SONO-VARIO

User Manual

SONO-VARIO

Standard

for General Bulk Goods

SONO-VARIO

Xtrem

for very high abrasive Goods like Gravel 4/32

and Grit

IMKO Micromodultechnik GmbH

Im Stöck 2

D - 76275 Ettlingen

Telefon: +49 - (0)7243 - 5921 - 0

Fax: +49 - (0)7243 - 90856 e-mail: [email protected]

I:\publik\TECH_MAN\TRIME-SONO\ENGLISH\SONO-VARIO\SONO-VARIO-Xtrem-MAN-Vers1_8-english.doc

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User Manual for SONO-VARIO

As of 1. August 2011

Thank you for buying an IMKO moisture probe.

Please carefully read these instructions in order to achieve best possible results with your

SONO-VARIO probe for the in-line moisture measurement. Should you have any questions or suggestions regarding your new probe after reading, please do not hesitate to contact our authorised dealers or IMKO directly. We will gladly help you.

List of Content:

1.

 

Instrument Description SONO-VARIO ...................................................................................... 4

 

1.1.1.

 

The patented TRIME

®

TDR-Measuring Method ............................................................. 4

 

1.1.2.

 

TRIME

®

compared to other Measuring Methods ........................................................... 4

 

1.1.3.

 

Areas of Application with SONO-VARIOStandard and SONO-VARIOXtrem ................ 4

 

1.2.

 

Mode of Operation ................................................................................................................. 5

 

1.2.1.

 

Measurement value collection with pre-check, average value and filtering ................... 5

 

1.2.2.

 

Determination of the mineral Concentration ................................................................... 5

 

1.2.3.

 

Temperature Measurement ............................................................................................ 5

 

1.2.4.

 

Analogue Outputs ........................................................................................................... 5

 

1.2.5.

 

The serial RS485 interface ............................................................................................. 6

 

1.2.6.

 

Error Reports and Error Messages ................................................................................ 6

 

1.3.

 

Configuration of the Measure Mode ...................................................................................... 7

 

1.4.

 

Operation Mode CA and CF at non-continuous Material Flow .............................................. 7

 

1.4.1.

 

Average Time in the measurement mode CA and CF ................................................... 9

 

1.5.

 

Calibration Curves ................................................................................................................. 9

 

1.5.1.

 

SONO-VARIO for measuring Moisture of Sand and Aggregates ................................ 12

 

1.5.2.

 

SONO-VARIO for measuring Moisture of Expanded Clay and Lightly Sand ............... 13

 

1.6.

 

Creating a linear Calibration Curve for a specific Material .................................................. 14

 

1.6.1.

 

Nonlinear calibration curves ......................................................................................... 14

 

1.7.

 

Connectivity to SONO Probes ............................................................................................. 16

 

1.7.1.

 

Connection Plug and Plug Pinning ............................................................................... 17

 

1.8.

 

Connection of the RS485 to the USB Module EXPERT ..................................................... 18

 

1.9.

 

Connection of the RS485 to the SM-USB Module from IMKO ............................................ 19

 

2.

 

Quick guide for the Software SONO-CONFIG ........................................................................ 21

 

2.1.1.

 

Scan of connected SONO probes on the RS485 interface .......................................... 21

 

2.1.2.

 

Configuration of Measure Mode ................................................................................... 22

 

2.1.3.

 

Analogue outputs of the SONO probe ......................................................................... 22

 

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2.1.4.

 

Selection of the individual Calibration Curves .............................................................. 23

 

2.1.5.

 

Test run in the respective Measurement Mode ............................................................ 24

 

2.1.6.

 

Basic Balancing in Air and Water .................................................................................. 25

 

3.

 

Installation of the Probe ............................................................................................................ 26

 

3.1.

 

Assembly Instructions .......................................................................................................... 26

 

3.2.

 

Assembly Dimensions .......................................................................................................... 27

 

3.3.

 

Mounting in curved Surfaces ................................................................................................ 29

 

3.4.

 

Gas- and waterproofed Installation ...................................................................................... 30

 

3.5.

 

Exchange of the Probe Head of the VARIOXtrem ............................................................... 31

 

3.5.1.

 

Basic Balancing of a new Probe Head.......................................................................... 32

 

4.

 

Technical Data SONO-VARIO ................................................................................................... 33

 

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1. Instrument Description SONO-VARIO

1.1.1. The patented TRIME

®

TDR-Measuring Method

The TDR technology (Time-Domain-Reflectometry) is a radar-based dielectric measuring procedure at which the transit times of electromagnetic pulses for the measurement of dielectric constants, respectively the moisture content are determined.

SONO-VARIO consists of a high grade steel casing with a wear-resistant sensor head with ceramic window. An integrated TRIME TDR measuring transducer is installed into the casing. A high frequency TDR pulse (1GHz), passes along wave guides and generates an electro-magnetic field around these guides and herewith also in the material surrounding the probe. Using a new patented measuring method, IMKO has achieved to measure the transit time of this pulse with a resolution of

1 picosecond (1x10

-12

), 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 via a serial RS485 interface.

1.1.2. TRIME

®

compared to other Measuring Methods

In contrary to conventional capacitive or microwave measuring methods, the TRIME

®

technology

(Time-Domain-Reflectometry with Intelligent Micromodule Elements) does not only enable the measuring of the moisture but also to verify if the mineral concentration specified in a recipe has been complied with. This means more reliability at the production.

TRIME-TDR technology operates in the ideal frequency range between 600MHz and 1,2 GHz.

Capacitive measuring methods (also referred to as Frequency-Domain-Technology) , depending on the device, operate within a frequency range 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 with SONO-VARIO

Standard

and SONO-VARIO

Xtrem

SONO-VARIO is suited for installation into containers, hoppers and silos.

 The

Standard

is suited for measuring of normal abrasive materials. The probe head consists of stainless steel with a rectangular ceramic window.

 The

Xtrem is suited for measuring of very high abrasive materials like gravel 4/32 and grit. The probe head consists of hardened steel with a rectangular special ceramic window.

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1.2. Mode of Operation

1.2.1. Measurement value collection with pre-check, average value and filtering

SONO-VARIO measures internally at a rate of 100 measurements per seconds and issues the measurement value at a cycle time of up to 200 milliseconds at the analogue output. In these 200 milliseconds a probe-internal pre-check of the moisture values is already carried out, i.e. only plausible and physically pre-averaged measurement values are be used for the further data processing. This increases the reliability for the recording of the measured values to a downstream control system significantly.

In the Measurement Mode CS (Cyclic-Successive), an average value is not accumulated and the cycle time here is 200 milliseconds. In the Measurement Mode CA and CF (Average), not the momentarily measured individual values are directly issued, but an average value is accumulated via a variable number of measurements in order to filter out temporary variations. These variations can be caused by inhomogeneous moisture distribution in the material surrounding the sensor head. The delivery scope of SONO-VARIO includes suited parameters for the averaging period and a universally applicable filter function deployable for currently usual applications. The time for the average value accumulation, as well as various filter functions, can be adjusted for special applications.

1.2.2. Determination of the mineral Concentration

With the radar-based TRIME measurement method, it is now possible for the first time, not only to measure the moisture, but also to provide information regarding the 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 (RbC – Radar-based-Conductivity) in dS/m as characteristic value which is determined in dependency of the mineral concentration and is issued as an unscaled value. The RbC-measurement range of the SONO-VARIO is 0..12dS/m

1.2.3. Temperature Measurement

A temperature sensor is installed into the SONO-VARIO which establishes the casing temperature

3mm beneath the sensor surface. The temperature can optionally be issued at the analogue output 2.

As the TRIME electronics operates with a power of approximately 1.5 W, the probe casing does slightly heat up. A measurement of the material temperature is therefore only possible to a certain degree. The material temperature can be determined after an external calibration and compensation of the sensor self-heating.

1.2.4. Analogue Outputs

The measurement values are issued as a current signal via the analogue output. With the help of the service program SONO-CONFIG, the SONO-VARIO can be set to the two versions for 0..20mA or

4..20mA. Furthermore, it is also possible to variably adjust the moisture dynamic range e.g. to 0-10%,

0-20% or 0-30%. For a 0-10V DC voltage output, a 500R resistor can be installed in order to reach a

0..10V output.

Analogue Output 1: Moisture in % (0…20%, variable adjustable)

Analogue Output 2: Conductivity (RbC) or optionally the temperature.

In addition, there is also the option to split the analogue output 2 into two ranges: into

4..11mA for the temperature and 12..20mA for the conductivity. The analogue output

2 hereby changes over into an adjustable one-second cycle between these two

(current) measurement windows.

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For the analogue outputs 1 and 2 there are thus two adjustable options:

Analog Output: (two possible selections)

0..20mA 4..20mA

Output Channel 1 and 2: (three possible selections)

1. Moist, Temp. Analogue output 1 for moisture, output 2 for temperature. or

2. Moist, Conductivity Analogue output 1 for moisture, output 2 for conductivity in

a range of 0..20dS/m. or

3. Moist, Temp/Conductivity Analogue output 1 for moisture, output 2 for both, temperature and conductivity with an automatic current-window change.

For analogue output 1 and 2 the moisture dynamic range and temperature dynamic range can be variably adjusted. The moisture dynamic range should not exceed

100%

Moisture Range: Temp. Range:

Maximum: e.g. 20 for sand (Set in %) Maximum: 100 °C

1.2.5. The serial RS485 interface

SONO-VARIO is equipped with a standard RS485 interface to serially readout individual parameters or measurement values. An easy to implement data transfer protocol enables the connection of several sensors/probes at the RS485-Interface. In addition, the SONO-VARIO can be directly connected to the USB port of a PC, in order to adjust individual measuring parameters or conduct calibrations, via the RS485 USB Module which can be provided by IMKO.

1.2.6. Error Reports and Error Messages

SONO-VARIO is very fault-tolerant. This enables failure-free operation. Error messages can be recalled via the serial RS485 interface.

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1.3. Configuration of the Measure Mode

The configuration of SONO-VARIO is preset in the factory before delivery. A process-related later optimisation of this device-internal setting is possible with the help of the service program SONO-

CONFIG. For all activities regarding parameter setting and calibration the probe can be directly connected via the RS485 interface to the PC via a RS485 USB-Module which is available from IMKO.

The following settings of SONO-VARIO can be amended with the service program SONO-CONFIG:

Measurement-Mode and Parameters:

 Measurement Mode A-On-Request (only in network operation for the retrieval of measurement values via the RS485 interface).

 Measurement Mode C Cyclic:

SONO-VARIO is supplied ex factory with suited parameters in Mode CS for bulk goods.

Mode CS: (Cyclic-Successive) For very short measuring processes (e.g. 5…20 seconds) without floating average, with internal up to 100 measurements per second and a cycle time of

250 milliseconds at the analogue output. Measurement mode CS can also be used for getting raw data from the SONO-probe without averaging and filtering.

Mode CA: (Cyclic-Average-Filter) For relative short measuring processes with continual average value, filtering and an accuracy of up to 0.1%

Mode CF: (Cyclic-Float-Average) for continual average value with filtering and an accuracy of up to 0.1% for very slowly measuring processes, e.g. in fluidized bed dryers, conveyor belts, etc.

Mode CK: (Cyclic-Kalman-Filter) Standard setting for SONO-MIX for use in fresh concrete mixer with continual average value with special dynamic Kalman filtering and an accuracy of up to 0.1%.

 Calibration (if completely different materials are deployed)

Each of these settings will be preserved after shut down of the probe and is therefore stored on a permanent basis.

1.4. Operation Mode CA and CF at non-continuous Material Flow

For mode Ca and CF the SONO-VARIO is supplied ex factory with suited parameters for the averaging time and with a universally deployable filter function suited for most currently applications.

The setting options and special functions of the SONO-VARIO 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.

Detection of malfunctions at the probe head

SONO-VARIO is able to identify, if temporarily no or less material is at the probe head and can filter out such inaccurate measurement values (Filter-Lower-Limit). Particular attention should be directed at those time periods in which the measurement area of the probe is only partially filled with material

8/34 for a longer time, i.e. the material (sand) temporarily no longer completely covers the probe head.

During these periods (Lower-Limit-Keep-Time), the probe would establish a value that is too low. The

Lower-Limit-Keep-Time sets the maximum possible time where the probe could determine inaccurate (too low) measurement values.

Furthermore, the passing or wiping of the probe head with metal blades or wipers can lead to the establishment of too high measurement values (Filter-Upper-Limit). The Upper-Limit-Keep-Time sets the maximum possible time where the probe would determine inaccurate (too high) measurement values.

Using a complex algorithm, SONO-VARIO is able to filter out such faulty individual measurement values. The standard settings in the Measurement Mode CA and CF for the filter functions depicted in the following have proven themselves to be useful for many applications and should only be altered for special applications.

Function Parameters in the Measurement

Mode CA, CF and CK

Average-Time

Standard Setting: 10

Setting Range: 1…20

Filter-Upper-Limit-Offset

Standard Setting: 5

Setting Range: 1….20

With the setting of 20, this parameter must be disabled for Mode CK !

Filter-Lower-Limit

Standard Setting: 2

Setting Range: 1.….20

With the setting of 20, this parameter must be disabled for Mode CK !

The time (in seconds) for the generation of the average value can be set with this parameter.

Too high measurement values generated due to metal wipers or blades are filtered out. The offset value in % is added to the dynamically calculated upper limit.

Too low measurement values generated due to insufficient material at the probe head are filtered out. The offset value in % is subtracted from the dynamically calculated lower limit with the negative sign.

Upper-Limit-Keep-Time

Standard Setting: 5

Setting Range: 1...100

With the setting of 100, this parameter must be disabled for Mode CK !

Lower-Limit-Keep-Time

Standard Setting: 30

Setting Range: 1...100

With the setting of 100, this parameter must be disabled for Mode CK !

The maximum duration (in seconds) of the filter function for Upper-Limit-failures (too high measurement values) can be set with this parameter.

The maximum duration (in seconds) of the filter function for Lower-Limit-failures (too low measurement values) for longer-lasting

"material gaps", ie the time in which no material is located on the probe, can be bridged.

Kalman Filter-Parameter in

Measurement Mode CK:

Q-Parameter

Standard Setting: 1x10

-5

Setting Range: 0.01…1x10

-7

R-Parameter

Standard Setting: 0.033

Setting Range: 0.01 ….. 0.1

This Kalman filter parameter Q is used to characterize the systemic measurement error. It is recommended to leave this parameter to the default setting!

This Kalman filter parameter R is used for smoothing the measurement error. The lower this parameter, the faster is the response to smaller changes in the moisture readings. The

K-Parameter

Standard Setting: 0.01

Setting Range: 0.01 ….. 0.2

9/34 higher this parameter is the more smoothed the measured value, but with a delayed reaction time. It is recommended to leave this parameter to the default setting!

This Kalman filter parameter K is used for a predynamic behaviour of the Kalman Filter for higher changes in the moisture reading, i.e. the reaction rate of the measurement signal can be affected hereby. The K-parameter is related to the Average-Time. It is recommended to leave this parameter to the default setting!

1.4.1. Average Time in the measurement mode CA and CF

SONO-VARIO establishes every 200 milliseconds a new single measurement value which is 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-VARIO.

The longer this time is selected, the more inert is the reaction rate, if differently moist material passes the probe. A longer averaging time results in a more stable measurement value. This should in particular be taken into consideration, if the SONO-VARIO is deployed in different applications in order to compensate measurement value variations due to differently moist materials.

At the point of time of delivery, the Average Time is set to 4 seconds. This value has proven itself to be useful for many types of applications. At applications which require a faster reaction rate, a smaller value can be set. Should the display be too “unstable”, it is recommended to select a higher value.

1.5. Calibration Curves

SONO-VARIO is supplied with a universal calibration curve for sand (Cal1: Universal Sand Mix). A maximum of 15 different calibration curves (CAL1 ... Cal15) are stored inside the SONO probe and can optionally be activated via the program SONO-CONFIG.

A preliminary test of an appropriate calibration curve (Cal1. .15) can be activated in the menu

"Calibration" and in the window “Material Property Calibration" by selecting the desired calibration curve (Cal1...Cal15) and with using the button “Set Active Calib”. The finally desired and possibly altered calibration curve (Cal1. .15) which is activated after switching on the probes power supply will be adjusted with the button "Set Default Calib”.

Nonlinear calibrations are possible with polynomials up to 5th grade (coefficients m0...m5).

IMKO publish on its website more suitable calibration coefficients for different materials. These calibration coefficients can be entered and stored in the SONO probe by hand (Cal14 and Cal15) with the help of SONO-CONFIG.

The following charts (Cal.1 .. 15) show different selectable calibration curves which are stored inside the SONO probe.

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).

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1.5.1. SONO-VARIO for measuring Moisture of Sand and Aggregates

The TRIME-TDR technology with the radar method offers high reliability for measuring moisture of sand and aggregates, as different grain sizes, unlike other measurement techniques such as microwave technology, do not cause any distortion of the measurement result.

The calibration curve Cal1 "Universal Sand Mix" is suitable for measuring the moisture in bulk sand, gravel and gravel/sand granulates. The deviations to the universal calibration curve Cal1 are approximately +-0.5%, depending on the moisture range, for the below listed gravel/sand types.

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1.5.2. SONO-VARIO for measuring Moisture of Expanded Clay and Lightly Sand

Concerning the material density, expanded clay and lightly sand differ significantly in comparison to sand and gravel. Therefore a separate calibration for each material is necessary. It is to consider that expanded clay below a moisture level of 12% still can absorb more water, ie here it must be calculated with more addition of water into a mixture. At moisture levels above 12% (the maximum core moisture of expanded clay), the surface water of the expanded clay would act as a free addition of water and the addition of water into a mixture should be reduced.

For measuring these two materials the probe calibration Cal10 or Cal11 can be selected.

If you want to use a single SONO probe with the calibration Cal1 for both normal sand/gravel as well as these two materials, then there is the possibility with a simple mathematical conversion inside a

PLC. Requirement would be that the PLC knows when and what material is to be measured. You may convert the following:

MoistureLightlySand = MeasurementValueCal1 * Factor of 4

MoistureExpandedClay = MeasurementValueCal1 * Factor of 4.8 + 3.2 Offset

It is to consider that this correction calculation for expanded clay can only be measured above 3.2%, which in practice would be acceptable as it is unlikely that in plant operation the moisture in expanded clay is below 3.2%.

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1.6. Creating a linear Calibration Curve for a specific Material

The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with the help of SONO-CONFIG. Therefore, two measurement points need to be identified with the probe.

Point P1 at dried material and point P2 at moist material where the points P1 and P2 should be far enough apart to get a best possible calibration curve. The moisture content of the material at point P1 and P2 can be determined with laboratory measurement methods (oven drying). It is to consider that sufficient material is measured to get a representative value.

Under the menu "Calibration" and the window "Material Property Calibration" the calibration curves

CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes max. 1 minute). With the mouse pointer individual calibration curves can be tested with the SONOprobe 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").

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). I.e. 70ps (picoseconds) of the radar pulse time tpAve corresponds to 0% 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). I.e. tpAve of 500ps corresponds to 25% moisture content. The gravimetric moisture content of the material, e.g. 25% has to be determined with laboratory measurement methods (oven drying).

Step 3: With the two calibration points P1 and P2, the calibration coefficients m0 and m1 can be determined for the specific material (see next page).

Step 4: The coefficients m1 = 0.0581 and m0 = -4.05 (see next page) for the calibration curve Cal14 can be entered directly by hand and are stored in the probe by pressing the button “Set”. The name of the calibration curve can also be entered by hand. The selected calibration curve (e.g. Cal14) which is activated after switching on the probes power supply will be adjusted with the button "Set Default

Calib”.

Attention: Use “dot” as separator (0.0581), not comma !

1.6.1. Nonlinear calibration curves

SONO probes can also work with non-linear calibration curves with polynomials up to 5th grade.

Therefore it is necessary to calibrate with 4…8 different calibration points. To calculate nonlinear coefficients for polynomials up to 5th grade, the software tool TRIME-WinCal from IMKO can be used

(on request). It is also possible to use any mathematical program like MATLAB for finding a best possible nonlinear calibration curve with suitable coefficient parameters m0 to m5 which can be entered into the probe with help of SONO-CONFIG.

15/34

The following diagram shows a sample calculation for a linear calibration curve with the coefficients m0 and m1 for a specific material.

16/34

1.7. Connectivity to SONO Probes

17/34

1.7.1. Connection Plug and Plug Pinning

SONO-VARIO is supplied with a 10-pole MIL flange plug.

.

Assignment of the 10-pole MIL Plug and sensor cable connections:

Plug-PIN Sensor Connections Lead Colour

A

B

D

E

+7V….28V Power Supply

0V Power Supply red blue

1. Analogue Positive (+) Moisture green

1. Analogue Return Line (-) Moisture yellow white

K

E

2. Analogue Positive (+)

2. Analogue Return Line (-)

H Screen

(is grounded at the sensor. The plant must be properly grounded!) brown

(grey/pink)

(blue/red) pink grey transparent

18/34

1.8. Connection of the RS485 to the USB Module EXPERT

SONO-VARIO is equipped with a standard RS485 interface to serially readout individual parameters or measurement values. An easy to implement data transfer protocol enables the connection of several sensors/probes on the RS485-Interface. In addition, the SONO-VARIO can be directly connected to the USB port of a PC, in order to adjust individual measuring parameters or conduct calibrations, via the RS485 to USB-Module EXPERT which can be provided by IMKO.

How to start with the USB-Module EXPERT EX9531

 Install USB-Driver CDM 2.04.06.exe from USB-Stick.

 Connect the EX9531 to the USB-Port of the PC and the installation will be accomplished automatically.

 Connection of the SONO probe to the EX9531 via RS485A, RS485B and 0V.

 Check the setting of the COM-Ports in the Device-Manager und setup the specific COM-Port with the Baudrate of 9600 Baud in SONO-CONFIG with the button "Bus" and "Configuration" (COM1-

COM15 is possible).

 The SONO probe logs in the window „Probe List“ after max. 30 seconds with its serial number.

19/34

1.9. Connection of the RS485 to the SM-USB Module from IMKO

The SM-USB provides the ability to connect a SONO probe either to the standard RS485 interface or optionally to the IMP-Bus from IMKO, which enables the download of a new firmware to the SONO probe. Both connector ports are shown in the drawing below.

The SM-USB is signalling the status of power supply and the transmission signals with 4 LED´s. When using a dual-USB connector on the PC, it is possible to use the power supply for the SONO probe directly from the USB port of the PC without the use of the external AC adapter.

How to start with the USB-Module SM-USB from IMKO

 Install USB-Driver from USB-Stick.

 Connect the SM-USB to the USB-Port of the PC and the installation will be accomplished automatically.

 Connection of the SONO probe to the EX9531 via RS485A, RS485B and 0V.

 Check the setting of the COM-Ports in the Device-Manager und setup the specific COM-Port with the Baudrate of 9600 Baud in SONO-CONFIG with the button "Bus" and "Configuration" (COM1-

COM15 is possible).

 The SONO probe logs in the window „Probe List“ after max. 30 seconds with its serial number.

20/34

Note 1:

In the Device-Manager passes it as follows:

Control Panel

 System  Hardware  Device-Manager

Under the entry “Ports (COM & LPT) now the item “USB Serial Port (COMx)” is found.

COMx 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.

After changing the COMx port settings, SONO-CONFIG must be restarted.

21/34

2.

Quick guide for the 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 RS485 interface and displayed on the screen.

In the menu "Bus" and the window "Configuration" the PC can be configured to an available COMxport with the Baudrate of 9600 Baud.

2.1.1. Scan of connected SONO probes on the RS485 interface

In the menu "Bus" and the window "Scan Probes" the RS485 bus can be scanned for attached

SONO probes (takes max. 30 seconds).

SONO-CONFIG reports founded SONO probes with its serial number in the window “Probe List“.

22/34

2.1.2. Configuration of Measure Mode

In "Probe List" with "Config" and "Measure Mode & Parameters” the SONO probe can be adjusted to the desired mode CA, CF or CS (see Chapter “Configuration Measure Mode”).

2.1.3. Analogue outputs of the SONO probe

In the menu "Config" and the window "Analog Output" the analogue outputs of the SONO probe can be configured (see Chapter “Analogue outputs..”).

23/34

2.1.4. Selection of the individual Calibration Curves

In the menu "Calibration" and the window "Material Property Calibration" the calibration curves

CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes max. 1 minute). With the mouse pointer individual calibration curves can be activated and tested with the SONO-probe by activating the button "Set Active Calib". Furthermore, the individual calibration curves CAL1 to Cal15 can be adapted or modified with the calibration coefficients (see Chapter

“Creating a linear calibration curve”).

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 coefficients m1 = 0.0581 and m0 = -4.05 for individual calibration curves can be entered and adjusted directly by hand and are stored in the probe by pressing the “Set” button.

Attention: Use “dot” as separator (0.0581), not comma !

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2.1.5. Test run in the respective Measurement Mode

In the menu "Test" and the window "Test in Mode CA or CF" the measured moisture values

“MoistAve” (Average) of the SONO probe are displayed on the screen and can be parallel saved in a file.

In the menu "Test" and the window "Test in Mode CS" the measured single measurement values

“Moist” (5 values per second) of the SONO probe are displayed on the screen and parallel stored in a file. In „Test in Mode A“ single measurement values (without average) are displayed on the screen and can also be stored in a file.

Attention: for a test run in mode CA, CF, CS or A it must be ensured that the SONO probe was also set to this mode (Measure Mode CA, CF, CS, A). If this is not assured, the probe returns zero values.

Following measurement values are displayed on the screen:

MoistAve Moisture Value (Average)

MatTemp Temperature

Conduct Radar-based-Conductivity RbC

TDRAve TDR-Level (for special applications)

DeltaCount Number of single measurements which are used for the averaging.

tpAve Radar time (average) which corresponds to the respective moisture value.

By clicking „Save“ the recorded data is saved in a text file in the following path:

\SONO-CONFIG.exe-Pfad\MD\Dateiname

The name of the text file Statis+SN+yyyymmddHHMMSS.sts is assigned automatically with the serial number of the probe (SN) and date and time.

The data in the text file can be evaluated with Windows-EXCEL.

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2.1.6. Basic Balancing in Air and Water

SONO probe heads are identical and manufactured precisely. After an exchange of a probe head it is nevertheless advisable to verify the calibration and to check the basic calibration and if necessary to correct it with a “Basic Balancing”.

With a “Basic Balancing” two reference calibration measurements are to be carried out with known setpoints ("RefValues"). For the reference media, air and water (tap water) can be used.

Attention: Before performing a “Basic Balancing” it must be ensured that the SONO probe was set to

“Measure Mode” A. If this is not assured, the probe returns zero values. After a “Basic Balancing” the

SONO probe has to be set to “Measure Mode C” again.

In the menu "Calibration" and the window "Basic Balancing" the two set-point values of the radar time tp are displayed with 60ps and 1000ps.

1. Reference set-point A: tp=60ps in air (the surface of the probe head must be dry!!)

The first set-point can be activated with the mouse pointer by clicking to No.1. By activating the button "Do Measurement" the SONO probe determines the first reference set-point in air.

In the column „MeasValues“ the measured raw value of the radar time t is displayed (e.g.

1532.05 picoseconds).

2. Reference set-point B: tp=1000ps in water. The SONO probe head has to be covered with water in a height of about 50mm. The second set-point can be activated with the mouse pointer by clicking to No.2. By activating the button "Do Measurement" the SONO probe determines the second reference set-point in water. In the column „MeasValues“ the measured raw value of the radar time t is displayed.

3. By activating the button „Calculate Coeffs“ and „Coeffs

 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.

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3. Installation of the Probe

The installation conditions are strongly influenced by the constructional circumstances of the installation facility. The ideal installation location must be established individually. The following guidelines should hereby be observed.

3.1. Assembly Instructions

The following instructions should be followed when installing the probe:

 The installation locations may not be situated beneath the inlets for additives.

 In case of an uneven base, the probe must be installed at the highest point of the base. No water may accumulate at the probe head as this could falsify the measurement.

 Areas with strong turbulences are not ideal for the installation. There should be a continuous material flow above the probe head.

 The stirring movement of blades should be conducted without gap above the probe head.

 The probe should not be installed in the direct vicinity of electrical disturbing sources such as motors.

 In case of curved installation surfaces in containers, the centre of the probe head should be flush with the radius of the container wall without disturbing the radial material flow in the container. The probe may not project and come in contact with blades or wipers.

Attention! Risk of Breakage!

The probe head is made of hardened special steel and a very wear-resistant ceramic in order to warrant for a long life-span of the probe. In spite of the robust and wear-resistant construction, the ceramic plate may not be exposed to any blows as ceramic is prone to breakage.

In case of welding work at the plant, all probes must be completely electrically disconnected.

Any damage caused by faulty installation is not covered by the warranty!

Abrasive wear of sensor parts is not covered by the warranty!

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3.2. Assembly Dimensions

SONO-VARIO can either be installed at the base or the side wall of containers. One fact to consider is that the installation into the container base also enables the measurement of smaller material quantities. A mounting flange is available for SONO-VARIO. The flange can both be welded on to the base and the side wall of the container. The probe can be adjusted to the correct position, respectively correct installation height.

SONO-VARIO

Standard

:

SONO-VARIO

Xtrem

:

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Dimensions of the Mounting Flange

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3.3. Mounting in curved Surfaces

In order to prevent the probe head from projecting and interfering with wipers, the centre of the probe head should be flush with the radius of the wall. 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.

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3.4. Gas- and waterproofed Installation

For a pressure-tight installation in a temperature range from -20 ° C to +80 ° C, a flange kit is available (on request). The mounting flange can be welded to the container wall. Sealing is done with a 5.5mm thick O-ring which is fixed with a locking ring.

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3.5. Exchange of the Probe Head of the VARIO

Xtrem

At the SONO-VARIO

Xtrem

not only the ceramic plate but the whole metal/ceramic wear-resistant probe head can be exchanged.

This is how easy it is to exchange the wear-resistant probe head of the SONO-VARIO:

- Loosen the 4 fastening screws (look for the right sequence of washer and gasket rings).

- Lift off the probe head carefully so that the robust spring contacts in the interior are canted as

little as possible.

- Clean the surface inside the probe body for the O-Ring.

- Place on the probe head so that the two spring contacts are inserted in the contact bushings.

- Screw the 4 fastening screws back on. It is to consider, that the 4 screws “find” the 4 holes in the green epoxy plate inside the probe.

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3.5.1. Basic Balancing of a new Probe Head

The probe heads are all identical and are manufactured to fit precisely. In spite of this fact, after an exchange it is necessary to make a basic calibration in air and water, that SONO-MIX measures precise and accurate with the new probe head. Therefore some work-steps are required.

Basic calibration procedure:

1. Provide a small container with water in which the probe head can be plunged in. For the first calibration point in air the probe head must be completely dry. If appropriate dry it with a towel.

2. Unplug the blind cap of the calibration connector and plug in the calibration connector.

3. Plug in the MIL-connector with power supply to the probe. The blue LED is on for 3 seconds and start with a slow blinking for the next 10 seconds preparation time for the first point in air.

Therefore the dry probe head must be free in air. When the LED is on continual for 5 seconds the calibration is completed in air.

4. Now the blue LED starts with a quicker blinking during 10 seconds preparation time for the second point in water. During this 10 seconds the probe head must plunged in water. When the

LED is on continual for 5 seconds the calibration is completed in water. After that the LED is off.

5. If the calibration should be failed, the blue LED will be blinking continual.

6. Unplug the MIL connector and the calibration connector. Plug in the blind cap of the calibration connector. Plug in the MIL connector again. The blue LED should be on continual now. SONO-

MIX is ready to use. With strong pressing of a hand to the probe head, the analogue moisture output 4..20mA should be respond.

If necessary the basic balancing procedure could be repeated several times.

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4. Technical Data SONO-VARIO

SENSOR DESIGN

Casing: High Grade Steel V2A 1.4301

SONO-VARIO

Standard

: The probe head surface consists of stainless steel with abrasion-resistant aluminium oxide ceramic.

SONO-VARIO

Xtrem

: The probe head surface consists of hardened steel with highly abrasion-resistant special ceramic.

High-temperature versions up to 150°C with external measurement transformer

SONO-ES are available upon request!

MOUNTING

Sensor Dimensions:

SONO-VARIO

Standard

: 108 x 45mm (Diameter x Length)

SONO-VARIO

Xtrem

: 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 90% moisture are possible with a special calibration.

MEASUREMENT RANGE CONDUCTIVITY

The sensor, as a material-specific characteristic value, delivers the radar-based conductance

(RbC – Radar-based-Conductance) in a range of 0…12dS/m. The conductivity range is reduced in measurement ranges >50%.

MEASUREMENT RANGE TEMPERATURE

Measurement Range: 0°C …100°C

The temperature is measured 3mm beneath the wear-resistant sensor head inside the sensor casing and is issued at the analogue output 2. The material temperature can be measured with an external calibration and compensation of the sensor intrinsic-heating.

MEASUREMENT DATA-PREPROCESSING

MEASUREMENT MODE CA: (Cyclic-Average) For relative short measuring processes with continual average value, filtering and an accuracy of up to 0.1%

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 without floating average with internal up to 100 measurements per second and a cycle time of

200 milliseconds at the analogue output.

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SIGNAL OUTPUT

2 x Analogue Outputs 0(4)…20mA

Analogue Output 1: Moisture in % (0..20% variably adjustable)

Analogue Output 2: Conductivity (RbC) 0..20dS/m, or optionally the temperature.

In addition, there is the option to split the analogue output 2 into two ranges: into

4..11mA for the temperature and 12..20mA for the conductivity. The analogue output

2 hereby changes over into an adjustable 5 second cycle between these two

(current) measurement windows.

The two analogue outputs can be variably aligned with the SONO-CONFIG software.

For a 0-10V DC voltage output, a 500R resistor can be installed.

CALIBRATION

The sensor is provided with a universal calibration for sand. A maximum of 15 different calibrations can be stored. For special materials, variable calibrations with polynomials up to the 5 th

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 probe to industrial busses such as Profibus, Ethernet, etc. is possible via optional external modules (available upon request).

POWER SUPPLY

+7V to +28V DC, 1.5 W max.

AMBIENT CONDITIONS

0 - 70°C

A higher temperature range is available upon request!

MEASUREMENT FIELD EXPANSION

Approximately 50 - 80 mm, depending on material and moisture.

CONNECTOR PLUG

The sensor is equipped with a robust 10-pole MIL flange connector. Ready made connection cables with MIL connectors are available cable lengths of 4m, 10m, or 25 m.