Kistler 9230AT025 KiTorq DS Transmitter Wireless torque measuring system Owner's Manual

Instruction
Manual
KiTorq DS
System
KiTorq DS
Transmitter
Type 9230AT
KiTorq DS
On-board Receiver Unit
Type 9230AR
9230A_002-976e-02.24

Foreword
Foreword
Thank you for choosing a Kistler quality product
characterized by technical innovation, precision and long
life.
The information in this manual is subject to change without
notice. To keep pace with technical advancement, Kistler
reserves the right to make improvements and changes
to the product without obligation to notify any person or
organization of such changes.
© 2022 ... 2024 Kistler Group. Kistler Group products are
protected by various intellectual property rights. For more
details visit www.kistler.com. The Kistler Group includes
Kistler Holding AG and all its subsidiaries in Europe, Asia,
the Americas and Australia.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
[email protected]
Kistler Instrumente GmbH
Business Unit Vehicle Testing
Umberto-Nobile-Str. 14
71063 Sindelfingen
Germany
Tel. +49 7031 3090 0
[email protected]
www.kistler.com
9230A_002-976e-02.24
Page 1
KiTorq DS System, Type 9239AT... and Type 9230AR...
Contents
1.
Introduction..................................................................................................................................4
2.
Important notes............................................................................................................................5
2.1
For your safety.....................................................................................................................5
2.2
Disposal instructions for electrical and electronic equipment..............................................7
2.3
Handling of the KiTorq DS Transmitter Type 9230AT...........................................................8
2.4
Software upgrades and updates........................................................................................11
3.
Product description...................................................................................................................12
3.1
Overview............................................................................................................................12
3.2
System overview...............................................................................................................13
3.3
Accessories.......................................................................................................................14
3.4
Further documents............................................................................................................14
4.
Technical data............................................................................................................................15
4.1
Specifications KiTorq DS Transmitter, Type 9230AT... ......................................................15
4.2
Specifications On-board Receiver Unit, Type 9230AR......................................................16
5.
Installation and connections....................................................................................................17
5.1
Description of the KiTorq DS Transmitter, Type 9230AT... ................................................17
5.2
Assembly of the KiTorq DS Transmitter, Type 9230AT......................................................17
5.3
Description of the On-board Receiver Unit, Type 9230AR................................................18
6.
Commissioning..........................................................................................................................20
6.1
Charging the KiTorq DS Transmitter, Type 9230AT...........................................................20
6.2
Installing the KiTorq DS Transmitter..................................................................................22
6.3
Installation of the On-board Receiver Unit Type 9230AR..................................................24
6.4
Connecting to network.......................................................................................................27
6.5
Pairing of KiTorq Transmitter and On-board Unit...............................................................27
6.6
System setup using KiCenter............................................................................................29
6.7
Firmware update................................................................................................................43
Page 2
9230A_002-976e-02.24

7.
Troubleshooting.........................................................................................................................44
7.1
Cables and power supply..................................................................................................44
7.2
On-board Unit status display and LED .............................................................................44
7.3
Software............................................................................................................................44
7.4
CAN...................................................................................................................................45
7.5
Environmental conditions..................................................................................................45
7.6
EMC interference...............................................................................................................45
7.7
Service...............................................................................................................................46
8.
Maintenance and cleaning........................................................................................................47
8.1
Maintenance......................................................................................................................47
8.2
Cleaning............................................................................................................................47
9.
Other information.......................................................................................................................48
10.
Appendix.....................................................................................................................................49
11.
EU declaration of conformity....................................................................................................54
Total pages 55
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
1.
Introduction
Thank you for choosing a quality product from Kistler.
Please read through this manual thoroughly to enable you
to fully exploit the various features of your product.
To the extent permitted by law Kistler accepts no liability
if this instruction manual is not followed or products other
than those listed under Accessories are used.
Kistler offers a wide range of measurement products
through to turnkey solutions:
ƒ Piezoelectric sensors for measuring pressure, force,
torque, strain, acceleration, shock and vibration
ƒ Strain gage sensor systems for measuring force and
torque
ƒ Piezoelectric pressure sensors and transmitters with
matching measuring amplifiers
ƒ Matching measuring amplifiers (charge amplifiers,
piezoresistive amplifiers, etc.), displays and charge
calibrators
ƒ Electronic control, monitoring and evaluation units as
well as software for specific measurement applications
ƒ Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions
for the application fields engines, vehicles, manufacturing,
plastics and biomechanics sectors.
Our product and application brochures will provide you
with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found
either on-line or in this manual, please contact Kistler‘s
extensive support organization.
Page 4
9230A_002-976e-02.24
Important notes
2.
Important notes
This symbol stands for notes that enable
more effective and economical use of the
KiTorq DS system.
This symbol indicates which, if not followed,
may result in damage to the system or other
machinery, equipment, people and the
environment.
The warning of the danger must be heeded
and it must be met with the necessary
caution or care..
This symbol warns of a danger zone. It
is displayed on all safety warnings where
danger to life and limb for the operator or
other personnel exists. Strictly comply with
these instructions and act with particular care
in these cases. Pass all safety instructions
on to other users.
A recommendation is given to the customer
to use the product efficiently
2.1
For your safety
Observe the following remarks before you commission
the device. Kistler accepts no responsibility for damages
that could arise from improper use of this product.
Prerequisite for the proper and safe use of the device
is that it is correctly stored, professionally installed and
commissioned, as well as operated as intended and
carefully maintained.
Only persons who are familiar with the installation,
commissioning, operation and maintenance of comparable
devices and who possess the qualifications necessary for
the given task may work with the device.
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
Mounting a device on the outside of the vehicle may
invalidate the general operating permit of the vehicle
for use on public roads. Observe the relevant legal
requirements!
Risk of injury!
Do not mount the KiTorq DS On-board Receiver Unit,
monitor(s), or any other item in any location that may
come into contact with the airbag in the event of air bag
deployment.
If the KiTorq DS On-board Receiver Unit, monitor(s),
or any other item is placed in the passenger seat,
deactivate the air bag to prevent accidental contact with
the airbag in the event of air bag deployment.
Equipment must be mounted firmly and securely.
Improper use or mounting of the equipment may
affect the safety of the vehicle and/or occupants. The
equipment must not be mounted and/or operated in
any way that may compromise vehicle and/or occupant
safety.
Do not use defective or damaged equipment,
components and/or accessories.
Do not modify or change the equipment or its
accessories in any way.
Always observe the correct operating voltages when
connecting the equipment (power supply, data acquisition
and evaluation systems and other system components).
Use only original equipment, components and/or
accessories included in the scope of delivery.
We recommend using only the cables included in the
scope of delivery. If you think it is necessary to use
your own cables, take special note of the correct pin
assignment.
Kistler assumes no liability for damages caused due to
the use of cables other than those delivered by Kistler.
Page 6
9230A_002-976e-02.24
Important notes
Before and after each measuring run, check whether the
transmitter unit is still attached and undamaged.
Only use the device as specified. Otherwise, the protection
supplied by the device can be compromised.
For additional information, please contact Kistler:
+49 7031 3090 0
[email protected]
2.2
Disposal instructions for electrical and electronic equipment
Do not dispose of old electronic instruments in municipal
trash. For disposal when the product has come to the
end of its service life, please return it to an authorized
local electronic waste disposal service or contact
the nearest Kistler Instrument sales office for return
instructions.
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
2.3
Handling of the KiTorq DS Transmitter Type 9230AT...
The transmitter unit consists of two half-shells. A battery
half-shell and a telemetry half-shell. The battery half-shell
contains the Li-Ion batteries. The telemetry half-shell
contains the transmitter.
2.3.1 Further documents
UL (Underwriters Laboratories Inc.):
ƒ Standard for Lithium Batteries
ƒ UL 1642 - Fifth Edition, March 2012
UN (United Nations):
ƒ UN Recommendations on the Transport of Dangerous
Goods; Model Regulations.
ƒ UN Recommendations on the Transport of Dangerous
Goods; Manual of Tests and Criteria; Part III, subsection 38.3.
IEC (International Electrotechnical Commission):
EC62133-2:2017 specifies requirements and tests for
the safe operation of portable sealed secondary lithium
cells and batteries containing non-acid electrolyte, under
intended use and reasonably foreseeable misuse
2.3.2 Storing the KiTorq DS Transmitter
During storage, the two parts of the KiTorq DS Transmitter
must be separated.
Do not store the transmitter when mounted!
The seals cannot relieve themselves and watertightness
during reassembly is not guaranteed. Likewise, the
transmitter unit can be switched on unintentionally by the
vehicle unit.
Self discharge
Temperatures above room temperature can cause
increase self-discharge, which reduces the available
capacity of the cell.
Humidity above 95% RH should also be also be avoided
over a longer period of time.
Storage temperature
For optimal storage (longer than 3 months), the
recommended storage temp. of –20 to 25°C should not be
exceeded. Furthermore, protect from direct sunlight and
store in a dry, clean and well-ventilated place.
Page 8
9230A_002-976e-02.24
Important notes
Storage outside of these temperatures can lead to a
greater amount of self discharge, lower performance and
swelling of the battery cells.
Minimum charge level during storage
A minimum charge level of between 7.30 V - 7.50 V
(per cell 3.65 V - 3.75 V) at the beginning of storage is
necessary to prevent deep discharge.
If the battery volatage is close to the minimum charge
level of 6 V or 3 V/cell or even slightly below, the battery
must be charged as soon as possible to avoid irreversible
damage.
Charge the transmitter wth the supplied USB cable.
For safety reasons the charging electronics will only start
to recharge batteries whose cells have not fallen below a
critical voltage level.
A deep discharge (below 6.00 V – per cell 3.00 V) can
seriously and irreversibly influence the performance and
service life of the battery!
If the battery is to be stored for more than 3 months to
less than one year, proceed as follows:
ƒ Regular monitoring of the battery voltage, at least
once every 6 months
ƒ If necessary: Charge the battery up to 50 % of its
capacity
2.3.3 Using the KiTorq DS Transmitter after a long storage period
After a long storage period, the following procedure is
recommended:
ƒ Discharge the battery completely
ƒ Preferably, run a complete charge / discharge cycle.
Otherwise, it may take 2 to 3 cycles until the maximum
capacity is available again
ƒ Completely charge the battery
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
2.3.4 Safety information
ƒB
atteries may explode or cause burns, if disassembled,
crushed or exposed to fire or high temperatures.
ƒ Do not short or install with incorrect polarity.
ƒ Replace the battery only with the battery provided by
Kistler. Use of another battery may present a risk of fire
or explosion.
ƒ Caution – The battery used in this device may present
a risk of fire or chemical burn if mistreated. Do not
disassemble, heat above 100°C, or incinerate.
ƒ Dispose of used battery promptly. Keep away from
children.
ƒ Do not disassemble and do not dispose of in fire. Do
not exceed the maximum charging voltages, currents
and temperatures listed above.
2.3.5 Transporting the KiTorq DS Transmitters
Legal conditions
Due to the lithium ion battery installed, the KiTorq DS
Transmitters must be shipped as hazardous materials.
The UN number UN 3481 applies.
It is necessary to find out about details in the regulations
themselves.
The regulations as listed below are authoritative.
They must be complied with by the shipper on his own
responsibility for each commercial shipment of lithium-ion
batteries.
In particular, the energy content, along with other criteria,
is decisive in determining which dangerous goods
regulations or exemptions must be taken into account for
the transport of lithium-ion batteries.
The following regulations apply to the various modes of
transport:
ƒ Road / Rail: ADR/RID
ƒ Sea freight: IMDG COde
ƒ Air freight: IATA DGR
Page 10
9230A_002-976e-02.24
Important notes
The regulations are updated every one to two years.
Lithium-ion batteries are classified as follows:
ƒ UN 3480 Lithium-ion batteries
ƒ UN 3481 Lithium-ion batteries in equipment
ƒ UN 3481 Lithium-ion batteries packed with equipment
In individual cases, the involvement of a dangerous goods
expert may be necessary.
The interpretation and enforcement of the relevant
regulations is the responsibility of the authorities of
the federal states, which may, within the scope of their
discretion, make their own decisions, including decisions
that deviate from these instructions.
What should be considered when returning the goods?
The sender, the carrier and also, if applicable, the client
of the sender are responsible for the proper transport. In
principle, the same regulations apply to return shipments
as listed above.
Despite the greatest possible care in editing and writing
these recommendations, no liability can be accepted for
the content and completeness of these statements.
2.4
Software upgrades and updates
Kistler may occasionally supply upgrades or updates for
embedded software. Such upgrades or updates must
always be installed.
Kistler declines all liability for any direct or consequential
damages caused by products running on embedded
software that has not been upgraded or updated to the
latest available version.
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
3.
Product description
3.1
Overview
The KiTorq DS is Kistler's telemetry solution to measure
torque by means of strain gauge technology especially in
vehicle powertrains.
The modular design of the transmitter housing, that is
mounted to the rotating shaft detachably, allows for long
term reusablity of the transmitter module and power
supply (battery or accumulator). This innovative approach
leads to low operating costs of the system and contributes
to sustainability right at the very beginning of vehicle
development.
When used in conjunction with Kistler's wheel puls
transducers (WPT), the KiTorq DS can be used to
determine the drive power applied to each individual wheel
of vehicle and thereby to evaluate powertrain losses.
Kistler's KiCenter software is used to configure a
KiTorq DS measurement chain. Likewise it can be
employed as a data aquisition (DAQ) system which allows
for running a KiTorq DS as a stand alone solution.
The KiTorq DS ECU features both a CAN and a Kistler
DTI (Digital Transducer Interface) output making it easy
to integrate a KiTorq DS in a more comprehensive
measurement task.
Fig. 1:
Page 12
KiTorq DS On-board Receiver Unit, Type 9230AR
9230A_002-976e-02.24
Product description
3.2
Fig. 2:
KiTorq DS Transmitter, Type 9230AT
Fig. 3:
System overview of the KiTorq DS System
System overview
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
3.3
Accessories
3.3.1 Inculded accessories Transmitter
Ordering No.
Components
1x USB cable 2.0, Type A - C, L = 2 m
55247553
Transmitter 25 mm *:
– 4x screw M3x16
– 4x Loss Protection M3
55061187
55267217
Transmitter from 30 to 35 mm *:
– 4x screx M3x16, Tuflok Coating
– 2x screw M3x16
– 4x Loss Protection M3
55259772
55247052
55267217
Transmitter from 40 to 50 mm *:
– 4x screw M4x16, Tuflok Coating
– 2x screw M4x16
– 4x Loss Protection M4
55259723
55247053
55267218
* Screw head varies depending on the diameter of the transmitter
(25 mm: Hexagon socket; >25 mm: Hexalobular)
3.3.2 Included accessories On-board Receiver Unit
Ordering No.
Component
Power cable 2 m DTI sensor 8-pin LEMO
55155612
USB cable 1.8 m (LEMO → USB)
55155609
Ethernet cable 2 m (LEMO → RJ45)
55155608
CAN cable 2 m (LEMO → D-Sub 9-pin)
55155606
2x antenna, 2.4 GHz, with 7 m cable
55258179
KiCenter Software
18025602
Transport case for KiTorq DS
55258307
Parallel Pin Punches with guide sleeve
55259684
Set of screws for electronics
55123001
3.3.3 Optional accessories
Ordering No.
Component
3.4
Cable yellow/green 1m to car chassis
55259696
Wheel pulse transducer (WPT sensor)
CWPTA...
DTI cable, l = 0.5 m (LEMO → LEMO)
55155607
Analog cable, 1.5 m (LEMO → 8 x BNC)
55249611
Adapter sleeves
on request
Further documents
ƒ 002-609d - KiCenter – Installation Instructions
ƒ 003-616e - Datasheet KiTorq DS battery
Page 14
9230A_002-976e-02.24
Technical data
4.
Technical data
4.1
Specifications KiTorq DS Transmitter, Type 9230AT...
System specifications
Operating temperature range
°C
Power supply
Number of load cycles (0.5C/0.5C @21 ±2 °C)
–20 ... 60
Lithium-Ion battery
cycles
300
(~80 % of capacity)
Wireless standard
ISM band
GHz
2 402 ... 2 480
Transmitted channels
Torque
Nm
Temperature
°C
Battery voltage
V
Torque
Temperature
Voltage
Resolution
Bit
16
Battery operating time
h
≥24
Strain gauge
Ω
350 ... 1 500
Power supply
V
5
Sampling rate
Hz
1 000
Signal bandwidth
Hz
400
Channel torque
Temperature channel
Resistance temperature detector
PT100
Wiring
4-wire configuration
Constant current
mA
1
Input voltage range
mV
0 ... 0.625
Sampling rate
Hz
5
Pollution level
2
Use of the transmitter unit
Maximum altitude
9230A_002-976e-02.24
outdoor
m
2 000
Page 15
KiTorq DS System, Type 9239AT... and Type 9230AR...
4.2
Specifications On-board Receiver Unit, Type 9230AR...
System specifications
Dimensions (LxWxH), approx.
mm
Weight
grams
Operating temperature range
°C
Power supply
VDC
Power consumption max.
W
8,4
Inrush current
A
3
Wireless standard
171 x 126 x 95
1 120
–20 ... 50
12 ... 26
ISM band
GHz
2 402 ... 2 480
Bridging time
s
approx. 15
Switch-off delay
s
approx. 35
Latency of transmission
ms
Pollution level
2
Use of On-board Receiver Unit
Maximum altitude
221
indoor
m
2 000
to 31°C
%
80
40°C (linearly decreasing)
%
50
Maximum relative humidity
Data outputs
Digital output – CAN
CAN Bus – 2 nodes
2.0B
Baud rate
MBd
0.125 ... 1
Resolution (ADC)
Bit
16
Bit
16
Digital output – DTI
Resolution (ADC)
Analog output
Output range (selectable)
V
Resolution
Bit
16
USB (Full Speed)
2.0
Ethernet TCP/IP
yes
Torque,
temperature,
battery voltage
Transmitted measurement channels per wheel
Output rate
Page 16
±10 (±5, 0 ... 5, 0 ... 10)
Hz
1 000
9230A_002-976e-02.24
Installation and connections
5.
Installation and connections
5.1
Description of the KiTorq DS Transmitter, Type 9230AT...
Fig. 4:
5.2
KiTorq DS Transmitter, Type 9230AT...
1
LED display of the bridge supply
2
USB charging port
3
Status LEDs
Assembly of the KiTorq DS Transmitter, Type 9230AT
9230A_002-976e-02.24
Page 17
KiTorq DS System, Type 9239AT... and Type 9230AR...
For the assembly of the Transmitter the following parts
are needed:
ƒ 1x Battery half shell
ƒ 1x Transmitter half shell
ƒ 1x Pin punches
ƒ 1x Axis
ƒ Silicone grease (optional)
Put the two half shells together, so that the axis can be
pushed through the hinges.
The pin punches support the demnounting of the axis.
5.3
Description of the On-board Receiver Unit, Type 9230AR...
Fig. 5:
Page 18
KiTorq DS On-board Receiver Unit
9230A_002-976e-02.24
Installation and connections
a
Display
b
CAN
c
Analog output
d
Power / DTI
e
Ethernet / USB
f
WPT connections
g
Zero buttons
h
Antenna connections
Short-term undervoltages are bridged by the integrated
UPS.
If several On-board Receiver Units are used, only one
can be connected to the measurement computer via USB!
Otherwise, there are undefined system states due to IP
conflicts.
9230A_002-976e-02.24
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KiTorq DS System, Type 9239AT... and Type 9230AR...
6.
Commissioning
6.1
Charging the KiTorq DS Transmitter, Type 9230AT...
The KiTorq DS transmitter can be charged while
assembled.
Charge the transmitter only at ambient temperature
between 0 and 45°C
The optimal charging is between 4.8 ... 6 V with 1.5 A.
WARNING
During charge mode this product is a Class A* emission
product.
In charge mode this device may cause radio interference
in residential areas; in this case, the operator may be
required to take appropriate measures (Emission in
range 30 MHz to 1 GHz are over the limits of Class B*)
* Class A (higher emission limits, industrial area)
Equipment suitable for use in establishments other than
domestic and those directly connected to a low voltage
power supply network which supplies buildings used for
domestic purposes.
* Class B (lower emission limits, residential area)
Equipment for use in domestic establishments, and
in establishments directly connected to a low voltage
power supply network which supplies buildings used for
domestic purposes.
Use only a USB power supply for industrial or medical
environment!
Fig. 6:
Page 20
KiTorq DS Transmitter with USB charging cable
9230A_002-976e-02.24
Commissioning
Connect the power supply (for industrial or medical
environment) unit to the mains voltage, then plug the
USB-C connector into the transmitter unit.
If monitoring of the charging current is required, the use of
a power supply unit with a current display is recommended.
Fig. 7:
Charging device LEDs
Green
A supply voltage is applied.
Red
On:
Charging in progress
Off:
fully charged
Flash:Error, charge interrupted (temperature out of
charge range, temperature error, input voltage
too high, NTC error, timer error, µC error, battery
voltage too high)
After the battery is fully charged, disconnect the charging
cable from the transmitter and re-insert the protection plug
onto the transmitter.
Fig. 8:
9230A_002-976e-02.24
Transmitter, power plug
Page 21
KiTorq DS System, Type 9239AT... and Type 9230AR...
6.2
Installing the KiTorq DS Transmitter
The transmitter consists of two parts:
ƒ Transmitter
ƒ Battery package
C
A
B
Fig. 9:
KiTorq DS Transmitter, connections
A) Connection to the strain gauge via pogo pins
B) Connection to the battery package
C) Connection code (yellow label)
Fig. 10:
Page 22
KiTorq DS Transmitter, Battery package
9230A_002-976e-02.24
Commissioning
Align all parts properly before you start to assemble them.
Make sure that they fit into one another without using any
force.
Once the termination sleeve has been glued to the shaft
and the adhesive has hardened completely, the two halfshells of the transmitter housing can be mounted to the
shaft. The step by step mounting procedure is illustrated
in Fig. 16).
Fig. 11:
Installing the KiTorq DS Transmitter, Battery package
To begin with, place the two half shells on top of each
other and connect them with the supplied axle. Now the
transmitter unit can be placed on the adapter shell and
fastened with the supplied screws. For this purpose, we
recommend the screws with Tuflok coating.
Fig. 12:
9230A_002-976e-02.24
Installing the KiTorq DS Transmitter
Page 23
KiTorq DS System, Type 9239AT... and Type 9230AR...
6.3
Installation of the On-board Receiver Unit Type 9230AR...
The On-board Unit has to be positioned and secured in
the interior of the vehicle.
Risk of injury!
Do not mount the KiTorq DS On-board Receiver Unit
or any accessories in any location that may come
into contact with the airbag in the event of air bag
deployment.
If the KiTorq DS On-board Receiver Unit or any other
item is placed in the passenger seat, deactivate the air
bag to prevent accidental contact with the airbag in the
event of air bag deployment.
Equipment must be mounted firmly and securely.
Improper use or mounting of the equipment may
affect the safety of the vehicle and/or occupants. The
equipment must not be mounted and/or operated in
any way that may compromise vehicle and/or occupant
safety.
The On-board Receiver Unit must be conductively
connected to the vehicle ground/body. vehicle body.
If this is not already given by a mounting bracket, the
optional connection cable (55259696) must be used for
this purpose. be used for this purpose. Connect the cable
to an M2.5 thread of the front panel and to the body
using the enclosed mounting and check for conductivity.
The CAN bus for the KiTorq DS On-board Receiver Unit
is equipped with a 120 Ω termination resistor! The
resistance can be switched on / off via KiCenter, see
chapter 6.7.7.
Page 24
9230A_002-976e-02.24
Commissioning
6.3.1 General installation of the On-board Receiver Unit Type 9230AR...
The receiver unit is connected to the vehicle's power
supply. The power plug must be accessible at all times. In
the event of a faulty function, this plug must be pulled out.
Connect the power cable to a fused power supply of the
vehicle. The voltage values must match the unit (12-26
VDC) and the fuse must have a current rating of 5A.
Fig. 13:
On-board Receiver Unit installation – power supply
CAN or ANALOG
Use CAN or analog cable to connect to a data acquisition
system.
ETH or USB
To configure the system conncet it to a PC either via an
Ethernet or USB cable.
9230A_002-976e-02.24
Page 25
KiTorq DS System, Type 9239AT... and Type 9230AR...
ANT 1 and ANT 2:
Connect the antenna to the ANT 1 or ANT 2 connector
with a maximum with a maximum torque of 1 Nm.
Important Information on the installation of the antennas:
(Add picture from Folie 23)
ƒ Mount antennas as close as possible to the transmitter
unit (about 10 cm away).
ƒ Do not mount antenna behind or on metal parts:
ƒ Antenna should be as free as possible
ƒ Establish "line of sight" between antenna and
transmitter unit
ƒ Keep a distance of more than 40 cm between two
transmitting units
ƒ Do not lay the antenna cable over sharp edges or kink
it.
ƒ Securely fasten the antenna cable so that it does not
slip during the measurement run
For configuration the system, see chapter 6.7
Only use original Kistler cables.
6.3.2 Optional: Mounting On-board Receiver Unit with DTI logger
Connect the DTI port to the DTI logger. Connect the DTI
logger to a PC via Ethernet to configure the system and to
be able to record measurement data.
For configuring the system, see Chapter 6.7
Page 26
9230A_002-976e-02.24
Commissioning
6.4
Connecting to network
Ensure that the Onboard Receiver Unit is connected to
the computer with a USB or Ethernet cable; For details,
see chapter 5.3.
If measurement data is to be recorded via the KiCenter,
an Ethernet connection is mandatory.
6.5
Pairing of KiTorq Transmitter and On-board Unit
Step 1
The transmitter half-shell is powered by the battery halfshell as soon as the half-shells are brought together. The
Transmitter will go to stand-by mode right after it has been
energized.
It is important, that the battery is charged.
Only screw or unscrew the antenna cable on the receiver
unit when it is switched off.
9230A_002-976e-02.24
Page 27
KiTorq DS System, Type 9239AT... and Type 9230AR...
Step 2
1. Connect antenna cable(s). (ANT1 and/or ANT2)
2. Connect analog cable (AO) or CAN cable (CAN) or
both (AO and CAN)
3. Connect the ETH/USB cable (two different cables
available with USB or RJ45 connector)
4. Connect the Power/DTI cable
5. Connect the USB or ETH to the PC
6. POWER the On-board Receiver Unit
Fig. 14:
On-board Receiver Unit – pairing: power on
It takes approx. 20 seconds until the device is ON!
This behavior relates to the uninterruptible power supply
(UPS).
Fig. 15:
Page 28
On-board Receiver Unit installation – pairing: booting
9230A_002-976e-02.24
Commissioning
7. On-board Unit is booting.
8. After the boot process – the On-board Unit is showing
the IP address. Note it down; you will need it for the
device configuration in KiCenter.
9. “Browse All” in the KiCenter software.
10. Transmitter is connected to the Receiver if the
GREEN LED is ON.
11. The On-board Receiver Unit and the transmitter have
to be recognized by KiCenter. See next chapter for
more information.
12. If it is the first connection: write the connection code in
the sensor configuration.
ID addresses change when the system is connected via
USB, Ethernet or without cable.
6.6
System setup using KiCenter
For the configuration of the receiver unit, the use of the of
the KiCenter software is required. In addition to the system
and sensor settings, it also includes other functions for
managing sensors and settings. The software also offers
the option to record the measurement data.
Always use the current version of KiCenter. Check the
Kistler website www.kistler.com periodically for any
updates.
6.6.1 KiCenter: system requirements
ƒ Operating system: Windows 10
ƒ 1-GHz processor or higher with 32 Bit (x 86) or 64 Bit
(x 64)
ƒ Mind. 4 GB RAM
ƒ 500 MB free hard disk space
ƒ For using the measurement functionality, a more
powerful configuration is recommended (e.g. Intel Core
i5 8th generation with 8 GB RAM)
9230A_002-976e-02.24
Page 29
KiTorq DS System, Type 9239AT... and Type 9230AR...
For information see the KiCenter installation manual no.
002-609e.
Windows is a registered trademark of Microsoft Corporation.
Intel is a registered trademark of Intel Corporation.
Page 30
9230A_002-976e-02.24
Commissioning
6.6.2 KiCenter: sensor and system settings
After KiCenter starts, the KiTorq DS On-board Receiver
Unit will have a green status in the "Device Tree" with its
serial number. If this is not the case, click the "Browse
All" button again to search for connected devices. If it still
does not connect after doing this, check the USB or LAN
cable connection as well as the IP adress of the KiRoad
Wireless Onboard Unit and the network settings of your
computer.
All data and changes made in the KiCenter user interface
or the web browser are only transferred to the KiTorq DS
On-board Receiver Unit after you have clicked the "Save
to Device" button. As long as this has not been done, the
changes are only temporary and will be discarded when
they are loaded again with "Refresh from Device" or after
the system is restarted.
Fig. 16:
9230A_002-976e-02.24
KiCenter screen view of the Status Page
(Device Tree)
Page 31
KiTorq DS System, Type 9239AT... and Type 9230AR...
A node and 4 pages are displayed in the "Device Tree":
ƒ Measurement Display
ƒ Sensor Configuration
ƒ Sensor Calibration
ƒ CAN Bus
as well as the sensor designation and the serial number.
The following pages explain the options for system
configuration, operation and data display.
In the Device Tree, click the node for the KiTorq DS
On-board Receiver Unit. This calls up the System Status,
which provides an overview of the connected wheel
torque sensors as well as their status.
Fig. 17:
KiCenter screen view of the Status Page
(Device Tree)
ƒ The default view is divided into tiles
- System status
- Unit of the torque transmitter unit (max. 2x)
ƒ Network IP: the TCP/IP address for the on-board unit
ƒ DHCP: Status as to whether DHCP is on or off
ƒ Total operating hours: displays the cumulative
operating hours for the on-board unit
ƒ Operating hours in the service interval: displays the
cumulative operating hours for the On-board Unit
since the last service interval with Kistler
Page 32
9230A_002-976e-02.24
Commissioning
A
Fig. 18:
KiCenter screen view of the Status Page (Device
Tree)
The wheel torque transducer tiles display the most important, current measured values for the individual wheel
torque transducers as well as additional information:
ƒ Connection Code: the different codes of the
connection
ƒ Operating Mode:
ƒ Torque: the currently measured torque in [Nm]
ƒ Voltage: the current battery voltage in [V]
ƒ RSSI: the signal strength of the wireless transmission
in [dBm]
A) Set Sleep: switch the transmitter in the standby mode
9230A_002-976e-02.24
Page 33
KiTorq DS System, Type 9239AT... and Type 9230AR...
Voltage lower than 7 V leads to a "low voltage" warning
message on the receiver unit and in the KiCenter.
Voltage lower than 6.3 V leads to the receiver unit
switching off the transmitting units by the receiving unit
(sleep mode).
If the voltage falls below 6.2 V, a hardware undervoltage
shutdown.
Note: Set alarm to voltage!
A signal strength above –50 dBm indicates good
transmission quality.
A signal strength of less than –70 dBm means there is
weak signal quality and can lead to breaks in the signal.
In this case, check the installation of the antennas.
If you save the settings of the device via the KiCenter
("Save to device"), the transmitting units are woken up
again.
6.6.3 KiCenter: measurement display
B
Fig. 19:
Page 34
KiCenter screen view -- Measurement Display
9230A_002-976e-02.24
Commissioning
The measurement display is mainly used most of all
to monitor the correct functioning of the system. Thus
the system status and the current measuring range are
displayed.
In addition, the measurement data for the individual
KiTorq DS transmitter is displayed in order to check the
plausibility of the measurement data.
B) -> 0 <-: Reset (zero adjustment) of an individual
transmitter. This is only permanently saved in the
receiver unit by "Save to Device". permanently stored
in the receiving unit.
6.6.4 KiCenter: sensor configuration
Fig. 20:
KiCenter screen view -- Sensor Configuration
This sub-menu is used to configure the KiTorq DS
transmitter and the network settings
9230A_002-976e-02.24
Page 35
KiTorq DS System, Type 9239AT... and Type 9230AR...
Zero
Settings for zero point determination:
Activate averaging and its duration.
Deleting the stored zero point values.
Unit 1 / Unit 2
ƒ Connection Code: The connection code has to be
entered in the sensor configuration.
NOTE: The connection code is written on the
transmitter unit. The connection code is required for a
proper connection.
ƒ Gain: analog gain factor for the strain gauge
Factor 1: 16
Factor 2: 32
Wireless Channel
ƒ Recommendation to set different channels to avoid
interference between the transmitters (Unit 1 and
Unit 2)
– Channel 1: 2,402 GHz
– Channel 2: 2,415 GHz
– Channel 3: 2,428 GHz
– Channel 4: 2,441 GHz
– Channel 5: 2,454 GHz
– Channel 6: 2,467 GHz
– Channel 7: 2,480 GHz
ƒ Angular Encoder Steps: Option. For more information
refer to the WPT manual 002-612e.
Battery
Monitoring of the temperature of the transmitter unit by the
sensor in the telemetry module: The temperature of the
batteries must not exceed 60°C! The warning messages
are shown in the display of the receiver unit and in the
KiCenter. With other measurement technology, it is strongly
recommended to set up an alarm on the temperature signal.
Network Settings
DHCP Preset: Enabled.
This is used to manually assign an IP address if DHCP is
not to be used when using a LAN cable.
If the checkbox is checked, the system automatically
assigns the IP address and the subnet mask when it
connects to a DHCP server.
If the checkbox is not checked, the necessary settings
can be entered manually. To do this, contact your network
administrator.
Page 36
9230A_002-976e-02.24
Commissioning
With static IP address the device is detected much faster.
Fig. 21:
KiCenter screen view Sensor Configuration, Save To
Device
The IP numbers change depending on the cable and
whether a remote station is connected. This is indicated
by the display.
Use button "Save To Device" after any change!
9230A_002-976e-02.24
Page 37
KiTorq DS System, Type 9239AT... and Type 9230AR...
6.6.5 KiCenter: sensor calibration
Fig. 22:
This sub-menu is used for the settings for the
calibration and amplification factor.
If the torque value is displayed with a negative sign, an
inversion can be made by means of the switch.
The sensitivity is the factor of the calibrated shaft, which
should be fill in by the user.
Select the gain factor so that the desired measuring range
is achieved at the given sensitivity.
Page 38
9230A_002-976e-02.24
Commissioning
6.6.6 KiCenter: analog output
The output for the analog channels can be configured on
the "Analog Output" page. The desired leveling and offset
can be set here.
The analog outputs are only fully functioning when the
On-board Unit was purchased with the "Calibrated Analog
Outputs" option.
If the On-board Unit does not have calibrated analog
outputs, these can also be calibrated retrospectively.
Fig. 23:
KiCenter screen view -- Analog Output
Common
The output range can be set for all channels (+-10 V, 0-5
V, 0-10 V and +-5 V).
Enable Individual Output
By disabling the "Global Output Range", different output
ranges can be assigned to the individual channels.
9230A_002-976e-02.24
Page 39
KiTorq DS System, Type 9239AT... and Type 9230AR...
6.6.7 KiCenter: CAN bus
The settings for the CAN bus can be adjusted on the
"CAN Bus" page.
Fig. 24:
KiCenter screen view – CAN Bus
Baud Rate
Preset: 1 MBaud
Transmission speed of the CAN bus protocol. Must match
the settings in the data acquisition system.
Data Format
Preset: Intel
You can choose between Intel and Motorola formats
CAN Termination Resistor
Preset: Enabled
Must be enabled in the event of direct connection between
the On-board Receiver Unit and data acquisition. The
termination resistor must only be turned off if the On-board
Receiver Unit in the CAN bus is connected between the
data acquisition and the On-board Receiver Unit.
Page 40
9230A_002-976e-02.24
Commissioning
Send Mode
ƒ Continuous Transmission: the data is transmitted
continuously with the set interval time.
ƒ Trigger Frame Mode: a measurement data packet is
sent upon "Request" of the data acquisition where this
sends a frame with the set address to the On-board
Receiver Unit.
CAN Frame Settings
It is possible to turn individual CAN frames on or off. To do
this, enable or disable the respective CAN frame with the
checkboxes. The signals contained in the respective CAN
frame can be found behind the ID fields.
An ID needs to be assigned to just the first data frame
in the basic settings. The other frames will be numbered
automatically in consecutive order.
Enable Individual CAN Addressing
If the checkbox is selected, then an individual address
can be assigned for each CAN frame. The "Status" CAN
frame has its own transmission interval. The interval can
be entered under "Send Interval Status" in ms.
Creating a CAN DB
It is possible to generate CAN database files (CAN DB)
using the KiCenter software.
CAN DB can only be created on the Status page.
In order to begin generating a CAN DB, click the top right
button "Create CAN DB File".
9230A_002-976e-02.24
Page 41
KiTorq DS System, Type 9239AT... and Type 9230AR...
Fig. 25:
KiCenter screen view of the Status Page (Device
Center) - Create CAN DB
After selecting the option, you will be prompted to choose
a secure location for this file. The CAN-DB file can then
be used for easier configuration of the data acquisition
system.
Page 42
9230A_002-976e-02.24
Commissioning
6.7
Firmware update
Because the On-board Receiver Unit are constantly
undergoing development, it may be necessary to update
the firmware for them. This chapter describes how to do
this using KiCenter.
Before doing a firmware update, ensure that the data
connection between the PC and the sensor, as well as the
power supplies to the PC and the sensor are connected
properly. Interruptions to the communication link, the
power supply to the sensor, or a computer crash during
the update can cause irreparable damage to the sensor
programming.
9230A_002-976e-02.24
Page 43
KiTorq DS System, Type 9239AT... and Type 9230AR...
7.
Troubleshooting
7.1
Cables and power supply
ƒ Check that all connections are properly connected
and that the system is connected to an appropriately
designed power supply.
ƒ Check that the correct cables have been used for all
connections.
ƒ The following problem can result from incorrect or
incomplete cable connections and/or the use of an
inappropriate power supply:
- The output signal cannot be received by the
connected PC and/or the data processing system.
7.2
On-board Unit status display and LED
The status display provides information about the system
status, i.e. number of connected transmitters, IP address.
7.3
Software
ƒ If one or more output signals are incorrect, the sensor
may have been set-up incorrectly via the KiCenter
software. Check all of the settings in KiCenter:
- All analog voltage settings must be within range and
conform with the settings for the data acquisition
system to which they are connected.
- All digital pulse and resolution settings must be set
within range and conform with the settings for the
data acquisition system to which they are connected.
- Check all offset values.
ƒ If no output signals are available despite having the
correct connections, use the KiCenter test function to
determine whether all outputs are fully operational.
ƒ For connection problems to the PC, see the appendix.
Page 44
9230A_002-976e-02.24
Troubleshooting
7.4
CAN
Problem: There are no messages on the CAN bus or
incorrect data is being received.
Check to ensure that:
ƒ The electronics unit has power.
ƒ The evaluation system is connected to the On-board
Unit.
ƒ The evaluation system and the sensor electronics
use the same settings for baud rate, CAN identifiers,
identifier types, data format, and CAN termination
resistor.
ƒ If you are using a data acquisition system with an
acceptance filter, ensure that messages from the
sensor are not blocked or disabled.
ƒ The data processing system and the sensor
electronics operate using the same settings for the
type of measured values (signed or unsigned, number
of bits)
To avoid problems with incorrect data types or bit lengths,
we recommend using ".dbc" files.
A ".dbc" file with specific settings can be created with the
KiCenter software.
7.5
Environmental conditions
Snow and moisture may affect the HF transmission quality
of the system.
7.6
EMC interference
The KiTorq DS system works with ISM band on the
frequency between 2.402 and 2.480 GHz. External
devices, such as other ISM networks and other EMC
emitters, may cause interference with the wireless
transmission.
Set smartphones and notebooks in the immediate vicinity
of the system to flight mode. Bluetooth transmitter in the
immediate vicinity interfere with the system.
If a ISM band is particularly congested, converting the
system to another ISM band is recommended.
9230A_002-976e-02.24
Page 45
KiTorq DS System, Type 9239AT... and Type 9230AR...
7.7
Service
If your system continues to function unsatisfactorily
despite the recommendations given above, please
contact us by phone: +49 7031 3090 0 or by e-mail:
[email protected]. Please provide the following
information:
ƒ A ".kdx" file saved from the KiCenter software as an
example of the problem or fault condition.
ƒ A list of all outputs that are having problems,
i.e. analog, digital, CAN, USB.
ƒ The serial numbers for all relevant components.
Page 46
9230A_002-976e-02.24
Maintenance and cleaning
8.
Maintenance and cleaning
8.1
Maintenance
In case of maintenance, please contact Kistler Instrumente
GmbH and its responsible contact person.
8.2
Cleaning
Kistler recommends regular lubrication of the visible seals
and the spring contacts.
Furthermore, Kistler recommends regular cleaning of the
outside of the transmitter unit with a damp cloth.
9230A_002-976e-02.24
Page 47
KiTorq DS System, Type 9239AT... and Type 9230AR...
9.
Other information
This information has been compiled from sources
considered to be authoritative and is accurate and
credible as of the creation date to the best of our
knowledge. However, there is no claim to completeness
or absolute credibility. Disclosure of this information does
not constitute an implicit or express guarantee.
This information relates to the specific products to which
they apply. It may not apply to these products if the
products are used in combination with other devices or in
a process. It is the responsibility of the user to verify the
suitability and completeness of this information for his or
her specific purpose.
Page 48
9230A_002-976e-02.24
Appendix
10. Appendix
A. Dimensions
9230A_002-976e-02.24
Page 49
weder kopiert noch vervielfältigt, noch an Drittpersonen
mitgeteilt oder zugänglich gemacht werden.
Page 50
_A2q /KIWAG-SWX_A2q
Vers. 13-Dez-2021/ Vers. 13-Dez-2021
83,5
78,5
83,5
KIWAG-SWX_A2q / Vers. 13-Dez-2021
68,5
KiTorq DS 35mm
KiTorq
DS 40mm
KiTorq
DS 40mm
87
87 87
87
87
87
87
KiTorq
DS 25mm
KiTorq
DS 25mm
87
87
87
87
87
87
68,5
KiTorq DS 50mm
Das Urheberrecht an dieser Zeichnung, die dem Empfänger
persönlich anvertraut wird, verbleibt unserer Firma.
Ohne unsere schriftliche Genehmigung darf die Zeichnung
weder kopiert noch vervielfältigt, noch an Drittpersonen
mitgeteilt oder zugänglich gemacht werden.
87
87
87
KiTorq DS System, Type 9239AT... and Type 9230AR...
KiTorq DS 25mm
KiTorq
DS 30mm
KiTorq
DS 30mm
68,5
73,5
83,5
88,5
73,5
KiTorq
DS
40mm
KiTorq
DS
45mm
KiTorq
DS 45mm
88,5
9230A_002-976e-02.24
Appendix
73,5
78,5
73,5
88,5
88,5
87
KiTorq
DS 50mm
KiTorq
DS 50mm
87
87
87
KiTorq
DS 45mm
KiTorq
DS 45mm
78,5
93,5
93,5
Erstmals verwendet
Erstmals verwendet
Änderung
ÄnderungDatum
Werkstoff
Werkstoff
Ersatz für
Datum
Ersatz für
Ers
KiTorqKiTorq
DS - Abmessungen
DS - Abmessu
9230A_002-976e-02.24
gez.
gez.
gepr.
gepr.
ges.
ges.
measure. analyze.
innovate.
measure.
analy
Page 51
KiTorq DS System, Type 9239AT... and Type 9230AR...
B. Pin assignment
Fig. 26:
Connector view front plate
Power / DTI (EGJ.1B.308.CLD, male)
Pin
1
2
3
4
5
6
7
8
Page 52
Signal
RS485 P
RS485 N
VIN_EXT
VIN_EXT
GND_EXT
GND_EXT
9230A_002-976e-02.24
Appendix
ETH / USB (EGB.1B.307.CLN, female)
Pin
1
2
3
4
5
6
7
Signal
TX+
TX–
RX+
RX–
USB D+
USB D–
GND
CAN (EGG.0B.307.CLN, female)
Pin
1
2
3
4
5
6
7
Signal
CAN-H
CAN-L
GND
GND
NC
NC
NC
CAN (EGG.0B.307.CLN, female)
Pin
1
2
3
4
5
6
7
8
9
10
Signal
Ana_Out 1
Ana_Out 2
Ana_Out 3
Ana_Out 4
AGND
Ana_Out 5
Ana_Out 6
Ana_Out 7
Ana_Out 8
AGND
WPT 1/2 (EGG.1B.306.CLN, female)
Pin
1
2
3
4
5
6
9230A_002-976e-02.24
Signal
A
B
+5 V (Imax = 150 mA)
+12 V (Imax = 150 mA)
DGND
0
Page 53
KiTorq DS System, Type 9239AT... and Type 9230AR...
11. EU declaration of conformity
DocuSign Envelope ID: 23A6B566-C7BB-429B-9F7F-DA1DC1A1FAE5
EU Declaration of Conformity
EU-Konformitätserklärung
Déclaration UE de conformité
The manufacturer / Der Hersteller / Le Fabricant:
Kistler Instrumente GmbH, Umberto-Nobile-Straße 14, D-71063 Sindelfingen, Germany
hereby declares that the product /
erklärt hiermit, dass das Produkt /
déclare que le présente produit:
Name / Name / Nom
Type / Typ / Type
Modules / Module / Modules
Options / Optionen / Options
KiTorq DS On-Board Unit
9230AR
none / keine / sans
all / alle / toutes
complies with the following provisions of directives /
die folgenden Bestimmungen der Richtlinien erfüllt /
est conforme aux dispositions suivantes des directives:
2014/53/EU
2011/65/EU
(Radio equipment / Funkanlagen / Radioélectriques)
(ROHS incl. EU/2015/863)
The following harmonised standards were applied /
Folgende harmonisierte Normen wurden angewandt /
Les normes harmonisées suivantes furent appliquées:
EMC Emission and Immunity / EMV Störaussendung und Störfestigkeit / Emission et Immunité EMC
EN 301 489-1 V2.2.3
EN 301 489-17 V3.2.4
EN 61000-6-2:2019
Efficient use of radio spectrum / effiziente Nutzung von Funkfrequenzen / utilisation efficace du spectre
radio
EN 300 328 V2.2.2
Safety / Sicherheit / Sécurité
EN 61010-1:2020
Kistler Instrumente GmbH, Sindelfingen
Sindelfingen, Dezember 2023
i.V. Dr. Simon Regitz
Head of CR&D Systems
Page 54
9230A_002-976e-02.24
EU declaration of conformity
DocuSign Envelope ID: 23A6B566-C7BB-429B-9F7F-DA1DC1A1FAE5
EU Declaration of Conformity
EU-Konformitätserklärung
Déclaration UE de conformité
The manufacturer / Der Hersteller / Le Fabricant:
Kistler Instrumente GmbH, Umberto-Nobile-Straße 14, D-71063 Sindelfingen, Germany
hereby declares that the product /
erklärt hiermit, dass das Produkt /
déclare que le présente produit:
Name / Name / Nom
Type / Typ / Type
Modules / Module / Modules
Options / Optionen / Options
KiTorq DS Transmitter
9230T025 / 9230T030 / 9230T035 / 9230T40 / 9230T045 / 9230T050
none / keine / sans
all / alle / toutes
complies with the following provisions of directives /
die folgenden Bestimmungen der Richtlinien erfüllt /
est conforme aux dispositions suivantes des directives:
2014/53/EU
2011/65/EU
(Radio equipment / Funkanlagen / Radioélectriques)
(ROHS incl. EU/2015/863)
The following harmonised standards were applied /
Folgende harmonisierte Normen wurden angewandt /
Les normes harmonisées suivantes furent appliquées:
EMC Emission and Immunity / EMV Störaussendung und Störfestigkeit / Emission et Immunité EMC
EN 301 489-1 V2.2.3
EN 301 489-17 V3.2.4
EN 61000-6-2:2019
Efficient use of radio spectrum / effiziente Nutzung von Funkfrequenzen / utilisation efficace du spectre
radio
EN 300 328 V2.2.2
Safety / Sicherheit / Sécurité
EN 61010-1:2020
Kistler Instrumente GmbH, Sindelfingen
Sindelfingen, Dezember 2023
i.V. Dr. Simon Regitz
Head of CR&D Systems
9230A_002-976e-02.24
Page 55
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