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User Manual SONO-VARIO

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2. 5 1 2 8 Material Temperature 5 1 2 4 Temperature compensation of the internal 5 9 11 ee 6 1 2 1 serial RS485 and IMP Bus 7 1 2 2 The IMP Bus as a user friendly network 7 1 2 8 Error Reports and Error 7 2 Configuration of the Measure Mode 8 2 1 Cyclic operation modes CA CF CH and 8 2 1 1 Average Time in the measurement mode and CF 10 2 1 2 Filtering at material gaps in mode CA and 10 2 1 3 Mode CC automatic summation of a moisture quantity during one batch process 11 2 1 4 CH Automatic Moisture Measurement in one Batch 13 2 2 Overview of single modes for different applications 14 3 Initial operation and 15 31 Adjustments for initial nennen 15 3 2 Selection of the calibration curve to 5 15 3 3 Calibration Set A for general bulk
3. 2 2 Rasa Ras Re nnnannnnan nun 45 IMKO 4 MICROMODULTECHNI 4 48 1 Instrument Description p 1 1 1 The patented TRIME TDR Measuring Method The TDR technology Time Domain Reflectometry is a radar based dielectric measuring procedure at which the transit times of electromagnetic pulses for the measurement of dielectric constants respectively the moisture content are determined SONO VARIO LD consists of a high grade steel casing with a wear resistant sensor head with ceramic window An integrated TRIME TDR measuring transducer is installed into the casing A high frequency TDR pulse 1GHz passes along wave guides and generates an electro magnetic field around these guides and herewith also in the material surrounding the probe Using a new patented measuring method IMKO has achieved to measure the transit time of this pulse with a resolution of 1 picosecond 1x1 07 consequently determine the moisture and the conductivity of the measured material The established moisture content as well as the conductivity respectively the temperature can either be uploaded directly into a SPC via two analogue outputs 0 4 20 mA or recalled a serial RS485 interface 1 1 2 TRIME compared to other Measuring Methods In contrary to conventional capacitive or microwave measuring methods the TRIME technology Time Domain Reflectometry with Intelligent Micromodule Elements does
4. 31 At AS DINENSION ee 32 4 8 Mounting in curved 99 34 4 9 Gas and waterproofed Installation in a Tube or 34 4 10 Exchange of the Probe Head of the 35 4 10 1 Basic Balancing of a new Probe 36 Connection of the RS485 to the SM USB Module from IMKO 37 Quick Guide for the Commissioning Software SONO CONFIG c cree eeeeeern 39 6 1 1 Scan of connected SONO probes on the serial interface 39 6 1 2 Configuration of Measure Mode and serial SONO interface 40 6 1 3 Set analogue outputs of the SONO 40 6 1 4 Selection of the individual Calibration Curves 41 6 1 5 Test run in the respective Measurement Mode 42 6 1 6 Measure Run in 42 6 1 7 Basic Balancing in Air and 43 6 1 8 Offsetting the material temperature 44 6 1 9 Compensation of the electronic 44 Technical Data
5. e g 20 inactiv inactiv 100 e g 10 inactiv e g 10 e g 10 inactiv e NO inactiv At the end ofa screw conveyor Long term process IMKO 4 MICROMODULTECHNI 15 48 3 Initial operation and installation 3 1 Adjustments for initial operation The term adjustment refers in this case to the correct setting of the calibration curve and zero offset depending on material type and installation place where an absolute moisture value with an accuracy of 0 1 is important The SONO VARIO LD can only be adjusted when installed in the plant as the location and the bulk density of the material have a significant influence on moisture measurement Adjustment must be carried out separately for every dried product Moisture measurement is dependent on the following parameters Location e g metallic objects within the field of measurement Bulk density of the material of material product As soon as one of these parameters changes another calibration curve or an adjustment must be chosen If all possible grain types are adjusted it is only necessary to select the right calibration curve when changing the grain type in the plant 3 2 Selection of the calibration curve Cal1 to Cal15 Up to 15 different calibration curves CAL1 Cal15 can be stored inside the SONO VARIO LD Two calibration sets can be used for eac
6. 4 Ly of 1 1 ew 4 BEE BE 1 LLL I 1 S 1 1 T 1 7 EU SU SE N tpAve Radartime in Picoseconds The coefficient m is calculated from the slope of the curve Cal14 Delta y 25 0 Coefficient m 0 0581 Delta x 900 70 The coefficient my is the offset on the y axis at x 0 Coefficient mg Y2 m4 X2 25 0 0581 500 4 05 24 48 4 Connectivity to SONO Probes IMKO MICROMODULTECHNIK 5 03005 10 seqoud ONOS 19410 ay I q1OIHVA ONOS 1 xs ejdsiq q31 zen i 2 A l OIHVA ONOS ue o 10 ejep A yoinb Ajisee ejdurexe 104 eqoid eu ey sjuew t 3sn pe 5 4NOO ONOS eqoud ONOS nof Pauuoo ui 2 2 2 2 gt gt 4 x 22 OlHVA ONOS N d m a eyeudoudde ue S euljuo seqoud ONOS 2 ajqissod s 1 _ __ euo e puels yM 5 6 5 IMKO
7. VOUYER LL des TT TAA TE ptt ttt ete AAA _ 49 _ _ 335 _ _ liil NNNNM ___ _ __ Bart E IR LLL AL ALS TTT TTT TT Tt Ty tt tT TT TT TT TT TT TIMI _ENAN E RR LLL LL NA LI U Pe Pe Rh UREA L _ eee eR VK NANI __ __ 299 A TT A _ TT TTT Tt te eT TE TT TY PTT Sse LL NN LILLELLITI ELS LIII ILLE LIT LLLI _ PT TTT _ 5 AN __ ___ TIAN in _ LI LLL LLL __ T nn ER ER _ T T T _ T T T __
8. __ __ _ ___ __ LLLLILLLLLILILLLL LL E LLL EL EIL Li _ __ _ __ LLL LLL LLL LL __ __ LLL ptt __ _ _ __ _ _ __ __ LLL LLL LLL LL LLLI ES E uU O UI 9JnjSIO N 400 tpAve Radartime in Picoseconds 150 200 250 300 350 100 60ps 90 in Air MICROMODULTECHNIK GMBH 17 48 Spuoo2esooilgd ul 008 00 009 009 OOV 00 002 001 nn A __ FEECHEHHHEEEEEHHHHHEEHHHFFFF FF FF FF FF a LL LL LLL LLL A a 1 Le A VA __ 1 _
9. 15 3 4 Calibration Set B for different grain nnn 18 3 4 1 Selection and application of the reference 20 3 4 2 Recording measurement data in trial operation 20 3 4 3 Setting the calibration curve 21 3 4 4 example for an offset setting for 21 3 5 Creating a linear Calibration Curve for a specific 22 3 5 1 Nonlinear calibration nnne nnne nnn nnn 23 4 Connectivity to SONO Probes ea 24 4 1 1 Connection Plug and Plug Pinning eseeeeeeessssssseeeernnnneeennnnnn nnne 25 4 1 2 Analogue Output 0 10V with a 25 4 1 3 Connection diagramm with 26 IMKO 3 48 4 2 Installation of the Probe 27 4 3 Further important Assembly 28 4 4 What to do if the Material Flow is not 29 4 5 Installation of SONO VARIO LD inside a Screw Conveyor 30 4 6 Protection of the 5 Connector against
10. RE EANA 62 1 _ _ Ake ___ fe 1 P 5 __ Aa d l 7 __ __ 51 __ __ _ ____ __ uUOHEJQITIED ONO PET Ol 0 06 OV Ul BINISIOW IMKOA MICROMODULTECHNI 18 48 3 4 Calibration Set B for different grain types If the installation is at the discharge hopper For displaying correct moisture values it is to taken into account that a suitable calibration curve is to adjust depending on grain type A zero offset of SONO VARIO LD
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12. Step 1 The radar pulse time tpAve of the probe is measured with dried material Ideally this takes place during operation of a mixer dryer in order to take into account possible density fluctuations of the material It is recommended to detect multiple measurement values for finding a best average value for tpAve The result is the first calibration point P1 e g 70 0 l e 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 P1 e g 190 7 where a tpAve of 190ps corresponds to a moisture content of 7 The gravimetric moisture content of the material e g 7 has to be determined with laboratory measurement methods oven drying Step 2 The radar pulse time tpAve of the probe is measured with moist material Ideally this also takes place during operation of a mixer dryer Again it is recommended to detect multiple measurement values of tpAve for finding a best average value The result is the second calibration point P2 with X2 Y2 e g 500 25 l e tpAve of 500ps corresponds to 25 moisture content The gravimetric moisture content of the material e g 2596 has to be determined with laboratory measurement methods oven drying Step 3 With the two calibration points P1 and P2 the calibration coefficients 0 and m1 can be determined for the specific material see next page Step 4 The coefficients m1 0 0581 and 4 05 see next
13. IMKO MICROMODULTECHNIK F GMBH 35 48 4 10 Exchange of the Probe Head of the VARIOxtrem Lb At the SONO VARIO LDxtrem and VARIOLD not only the ceramic plate but the whole metal ceramic wear resistant probe head can be exchanged This is how easy it is to exchange the wear resistant probe head Loosen the 4 fastening screws look for the right sequence of washer and gasket rings Lift off the probe 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 the probe head so that the two spring contacts are inserted in the contact bushings Screw the 4 fastening screws back on It is to consider that the 4 screws find the 4 holes in the green epoxy plate inside the probe Wear resistant Sensor Head N Hardened Steel Ceramic Window with Compound Pad O Ring Contact Bushing Probe Body 2 G 4 x Fastening Screws for Wear resistant Sensor Head MICROMODULTECHNI 36 48 4 10 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 is necessary to make a basic calibration in air and water that SONO VARIO p measures precise and accurate with the new probe head Therefore some work steps are required Basic calibration procedure 1 Provide a small containe
14. 9 48 Parameters in the Measurement Mode CA CF Standard Setting 25 Setting Range 1 20 Unit Seconds Filter Upper Limit Offset Standard Setting 25 Setting Range 1 20 Unit Absolut Filter Lower Limit Offset Standard Setting 25 Setting Range 1 20 Unit Absolut Upper Limit Keep Time Standard Seiting 10 Setting Range 1 100 Unit Absolut Lower Limit Keep Time Standard Setting 10 Setting Range 1 100s Unit Seconds Moisture Threshold start threshold in moisture Standard Setting 0 1 Setting Range 0 100 Unit Absolut No Material Delay period time Standard Seiting 10s Setting Range 1 100 Unit Seconds Boost Standard Setting 35nn Setting Range 1 100 Unit without unit Offset Standard Setting 0 5 Setting Range 0 5 Unit Absolut Weight Standard Setting 5 values Setting Range 0 50 Unit Measurement Values IMKOA MICROMODULTECHNI Function CA CF Time in seconds for the generation of the average value can be set with this parameter CC CH CK Setting of the time for calculation of the trend or expectation value for the Boost amp Offset function CA CC CF CH 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 CA CC CF CH CK Too low measurement val
15. Filter Lower Limit 2 abs 25 Upper Limit Keep Time s 0 Lower Limit Keep Timels 0 Moisture Threshold abs 0 1 No Material Delayfs 10 Boost nn 35 Offset abs 10 5 W eight no values Invalid Measure Count no values 2 Moist Std Deviation Count no values 5 m Algorithmus Parameters Quick Quick Precision Meas Times no values 2 Set Close 6 1 3 Set analogue outputs of the SONO probe In the menu Config and the window Analog Output the two analogue outputs of the SONO probe can be configured see Chapter Analogue outputs Analog Output Dutput Current C 0 20 C 20 0m C 20 4m Output Channels Moist Temp Moist Conduct C Moist T emp Conduct C Moist MoistStdDev m Moisture Range m Temperature Range r EC Trime mS cm r Moist Std Deviation Max 20 Set Max 100 Set 0 20 C 0 50 0 Set Min 0 Set Min 0 Set Simulate IMKO MICROMODULTECHNIK F GMBH 41 48 6 1 4 Selection of the individual Calibration Curves In the menu Calibration and the window Material Property Calibration the calibration curves to 15 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 cur
16. MICROMODULTECHNIK F GMBH 25 48 4 1 1 Connection Plug and Plug Pinning SONO VARIO LD is supplied with a 10 pole MIL flange plug Cm QU Assignment of the 10 pole MIL Plug and sensor cable connections Sensor Connections 7V 24V Power Supply OV Power Supply 1 Analogue Positive Moisture 1 Analogue Return Line Moisture RS485 A RS485 B rt IMP Bus grey pink grey pink com IMP Bus blue red blue red 2 Analogue Positive Screen transparent transparent is grounded at the sensor The plant must be properly grounded 4 1 2 Analogue Output 0 10V with a Shunt Resistor There PLC s which have no current inputs 0 20mA but voltage inputs 0 10V With the help of a shunt resistor with 500 ohm in the delivery included it is possible to generate a 0 10V signal from the IMKO MICROMODULTECHNIK F GMBH 26 48 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 diagramm with SONO VIEW SONO SILO x SONO VARIO 24V DC Power Suppl a 0V DC or GND IMP Bus COM vee nl u m um Connection to further SONO probes Connection to further SONO probes 1 An
17. 14 48 2 2 Overview of single modes for different applications The following table gives an overview about possible parameter settings in different modes Application Installation and specific Parameters Operating Mode Average Time Filter Upper Limit Offset Filter Lower Limit Offset Upper Limit Keep Time Lower Limit Keep Time Moisture Threshold No Material Delay Offset Weight Invalid Measure Count Sand Gravel under a silo flap EN inactiv 100 inactiv 100 2 For very difficult applications where it is not certain which mode is the best inside the SONO probe we recommend to select mode CA with averaging time 1 second With help of the software SONO CONFIG a data record can be stored directly during process conditions After forwarding this data set to IMKO we would be pleased to be at your disposal for finding the best suitable working mode Above a conveyor belt CH 2 inactiv 100 inactiv 100 inactiv 0 1 e e 10 35 5 2 O1 Inside a mixer inactiv 100 inactiv 100 inactiv NO NO O1 inactiv Inside a fluid bed dryer inactiv 100 inactiv 100 inactiv e NO NO inactiv gt screw conveyor with filtering options due to metal Spiral Gene rally simple appli cations A
18. Eo Serial Bridge 2 Prolific USB to Serial Bridge COM3 Sktandardm ligige Seriell Ober Bluetooth verbindung 14 Standardm gige Seriell Gber Bluetooth verbindung COMIS Standardm gige Seriell Gber Bluetooth verbindung TOMIE Standardm ligige Seriell Gber Bluetooth Verbindung COMI F Standardm gige Seriell Gber Bluetooth verbindung 18 E USB Serial Port e Audio wideo und Gamecontroller 38 Bildbearbeitungsger ate Eluetooth Funkger te set must be between COM1 COM9 and it should be ensured that there is no double occupancy of the interfaces If it comes to conflicts among the serial port or the USB SM has been found in a higher COM port the COM port number can be adjusted manually By double clicking on USB Serial Port you can go into the properties menu where you see connection settings with Advanced button the COM port number can be switched to a free number Eigenschaften von USB Serial Port Erweiterte Einstellungen fiir COM4 Allgemein Anschlusseinstellungen Treiber Details COM Anschlussnummer COM1 bereits belegt Bits pro Sekunde 9600 USB Packetgr en 2 Reduzieren Sie die Werte u bereits belegt Baudraten zu beheben Datenbits COMS bereits belegt Erh hen Sie die Werte f r ei COM6 Partt COM bereits belegt NEN MI Empfangen Bytes bere
19. With e g Boost 35 a single measurement value is weighted with only 6596 100 35 for a new average value CA CF inactive CC CH CK Non linearities in the process can be compensated by higher weighting of higher values Can be used e g in fluid bed dryers or under silo flaps where non linearities can occur due to changes in the material density during process Offset works together with the parameter Average time CA CF CK inactive CH Smoothing factor for analog output setting This parameter influences the reaction response time with factor 3 E g 15 values responds to a reaction time of 15 3 5 seconds IMKO MICROMODULTECHNIK F GMBH Invalid Measure Count otandard Setting 2 values Setting Range 0 10 Unit Measurement Values with 3 single values per second Moisture Std Deviation Count otandard Setting 5 values Setting Range 0 20 Unit Measurement Values with 3 single values per second Quick und Quick Precision With Meas Time no values Unit without unit 10 48 CK The reaction response time works nearly 1 1 E g 15 values responds to a reaction time of 15 seconds CA CF CK inactive CC CH Number of discarded poor measurement values after the start of a new batch when No Material Delay has triggered The first measurement values will be rejected e g due to dripping water CA CC CF CH CK If the parameters Temperature or EC TRIME RbC are not needed the analogu
20. belts For wood chips and other very loose materials which show a bad flowability an installation inside a Screw conveyor is recommended due to better and homogenuous densities inside a screw conveyor IMKO 4 5 48 MICROMODULTECHNI 1 2 Mode of Operation 1 2 1 Measurement value collection with pre check average value and filtering SONO probes measure internally at very high cycle rates of 10 kHz and update the measurement value at a cycle time of 280 milliseconds at the analogue output In these 280 milliseconds a probe internal pre check of the moisture value 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 programmable control system PLC significantly In the Measurement Mode CS Cyclic Successive an average value is not accumulated and the cycle time here is 200 milliseconds In the Measurement Mode CA CF CH CC and CK not the momentarily measured individual values are directly issued but an average value is accumulated via a variable number of measurements in order to filter out temporary variations These variations can be caused by inhomogeneous moisture distribution in the material surrounding the sensor head The delivery scope of SONO probes includes suited parameters for the averaging period and a universally applicable filter function
21. could be also necessary due to installation place If the outfeed is continually and the SONO VARIO LD is continually covered with grain then the calibration curve has to be selected with TC Temperature Compensation However if the outfeed is batch by batch then the calibration curve has to be selected without TC because the temperature sensor at SONO probe measures most of the time the air temperature not the grain temperature which would lead to measurement failures The following charts Cal 1 Cal15 show different selectable calibration curves which are stored inside the SONO VARIO LD Plotted is on the y axis the gravimetric moisture MoistAve and on the x axis depending on the calibration curve the associated radar time tpAve in picoseconds With the software SONO CONFIG the radar time tpAve is shown on the screen parallel to the moisture value MoistAve see Quick Guide for the Software SONO CONFIG Calibration Recommended Bulk Application Curve for grain type density of grain type Maize without TC 6 75 Installation at the discharge hopper The outfeed is TC batch by batch and it is not secured that the SONO Temperature VARIO LD is continually covered with grain Compensation Cal2 Maize with TC 0 75 installation at the beginning of the heating zone is not allowed due to high temperature range pre setted after delivery B Installation at the discharge hopper The outfeed is continually a
22. generally low temperature drift SONO probes are presetted at delivery for standard ambient conditions with the parameter TempComp 0 2 Dependent on SONO probe type this parameter TempComp can be adjusted for higher temperature IMKO MICROMODULTECHNIK F GMBH 6 48 ranges up to 120 C for special version to values up to TempComp 0 75 But it is to consider that it is necessary to make a Basic Balancing of the SONO probe in air and water if the parameter TempComp is changed to another value as TempComp 0 2 The parameter TempComp can be changed with the software tool SONO CONFIG in the menu Calibration and the window Electronic Temperature Compensation Attention When changing the TempComp parameter a new basic balancing of the F SONO probe is necessary 1 2 5 Analogue Outputs The measurement values are issued as a current signal via the analogue output With the help of the service program SONO CONFIG the SONO probe can be set to the two versions for 0 20mA or 4 20mA Furthermore it is also possible to variably adjust the moisture dynamic range e g to 0 10 0 20 0 30 Fora 0 10 DC voltage output a 500R resistor be installed in order to reach 0 10V output Analogue Output 1 Moisture in 0 20 variable adjustable Analogue Output 2 Conductivity EC TRIME or optionally the temperature In addition there is also the option to split the analogue output 2 into two ranges into 4 11mA for the temp
23. max 24 V DC With unstabilzed power supply there is the risk of overvoltage We strongly suggest not to use unstabilized power supplies Attention Risk of Malfunction In larger concrete plants it could be possible that there are used different mass potentials for different power lines especially if the PLC 15 installed in larger distance to the moisture probe Here it could come to problems that the analogue moisture signal 0 4 20mA could not be measured correctly in the PLC With such a problem we recommend to use an isolated powerbox for the SONO probe Available upon request by IMKO Any damage caused by faulty installation is not covered by the warranty Abrasive wear of sensor parts is not covered by the warranty MICROMODULTECHNIK F GMBH 29 48 4 4 What to do if the Material Flow is not optimal There are plants where the material flow is so bright that the material height is too less above the probes surface Following picture shows a funnel chute where guiding plates left and right and also above the probe are bundling the material flow Especially with sticky sand or other sticky materials it is recommended that the quiding plates are coated with PTFE Please consider The minimum material height above the probes surface is 30mm It is also possible to implement filter functions in the SONO probe with Upper and Lower Limit please take a look under chapter Operation IMKO MIC
24. not only enable the measuring of the moisture but also to verify if the mineral concentration specified in a recipe has been complied with This means more reliability at the production TRIME TDR technology operates in the ideal frequency range between 600MHz and 1 2 GHz Capacitive measuring methods also referred to as Frequency Domain Technology depending on the device operate within a frequency range between 5MHz and 40MHz and are therefore prone to interference due to disturbance such as the temperature and the mineral contents of the measured material Microwave measuring systems operate with high frequencies 2GHz At these frequencies nonlinearities are generated which require very complex compensation For this reason microwave measuring methods are more sensitive in regard to temperature variation SONO probes calibrate themselves in the event of abrasion due to a novel and innovative probe design This consequently means longer maintenance intervals and at the same time more precise measurement values The modular TRIME technology enables a manifold of special applications without much effort due to the fact that it can be variably adjusted to many applications 1 1 3 Areas of Application for the SONO VARIO_p SONO VARIO LD is suited for moisture measurement of different materials with medium density like grain types wood pellets animal food and others An installation is possible into containers hoppers and above conveyor
25. page for the calibration curve Cal14 can be entered directly by hand and are stored in the probe by pressing the button Set The name of the calibration curve can also be entered by hand The selected calibration curve e g Cal14 which is activated after switching on the probes power supply will be adjusted with the button Set Default Calib 2 Attention Use dot as separator 0 0581 not comma 3 5 1 IMKO MICROMODULTECHNIK F GMBH 23 48 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 to m5 which can be entered into the probe with help of SONO CONFIG The following diagram shows a sample calculation for a linear calibration curve with the coefficients and m1 for a specific material 50 grav Moisture in gt e e e Puno MEN e e N e e e e I e e T
26. value can be adjusted with help of the program SONO CONFIG Despite SONO probes show a generally low temperature drift it could be necessary to compensate a temperature drift in special applications SONO probes offer two possibilities for temperature compensation Temperature compensation for the measured material Water and special materials like oil fruits and others can show a dependency of the dielectric permittivity when using SONO probes at high temperature ranges The dielectric permittivity is the raw parameter for measuring water content with SONO probes If special materials show a very special temperature drift e g in lower temperatures a higher drift than in higher temperatures than it could be necessary to make a more elaborate temperature compensation Therefore it is necessary to measure in parallel the material temperature with the temperature sensor which is placed inside the SONO probe Normally this is related with high efforts in laboratory works SONO probes offer the possibility to set special temperature compensation parameters tO to 15 for every calibration curve of Cal15 see chapter Selection of the individual calibration curve Please contact IMKO should you need any assistance in this area 1 2 4 Temperature compensation of the internal SONO electronic With this method of temperature compensation a possible temperature drift of the SONO electronic can be compensated Because the SONO electronic shows a
27. water in a height of about 50mm The second set point can be activated with the mouse pointer by clicking to No 2 By activating the button Do Measurement the SONO probe determines the second reference set point in water In the column MeasValues the measured raw value of the radar time t is displayed activating the button Calculate Coeffs and Coeffs gt Probe the alignment data is calculated automatically and is stored in the SONO probe non volatile With a Test run in Mode A the radar time tp of the SONO probe should be now 60ps in air and 1000ps in water Basic Balancing RefValuesitp ps MoistValues MeasValues t ps 1 0 0 2 100 0 Coefficients lt Calculated gt lt in File gt lt in Probe gt b 1883 74 b1 1 24275 Do Measurement Calculate Coeffs Coeffs gt Probe Close MICROMODULTECHNI 44 48 6 1 8 Offsetting the material temperature sensor In the menu Calibration and the window Material Temp Offset a zero point offset can be adjusted for the material temperatur sensor which is installed inside the SONO probe In this example a E SOT temperature deviation of 5 C is produced by inside self warming of the SONO probe The correction value 5 can be setted in the CoeffO window Material Temp Offset Coeffi Coeffo The example shows the parameters for displaying the temperature in the unit Degree Fahrenheit Mat
28. 1 has been exceeded and the probe starts automatically with the continuous accumulation of measurement values yellow curve IMKO MICROMODULTECHNIK F GMBH The last freezed summerized and averaged moisture value is freezed at the analogue output until the No Material Delay time of e g 5 seconds has expired and a new batch process starts un adjustable No Material Delay e g 5 seconds Time Start of second batch process After the period of No Material Delay e g 5 seconds the SONO probe recognizes that the threshold of 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 1 4 Mode CH Automatic Moisture Measurement in one Batch Mode CH can be used for applications in the construction industry If the SONO probe is installed under a silo flap Mode CH can measure moisture when batch cycles are very short down to 5 seconds and perhaps shorter Mode CH executes an automatic filtering with Invalid Measure Count e g if dripping water occurs or for filtering out the first false measurements after opening the silo flap The measurement cycle starts if the probe detects the Moisture Threshold value and freeze the analogue output value until the next cycle Mode CH Cyclic Hold is identically to Mode CC but without summation IMKO 4 MICROMODULTECHNI
29. 28 25 06 2015 84 5 84 5 10 34 27 25 06 2015 84 6 84 5 10 34 26 25 06 2015 84 5 846 10 34 25 25 06 2015 84 5 84 5 10 34 24 25 06 2015 84 5 84 6 84 6 846 84 6 84 5 10 34 23 25 06 2015 10 34 22 25 06 2015 J CJ GO hJ GJ CJ hJ GJ GJ hJ worn GJ urn 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 XSSONO 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 6 1 6 Measure Run in Datalogging Operation In the menu Datalogging 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 IMKO MICROMODULTECHNIK F GMBH 43 48 6 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 nevertheles
30. 70 C Minimum 0 Minimum 0 Conductivity Range 0 20dS m or 0 50dS m Dependent on probe type and moisture range SONO probes can measure pore water conductivities EC TRIME in ranges of 5dS m up to 50dS m 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 in order to adjust individual measuring parameters or conduct calibrations Please consider The initial default setting of the serial interface is pre setted for the IMP Bus To operate with the RS485 inside the SONO probe it is necessary to switch and activate the RS485 interface with help of the modul SM USB or SONO VIEW In the Support 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 The RS485 is usually not galvanically isolated and therefore raises the danger of mass gr
31. If the PLC already accumulates single moisture values in higher cycle rates than an additional automatic summation of a moisture quantity inside the SONO probe during one batch process will produce errors Here mode CS is recommended 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 constant material covering above the probe head 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 detection of the probe will be shifted up and the probe would not be detect a moisture low value below the Moisture Threshold 13 48 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 5 A Short interruptions 5 were bridged 2 nn 5 Characteristic of moisture curve in sand Adjustable Moisture 1 Start of first batch process The SONO probe recognizes that the adjustable moisture threshold of e g
32. ROMODULTECHNI 30 48 4 5 Installation of SONO VARIO LD inside a Screw Conveyor The installation of SONO VARIO LD inside a screw conveyor ensures optimum conditions concerning material flow and material density because the measured material is not loose but is condensed by the screw 30 Cut out of the spiral SONO probe The SONO probe can be installed along the screw conveyor It is recommended to attain a mounting angle with a limit value of 30 to ensure that enough material lies above the probe s surface Optionally the spiral conveyor can be cutted so that a plug formation ensures that enough materials lies above the probes s surface lt is also possible to install the probe at the end of the screw conveyor where it is also ensured that enough material in a backlog with a relative constant density lies above the 5 surface It is recommended to use measurement mode CF if the spiral is cutted out of if the probe is installed at the end of the screw conveyor Furthermore it is possible to install the SONO probe in the middle of the screw conveyor without a cut out of the spiral Here it is necessary to set appropriate filter algorithms because the metal of the spiral has an influence of the measurement The appropriate parameters have to be found dependent on screw velocity It is recommended to use measurement mode CK if the probe is installed in the middle of the screw conveyor without a c
33. User Manual SONO VARIO SONO VARIO for Moisture Measurements of Materials with medium Density IMKO Micromodultechnik GmbH Telefon Im Stock 2 Fax D 76275 Ettlingen e mail http I publik TECH_MAN TRIME SONO ENGLISH SONO VARIO LD Manual_SONO VARIO LD_V2_3 docx 49 0 7243 5921 0 49 0 7243 90856 info imko de www imko de IMKO MICROMODULTECHNIK F GMBH 2 48 User Manual for SONO VARIO LD As of 03 July 2015 Thank you for buying an IMKO moisture probe Please carefully read these instructions in order to achieve best possible results with your SONO VARIO LD probe for the in line moisture measurement Should you have any questions or suggestions regarding your new probe after reading please do not hesitate to contact our authorised dealers or IMKO directly We will gladly help you List of Content 1 Instrument Description SONO VARIO 2 4 42604440000 4 1 1 1 The patented TRIME TDR Measuring Method 4 1 1 2 TRIME compared to other Measuring Methods 222 00 4 1 1 3 Areas of Application for the 4 coe 586 5 1 2 1 Measurement value collection with pre check average value and filtering 5 1 2 2 Determination of the mineral concentration with EC TRIME
34. alog Positiv 1 Analog Positiv 1 Analog Positiv 1 Analog Positiv 0 4 20mA PLC 0 4 20mA SONO VIEW Analogue input or Analogue input Installation in the control moisture ee moisture Distribution Cabinet distribution cabinet IMKO 27 48 MICROMODULTECHNIK P GMBH 4 2 Installation of the Probe The installation conditions are strongly influenced by the constructional circumstances of the installation facility The ideal installation location must be established individually For measuring bulk goods the SONO VARIO should ideally be installed under a silo valve which has many advantages see below X Installation of the SONO VARIO for measuring bulk goods under a silo valve or on a conveyor belt Dependent on material it is important to find the suitable angle of the mounting plate It should be not too steep but also not too flat and the flowing material should cover the probes surface completely during flowing The installation inside a silo could be also possible but it must be observed that during filling and emptying no material e g sand can be stick on the probes surface which could be result in measurement errors The following instructions should be followed when installing the probe The SONO VARIO LD should be installed ideally under a valve of the silo which has many advantages 1 material flows constant and therefore the material density is cons
35. any applications and should only be altered for special applications IMKO MICROMODULTECHNIK F GMBH 11 48 It is appropriate to bridge material gaps mode CA with Upper and Lower Limit Offsets and Keep Time For example the Lower Limit Offset could be adjusted with 2 with a Lower Limit Keep Time of 5 seconds If the SONO probe determines a moisture value which is 2 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 work here with 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 15 described with SONO parameters Sufficient material for an accurately moisture measurement value of e g 8 Material gaps over e g 3 seconds which must be bridged for an accurately measurement with a Lower Limit Keep Time of 5 seconds et 2 t 37 4 RS ws 2 um The following parameter setting in mode fits a high pass filtering for bridging material gaps Average Mode under Average Average Parameters Average Time s EN Filter Upper Limit Filter Lower Limit Offset 20000 Upper Limit Keep Time mo Lower Limit Keep Time Bo The Filter Upp
36. deployable for currently usual applications The time for the average value accumulation as well as various filter functions can be adjusted for special applications 1 2 2 Determination of the mineral concentration with EC TRIME With the radar based TRIME measurement method it is now possible for the first time not only to measure the moisture but also to provide information regarding the conductivity respectively the mineral concentration or the composition of a special material Hereby the attenuation of the radar pulse in the measured volume fraction of the material is determined This novel and innovative measurement delivers a radar based conductance value EC TRIME in dS m as characteristic value which is determined in dependency of the mineral concentration and is issued as an unscaled value EC TRIME measurement range of the SONO probe is 0 12dS m 1 2 3 Material Temperature Measurement A temperature sensor is installed into the SONO probe which establishes the casing temperature 3mm beneath the sensor surface The temperature can optionally be issued at the analogue output2 As the TRIME electronics operates with a power of approximately 1 5 W the probe casing does slightly heat up A measurement of the material temperature is therefore only possible to a certain degree The material temperature can be determined after an external calibration and compensation of the sensor self heating The offset of the measured temperature
37. der deliverable by IMKO the SONO VARIO can be placed above conveyor belt Particularly with inhomogeneous or loose sand the material can be constantly condensed which leads to higher measurement results Areas with strong turbulences are not ideal for the installation There should be a continuous material flow above the probe head e For special installations inside mixing containers it should be noted that the stirring movement of blades should be conducted without gaps above the probe head e he probe should not be installed in the direct vicinity of electrical disturbing sources such as motors e n case of curved installation surfaces in containers the centre of the probe head should be flush with the radius of the container wall without disturbing the radial material flow in the container The probe may not project and come in contact with blades or wipers e he probe connector should be protected against splashing water after installation 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 Attention Risk of Overvoltage In case of welding work at the plant all probes must be completely electrically disconnected SONO probes need a stabilized power supply with 7V DC to
38. e output 2 can be setted tot he mode Moist Moist Std Deviation In this mode the standard deviation of all single moisture values can be outputted With this function the homogeneity of the single measurement values can be determined and it is possible to control a regulating process e g pressure regulation CA CC CF CH CK CS Recommended is Quick Precision with Meas Timez2 where the TDR pulse is detected precisely For still a little better accuracies Meas Time can be increased however the single measurement cycle is increased by 60 milliseconds per step e g from 280ms to 340ms Older SONO probe versions do not have this Quick Precision function 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 T
39. er 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 296 of the average value After 5 seconds the average value is deleted and a new average value building starts The Keep Time function stops if a single measurement value lies within the Limit values 2 1 3 Mode CC automatic summation of a moisture quantity during one batch process Simple PLCs are often unable to record moisture measurement values during one longer batch process with averaging and data storage Furthermore there are applications without a PLC where accumulated moisture values of one batch process should be displayed to the operating staff for a longer time Previously available microwave moisture probes on the market show two disadvantages 1 Such microwave probes need a switching signal from a PLC for starting the averaging of the probe This increases the cabling effort 2 Material gaps during one batch process will lead to zero measurement values which falsify the accumulated measurement value considerably recipe errors can occur Unlike current microwave probes SONO probes work in mode CC with automatic summation where it is really ensured that the measured material has contact with the probe This increases the reliability for the moisture measurement during one complete batch process The summat
40. erature and 12 20mA for the conductivity The analogue output two hereby changes over into an adjustable one second cycle between these two current measurement windows For the analogue outputs 1 and 2 there are thus two adjustable options Analog Output two possible selections 0 20 4 20mA For very special PLC applications the current output can be inverted into 20mA 0mA or 20mA 4mA Analogue Output Channel 1 and 2 The two analogue outputs of the SONO probe can be adjusted into one to four possible selections 1 Moist Temp Analogue output 1 for moisture output 2 for material temperature Analogue output 1 for moisture output 2 for Moist Conduct ed conductivity ranges of 0 20dS mS or 50dS m Moist Analogue output 1 for moisture output 2 for both temperature and conductivity EC Temp Conductivity TRIME with an automatic current window change in cycles of 5 seconds Moist Analogue output 1 for moisture output 2 for the standard deviation based on the single MoistSTdDev moisture values This function is useful in e g fluid bed drier for air volume control IMKO MICROMODULTECHNIK F GMBH 7 48 i Adjustment for the Measurement Ranges 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 Maximum
41. erial Temp Offset Temp CoeffixMeasured Temp Coeff0 Coeffi Coeff 6 1 9 Compensation of the electronic temperature e With this method of temperature compensation a possible temperature drift of the SONO electronic can be compensated Temperature Compensation Now TempComp Because the SONO electronic shows a generally low temperature loz drift SONO probes are presetted at delivery for standard ambient conditions with the parameter 0 2 Dependent on New TempComp SONO probe type this parameter TempComp can be adjusted for o higher temperature ranges up to 120 C for special high u temperature version to values up to 0 75 But it is to consider that it is necessary to make a Basic Balancing of the SONO probe in air and water if the parameter TempComp is Set TempCom changed to another value as 0 2 parameter TempComp can be changed with the software tool SONO CONFIG in the menu Calibration and the window Electronic Temperature Compensation Attention When changing the TempComp parameter a new basic balancing of the SONO probe is necessary IMKO MICROMODULTECHNIK F GMBH 45 48 i 7 Technical Data SONO VARIO LD SENSOR DESIGN Casing High Grade Steel V2A 1 4301 SONO VARIOLD The probe head surface consists of stainless steel with abrasion resistant special ceramic Available are high temperature versions of the SONO VARIO LD
42. eter Probe Height 71mm Mounting Flange SONO VARIOxtrem MICROMODULTECHNIK GMBH 33 48 Dimensions of the Mounting Flange Vessel Wall Mounting Flange SONO VARIO 132mm 86mm screw M6 IMKO MICROMODULTECHNI 34 48 4 8 Mounting in curved Surfaces In order to prevent the probe head from projecting and interfering with wipers the centre of the probe head should be flush with the radius of the wall The ceramic must be laterally aligned to the rotational axis as the gap towards the wipers is smallest in this position In order to ensure that the probe head is completely covered with material the probe is best positioned near the base In order to prevent water from accumulating above the sensor head which could falsify the measurement an installation angle of approximately 30 above the base centre is recommended Fill the crack with sand or silicone sealing compound The centre of the sensor head should be flush with the radius of the vessel wall The sensor may not project The ceramic must be laterally aligned to the rotational axis Welded on Mounting Frame Vessel Wall Probe SONO VARIO 4 9 Gas and waterproofed Installation in a Tube or Container For a pressure tight installation of a SONO probe in a vessel or a tube a flange installation is recommended For such applications we recommend to use IMKO s moisture probe SONO FLANGE Information upon request
43. f the SONO VARIO LD at the discharge in the delivery or in the storage area As a general rule only the moisture range close to the reference input is of significance for trial operation i e when determining the switch position for maize checking should be done at about 15 lt is more important that the SONO VARIO LD is exactly correct in the lower area of measurement It is of less importance whether SONO VARIO LD measures 26 instead of 28 in the upper range When extracting a sample or checking the lower reference input e g 15 a single sample is of course insufficient A single sample possibly even extracted from quite a different point than in the direct vicinity of the probe is not at all representative i e several samples must be taken directly at the probe and averaged At the start of trial operation the suitable calibration curve can be set When all the preparations for extracting samples and measuring them have been made the grain dryer can be started up Now a sample of grain must be taken continuously ideally every 15 minutes The SONO VARIO LD reading and the selected calibration curve are to be noted simultaneously with every extracted sample This is compared with the appropriate offline determined reference value which 15 also to be noted As soon as the moisture is near the target moisture the calibration curve should be set to the best possible value which is the nearest to the reference value In the followi
44. fig Configuration Scan Probes Serial Port Use the selected Automatically search the port 6 1 1 Scan of connected SONO probes on the serial interface In the menu Bus and the window Scan Probes the serial bus can be scanned for attached SONO probes takes max 30 seconds SONO CONFIG reports one or more connected and founded SONO probes with its serial number in the window Probe List One SONO probe can be selected by klicking Probe List Ext Config Calibration Test Measure No SerialNo ResetBaudrate SONO VARIO 2 06 2 200603 MICROMODULTECHNI 40 48 6 1 2 Configuration of Measure Mode and serial SONO interface In Probe List with Config and Measure Mode amp Parameters the SONO probe can be adjusted to the desired measure mode CA CF CS CK CC or CH see Chapter Configuration Measure Mode Furthermore the serial interface inside the SONO probe can be selected to IMP Bus 5485 or both interfaces Due to very robust behavior it is recommended to select the IMP Bus Measure Mode amp Parameters Default Cycle Mode Cycli Set Default uas _Set Defaut TEENI Select Bus m Measure Mode amp Parameters Actual Cycle Mode Cyclic gt Average Mode of Mode CH Cyclic AverageHc Kalman with Boost C Nc Offset with Moist4ve 10 6 C RS485 Average Parameters Average Time s 2 Set Filter Upper Limit abs 25
45. g time increases many times over It therefore requires a lot of time and effort to check this very representative value with a reference instrument that shows a sample quantity in the millilitre range There are also factors that can affect measurement such as temperature and conductivity that can be ignored when using SONO VARIO LD due to the TDR radar method of measurement Thus the most suitable method for determining the exact moisture of the grain is to use a drying oven Here too the sample volume is of decisive importance and should be at 0 5 litres When extracting the sample and taking reference measuremenis the following must be observed samples for the reference measurements should be extracted from as close as possible to the probe The distribution of moisture in the grain dryer can vary greatly When using a calibrated instrument with small sample volumes several samples must be extracted and their arithmetical average calculated Please note that calibrated instruments can also produce incorrect measurements that can lie between 2 in the lower and even 5 in the upper moisture range After the dryer or the silo has been filled the SONO VARIO LD moisture value must show a valid reading 3 4 2 Recording measurement data in trial operation The selection of the calibration curve can only be adjusted in real operation or in realistic trial operation The following description is based on the implementation o
46. h set with to Cal15 Calibration Set A for general bulk goods like wood chips pellets powder pet food etc Calibration Set B for different types of grain and corn like maize wheat barley soja etc The different calibration curves 15 be activated in two ways A With the stand alone module SONO VIEW the calibration curve can be selected and activated B calibration curve Cal1 15 can be activated with the module SM USB which is connected via a PC 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 3 3 Calibration Set A for general bulk goods The charts Cal 1 15 in the next two pages show different selectable calibration curves which are stored inside the SONO probe Plotted is on the y axis the gravimetric moisture MoistAve and on the x axis depending on the calibration curve the associated radar time tpAve in picoseconds With the software SONO CONFIG the radar time tpAve is shown on the screen parallel to the moisture value MoistAve see Quick Guide for the Software SONO CONFIG In air SONO probes measure typically 60 picoseconds radar time in water 1000 picoseconds
47. his 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 longer time i e the material sand temporarily no longer completely covers the probe head During these periods Lower Limit Keep Time the probe would establish a value that is too low The Lower Limit Keep Time sets the maximum possible time where the probe could determine inaccurate too low measurement values Furthermore the passing or wiping of the probe head with metal blades or wipers can lead to the establishment of too high measurement values Filter Upper Limit Upper Limit Keep Time sets the maximum possible time where the probe would determine inaccurate too high measurement values Using a complex algorithm SONO probes are able to filter out such faulty individual measurement values The standard settings in the Measurement Mode CA and CF for the filter functions depicted in the following have proven themselves to be useful for m
48. indings or interferences which can lead to considerably security problems An 5485 network needs shielded and twisted pair cables especially for long distances Depending on the topology of the network it is necessary to place 1000hm termination resistors at sensitive locations In practice this means considerable specialist effort and insurmountable problems The robust IMP Bus ensures security SONO probes have in parallel to the standard RS485 interface the robust galvanically isolated IMP Bus which means increased safety The serial data line is isolated from the probe s power supply and the complete sensor network is therefore independent from single ground potentials and different grid phases Furthermore the IMP Bus transmit its data packets not as voltage signals but rather as current signals which also works at already existing longer cables A special shielded cable is not necessary and also stub lines are no problem 1 2 3 Error Reports and Error Messages SONO probes are very fault tolerant This enables failure free operation Error messages can be recalled via the serial interface IMKO MICROMODULTECHNIK F GMBH 8 48 2 Configuration of the Measure Mode The configuration of SONO probe is preset in the factory before delivery A process related later optimisation of this device internal setting is possible with the help of the service program SONO CONFIG For all activities regarding parameter setting and calibration the pr
49. ion is only working if material fits at the probe Due to precise moisture measurement also in the lower moisture range IMKO MICROMODULTECHNIK F GMBH 1 2 48 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 will start With the parameter Moisture Threshold the SONO probe can be configured to the start moisture level where the summation starts automatically Due to an automatic recalibration of SONO probes it is ensured that the zero point will be precisely controlled The start level could be variably set dependent to the plant Recommended 15 a level with e g 0 5 to 1 With the parameter No Material Delay a time range can be set where the SONO probe is again ready to start a new batch process Are there short material gaps during a batch process which are shorter than the No Material Delay with no material at the probes surface then the SONO probe pauses shortly with the summation 15 the pause greater as the No Material Delay then the probe is ready to start a new batch process Please note
50. its belegt COMS bereits belegt Stoppbits ne COMI bereks 12 bereits belegt COM13 bereits belegt Flusssteuerung BM Einstellungen 14 ees Allgemeine Optionen Reduzieren Sie die Werte un COM15 bereits belegt OM COMI bereits belegt PlugPlay f r serielle Schnittstelle verringern Wiederherstellen COM1 bereits belegt Serieller Drucker Wartezeit ms COM18 bereits belegt 19 Abbrechen der Kommunikation wenn das Ger t 20 bereits belegt ausgeschaltet wird Timeouts 21 Event bei unvorhergesehener Entfernung des COMZZ Ger ts COM23 Minimale Anzahle der Lese Tl 24 Beim Schlie en der Verbindung RTS aktiv setzen 25 bereits belegt Abschalten der Modemansteuerung beim Minimale Anzahle der Schreid 26 Hochfahren des Ger ts hk Bb K After changing the port settings must be restarted IMKO MICROMODULTECHNIK F GMBH 39 48 6 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 SonoCon
51. lug in the for 10s LED is blinking calibration SONO MIX is calibration connector Preparation Air quicker 10s Water connector ready to use Plug in the Plunge the i T ith time for calibration 9 calibration Unplug MIL Screw blind cap u calibration completed probe head completed connector and of calibration power supply or successfully into water successfully plug it again connector lvi 171 of lee NE 3seconds 10 seconds 5 seconds 10 seconds 5 seconds Calibration Connector MIL Blue LED Connector IMKO MICROMODULTECHNIK F GMBH 37 48 5 Connection of the RS485 to the SM USB Module from IMKO The SM USB provides the ability to connect a SONO probe either to the standard RS485 interface or to the IMP Bus from IMKO In fact that the IMP Bus is more robust and enables the download of a new firmware to the SONO probe the SONO probes are presetted ex factory to the IMP Bus So it is recommended to use the IMP Bus for a serial communication Both connector ports are shown in the drawing below The SM USB is signalling the status of power supply and the transmission signals with 4 LED s When using a dual USB connector on the 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 MN Pin RS485B Lead Col
52. nd the SONO VARIO LD is continually covered with grain 19 Rape and oilseeds 0 65 No temperature compensation necessary without TC Cal10 Sunflower seeds 0 30 No temperature compensation necessary without TC Cal1 1 ooya without TC opecial calibration curve Cal12 Soya with TC Special calibration curve 15 1 10 tp lL ibrati Radar time and reference calibration for test MICROMODULTECHNIK GMBH 2 08 X1 ML auyo efos away 5 sdey ae 2 08 AL 35295 3L 335125 2 08 31 uaddoy Y SIBI uszi2AM auyo uasdoy EN uazia M e 19 48 di pamyoy f apona IMKOA MICROMODULTECHNI 20 48 3 4 1 Selection and application of the reference method In order to adjust the SONO VARIO LD for precise absolute measurements at the discharge an off measurement method must be available to serve as a reference It must provide a high degree of absolute precision and function with large sample volumes Most commercially available grain moisture measuring systems leave a great deal to be desired regarding both of these aspects The SONO VARIO LD measures the average value continuously over a volume of 1 2 litres In moving grain the measurement volume acquired in the averagin
53. ng you will find a ready to use form for entering the measurements Where continuous flow dryers are concerned at least 10 to 20 measurements should be available in the range between the minimum and maximum permissible moisture content after drying The measurements from the still very damp discharged grain during the charge phase should be noted but not used for the purposes of adjustment For rotary dryers only the measurements take towards the end of the drying process are of relevance to adjustment Here too at least 10 measurements are to have been documented Density and moisture distribution effects in the grain can cause too low measurements during the first one to two hours These values should not be used for the adjustment IMKO 21 48 MICROMODULTECHNIK F GMBH 3 4 3 Setting the calibration curve adjustment The appropriate setting of the calibration curve should be determined on the adjustment protocol Only the measurements near the target moisture should be taken into account 3 4 4 An example for an offset setting for wheat Note SONO VAHIO LD is pre installed to calibration curve for wheat A continuous flow dryer is to set for wheat A SONO VARIO LD has been installed whose probe is located in the direct vicinity of the discharge point To start with the calibration curve is set to Cal for wheat The dryer is started up and measurement recording commences It is not until the moisture at the discharge
54. obe can be directly connected via the serial interface to the PC with SM USB Module or the SONO VIEW display module which are available from IMKO The following settings of SONO probes can be amended with the service program SONO CONFIG Measurement Mode and Parameters Measurement Mode A On Request only in network operation for the retrieval of measurement values via the serial interface Measurement Mode C Cyclic SONO VARIO is supplied ex factory with suited parameters in Mode CH for measuring moisture of sand and gravel For other applications mode CA could be usable Up to 6 different modes can be adjusted Mode CS Cyclic Successive For very short measuring processes e g 2 10 seconds without floating average and without filter functions with internal up to 100 measurements per second and a cycle time of 250 milliseconds at the analogue output Measurement mode CS can also be used for getting raw data from the SONO probe without averaging and filtering Mode 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 for use in fresh concrete mixer with continual average value with s
55. obe to industrial busses such as Profibus Ethernet etc is possible via optional external modules available upon request POWER SUPPLY 7V to 24V DC 1 5 W max Attention Do not use unstabilized power supplies AMBIENT CONDITIONS 0 70 On request Version with higher temperature range MEASUREMENT FIELD EXPANSION SONO VARIOLD Approximately 70 100 mm depending on material and moisture CONNECTOR PLUG The sensor is equipped with a robust 10 pole MIL flange connector Readymade connection cables with MIL connectors are available in cable lengths of 4m 10m or 25 m MICROMODULTECHNIK GMBH 47 48 MICROMODULTECHNIK GMBH 48 48 Precise Moisture Measurement in hydrology forestry agriculture environmental and earth science civil engineering as well as individual applications
56. our brown Pin F RS485A Lead Colour white 12VDC IMP Bus Connector With the option to accomplish a download of the firmware for the SONO probe Pin Power Supply Pin A 12VDC Power Supply 7 Pin rt Lead Colour greylpink Pin J com Lead Colour blue red 2 How to start with the USB Module SM USB from IMKO e Install USB Driver from USB Stick Connect the SM USB to the USB Port of the PC and the installation will be accomplished automatically e Install Software SONOConfig SetUp msi from USB Stick Connection of the SONO probe to the EX9531 via RS485A RS485B and OV e Check the setting of the COM Ports in the Device Manager und setup the specific COM Port with the Baudrate of 9600 Baud in SONO CONFIG with the button Bus and Configuration 1 COM15 is possible e Start Scan probes in SONOConfig The SONO probe logs in the window Probe List after max 30 seconds with its serial number Note 1 In the Device Manager passes it as follows IMKO MICROMODULTECHNIK F GMBH 38 48 Control Panel gt System gt Hardware gt Device Manager 12 Ger te Manager Datei Aktion Ansicht E E eb En a W 5 50 Under the entry COM amp LPT now the 2 7 eaten item USB Serial Port COMx is found 2 ECP Druckeranschluss LPT1 E Intel R Active Management Technology SOL COMO Kommunikationsanschluss COM Prolific USB
57. pecial 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 Mode CH is recommended for applications in the construction industry If the SONO probe is installed under a silo flap Mode CH can measure moisture when batch cycles are very short down to 2 seconds Mode CH executes an automatic filtering e g if dripping water occurs Each of these settings will be preserved after shut down of the probe and is therefore stored on a permanent basis 2 1 Cyclic operation modes CA CF CH CC and CK For the cyclic modes the SONO probes are supplied ex factory with suited parameters for the averaging time and with a universally deployable filter function suited for most currently applications The setting options and special functions of SONO probes depicted in this chapter are only rarely required It is necessary to take into consideration that the modification of the settings or the realisation of these special functions may lead to faulty operation of 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
58. point falls below 1896 that the measurements become of real interest and can be used for the adjustment process Analysis can start as soon as about 10 to 20 measurements are available in the range from 12 to 18 IMKO MICROMODULTECHNIK F GMBH 22 48 3 5 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 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen takes max 1 minute With the mouse pointer individual calibration curves can be tested with the SONO probe by activating the button Set Active Calib The measurement of the moisture value MoistAve with the associated radar time tpAve at point P1 and P2 is started using the program SONO CONFIG in the sub menu Test and Test in Mode CF see Quick Guide for the Software SONO CONFIG
59. r with water in which the probe head can be plunged in For the first calibration point in air the probe head must be completely dry If appropriate dry it with towel Unplug the blind cap of the calibration connector and plug in the calibration connector Plug in the MIL connector with power supply to the probe The blue LED is on for 3 seconds and start with a slow blinking for the next 10 seconds preparation time for the first calibration point in air Therefore the dry probe head must be free in air When the LED is on continual for 5 seconds the first calibration point is completed in air Now the blue LED starts with a quicker blinking during 10 seconds preparation time for the second point in water During this 10 seconds the probe head must be plunged in water When the LED 15 on continual for 5 seconds the calibration is completed in water After that the LED is off If the calibration should be failed the blue LED will be blinking continual Unplug the MIL connector and the calibration connector Plug in the blind cap of the calibration connector Plug in the MIL connector again The blue LED should be active continual now SONO VARIO LD 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 EM Unplug the continual P
60. s advisable to verify the calibration and to check the basic calibration and if necessary to correct it with a Basic Balancing With a Basic Balancing two reference calibration measurements are to be carried out with known set points RefValues For the reference media different calibration materials are used dependent on the SONO probe type For SONO probes with a ceramic measurement window air and water tap water is used For other SONO probes like SONO GS1 glass beads are used for basic calibrations on request Attention Before performing a Basic Balancing it must be ensured that the SONO probe was set to Measure Mode A If this is 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 be dry The first set point can be activated with the mouse pointer by clicking to No 1 By activating the button Do Measurement the SONO probe determines the first reference set point in air In the column MeasValues the measured raw value of the radar time t is displayed e g 1532 05 picoseconds 2 Reference set point B tp 1000ps in water The SONO probe head has to be covered with
61. st run in the respective Measurement Mode In the menu Test and the window Test in Mode CA to CF the measured moisture values MoistAve Average of the SONO probe are displayed on the screen and can be parallel saved in a file In the menu Test and the window Test in Mode CS the measured single measurement values Moist 5 values 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 CH CC CF CS or A it must be ensured that the 50 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 CH Cyclic Average Hold Tme Date Moistave MatTemp EC Trme TDRAve DeltaCnt 1 Moist2 Moist3 Moist4 TDR1 TDR2 TDR3 10 34 41 25 06 2015 84 5 84 5 10 34 40 25 06 2015 845 845 10 34 39 25 06 2015 84 6 84 5 Max Graph Time s 10 34 38 25 06 2015 84 6 84 6 po 10 34 37 25 06 2015 846 846 10 34 36 25 06 2015 846 846 10 34 35 25 06 2015 846 84 6 10 34 34 25 06 2015 84 5 84 5 846 84 6 10 34 33 25 06 2015 8445 84 6 84 5 846 Interval s 0 Measure List Graph won C tun b CJ Ne 10 34 32 25 06 2015 10 34 31 25 06 2015 10 34 30 25 06 2015 84 6 84 5 10 34 29 25 06 2015 84 6 846 10 34
62. tant which guarantees more precise measurement values 2 Due to higher material pressure the probe s surface is cleaned continously Material sticking and therefore measurement errors are be prevented 3 SONO VAHIO can detect clearly the start and the end of a batch process So the SONO VARIO can calculate an automatic summation of the moisture quantity during one batch process in mode CC Even short batches with few material can be precisely measured Further advantage is that the PLC programming can be made more simple without switching signals Unfavourable conditions for moisture probes occur if the probes are installed inside silos or inside the outlets There are materials which are sticky and adhere even at near vertical walls Such an installation place inside a silo can lead to measurement failures because the SONO probe cannot be controlled visually IMKO MICROMODULTECHNIK F GMBH 28 48 4 3 Further important Assembly Instructions The following instructions should be followed when installing the probe The universal holder should be installed direct under a silo flap so that the flowing material covers the moisture probe completely e The installation locations may not be situated beneath the inlets for additives e n case of an uneven base the probe must be installed at the highest point of the base No water may accumulate at the probe head as this could falsify the measurement e With the universal hol
63. thout floating average with internal up to 100 measurements per second and a cycle time of 200 milliseconds at the analogue output 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 IMKO MICROMODULTECHNIK F GMBH 46 48 SIGNAL OUTPUT 2 x Analogue Outputs 0 4 20mA Analogue Output 1 Moisture in e g 0 20 variably adjustable Analogue Output 2 Conductivity EC TRIME 0 20dS m or optionally the temperature or the standard deviation In addition there is the option to split the analogue output 2 into two ranges into 4 11mA for the temperature and 12 20mA for the conductivity The analogue output 2 hereby changes over into an adjustable 5 second cycle between these two current measurement windows The two analogue outputs can be variably aligned with the SONO CONFIG software For a 0 10V DC voltage output a 500R resistor can be installed CALIBRATION A maximum of 15 different calibrations can be stored inside the probe For special materials variable calibrations with polynomials up to the 5 order are possible A zero point correction can be performed easily with the SONO CONFIG software COMMUNICATION A RS485 interface enables network operation of the probe whereby a data bus protocol for the connection of several SONO probes to the RS485 is implemented by default The connection of the pr
64. ues generated due to insufficient material at the probe head are filtered out The offset value in is subtracted from the dynamically calculated lower limit with the negative sign CA CC CF CH CK The maximum duration in seconds of the filter function for Upper Limit failures too high measurement values can be set with this parameter CA CC CF CH CK 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 where no material is located on the probe s surface can be bridged CA CF CK inactive CC CH The accumulation of moisture values starts above the Moisture Threshold and from here the analogue signal is outputted The accumulation pauses and will be frozen if the moisture level is below the threshold value The No Material Delay time starts and material gaps disturbance can be eliminated inactive CC CH The accumulation stopps if the moisture value is below the Moisture Threshold The accumulation pauses for the period of the setted delay time and will be frozen if the moisture level is below the threshold value The SONO probes starts again ina new batch with a new accumulation after the setted time span of the No Material Delay is completely exceeded CA CF inactive CC CH CK Defines how strong single measurement values are weighted dependent on deviation to the current expected average value
65. up to 150 C with external measurement transformer SONO ES upon request MOUNTING Sensor Dimensions SONO VARIOLD 108 x 71mm Diameter x Length The mounting flange can be screwed on to the rear side of any container hopper or silo MEASUREMENT RANGE MOISTURE The sensor measures from 0 up to the point of material saturation Measurement ranges up to 100 moisture pure water are possible with a special calibration MEASUREMENT RANGE CONDUCTIVITY The sensor as a material specific characteristic value delivers the radar based conductance RoC Radar based Conductance in a range of 0 12dS m The conductivity range is reduced in moisture measurement ranges gt 50 MEASUREMENT RANGE TEMPERATURE Measurement Range 0 C 70 C The temperature is measured 3mm beneath the wear resistant sensor head inside the sensor casing and is issued at the analogue output 2 The material temperature can be measured with an external calibration and compensation of the sensor intrinsic heating On request version with higher temperature range MEASUREMENT DATA PREPROCESSING MEASUREMENT MODE CA Cyclic Average For relative short measuring processes with continual average value filtering and an accuracy of up to 0 1 MEASUREMENT CF Cyclic Float Average For very slow measuring processes with floating average value filtering and an accuracy of up to 0 1 MEASUREMENT MODE CS Cyclic Successive For very short measuring processes wi
66. ut out of the spiral Please take also a look the chapter Overview of single modes for different applications IMKO MICROMODULTECHNIK F GMBH 31 48 4 6 Protection of the Probe s Connector against Abrasion If sand and gravel flows above the buffle plate and could touch the probe connector of the SONO probe than it is recommended to mount an extra protection for the probe s connector This is feasible e g with a commercial flexible garden hose with an inner diameter of 27mm The hose can be slotted longitudinally and can be mounted around the connector and the cable It could be fixed with cable ties The following picture shows this solution for protection of the probe s connector s Alternatively the included shrink sleeve over the cable can be used After installation of the SONO probe and connection of the MIL connector the shrink sleeve can be shrinked with a hot air blower IMKO MICROMODULTECHNIK F GMBH 32 48 4 7 Assembly Dimensions SONO VARIO LD can either be installed at the base or the side wall of containers One fact to consider is that the installation into the container base also enables the measurement of smaller material quantities A mounting flange is available for SONO VARIO LD The flange can both be welded on to the base and the side wall of the container The probe can be adjusted to the correct position respectively correct installation height SONO VARIOLD 108mm Probe Diam
67. ves CAL1 to Cal15 be adapted or modified with the calibration coefficients see Chapter Creating a linear calibration curve Material Property Calibration Calibration Item Please select one calibration from Call to Call5 to operate Set Active Calib Cal CallD P CalName in Probe MatlD P TemlD P DenID P No Calibration Default Calibration Item Universal S 1 Sand bulk density 1 6 Sand bulk density 1 7 Set Default Calib Sand bulk density 1 8 Sand bulk density 1 9 Gravel Grit Calibration Name Wood Shavings Universal and Mix Brown coal granulate 50 0 Salz sano Material Coeffs Temp Coeffs ewage sludge aW Linear 0 20 0 cO CD Cn CO n2 C Aur to Water 0 06 1 10tp 7 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 be entered in the window Calibration The coefficients to m1 for linear curves and to m5 for non linear curves can be entered 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 not comma for coefficients to m5 MICROMODULTECHNIK F GMBH 42 48 6 1 5 Te

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