TMS 9000 Torque Measurement System
Contents
1. Tighten all bolts in incremental steps to the bolt manufacturers rated torque specification Use the respective sequence illustration shown below depending on the number of bolts the sensor requires This bolting sequence applies to both bolt circles of the torque sensor Honeywell e Sensing and Control 3 TMS 9000 Torque Measurement System November 2006 008 0688 00 Installation and Set up Torque Sensor The TMS 9000 series torque sensors may be operated horizontally vertically or any angle in between provided the load is applied through the loading axis All torque sensors in this series have bolt patterns that mate directly to standard industrial couplings When mounted one of the flanges should be mated to a good quality double flex coupling or a driveshaft arrangement that incorporates universal joints at each end This is designed to compensate for angular and parallel misalignment Avoid applications that place extraneous loads on the torque sensor Caliper Coupling Module The caliper coupling module must be firmly mounted to a non rotating support structure It must be aligned with the epoxy glass annular printed circuit board antenna so that the air gap between the caliper and the antenna is approximately equal on both sides Care should be taken to avoid any items touching one another and consideration should be given to the effects of vibration as well as the free play in any driveshaft sliding joint2. CalSteps 5 CalReset Apply 100 Nm and set CalValue1 100 Apply 50 Nm and set CalValue2 50 Apply 0 Nm and set CalValue3 0 Apply 50 Nm and set CalValue4 50 Apply 100 Nm and set CalValue5 100 e To obtain a frequency output of 5 KHz at 10 Nm and 15 kHz at 80 Nm then the parameters would be AnOutLow 10 and AnOutHigh 80 The device will then be fully calibrated Note that for best results and to conform to accepted calibration practice the unit under test should be exercised three times at the full load in the direction of loading prior to the setting of calibration points This is especially important when calibrating in both the clockwise and the counterclockwise directions Please contact the factory for a detailed description of calibration practice and procedure If an alternative analog output is selected at a later date or if different settings are chosen for the AnOutHigh Low parameters later it is not necessary to repeat the loading calibration because all analog outputs are digitally driven N ber 2006 TMS 9000 Torque Measurement System E Troubleshooting Problem Possible Solutions Power On light is not Check that 12VDC is being applied to the correct terminals J1 showing and at the correct polarity In certain cases for example where the caliper coupling module has been left in direct contact with a metal surface for some time the internal thermal protection circuit may have activat
3. 2 147 52 300 3600 406 73 300 2655 4 221 28 400 4800 542 30 400 3540 5 295 04 500 6000 677 88 500 4425 6 368 80 600 7200 813 45 600 5310 7 442 56 700 8400 949 03 700 6195 8 516 32 800 9600 1084 6 800 7081 0 590 08 900 10800 1220 2 900 7966 1 663 84 1000 12000 1355 8 1000 8851 2 737 60 2000 24000 2711 5 2000 17702 1475 2 3000 36000 4067 3 3000 26554 2212 8 4000 48000 5423 0 4000 35405 2950 4 5000 60000 6778 8 5000 44256 3688 0 6000 72000 8134 5 6000 53107 4425 6 7000 84000 9490 3 7000 61958 5163 2 8000 96000 10846 8000 70810 5900 8 9000 108000 12202 9000 79661 6638 4 10000 120000 13558 10000 88512 7376 0 20000 240000 27115 20000 177024 14752 30000 360000 40673 30000 265536 22128 40000 480000 54230 40000 354048 29504 50000 600000 67788 50000 442559 36880 60000 720000 81345 60000 531071 44256 70000 840000 94903 70000 619583 51632 80000 960000 108460 80000 708095 59008 90000 1080000 122018 90000 796607 66384 100000 1200000 135575 100000 885119 73760 Honeywell e Sensing and Control 13 TMS 9000 Torque Measurement System Specifications Electronics November 2006 008 0688 00 Power supply Protection Analog output signals 4 20 mA 10 VDC 10 kHz 5 kHz 60 kHz 20 kHz zero torque 60 kHz 12 V DC 10 0 75A 9W maximum Reverse polarity connection or fault condition will trip the internal thermal fuse self resetting zero torque 12 mA zero torque 0 V zero torque 10 k
4. default select JP2 Secondary RS232 RS485 default select JP3 JP4 6 Honeywell e Sensing and Control November 2006 008 0688 00 November 2006 TMS 9000 Torque Measurement System 008 0688 00 Command Set Below is the list of parameters supported by the TMS 9000 corresponding to firmware version v1 38 Parameter Name AnOutHigh AnOutLow AuxOPType BaudRate CalCnts1 CalCnts9 CalPoints CalReset CalValue1 to CalValue9 FastMode Mode reporting access used by TMS Toolkit software to extract parameter information from the device Read only Sets or returns the value in engineering units applied to the input that will give 100 maximum positive full Read write scale output on the analog outputs To invert the output polarity enter the required negative full scale output value Sets or returns the value in engineering units applied to the input that will give 0 minimum negative full scale Read write output on the analog outputs To invert the output polarity enter the required positive full scale output value Not yet supported Not yet supported Not yet supported Read only Internal calibration data This is read only via TMS Toolkit and is viewable only in CAL level access These Read only parameters are exposed to enable the saving and loading of calibration data only Sets the number of calibration points in use Value must be between 2 and 9 Any ch
5. events which are not of interest A safe value to use when setting up is 5000 which corresponds to 50 of FS the reduce the threshold later if required Now consider an input change of 0 1 Nm which is below the threshold and therefore subjected to filtering The difference between the input and the output is 0 1 Nm so this is the change that will be used by the filter comparator If the FiltSteps parameter is set to 10 then the output of the TMS 9000 will be incremented towards the input in 10 steps as follows 1 2 0 1 Nm 1 3 0 1 Nm 1 4 0 1 Nm 1 5 0 1 Nm 1 9 0 1 Nm 1 10 0 1 Nm The filter update rate being 1000 Hz gives an update period of 1 1000 0 001 seconds therefore the filter will settle to 63 of its final value in 0 01 seconds being 0 001 FiltSteps Using the formula described in the table above it can be seen that the filter will settle to within 99 9 of its final value in 0 07 seconds being 0 001 FiltSteps 7 Honeywell e Sensing and Control C 3 N ber 2006 TMS 9000 Torque Measurement System E Quick Look Up Table to 39 9 of Final Value Equivalent to FiltSteps seconds Cut Off Frequency of Hz setting required 78 0 16 Hz 1000 3 58 0 32 Hz 500 1 45 0 79 Hz 200 0 7S 1 59 Hz 100 0 35 s 3 17 Hz 50 0 14s 7 94 Hz 20 0 07 s 15 87 Hz 10 0 035 s 31 75 Hz 5 0 014s 79 37 Hz 2 0 007 s 158 73 Hz 1 NOTE The setting of FiltLevel is of great importance
6. filter that behaves like an RC circuit It has two user settings the first being a level set by the parameter FiltLevel and the second being a filter weight set by the parameter FiltSteps The level works as a threshold above which the filter is reset to allow a fast response to a event that exceeded the threshold This is useful in the case when well damped steady state data is required but when significant fast transients and disturbances should not be filtered out The weight of the filter is set by increasing the number of filter steps which in turn increases the time constant of the RC filter increasing the damping effect The settings of any of the TMS 9000 parameters can be changed at any time via the RS232 communications link Changing parameters while the system is running will take effect immediately and in the case of filter setting changes will become effective as soon as the filter flushes through The TMS Toolkit software supplied with the TMS 9000 system simplifies the task of changing settings although any character based communications software could be used instead e g HyperTerminal Filter Operation Detailed Description Consider the input signal as being V and the output signal being V In a steady state situation V will equal V When V changes the extent of the change is compared with the threshold which is set as a proportion of the full scale sensi
7. of the input and output using floating point values for convenience of the user and the linearizing routine can use up to 9 data points user selectable so a significant amount of processor power is consumed during these floating point calculations The next process is digital filtering using a parameter driven recursive algorithm that performs output smoothing but also provides a separate parameter that controls a filter bypass in the event of a significant change in input being required to be reflected through to the output without delay The filtered data is then converted to the required analog output format or formats the TMS 9000 can drive the voltage or current loop output at the same time as providing a frequency output using the output scaling parameters that are independent from the input calibration The rate at which the microprocessor can perform the separate linearizing and scaling calculations is the limiting factor in determining the available bandwidth of the TMS 9000 To provide a faster response for users that want to analyze the dynamic data a FASTMODE is provided and in this mode the data is piped directly from the rotor to the analog voltage output The benefit of this mode is that the analog voltage output is updated at the maximum data rate which is eight times faster than the normal mode rate The penalty of using fastmode is that the scaling and linearizing stages are bypassed so the
8. other warranties expressed or implied including those of merchantability and fitness for a particular purpose In no event shall Honeywell be liable for consequential special or indirect damages While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use Honeywell International Inc Sensing amp Control Sensotec Lebow 2080 Arlingate Lane Columbus OH 43228 www honeywell com sensotec Printed in USA November 2006 SALES AND SERVICE Honeywell serves its customers through a worldwide network of sales offices representatives and distributors For application assistance current specifications pricing or name of the nearest Authorized Distributor contact your local sales office or E mail sales sensotec com Internet www honeywell com sensotec Phone and Fax Tel 614 850 5000 Fax 614 850 1111 Honeywell Copyright 2006 Honeywell International Inc All rights reserved
9. provides a quick reference to the data rates available in either of two available modes Mode Data rate NORMAL When FILTSTEPS gt 1 data rate is 1104 results per second NORMAL When FILTSTEPS 1 data rate is 2207 results per second FASTMODE 8828 results per second Note that the analog voltage output channel should be only channel is use for any data rate above 1104 results per second Therefore OPTYPE should be set to 1 Note that any traffic on the RS 232 port caused by TMS Toolkit or any other communications package will disrupt the flow of data due to the interrupts that are generated by the external software Honeywell e Sensing and Control D 4 N ber 2006 TMS 9000 Torque Measurement System E The following examples assume that either the TMS Toolkit is available and running in CAL user mode or that a hard copy of the parameters list is available and is valid Example 1 Theoretical determination of analog output value The relationship between torque and digital counts can be determined by reference to the parameters held in the TMS 9000 When in FASTMODE the digital counts received from the rotor are simply piped through to the analog voltage output channel so the counts values can be used to determine the expected analog output values actual values may vary within the calibration accuracy of the analog output channel usually within 0 1 FS Consider a sensor with a 2000Nm full scale torque measuring
10. set Read write a threshold of 10 of the sensor rated capacity then FiltLevel 1000 For a step change in input which is greater than FiltLevel 10000 100 the new input value will be passed immediately to the output For a step change in input which is below the threshold set by FiltLevel the output is filtered according to the setting of FiltSteps NOTE when FiltLevel is set to 0 or 1 digital filtering is disabled Factory default value is 100 representing a threshold of 1 of sensor rated capacity refer to the factory calibration data sheet or the rating plate attached to the sensor to confirm the rated capacity Used to set the response time of the digital filter Used in conjunction with FiltLevel to control the digital filtering Read write behavior Value range is 1 through 1000 Filtering takes the form of an RC equivalent where a change in input value which is greater than the threshold set by FiltLevel causes the output value to be incremented in the number of steps set by FiltSteps The filter refresh rate is 1200 Hz Factory default setting is 10 which in conjunction with the factory default setting of FiltLevel 100 provides for an output increment in the form of x 2 x 3 x 4 x 5 x 6 x 10 where x step change in input of more than FiltLevel 10000 rated capacity Given the filter update rate of 1200 Hz the settling time to 63 final value will be 8 3 ms Update rate divided by FiltSteps and to 1 final value
11. when adjusting the filter settings Unexpected torsional spikes and vibration noise can cause the frequent resetting of the filter If in doubt increase FiltLevel range 1 through 100000 When FiltLevel 1 the filter is bypassed and the torque value is delivered to the output processor at a rate of 2207 Hz thereby providing a 3dB cut off of 350 Hz When FastMode 1 the scaling and linearizing algorithms are bypassed and the raw ADC count value is delivered to the output processor at a rate of 8828 Hz thereby providing a 3 dB cut off of 1400 Hz Reference and Equations To calculate the setting of FiltSteps required for a particular 3dB cut off frequency use FiltSteps Update rate Frequency 6 3 To calculate the 3dB cut off frequency for a particular setting of FiltSteps use Frequency Update rate FiltSteps 6 3 NOTE the 3 dB point is also known as the half power point and occurs when the output voltage is equal to 71 of the input or output power is 50 of the input power OB 20 Log Vou Vin dB 10 Log P P oul in Honeywell e Sensing and Control C 4 TMS 9000 Torque Measurement System November 2006 008 0688 00 Sample Charts Waiting for trigger q 1i CH2 2 01V CH3E0 86V De 1 1 DG 1 1 2004 06 21 12 45 01 2s div NORM 500S s INPUT Square Wave 0 1 Hz OUPUT Analog Voltage FiltLevel 10000 FiltSteps 1000 Settling time to 99 is giv
12. Honeywell Sensotec Lebow Operating Instructions for the Rev D Nov 2006 TMS9000 Torque Measurement 008 0688 00 Sensing and Control N ber 2006 TMS 9000 Torque Measurement System E Intended Use Rotating torque sensors are intended for use and a suitable load They are also used to between a power source and its load They may measure the torque required to operate a given be used to measure the power output of a drive load such as an electric motor or gasoline engine 2 Honeywell e Sensing and Control TMS 9000 Torque Measurement System November 2006 008 0688 00 Operating Principles Torque Sensor Lebow Torque Sensors are designed structures that perform in a predictable and repeatable manner when a torque is applied This torque is translated into a signal voltage by the resistance change of strain gages which are attached to the torque sensor structure The change in resistance indicates the degree of deformation and in turn the torque on the structure The strain gages are connected in a 4 arm Wheatstone Bridge configuration which acts as an adding and subtracting electrical network and allows compensation for temperature effects as well as cancellation of signals caused by extraneous loading When the torque sensor is rotating a means must be provided to transfer an excitation voltage to the rotational element from a stationary surface and also to transfer the torque signal from the rotational eleme
13. Hz Output drive capability e 4 20 mA e 10 VDC e Frequency Digital resolution e Normal mode e Hi res mode RF carrier frequency Accuracy e Electronics e Sensor e System Temperature Range e Operating e Compensated e Zero temp stability e Gain temp stability 500 Ohms max 2 k Ohms min 4 0 V p p into 100 k Ohms min load 1k Ohms 16 bit 0 01 FS 19 bit 0 001 FS 6 78 MHz 0 002 FS typical 0 050 FS typical refer to system calibration data sheet 40 to 85 C 40 to 185 F 10 to 50 C 14 to 122 F lt 0 0025 FS C lt 0 001 FS C 14 Honeywell e Sensing and Control Frequency response e Input sampling rate 17 656 samples sec e Anti aliasing filter fixed e Telemetry update rate 8 828 kHz e Fast mode data 4 1 kHz throughput rate 8 828 kHz e Normal mode data throughput rate 1 104 kHz e Analog output bandwidth max 3 kHz 3 db e Group delay typical normal mode 2 5 ms e Group delay typical fast mode 1 2 ms Digital filtering FIR mode 0 1 through 1000 Hz IIR mode recursive algorithm Cable length Using RG58 cable 13 9 meters 45 6 or multiples thereof max 10x standard Using Belden 89907 17 6 meters 57 1 cable or multiples thereof Enclosure rating NEMA 4 IP65 EMC immunity 10V m S30MHz 1 GHz N 2 TMS 9000 Torque Measurement System UEA Shunt Calibration An electrical signal equivalent to that produced by a known load c
14. MA4 or IP65 environmental part plug and socket connectors and the conditions occasional water splash The RF connection details are shown in Figure 2 connection is made via the standard BNC All cable connections should pass through the connector and IP65 rated cable assemblies can cable glands which when properly assembled be supplied upon request provide adequate sealing to allow the module to Figure 2 RS485 A 5o O e O RS485 B Primary RS232 v FS port RS232 RXD o RS232 TXD o Y7 RS2320V o RS485 A Secondary RS485 B expansion RS232 V port RS232 RXD 2 Li mave RS232 TXD S J8 RS232 0V o Expansion Connector J13 Power 0V ne BNC connector to Calliper module Via standard RG58 co axial cable Length 13 9m 45 6 ft or multiples thereof Via standard Belden 89907 cable Length 17 6m 57 ft or multiples thereof Honeywell e Sensing and Control 5 TMS 9000 Torque Measurement System TABLE 1 Connector and Jumper Functions Connector Function DC Power 12 V Primary RS485 port Secondary RS485 port Current loop output Voltage output Frequency output Primary RS232 port NOTE THIS IS THE DEFAULT COMMUNICATIONS PORT J8 Secondary RS232 port Factory use only J10 Factory use only J11 J12 J13 Expansion port J14 Memory expansion port JP1 Primary RS232 RS485
15. RMAL BW 20MHz CH2 0 00V Zoom 10K Type EDGE CH3 CH3 0 00V Delay 0 0ns CH4 0 0 Hold Off 0 2us Honeywell e Sensing and Control C 6 N ber 2006 TMS 9000 Torque Measurement System EU APPENDIX D Manual Supplement for TMS9000 SPM FASTMODE Operation and Settings This supplement provides information related to v1 30 firmware and above Intended Use This supplement is intended for the purpose of Manual and the TMS Toolkit User Manual both describing the function and operation of the of which are supplied with a TMS 9000 Torque FASTMODE feature that is included in the TMS Measuring System 9000 version 1 30 firmware and above It should be used in conjunction with the TMS 9000 User Honeywell e Sensing and Control D 1 TMS 9000 Torque Measurement System November 2006 008 0688 00 FASTMODE Operation General Description The flow of data in the TMS 9000 is subjected to various forms of processing as it passes from input to output This process is best described by use of a flow chart as follows Digitizing of the strain gage input signal Modulation and data transmission Demodulation and data recovery Scaling and linearizing Filtering Convert to analog output Normal mode The data is transmitted from the rotor at the maximum data rate but the rate has to be slowed down for linearizing and scaling due to the amount of processing required the TMS 9000 features independent scaling
16. a new current Value of zero Returns indication of 1 if the previous ZeroNow command was successful in setting the current Value to zero Read only and returns 0 if the action was limited by ZeroLimit ZeroLimit The limit in engineering units at which the ZeroNow command will be allowed to operate relative to the Read Write computed Value at zero load that was stored during the calibration process Therefore ZeroLimit represents the maximum allowable difference between the calibration zero and the current zero If the ZeroNow command is issued when the current Value is greater than ZeroLimit then the current Value will be moved to the extent allowed by ZeroLimit and the flag ZeroOK will be set to 0 Factory setting is 50 of the calibrated range Note that ZeroLimit is a bipolar setting so it will be applied to both directions and around the calibration zero value ZeroPVal Internal system zero data This is read only via TMS Toolkit and is viewable only in CAL level access This Read only parameter is exposed to enable the saving and loading of calibration and zero data Honeywell e Sensing and Control 9 TMS 9000 Torque Measurement System November 2006 008 0688 00 System Calibration The TMS 9000 features nine point linearization and all calibration is achieved using the following parameters CalSteps CalReset CalValuet CalValue2 CalValue3 CalValue4 CalValue5 CalValue6 CalValue7 CalVal
17. al feature operates by switching in a high precision shunt resistor across one of the arms of the strain gage bride on the rotor The change in output that occurs due to this shunting is repeatable and is often used as a means of calibration During factory calibration the apparent change in torque output due to shunt cal will have been recorded and this value can be used to re calibrate the analog voltage output when in FASTMODE Consider a sensor with a 2250 Lbf in measuring range The factory calibration certificate will include the changes due to shunt cal as a list of effects such as follows Shunt Calibration at Analog Output Settings Lbfin V mA Hz 10 Hz 60 High Low Units Note Hz 10 denotes 10 kHz range 10 kHz 5 kHz Hz 60 denotes 60 kHz range 60 kHz 20 kHz When in FASTMODE the shunt cal values for voltage current and frequency are invalid because the scaling module is bypassed so the only piece of information that remains valid and that we need to use from this data table is the apparent change in TORQUE due to shunt cal and in the case of this example itis 1692 2 Lbf in It follows that the change in analog voltage output when in FASTMODE will represent 1692 2 Lbf in The exception to this case will be when a value has been set for SCSCALE This parameter allows the effect of shunt cal to be varied according to the value set The default is 1 and any other value acts as a multiplier but on
18. an be obtained by activating the shunt calibration function The shunt calibration function is built in to the sensor itself and it is therefore necessary for the Rotor Active light to be showing before the function can be operated By design the caliper coupling module is more sensitive to receiving data than it is to transmitting data therefore it may be necessary to adjust the caliper coupling module position to ensure good two way communications prior to using the shunt cal function The shunt calibration function is achieved by connecting a high precision resistor of know value in parallel shunt with one arm of the strain gage Wheatstone bridge The connection is made by a solid state switch under the control of the microprocessor on the rotating sensor when commanded by the remote Signal Processing Module This switch can be activated via the pushbutton on the face of the signal processing module The shunt calibration value is determined during factory calibration of the torque sensor The shunt calibration function is a very useful aid when setting up the system or when fault finding In applications where it is not possible nor practicable to perform dead weight system calibration the shunt calibration function can be used as an alternative at the cost of some loss of calibration accuracy To provide for this eventuality the shunt calibration value is factory set to represent between 50 and 95 of full scale and is achieved by using
19. ange in CalPoints should Read write be followed by a CalReset command to clear the previous unwanted calibration data from the memories NOTE all calibration data and all analog output setting data will be cleared by CalReset It is recommended to save the parameter list before invoking CalReset Resets all calibration information When the reset command is issued all calibration data and all settings of the Command analog outputs AnOutHigh and AnOutLow are cleared so no reliable output will be available until all of the calibration points specified by the CalPoints parameter and the required values of AnOutHigh and AnOutLow have been entered NOTE all calibration data and all analog output setting data will be cleared by CalReset It is recommended to save the parameter list before invoking CalReset These values are written in engineering units when the appropriate load is applied Each of the nine parameters Read write can be written at any time See Calibration section later in this document NOTE the values entered MUST be in ascending order starting with CalValue1 negative values count as lower than positive values The number of calibration points entered must be equal to the number of calibration points activated by CalPoints NOTE the existing calibration data is overwritten by any new input of CalValue1 9 It is recommended to save the parameter list before entering new values Returns the raw A D counts valu
20. d Read write value is the amount of zero offset being applied to the true Value To zero the system this parameter should be set in engineering units to the value read when the system is supposed to be displaying zero The action of SysZero may be limited by ZeroLimit as described above in which case the flag ZeroOK will be set to 0 Note that when any calibration parameter CalValue1 9 CalReset is changed the value of SysZero is set to 0 and any zero offset is cancelled This function when used with ZeroLimit allows the current Value to be offset to any desired level remember to consider the dynamic loading range of the sensor itself when applying large offsets 8 Honeywell e Sensing and Control N ber 2006 TMS 9000 Torque Measurement System T T Text memo field in which the name of the engineering units used for calibration can be stored for recall later Read Write Note that when reading some characters via a 7 segment display TMS Toolkit uses a virtual 7 segment display some characters such as M will not display correctly Returns the value of the applied torque in calibrated engineering units Read only Returns the software version Read only Sets the current Value to zero unless limited by ZeroLimit as described above The action performed by Command ZeroNow is to clear any previous zero offset then compare the true Value to ZeroLimit then to the extent allowable by ZeroLimit write the true Value to SysZero resulting in
21. e derived from the ADC on the rotating sensor Read only The ErrFlag parameter will indicate any errors that have occurred by returning a numeric value that is Read only comprised of binary values representing the various error states i e the binary values for each error are added together to produce the ErrFlag value The error states are not retained between power cycles Decimal Value Error Description 0 No error 1 Power cycled 2 Output clamped 4 Watchdog reset Once the errors have been read they can be reset using the RstErrFlag command Used to initiate raw throughput of data without scaling or filtering Set this parameter to 1 to enable fast mode Read write This setting is volatile so the device will revert to normal mode after the next Reset or the next power up Set to zero to disable fast mode When in fast mode the internal raw A D counts results are fed directly to the analog output voltage or current without any scaling or filtering giving a data throughput rate of 8 8 kHz when FiltLevel 1 NOTE the frequency output is not supported in fast mode The fast mode can be scaled in the user s data acquisition system by using the shunt cal facility and is intended to be used for dynamic measurements only Honeywell e Sensing and Control 7 N ber 2006 TMS 9000 Torque Measurement System A ee FiltLevel Used to set the threshold of operation of the digital filter Values are set as parts per 10000 meaning that to
22. e the caliper coupling module to try and achieve coupling and shunt cal functionality in an alternative position Check that there are no metal parts flanges covers etc within one and a half inches 40mm of the caliper coupling surfaces Check that the power supply is actually 12 VDC when the caliper coupling module is in the appropriate position some power supplies have built in protection circuits that cause a reduction in supply voltage when current demands increase Cannot communicate Check all wiring If using the RS232 port check that the Rx pin of the host computer is connected to the Tx pin of the TMS 9000 and vice versa Check that the communications cable being used is of high quality or try a shorter length of cable RS232 is sensitive to cable length and grounding issues especially when used with laptop computers where grounding is uncertain Honeywell e Sensing and Control 11 N TMS 9000 Torque Measurement System shined et Cannot communicate Check that the correct serial port is selected in the software or TMS Toolkit When using Windows the serial port in use can be found by using the CONTROL PANEL SYSTEM HARDWARE DEVICE MANAGER COM ports functions On older desktop PC s the COM1 port is already in use for the mouse so a different COM port should be selected If using a USB to Serial adapter Windows assigns the COM port designations dynamically so they may change whenever the
23. e the wires from the DAQ system through the conduit hole labeled frequency to the desired output connector on the option board Twisted pair 2 conductor shielded wire is recommended for best performance Strip off about 14 of insulation from the wire and tin the ends with solder Loosen the screws on the connector and slide the wires into the connector next to the resistor leads Remember the ground or common wire must be attached to the left side of the connector 7 Re attach the SPM cover and tighten the cover screws 8 Continue with system installation as described in the TMS9000 user manual Honeywell e Sensing and Control A 1 N ber 2006 TMS 9000 Torque Measurement System Pe APPENDIX B Manual Supplement for TMS9000 SPM Remote Shunt Cal Option This supplement provides information on the operation and specifications of the TMS9000 SPM with the Remote Shunt Cal Option P N 064 LW37039 Overview The TMS9000 SPM with Remote Shunt Cal option allows the user to remotely activate and deactivate the shunt cal mode via an external switch and cable Setup The Remote Shunt Cal option is installed and tested at the factory A six pin circular connector is mounted to the front panel of the SPM box as a connection point for the remote shunt cal switch A mating connector 023 LW181 034 is provided so the user can attach a cable between the SPM and the customer supplied switch 1 Connect a two conductor cable between the remote s
24. ectronics module The data that is transmitted across the telemetry gap consists of 8 828 results per second at a resolution of 16 bit and it is this data that is then piped directly to the analog voltage output whenever FASTMODE is turned on The analog voltage output channel is a 16 bit digital to analog converter with a bandwidth of greater than 3 kHz therefore the expected analog output voltage for a full scale torque measurement can be calculated by reference to the calibration data tables held in the TMS 9000 Assuming that the factory calibrated or user re calibrated data tables can be accessed using the CAL user mode of the TMS Toolkit the output calibration can be determined using this theoretical method an example of which will be given later When the TMS Toolkit is not available the user will need to perform a physical system calibration by placing a known torque on the sensor and measuring the change in the analog output voltage In cases where the shunt calibration value is known the change in output due to shunt calibration can be measured and the result extrapolated to give a full scale equivalent Note that this result will need to be adjusted when the shunt cal scaling feature has been used SCSCALE is something other than 1 An example of calculating the analog output voltage by using shunt cal and the SCSCALE parameter is also given later Normal mode and FASTMODE data update rates The table below
25. ed To reset this condition remove power and wait ten minutes before restoring power Rotor Active light is not Check that the RF cable is in good condition and is of the showing correct length look for damage to the outer sheath that may indicate that the cable has been crushed at some time Check that the caliper coupling module has been correctly positioned in close proximity to the rotating antenna Use the positioning guide that was supplied with the system to confirm the position Move the caliper coupling module to try and achieve coupling in an alternative position Check that there are no metal parts flanges covers etc within one and a half inches 40mm of the caliper coupling surfaces Check that the power supply is actually 12 VDC when the caliper coupling module is in the appropriate position some power supplies have built in protection circuits that cause a reduction in supply voltage when current demands increase Shunt calibration does not Check that the Rotor Active light is showing prior to using the operate shunt calibration function Check that the RF cable is in good condition and is of the correct length look for damage to the outer sheath that may indicate that the cable has been crushed at some time Check that the caliper coupling module has been correctly positioned in close proximity to the rotating antenna Use the positioning guide that was supplied with the system to confirm the position Mov
26. en by 5 0 001 1000 5 seconds 3 ut i 4 T1 Measure Item Delay Time Range ALL Scan Cursor OFF Setup Setup T2 EXEC 2 8 kiv Filter Offset Record Length Trigger Smoothing OFF CH1 0 000V Main 10K Mode NORMAL BW 20MHz CH2 0 00V Zoom 10K Type EDGE CH3 CH3 0 00 Delay 0 0ns CH4 0 0V Hold Off 0 2us Waiting for trigger q 2004 06 21 13 02 48 1i CH2 2 01 CH3 0 86V 1s div DC 1 1 DG 1 1 NORM 1kS s 2p traced pai leisi 2 Wek ae 3 AUTO AT LYL PoR SRA SINGLE N SGL Filter Offset Record Length Trigger Smoothing OFF CH1 0 000V Main 10K Mode NORMAL BW 20MHz CH2 0 00V Zoom 10K Type EDGE CH3 CH3 0 00 Delay 0 0ns CH4 0 0 Hold Off 0 2us Therefore overdamped response only reaching 60 of full scale p p INPUT Square Wave 0 4 Hz OUPUT Analog Voltage FiltLevel 10000 FiltSteps 1000 Settling time to 99 is given by 5 0 001 1000 5 seconds value Honeywell e Sensing and Control C 5 N ber 2006 TMS 9000 Torque Measurement System E Sample Charts q 2004 06 21 16 11 23 CH2 2 01V gt 10ms div INPUT Square Wave 16 Hz OUPUT Analog Voltage FiltLevel 10000 FiltSteps 38 Settling time to 63 is given by 0 001 38 0 038 seconds Therefore overdamped response Filter Offset Record Length Trigger Smoothing OFF CH1 0 000V Main 10K Mode NO
27. en using RG58 50 ohm cable the length must be maintained at 13 9 metres 45 6 feet or a multiple thereof When using Belden 89907 cable length must be maintained at 17 6 metres 57 feet or a multiple thereof For cable runs of less than 0 6 metre 2 feet the cable that is provided with the unit can be cut to the required length Otherwise simply coil up any excess length Signal Processing Module The receiver is mounted remotely with the coaxial cable being the only connection between it and the caliper coupling module The receiver has holes provided for permanent mounting Request the appropriate certified drawing from Lebow before making fixtures When deciding where to locate the signal processing module consideration should be given to the type of output that will be used If the analog voltage or current output is to be used then the signal processing module should be mounted in an area of low electrical noise and the connection between the module and the data acquisition equipment should be as short as possible and should be made up from double screened twisted pair cable If the frequency output or the digital output is to be used then the signal processing module can be mounted in the electrically noisy area provided that good quality dual screened twisted pair cables are used N ber 2006 TMS 9000 Torque Measurement System E Electrical Connections The signal processing module features two be operated in NE
28. equencies and with various filtering characteristics When using FASTMODE the DAC is being updated at a rate of 8828 Hz therefore staircasing is reduced as a result of the much faster update rate Honeywell e Sensing and Control D 7 A WARNING MISUSE OF DOCUMENTATION e The information presented in this product sheet is for reference only Do not use this document as product installation guide e Complete installation operation and maintenance information is provided in the instructions supplied with each product Failure to comply with these instructions could A WARNING PERSONAL INJURY DO NOT USE these products as safety or emergency stop devices or in any other application where failure of the product could result in personal injury Failure to comply with these instructions could result in death or serious injury result in death or serious injury WARRANTY REMEDY Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship Honeywell s standard product warranty applies unless agreed to otherwise by Honeywell in writing please refer to your order acknowledgement or consult your local sales office for specific warranty details If warranted goods are returned to Honeywell during the period of coverage Honeywell will repair or replace at its option without charge those items it finds defective The foregoing is buyer s sole remedy and is in lieu of all
29. given by the following table of Final Value Time to Settle 63 Filter Update rate FiltSteps 99 Filter Update rate FiltSteps 5 99 9 Filter Update rate FiltSteps 7 Where the Update Rate is the period in seconds 1 f fixed at 0 001s for firmware v1 30 and above AND Where the change in input signal magnitude is below the threshold set by FiltLevel Honeywell e Sensing and Control C 2 N 2 TMS 9000 Torque Measurement System MUA There follows an example of typical filter settings as applicable to a standard production TMS 9000 torque measuring system Consider a sensor with a 1000Nm full scale torque measuring range Consider a test running at steady state torque of 550 Nm Consider FiltLevel set at 1000 The unit of measure for FiltLevel approximates to 0 01 FS where FS is the full scale of the sensor therefore a FiltLevel of 1000 sets a threshold of change of 10 of FS which in this example is 100 Nm above which the filter is reset and the output value becomes equal to the input value again Note that the threshold is with respect to the current value and not with respect to zero torque Therefore if the torque is fluctuating within a band of less than 100 Nm the filter performance will be determined by FiltSteps alone In the case where torsional vibrations and spikes may be present in the input signal then the threshold set by FiltLevel should be raised so that the filter is not being reset by
30. high grade resistors that exhibit very low thermal sensitivity Storage and Recalibration This torque measurement system may be stored for an indefinite period in a dry place at room temperature Recalibration should follow your normal instrumentation certification schedule Honeywell e Sensing and Control 15 November 2006 008 0688 00 APPENDIX TMS 9000 Torque Measurement System SUPPLEMENTARY INFORMATION RELEVANT TO YOUR USER MANUAL TMS 9000 TORQUE MEASUREMENT SYSTEM Appendix A Supplement for TMS 9000 SPM Square Wave Output Option Appendix B Supplement for TMS 9000 SPM Remote Shunt Cal Option Appendix C Supplement for TMS 9000 SPM Digital Filter Settings Appendix D Supplement for TMS 9000 FASTMODE Operation 16 Honeywell e Sensing and Control N ber 2006 TMS 9000 Torque Measurement System oaao APPENDIX A Manual Supplement for TMS9000 SPM Square Wave Output Option This supplement provides information on the operation and specifications of the TMS9000 SPM with the Square Wave Output Option P N 064 LW37040 Overview The Square Wave Output Option is a plug in module for the SPM that converts the sine wave analog frequency output of the SPM to a square wave that is compatible with most RS 422 and RS 485 type inputs to data acquisition systems and frequency pulse counters The frequency of the square wave is equal to the frequency of the standard sine wave output The square wave output is available in th
31. ly when the scaling module is operating For FASTMODE operation the scaling module is bypassed so the effect of shunt cal will be the original effect as manufactured and may be significantly different from the calibration certificate value To compensate for any value of SCSCALE calculate as follows Certificated change in torque due to shunt cal is 1692 2 Lbf in Value set for SCSCALE is 1 5 Actual change due to shunt cal is 1692 2 1 5 1128 13 Lbf in If SCSCALE is 1 then no calculation is necessary Honeywell e Sensing and Control D 6 N ber 2006 TMS 9000 Torque Measurement System E Analog Output characteristics The analog output channel is specified for a bandwidth of 3 kHz so there is no output filtering that follows the digital to analog converter DAC This can lead to a staircasing effect when the DAC is being updated at a relatively slow rate such as 1104Hz For users that do not require wide bandwidth this staircasing will not be a problem and can be eliminated from the measurement by applying a suitable sampling rate at the data acquisition end Typically a sampling rate of one quarter of the TMS 9000 DAC update rate or less would be sufficient to solve this problem For applications where the fidelity of the output waveform is of prime importance the solution to staircasing is to add a filter network across the analog voltage output terminals Such networks are available from Lebow in a range of cut off fr
32. nt back to the stationary surface This is accomplished through the use of digital telemetry Principle of Telemetry The digital telemetry system consists of a receiver transmitter module a caliper style coupling module and a signal processing module The receiver transmitter module is an integral part of the torque sensor and is connected to the strain gauges and to the epoxy glass annular printed circuit board that contains the rotating antenna system Within the receiver transmitter module the sensor signals are amplified digitized and are then used to modulate the radio frequency carrier wave that is detected by the antenna after being transmitted across the air gap by the caliper coupling module That same carrier wave is rectified to provide power to drive the strain gauges and the electronic components in the module which is managed by a miniature microprocessor The caliper coupling module connects to the signal processing module via a simple co axial cable The detector circuitry in the signal processing module recovers the digital measurement data from the torque sensor and passes it to the second microprocessor for scaling and linearizing The third microprocessor provides the drive to the two analog outputs as well as the standard digital interfaces and the optional digital interface modules Extensive facilities are provided in software for setup and configuration of the complete system Bolting Information
33. range Calibration values most likely to have been used will be approximately 2000 0 and 2000 Nm The actual values used may have been adjusted to take account of local gravity and buoyancy and can be seen from the parameters CALVALUE1 2 and 3 Make a note of the actual values used and compare them to the values of CALCNTS1 2 and 3 The CALCNTSx values store the digital counts values that were output by the rotor for the load conditions given by the relevant CALVALUEx The analog voltage output channel is 16 bit and it will generate an output of 10V when it is driven by a counts value of 0 and will generate an output of 10V when driven by a COUNTS value of 65535 Therefore each count generates 0 0003052V starting from a base of 10V The analog voltage output will be generated in direct relationship to the statement above Therefore using the following data the analog voltage output will be CALVALUE1 1998 699 CALCNTS1 21553 Therefore at a load of 1998 699 Nm the analog Voltage will be 21553 0 0003052 10V 3 422V CALVALUE2 0 000000 CALCNTS2 32700 Therefore at a load of 0 Nm the analog Voltage will be 32700 0 0003052 10V 0 020V CALVALUE3 1 998 500 CALCNTS3 43842 Therefore at a load of 1998 500 Nm the analog Voltage will be 43842 0 0003052 10V 3 381V Honeywell e Sensing and Control D 5 N ber 2006 TMS 9000 Torque Measurement System E Example 2 Using the SHUNT CALIBRATION feature The shunt c
34. ree formats positive phase TTL level differential 5 VDC and negative phase TTL level 180 degrees out of phase compared to positive phase Setup The Square Wave Output Option is installed and tested at the factory A two pin green mating connector and 120 ohm termination resistor is provided with the SPM to connect between the output option board and the customer supplied data acquisition system DAQ counter or other device The following steps describe the process of connecting the SPM option board to the DAQ or counter 1 Be sure AC DC power supply module is not connected to a power source 2 Place the SPM on a flat workbench or table preferably with an ESD safe mat or cover to dissipate electrostatic voltages Wear an ESD safe grounded wrist strap while working inside the SPM box 3 Carefully remove the four screws of the SPM cover and slowly lift the cover off the SPM Take care not to damage the ribbon and ground wires connected to the inside of the cover 4 The square wave option module is installed just to the right of J3 and J8 on the main circuit board A twisted pair jumper cable connects between J6 of the main board frequency output and the J1 frequency input on the option board 5 Determine the desired output type On the option board the negative phase output is J2 differential output is J4 and positive phase is J5 The ground common point is on the left side of the output connectors J2 and J5 6 Rout
35. relationship between input and output becomes fixed and the only way to calibrate the output against the input is to calculate the expected change in output value by reference to the calibration data stored in the TMS 9000 or perform a physical system calibration or to use the SHUNT CAL feature Honeywell e Sensing and Control D 2 TMS 9000 Torque Measurement System The following diagram shows the change in data flow when using FASTMODE Digitizing of the strain gage input signal Modulation and data transmission Demodulation and data recovery Convert to analog output FAST mode November 2006 008 0688 00 Because of the significant change in output characteristics that takes place when FASTMODE is selected it is implemented as a VOLATILE setting therefore recycling the power or performing a soft reset will return the TMS 9000 to NORMAL mode As an indication to the user that FASTMODE is in operation the ROTOR ACTIVE light on the lid of the TMS 9000 Signal processing Modules SPM is de activated Honeywell e Sensing and Control D 3 TMS 9000 Torque Measurement System November 2006 008 0688 00 FASTMODE Operation Detailed Description The strain gage input value is digitized at a rate of 17 656 samples per second with 24 bit resolution but this amount of data is in excess of the capacity of the telemetry link so it is reduced by the simple averaging of every pair of A D results at the rotor el
36. s To assist in the process of aligning the caliper and the antenna a simple plastic alignment tool is provided with each system The tool is used to hold the required clearance between the caliper and the antenna while the caliper fixing bolts are being tightened and then is removed before the sensor is rotated The tolerances for end float axial are 4 5mm 3 16 and for run out radial are 1 0mm 1 16 For installations where run out cannot be controlled within the specified tolerance the secondary coupling position can be used This is achieved by placing the edge of the caliper in close proximity to the edge of the antenna In this position the run out tolerance can be at least doubled at the expense of a reduced signal to noise ratio caused by the higher incidence of data drop outs The axial 4 Honeywell e Sensing and Control tolerance is limited by the distance between the caliper sections The caliper can also be mounted such that only one side is in proximity to the antenna if the mounting arrangement does not allow for placing of the antenna between the two sides of the caliper Successful positioning of the caliper can be confirmed by the presence of the ROTOR ACTIVE light on the signal processing module The length of the RF cable connection between the caliper coupling module and the signal processing module is critical to system performance due to reflections and standing waves Wh
37. system is rebooted The serial port settings are automatically modified by TMS Toolkit so there is no need to change any of the settings in Windows The baud rate setting in TMS Toolkit should always be 38400 because that is the default baud rate of the TMS 9000 The TMS ID should be left blank because TMS Toolkit will search the connected port for any TMS device and will commence the communication automatically if present Refer to the TMS Toolkit User Manual for more information 12 Honeywell e Sensing and Control N ber 2006 TMS 9000 Torque Measurement System E Conversion Table Imperial Metric conversion Metric Imperial conversion Foot pounds inch pounds Nm Nm inch pounds foot pounds 1 12 1 35575 1 8 85119 0 73760 2 24 2 7115 2 17 702 1 4752 3 36 4 0673 3 26 554 2 2128 4 48 5 4230 4 35 405 2 9504 5 60 6 7788 5 44 256 3 6880 6 72 8 1345 6 53 107 4 4256 7 84 9 4903 7 61 958 5 1632 8 96 10 846 8 70 810 5 9008 9 108 12 202 9 79 661 6 6384 10 120 13 558 10 88 512 7 3760 20 240 27 115 20 177 02 14 752 30 360 40 673 30 265 54 22 128 40 480 54 230 40 354 05 29 504 50 600 67 788 50 442 56 36 880 60 720 81 345 60 531 07 44 256 70 840 94 903 70 619 58 51 632 80 960 108 46 80 708 10 59 008 90 1080 122 02 90 796 61 66 384 100 1200 135 58 100 885 12 73 760 200 2400 271 15 200 1770
38. tivity by the parameter FiltLevel If the change exceeds the threshold then the new input value is passed immediately to the output thereby resetting the filter If the change does not exceed the threshold then the output value V is updated by a fractional amount of the new value V until the output value equals the input value again The number of steps set by FiltSteps determines the number of fractional steps that are taken to increment the output value according to the following series 1 2 1 3 1 4 1 5 ete The output characteristic is therefore exponential and behaves in a predictable manner Honeywell e Sensing and Control C 1 N 2 TMS 9000 Torque Measurement System UEA To determine the settling time of the filter the The table below provides a quick reference to time taken to reach the V V condition it is determine the filter characteristic necessary to know both the filter update rate and the number of fractional steps The filter Note that this filter operates only when the update rate is fixed at 1000 Hz in the firmware change in the input is below the threshold set by v1 30 and above although other filter update FiltLevel rates can be made available upon request to the factory The cut off point in Hz is given by the expression Frequency 3dB update rate number of steps 6 3 Filter Settling Time The time required for the output to settle following a step change in input level is
39. ue8 CalValue9 The minimum number of calibration points is 2 Calibration points can be created in any order provided that the values they contain are in ascending order starting with CalValue1 Therefore the lowest or the most negative counter clockwise calibration point should be designated as CalValue1 The number of calibration points that are in use is set by the parameter CalPoints Any change to the value of CalPoints should be followed by the issuance of a CalReset command to clear the old calibration values from the EEPROM memories Calibration is achieved by applying known loads at each of the calibration points that are selected for use and then writing the engineering units value to the appropriate CalValuex parameter The analog outs are precalibrated in the factory so calibration of the input to the required output range is automatic and is dependent on the values entered for the parameters AnOutHigh AnOutLow AnOutHigh and AnOutLow are written to using the engineering units value at which the analog outputs are required to give the maximum and minimum outputs 10 Honeywell e Sensing and Control Available analog outputs are Voltage range is 10 to 10 volts Current output range is 4 to 20 mA Frequency range is 5 kHz to 15 kHz or alternatively 40 kHz to 80 kHz Calibration Example To calibrate from 100 to 100 Nm in five steps of 100 50 0 50 and 100 Nm Set
40. will be 41 7 ms Update rate divided by FiltSteps x 5 The settling time to 0 1 final value will be 58 3 ms Update rate divided by FiltSteps x 7 Mode reporting access used by TMS Toolkit software to extract parameter information from the device Read only Returns the model name TMS Read only string OpType Sets or returns the currently selected analog output where O current 1 voltage 2 frequency 10 kHz Read write 3 frequency 60 kHz 4 current and frequency 10 kHz 5 voltage and frequency 10 kHz 6 current and frequency 60 kHz 7 voltage and frequency 60 kHz Returns the number of parameters in the device Set to the index number of the required parameter ParaList Returns the information on the parameter indexed by Paraltem Read Format index paraname type a string string The value of type indicates the parameter s properties by the addition of the following numerical values Readable Writeable Command String Numeric Boolean Example 1 MODEL 33 In the above example where type 33 the parameter MODEL is a readable string Returns the value of the applied torque in percentage terms 0 100 where this range is the selected range over Read only which the analog outputs work and is set by AnOutLow and AnOutHigh ete Reset command to restart device and to implement parameter changes that require a reset SysZero Allows manual setting of the current Value or querying of the current zero offset being applied The returne
41. witch and the mating connector Solder one conductor to pin A of the mating connector and the other conductor to pin B Attach the strain relief to the connector 2 Attach the mating connector to the six pin connector on the SPM 3 After setting up the sensor and caliper module power on the SPM and verify the Power LED and the Rotor Active LED is lit on the top of the SPM Turn on the remote shunt cal switch and verify the Shunt Cal Mode LED is lit on the top of the SPM Turn off the remote shunt cal switch and verify the Shunt Cal Mode LED turns off 4 Setup of the Remote Shunt Cal Option is complete Honeywell e Sensing and Control B 1 TMS 9000 Torque Measurement System APPENDIX C November 2006 008 0688 00 Manual Supplement for TMS9000 SPM Digital Filter Settings This supplement provides information on the operation and specifications of the TMS9000 SPM with the Digital Filter Settings as they relate to v1 38 software Intended Use This supplement is intended for the purpose of describing the function and operation of the digital filtering algorithms that are included in the TMS 9000 version 1 38 firmware It should be used in conjunction with the TMS 9000 User Manual and the TMS Toolkit User Manual both of which are supplied with a TMS 9000 Torque Measuring System Filter Operation General Description The digital filter algorithm in the v1 30 and later firmware versions of the TMS 9000 is basically a recursive
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