Technical Manual
STRAINSERT CLEVIS PINS/BOLTS
MODEL CW-XXXXXXXXX
USER MANUAL
Strainsert Company
12 Union Hill Road
West Conshohocken, PA 18914
United States of America
Phone: 610-825-3310
Fax: 610-825-1734
http://www.strainsert.com
2015 Strainsert Company
Document CW-XXXXXXXXX
May 6, 2015
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Table of Contents
Introduction……………………………………………………………………………........................................... 4
Strainsert Wireless Load Monitoring System Capabilities…………………………………………………
4
Safety Information……………………………………………………………………………………………………………
5
Warranty Information………………………………………………………………………………………………………
6
Radio Requirements…………………………………………………………………………………………………………
7
System Overview……………………………………………………………………………………………………………..
8
Equipment……………………………………………………………………………………………………………………….. 9
Mini Gateway Mounting Requirements……………………………………………………………………………
10
Mini Gateway Front Port Identification……………………………………………………………………………. 10
Minimum System Requirements………………………………………………………………………………………
11
Software Installation………………………………………………………………………………………………………..
12
Hardware Installation………………………………………………………………………………………………………. 14
Application Quick Start-up……………………………………………………………………………………………….
15
Load Monitor Tab Field Descriptions………………………………………………………………………………..
22
Configuration Tab Field Description…………………………………………………………………………………. 24
Field Calibration Tab Field Description……………………………………………………………………………..
28
Field Calibration Procedure………………………………………………………………………………………………
30
Data Logging…………………………………………………………………………………………………………………….
33
Battery Installation / Replacement…………………………………………………………………………………..
34
Troubleshooting………………………………………………………………………………………………………………. 35
Customer Support……………………………………………………………………………………………………………. 37
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Introduction:
The STRAINSERT Wireless Load Sensing Clevis Pin/Bolt and Load Monitoring Software provides
a convenient method of displaying force readings on a computer through a wireless interface.
The program provides monitoring capability for up to 5 Load Sensing Clevis Pins/Bolts. These
can be configured as single axis, bi-axial, or dual bridge. Each Pin/Bolt includes a durable battery
capable of over 5000 hrs. of operations at line of sight distances up to 3000 feet. Data Logging
and Field calibration capabilities are also provided. All STRAINSERT Load Sensing Pins/Bolts are
internally gaged and protected inside high strength stainless steel bodies, which provides
protection from the environment and minimizes damage during installation and operation.
Strainsert Wireless System Capabilities
Sensor Type: Wireless Pin/Bolt (Uni-axial, Bi-axial, Dual Bridge) See Customer Drawing
(QXXXXX-100-1-B)
Bridge Resistance: 350 Ohms (Min.)
Bridge Type: Full Bridge
Minimum Sensitivity: 1-mV/V
Maximum Number of Sensors: 5 single, dual bridge, or bi-axial load sensors
Unipolar / Bipolar Operation
Units: lbs., KIPS, Tons, Metric Tons, kg, kN
Sensor Excitation: 2.075 VDC
Transmission Distance:
Range
Standard
Short
Minimum (ft)
30
1
Line of Sight (ft)
>3000
>500
Carrier Frequency: 916 Mhz Spread Spectrum Frequency Hopping
Data Update Rate: Readings are averaged over 250ms cycle and transmitted once a second.
A/D Resolution: 0.04% Unipolar Mode / 0.08% Bipolar Mode
Estimated Battery Life: 5,000 hours
Calibration: Field adjustable
Operating Temperature: -10 to 65 Deg. C (14 to 149 Deg. F)
Enclosure Dimensions: Per Customer Drawing
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Safety Information
General Safety
Do not install or work on this equipment unless you have read and understand the instructions
and warnings in this Manual. Proper care is your responsibility
Failure to heed any warnings may result in serious injury or death.
WARNING!
!
Use caution and follow applicable safety procedures when using wireless sensors. This
program DOES NOT provide safety or emergency stop devices.
CAUTION!
!
Improper scaling of the Load Pin may result in readings that do not represent actual
applied loads and may cause damage to pin and/or the surrounding structure, in addition
to potential personal injury. The Customer must verify that all data entry values are
correct and are entered in the proper fields.
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Warranty Information
The Two Year Guarantee
Strainsert wireless force sensor products are guaranteed for a period of two years, after
shipment to original purchaser, against any malfunction due to defects in materials or
workmanship
Strainsert Company is not liable for consequential or contingent damages and its liability is
strictly limited to the original purchase price of the product or its repair or replacement at
Strainsert’s option.
Strainsert Company will repair or replace under warranty, and return transportation prepaid,
provided that:
•
•
•
•
•
Full explanation of malfunction or defect is transmitted in writing to Strainsert Company;
together with, if possible, application or short history of product use.
Authorization to return product is obtained from Strainsert Company.
Product is sent to Strainsert Company, 12 Union Hill Road, West Conshohocken, PA 19428,
prepaid, properly packaged and insured at full value.
Factory inspection and investigation discloses that malfunction or defect developed or appeared
during normal and proper usage of product.
This warranty is null and void in the event repairs or modifications are made by persons
unauthorized by Strainsert Company.
Notes:
1. To initiate warranty repair work, ALL above conditions must be complied with fully.
2. For beyond warranty repair work, the same conditions apply.
3. Calibration and/or investigation charges may apply when Strainsert products returned
for warranty repair prove to be free of defect, and the problem lies in systems,
components, circuits, test set-ups, etc., for which Strainsert has no responsibility.
4. For some special systems, Strainsert may utilize other manufacturers products. In these
cases, the original equipment manufacturers warranty will apply.
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Radio Requirements
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may
cause undesired operation.
To comply with FCC and Industry Canada RF radiation exposure limits for general population,
the antenna(s) used for this transmitter must be installed such that a minimum separation
distance of 20cm is maintained between the radiator (antenna) and all persons at all times and
must not be co-located or operating in conjunction with any other antenna or transmitter.
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System Overview
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Equipment
1. Clevis Pin/Bolt Transmitter / Receivers – includes: battery, transmitter / receiver circuit
board, Model Nearson S161AH-915R, Fixed right-angle (Up to 5 units)
2. ModFLEX Mini Gateway – includes articulating antenna, USB cable (1ea.)
3. Load Monitoring System Installation CD (1ea.)
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Mini Gateway Mounting Requirements
Mini Gateway Front Port Identification
Green – Indicates that the Gateway module is operational (heartbeat)
Yellow – Indicates that there is activity on the host interface
Red – Indicates RF activity
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Minimum System Requirements for Software
Operating System: Windows XP Professional Version 202 Service Pack 3
Processor: 2GHz
RAM: 2GB
Hard Drive: 50MB of free space
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Software Installation
1. Prior to connecting the gateway USB, run the Strainsert Installer program from CD
provided. Minimum system requirements: Windows XP.
2. The installer will guide the user through the installation with prompts as follows:
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NOTE: It is recommended that the user perform a re-boot prior to the hardware installation.
Hardware Installation
1. Install Clevis Pin/Bolt in accordance with Customer drawing
2. Connect ModFLEX Mini Gateway USB cable to computer USB port.
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3. Connect the articulating antenna to Mini Gateway
4. Ensure that the gateway is operational by observing that the green Status LED (heart
beat) is blinking.
Application Quick Start-Up
1. After connecting the ModFLEX Mini Gateway, pc or lap top will install device drivers.
2. Re-boot your computer.
3. After re-boot, open Strainsert Load monitor application.
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4. The application will open to the Load Monitor tab which will be blank.
5. Select the Configuration tab.
6. On the Configuration tab select the Display Bridge #1 check box for single axis load cell
and Display Bridge #2 check box for dual bridge or bi-axial load cells under the Load
Monitor Display Options.
7. Enter the sensor Serial Number(s)
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8. Enter Bridge 1 / 2 Description fields (optional)
9. After selections, Save Configuration and Settings.
10. To establish communication between the gateway and the Transmitter / Receiver unit,
return to the Load Monitor tab.
11. The Load Monitor tab will display each selected sensor and bridge.
Note: The initial communication link may take up to 3 minutes to connect.
12. Each bridge will indicate the attempt to connect by displaying Searching in a message
for each sensor / bridge. NOTE: In the upper right corner of each sensor / bridge a red
circle with a slash indicates no communication
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Indicates No Communication
13. After communication is established, bars in the upper right corner will indicate signal
strength. The sensor / bridge load readings will be displayed in the selected units.
Indicates Communication established
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14. Ensure that both the yellow and red Status LEDs on the gateway are blinking.
15. With no-load on the sensor, use Zero icon to null the sensor / bridge
16. After zeroing the display, all readings are Gross measurements, which are indicated on
the display with a “G” to the right of the engineering units.
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17. The user may add any required Tare to the system at this point. Tare loads are stored
when the user presses the Set Tare icon under each sensor / bridge display.
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18. Press the Net/Gross button the left of the load display to toggle between the tared and
untared condition. The Net mode is indicated with a “N” to the right of the engineering
units.
19. The user may close out communication between the sensor and the gateway by
pressing the “X” in the upper right hand corner of the application window.
20. With all configuration settings saved, the user can re-open the application at a later time
and re-establish communication with the saved sensors.
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Load Monitor Tab Field Descriptions
Bridge 1 Description
Signal Strength Icon
Status Window
Net/Gross Toggle
Peak Value Reset
Valley Value Reset
Estimated Remaining Battery Life
Net/Gross Mode Indication
Units Selection
Tare Set
Sensor Display Zero
Bridge 1/2 Description: Configuration tab text field as assigned for user.
Status Window: Indicates communication status, Upper / Lower Limit condition, Over and Under Range
conditions. During normal operating conditions, the Status window is hidden.
Searching – wait period message during sensor / gateway communication synchronization
(may take up to 3 minutes)
No Comms – indicates no communication between gateway and sensor
OVER-RANGE – sensor A/D maximum exceeded
UNDER RANGE – sensor A/D minimum exceeded
Upper Limit Exceeded – Set on Configuration tab
Lower Limit Exceeded – Set on Configuration tab
Net/Gross Toggle: Enables user to switch between Gross and Net measurements based on user Set Tare
NOTE: If closed and re-opened at any time, the application will always open in the Gross
mode.
Peak Value Reset: clears the last stored peak reading.
Valley Value Reset: clears the last stored valley reading.
Sensor Display Zero: The Zero icon is used to null the sensor display with no load applied and is stored in
non-volatile memory within the Strainsert Load Monitor application. The allowable Zero Limit can be
changed on the Configuration tab. The default value is 5%. The maximum allowable Zero Limit is 40% of
the full scale range of the sensor A/D.
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Signal Strength Icon: color coded indication of relative transmission quality
Estimated Remaining Battery Life: percentage display of battery strength (remaining battery life is
relative to consumption; displayed percentage of battery output)
Net/Gross Mode Indication:
N – Indicates Net Mode
G – indicates Gross Mode
Units Selection: user selected engineering units set on Configuration tab with Units drop down. Default
units are “lbs”
Tare Set: stores the user applied tare weight in non-volatile memory within the Strainsert Load Monitor
application.
NOTE: The user can Tare up to the full range of the sensor A/D. However, the usable span of
the sensor is limited by the amount of Tare.
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Configuration Tab Field Descriptions
Enables Bridge #1 /#2 Display on
Load Monitor Tab
Enables Peak / Valley Display on
Load Monitor Tab
Bridge #1 /#2 Load Monitor Tab
Labels
Sensor Serial Number: user enters
exact serial number of sensor.
Note: Serial Number is the ID
required for the Load Monitor
application to synchronize with the
sensor receiver / transmitter.
Found on sensor nameplate
and/or Strainsert Calibration
Certificate
Note: “Q” is not required
Enter numeric found after the
dash in the serial number
If no letter suffix is included in
the serial number, leave blank.
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Upper Limit / Lower Limit– when
checked, allows the user to change the
Upper/ Lower Limit warning thresholds;
a Status Window is triggered on Load
Monitor Tab.
Defaults to unchecked;
Upper Limit defaults to sensor capacity
and cannot be edited if check box is left
unchecked.
Lower Limit defaults to 0 and can be
edited independent of the check box
Units selection drop down – defaults to
“lbs”.
User can choose from different engineering
units for display on the Load Monitor tab
Upper / Lower Limits are recalculated
based on the selection of units
Resolution – is the minimum unit of change
displayed on the Load Monitor tab (i.e.
100, 1000, etc.)
The choice of Resolution in the drop down
is limited by the sensor capacity, sensitivity
and the range of the A/D. The application
will determine what choices are allowed in
the drop down.
Multiplier defaults to 1.000000.
Can be used for custom scaling.
Note: When Multiplier is not
equal to the default, an “M” will
be displayed to the left of the
Net/Gross icon on the Load
Monitor tab
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Raw Count – When checked provides the user with the ability
to see the A/D counts for both bridges #1 / #2.
Defaults to unchecked
Capacity: 2,457 (Uni-polar Mode) / 1,229 (Bi-polar Mode)
A/D Over Range: 3,768 counts
A/D Under Range: 327 counts
Zero Limit – allowable percentage that can be
used to null the sensor output. This value is
stored within the application and is retained until
the user activates a new Zero.
Note 1: Default value is 5%
Note 2: The Zero amount is based on the absolute
full scale output of the A/D operating range.
Removes all sensor information
including Serial Number entries and any
previously saved configuration settings.
Resets all configuration settings
to original defaults but retains
serial number information.
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Transmission Range – there are two range selections:
1. Standard Range (default)
2. Short Range (sensor to transmitter distances
< 30-ft)
Save Configuration Settings –
user must save all configuration
changes after edits for changes
to take effect.
Password Protection – entry of a password disables
changes to the Configuration and Field Calibration tabs
Note: User must Save Configuration Settings prior to
attempting to set password
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Field Calibration Tab Field Descriptions
Device List – select sensor to be field calibrated from
the drop down
Shows a selected sensor
Select Bridge to be field calibrated
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Multiplier For Selected Sensor – displays the
Multiplier entered on the Configuration Tab.
Start Field Calibration – icon initiates the field
calibration sequence
Current Reading Resolution – gives the user the
ability to adjust precision during field calibration
to increase accuracy.
Current Reading (lbs) – displays the current live
weight reading.
Reset To Factory Defaults – pressing this icon
resets the field calibration back to the factory
default
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Field Calibration Procedure
1. Open Field Calibration Tab.
2. Select sensor serial number and bridge from the Device List on the Field Calibration tab.
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3. Click on Start Field Calibration icon.
Note: User can abort calibration at any time by pressing Cancel.
4. At prompt, remove all loads from the sensor including any tare weight.
5. At prompt, press OK to record the zero output at no load
6. If necessary, add any required tare load at this time.
7. Enter Applied Load into numeric field and press OK.
NOTE: Applied Load must be between 40 – 100% of the sensor capacity.
8. After prompt, pick up calibration load, wait for load to stabilize and press OK.
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9. Wait for prompt and press OK for acceptance or Cancel to abort.
10. Field Calibration is complete.
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Data Logging
Select Sensors To Log – select sensor to data log
by checking the appropriate box
Logging Duration – select Hours, Minutes and
Seconds for required data logging period
Recording Frequency – select Hours, Minutes
and Seconds for required recording interval
Data Log File Path – defaults to
C:\Strainsert_Log\LogFile_Startdate.txt
Note: user has option to rename file or change
file path by clicking on … icon.
Start Logging – press icon to commence
immediate data storage
Reset Log File Path – press icon to restore file
path to factory default.
Data Logging File Format – comma delimited text file
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Battery Installation / Replacement
1. Locate Battery cover and unscrew.
2. Pull battery from compartment.
3. Pull wires from the cavity around the battery compartment, thru slots.
4. The connector distance from the circuit board will only extend 2.5” from the end of the cover
plate.
5. Depress the clip on the connector to disconnect and remove the battery.
6. Firmly attach new battery connector to ensure connector clip locks in place.
7. Install wire and connector ahead of the battery.
8. Wires and connector need to be tucked into the cavity through the battery compartment.
9. The spring at the bottom of the battery compartment must be free of wires to freely compress.
10. With the battery in the compartment, securely tighten cap, which must have its o-ring installed
and properly seated, to provide an environmental seal.
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Troubleshooting
Problem
Possible Cause
Possible Solution
Wrong or invalid serial number
Verify serial number on sensor matches entry on
Configuration tab
Damaged or missing antenna
Verify antenna connection at both the sensor and
the gateway
Improper signal range selection
Change the range selection on the Configuration
tab. <30-ft “Short Range” and >30-ft “Standard
Range”
Obstructed RF signal path
Reposition antenna on either or both the sensor
and / or gateway.
Damaged sensor and / or gateway
Call Factory
Depleted or damaged battery cell
Remove and replace battery cell at sensor
Gateway / sensor communication
lock
Cycle sensor battery connection, Cycle gateway
USB and restart application
Sensor applied load exceeds
approximately 40% of rated
capacity
Remove applied load; call factory
Sensor bridge circuit possibly
damaged
Call Factory
No Communication
For a sensor configured for bi-polar Remove applied load; call factory
operation, applied load exceeds
approximately 40% of rated
capacity.
For a sensor configured for unipolar operation, applied load in
reverse direction exceeds
approximately 10% of rated
capacity
Check sensor orientation or applied load direction.
Sensor bridge circuit possibly
damaged
Call Factory
Page 35 of 37
Problem
No changes to displayed
readings in response to
change in applied load
Possible Cause
Possible Solution
Sensor bridge circuit possibly
damaged
Call Factory
Erratic displayed readings Sensor bridge circuit possibly
in response to stable
damaged
applied load
Call Factory
Page 36 of 37
Customer Support
Since 1960 Strainsert has pioneered the force transducer industry. Today, we continue to champion the
industry with our knowledgeable and dedicated technical, sales and manufacturing team. For application
assistance, product information, and troubleshooting contact Strainsert.
General Contact Information
Phone: 610-825-3310
Fax: 610-825-1734
Mailing Address:
12 Union Hill Road
West Conshohocken, PA 19428
Website: www.strainsert.com
E-Mail: [email protected]
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