorithmus Parame
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