IMKO TRIME-GW Series Manual de usuario

Manual

TRIME®-GW Line

More information:

www.imko.de

Moisture Sensor Experts

Thank you for purchasing this IMKO product

This manual is an original operating manual of the manufacturer.

The described instructions for use and commissioning are part of the products described and must be kept for

future installation or use.

Important!

Please read these instructions carefully to accomplish optimum results with your moisture probe. Please contact

your authorized dealer, distributor or service center for troubleshooting, questions or suggestions on your new

moisture probe. You may contact IMKO directly, to after exploring your local contact.

We look forward to helping you!

For warranty claims, please contact your local dealer, distributor or service center. The warranty does not include

any kind of willful damage to the device or its accessories or an operation outside of the product specification. Ple-

ase refer to the information in this manual. If you have any questions, please contact IMKO service. Don’t open the

device and do not try to repair the device yourself- the guarantee expires when the device is opened or modified.

In the course of product improvements, we reserve the right to make technical and visual changes to the device.

Content

1 Functional Description ................................................................................................ 5

1.1 The patented TRIME® TDR-Measuring Method ....................................................................................................5

1.2 TRIME® compared to other Measuring Methods .................................................................................................5

1.3 Areas of Application with TRIME-GW Line and the 1-Rod Probe...........................................................................5

2 Mode of Operation ..................................................................................................... 6

2.1 Measurement value collection with pre-check, average value and filtering.........................................................6

2.2 Temperature Measurement ...................................................................................................................................6

2.3 Temperature compensation when working at high temperatures ........................................................................6

2.4 Analogue Outputs ..................................................................................................................................................6

2.5 The serial RS485 and IMP-Bus interface .................................................................................................................7

2.6 The IMP-Bus as a user friendly network system.....................................................................................................7

2.7 Error Reports and Error Messages .........................................................................................................................7

3 Connectivity to TRIME-GW Line .................................................................................. 8

3.1 How to configure SONO-probes to appropriate operating and calibration parameters? .....................................8

3.2 System Setup with several TRIME-GW Line............................................................................................................9

3.3 Connection Plug and Plug Pinning .........................................................................................................................9

3.4 Analogue Output 0..10V with a Shunt-Resistor....................................................................................................10

4 TRIME-GW Line Installation ...................................................................................... 11

4.1 Schematic Diagram with Carrier Plate U-Profile...................................................................................................12

4.2 Installation on a steel girder with HEA-profile .....................................................................................................12

4.3 Carrier plate dimensions for 120mm steel girder ................................................................................................13

4.4 Installation of two carrier plates very close to each other...................................................................................15

5 Initial operation and adjustments ............................................................................. 16

5.1 Adjustment Guidelines for Moisture Measurements ..........................................................................................16

5.2 How to use the Calibration Curves Cal1 to Cal15.................................................................................................16

5.3 Calibration Curves Cal1 to Cal15...........................................................................................................................17

5.4 Selection and application of the reference method.............................................................................................18

5.5 Recording measurement data in trial operation ..................................................................................................19

5.6 Setting the calibration curve (adjustment)...........................................................................................................19

5.7 Selection of the individual Calibration Curves......................................................................................................20

5.8 Creating a linear Calibration Curve for a specific Material ..................................................................................21

5.9 Calculation for a linear 2-point calibration curve ................................................................................................21

5.10 Calculation for a linear 1-point calibration curve ................................................................................................22

5.11 Calculation for a non-linear calibration curve .....................................................................................................22

5.12 Configuration of the Measuring Mode.................................................................................................................22

5.13 Operation Mode CA and CF at non-continuous Material Flow ...........................................................................24

5.14 Filtering at material gaps in mode CA and CF.......................................................................................................25

5.15 Mode CC – automatic summation of a moisture quantity during one batch process ........................................26

6 Serial Connection to the SM-USB Module ................................................................ 28

7 Quick Guide for the Commissioning Software SONO-CONFIG ................................... 30

7.1 Scan of connected SONO probes on the serial interface .....................................................................................30

7.2 Configuration of serial SONO-interface ................................................................................................................31

7.3 Set analogue outputs of the SONO probe............................................................................................................31

7.4 Configuration of Measure Mode .........................................................................................................................32

7.5 Setting the precision of a single value measurement cycle .................................................................................33

7.6 Test run in the respective Measurement Mode ..................................................................................................33

7.7 “Measure” Run in Datalogging-Operation............................................................................................................34

7.8 Offsetting the material temperature sensor ........................................................................................................35

7.9 Compensation of the electronic temperature......................................................................................................36

8 Technical Data TRIME-GW Line.................................................................................. 37

9 Safty Notes ............................................................................................................... 38

1 Functional Description

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.

TRIME-GW Line consists of the measurement transformer TRIME-GW casing and the 1-rod-probe head. An

integrated TRIME TDR measuring transducer of IMKO´s SONO-series is installed into the TRIME-GW Line 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 patented measuring method, the

transit time of this pulse is determined with a resolution of <1 picosecond (1x10-12). Due to this high resolution

the moisture and the conductivity of the material is measured with a high precission.

The established moisture content, as well as the conductivity, respectively the temperature, can either be uploaded

directly into a PLC via two analogue outputs 0(4) ...20 mA or recalled via a serial RS485 interface.

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) offers precise measurement results which 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.

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.

1.3 Areas of Application with TRIME-GW Line and the 1-Rod Probe

The TRIME-GW Line with the 1-rod probe is suited for measuring in different materials directly inside a silo. The

1-rod probe requires a good flowability of the measured material in order to ensure that the material lies close to

the rods when the material is flowing.

The temperature of the measured material should not be higher than 60°C.

2 Mode of Operation

2.1 Measurement value collection with pre-check, average value and filtering

TRIME-GW Line measures internally at a very high rate of measurements per second and issues the resulting

measurement value at a cycle time of up to 200 milliseconds at the analogue output. Within this cycle time

of 200 milliseconds a probe-internal pre-check of the moisture values is included. Only plausible and physically

pre-averaged measurement values are used for the further data processing. This increases reliability and stability

of the measurement output at the interface of the probe.

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 of

the material. The delivery scope of TRIME-GW Line 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 and customized for special applications.

2.2 Temperature Measurement

A temperature sensor is installed on one stay bar of the 1-rod probe which establishes the measurement of the

material temperature. The temperature can optionally be transmitted at the analogue output 2.

2.3 Temperature compensation when working at high temperatures

Because the TRIME-GW Line measurement transformer works in other temperature ranges as the 1-rod-probe

inside the dryer, it is necessary to compensate the electronic separately from the 1-rod-probe. TRIME-GW Line

offers two possibilities for temperature compensation.

A) Temperature compensation of the internal TRIME-electronic

Despite the TRIME-GW Line electronic shows a generally low temperature drift, it is necessary to compensate a

temperature drift in applications for measuring moisture inside a grain dryer. With this method of temperature

compensation, a possible temperature drift of the TRIME-electronic can be compensated. For standard applications

in grain drying the compensation parameter is pre-set to TempComp = 0.2. For special applications it could be

necessary to adjust this parameter. But it is to consider that it is necessary to make a Basic-Balancing of the

TRIME-GW Line in air and dry glass beads if the parameter TempComp is changed to another value. The parameter

TempComp can be changed with the software tool SONO-CONFIG, in the menu "Calibration" and the window

"Temperature-Compensation".

B) Temperature compensation for the measured material

Water and special materials like maize, wheat and others, show a dependency of the dielectric permittivity when

using TRIME-GW Line at high temperature ranges. The dielectric permittivity is the raw parameter for measuring

water content with TRIME-GW Line. If special materials show this temperature drift, it could be necessary to use

a more elaborate temperature compensation. TRIME-GW Line offers the possibility to set special temperature

compensation parameters for every calibration curve Cal1 of Cal15 (see chapter “Selection of the individual

calibration curve”).

2.4 Analogue Outputs

The measurement values are transmitted as a current signal via the analogue output. With the help of the service

program SONO-CONFIG, the TRIME-GW Line 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 0-50%. 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…50%, variable adjustable)

Analogue Output 2: Temperature 0….100°C, variable adjustable

For the analogue outputs 1 and 2 there are two adjustable options: Analog Output: (two possible selections)

0..20mA 4..20mA

Output Channel 1 and 2: (three possible selections)

Moisture Temperature: Analogue output 1 for moisture, output 2 for temperature.

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. 50 for maize (Set in %) Maximum: 60°C

Minimum: 0 Minimum: 0°C

2.5 The serial RS485 and IMP-Bus interface

TRIME-GW Line is equipped with a standard RS485 as well as the IMP-Bus interface to set and readout individual

parameters or measurement values. An easy to implement data transfer protocol enables the connection of several

sensors/probes at the RS485-Interface. In addition, the TRIME-GW Line can be directly connected via the module

SM-USB to the USB port of a PC, in order to adjust individual measuring parameters or conduct calibrations.

NOTE:

The initial default setting of the serial interface is pre-set for the IMP-Bus. To operate with the RS485 it is

necessary to switch and activate the RS485 interface with help of the modul SM-USB. The transmission

protocol of TRIME-GW Line can be requested via “Contact us” on www.imko.de.

2.6 The IMP-Bus as a user friendly network system

With external power supply on site for the SONO probes, a simple 2-wire cable can be used for the networking. By

use of 4-wire cables, several probes can be also supplied with power.

Standard RS485-interfaces cause very often problems! They are not galvanically isolated and therefore raises the

danger of mass grindings or interferences which can lead to considerably security problems. An RS485 network

needs shielded and twisted pair cables, especially for long distances. Depending on the topology of the network,

it is necessary to place 100Ohm termination resistors at sensitive locations. In practice this means considerable

specialist effort and insurmountable problems.

The robust IMP-Bus ensures security. SONO-probes have in parallel to the standard RS485 interface the robust

IMP-Bus which is galvanically isolated which means increased safety. The serial data line is isolated from the

probe´s power supply and the complete sensor network is therefore independent from single ground potentials

and different grid phases. Furthermore, the IMP-Bus transmit its data packets not as voltage signals, but rather as

current signals which also works at already existing longer lines. A special shielded cable is not necessary and also

stub lines are no problem.

2.7 Error Reports and Error Messages

TRIME-GW Line is very fault-tolerant. This enables failure-free operation. Error messages can be recalled via the

serial interface.

3 Connectivity to TRIME-GW Line

Compatible to SONO probes

3.1 How to configure SONO-probes to appropriate operating and calibration parameters?

TRIME-GW Line is initially adjusted for the application for grain drying with the calibration curve Cal14, operation

mode CF and 3 seconds average time. The analogue outputs are adjusted to 4..20mA. With this pre-adjustment

TRIME-GW Line can be installed direct in the heating zone, without further adjustments. For operation at the

discharge hopper where an absolute moisture value is important, TRIME-GW Line has to be adjusted to a suitable

calibration curve Cal-x, depending on grain type and possibly to a zero-offset, depending on installation place.

There are two ways to configure and adjust a SONO-probe:

A: Online Configuration via SONO-VIEW

With the stand-alone device SONO-VIEW it is possible to configure SONO-probes online to an appropriate operating

mode, without the need to connect the SONO-probe to a PC. The operating mode depends on the application like

the moisture measurement under a silo flap, inside a dryer or mixer or on a conveyor belt. The SONO-probe can be

adapted via the SONO-VIEW to the appropriate operating mode like cyclic measurement, averaging, filtering, cu-

mulating and other powerful operating parameters. Furthermore, it is possible to select a calibration curve inside

a SONO-probe with zero-offset setting. All configuration parameters are stored in a non-volatile memory inside

the SONO-probe. This ensures that the analog output (e.g. 4-20mA) of the SONO-probe which could be connected

in parallel to a PLC, responds directly to the set configuration parameters.

B: Configuration via SM-USB

The SONO-probe is connected via the SM-USB and the RS485-interface to a PC. With help of the software tool

SONO-CONFIG it is possible to configurate SONO-probes to an appropriate operating mode. The operating mode

depends on the application like the moisture measurement under a silo flap, inside a mixer or on a conveyor belt.

The SONO-probe can be adapted to the appropriate operating mode like cyclic measurement, averaging, filtering,

cumulating and other powerful operating parameters. Furthermore, it is possible to select a calibration curve

inside a SONO-probe with zero-offset setting. All configuration parameters are stored in a non-volatile memory

inside the SONO-probe. So the analog output (e.g. 4-20mA) of the SONO-probe which could be connected in

parallel to a PLC, responds directly to the configuration parameters.

3.2 System Setup with several TRIME-GW Line

3.3 Connection Plug and Plug Pinning

TRIME-GW Line is supplied with a 10-pole MIL flange plug.

Plug-PIN Sensor Connections Lead Colour Lead Colour

A +12V….24V Power Supply Red Red

B 0V Power Supply Blue Blue

D 1. Analogue Positive (+) Moisture Green Green

E 1. Analogue Return Line (-) Moisture Yellow Yellow

F RS485 A Weiß White

G RS485 B Brown Brown

C (rt) IMP-Bus Grey/Pink Grey/Pink

J (com) IMP-Bus Blue/Red Blue/ed

K 2. Analogue Positive (+) Pink Pink

E 2. Analogue Return Line (-) Grey Grey

Screen

(is grounded at the sensor. The plant must

be properly grounded!)

Transparent Transparent

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

3.4 Analogue Output 0..10V with a Shunt-Resistor

With the help of a shunt resistor with 500 ohm (included in the delivery) 0..10V can be generated from the current

signal 0..20mA, in case the local PLC does not handle the recommended 4..20mA. Therefore the 500 Ohm shunt

resistor should be placed at the end of the line respectively at the input of the PLC. Following drawing shows the

wire connection.

NOTE:

The analogue output of TRIME-GW Line must be set to 0 to 20mA!

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