AMALGAMATED INSTRUMENT 05103V User manual

MODEL 05103V
WINDMONITOR
WITH VOLTAGE OUTPUTS
MARCH2002
MANUALPN05103V-90
ACN: 001 589 439
AMALGAMATED INSTRUMENT CO PTY LTD
Unit 5, 28 Leighton Place Hornsby Telephone:
NSW 2077 AUSTRALIA Facsimile:
[phone] e-mail: [email protected]
[phone] Internet: www.aicpl.com.au

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MODEL 05103V
WINDMONITOR
withVOLTAGEOUTPUTS
GENERAL
Power Requirement: 8 - 24 VDC (5mA @ 12 VDC)
Operating Temperature: -50 to 50°C (-58 to 122°F)
INTRODUCTION
The Wind Monitor measures horizontal wind speed and direction.
It is rugged and corrosion resistant, yet accurate and lightweight.
The housing, nose cone, propeller, and other components are
injection molded U.V. stabilized plastic. Both the propeller and
vertical shafts use stainless steel precision grade ball bearings.
Propeller rotation produces an AC sine wave signal with frequency
proportional to wind speed. Internal circuitry converts the raw
signal to a linear voltage output.
Vane position is sensed by a 10K ohm precision conductive plastic
potentiometer. This signal is also converted to voltage output.
The instrument mounts directly on standard one inch pipe, outside
diameter 34 mm (1.34"). An orientation ring is provided so the
instrument can be removed for maintenance and re-installed with-
out loss of wind direction reference. Both the sensor and the
orientation ring are secured to the mounting pipe by stainless steel
band clamps. Electrical connections are made in a junction box at
the base.
INITIAL CHECK-OUT
When the Wind Monitor is unpacked it should be checked carefully
for any signs of shipping damage.
Remove the plastic nut on the propeller shaft. Install the propeller
on the shaft with the serial number of the propeller facing forward
(into the wind). The instrument is aligned, balanced and fully
calibrated before shipment; however, it should be checked both
mechanically and electrically before installation. The vane and
propeller should easily rotate 360° without friction. Check vane
balance by holding the instrument base so the vane surface is
horizontal. It should have near neutral torque without any particular
tendency to rotate. A slight imbalance will not degrade perfor-
mance.
INSTALLATION
Proper placement of the instrument is very important. Eddies from
trees, buildings, or other structures can greatly influence wind
speed and wind direction observations. To get meaningful data for
most applications, locate the instrument well above or upwind from
obstructions. As a general rule, the air flow around a structure is
disturbed to twice the height of the structure upwind, six times the
height downwind, and up to twice the height of the structure above
ground. For some applications it may not be practical or necessary
to meet these requirements.
FAILURETO PROPERLY GROUNDTHE WIND MONITOR
MAY RESULT IN ERRONEOUS SIGNALS
ORTRANSDUCER DAMAGE.
Grounding the Wind Monitor is vitally important. Without proper
grounding, static electrical charge can build up during certain
atmospheric conditions and discharge through the transducers.
This discharge may cause erroneous signals or transducer failure.
To direct the discharge away from the transducers, the mounting
post assembly in which the transducers are mounted is made with
WINDSPEEDSPECIFICATIONSUMMARY
Range 0 to 60 m/s (130 mph), gust survival
100 m/s (220 mph)
Sensor 18 cm diameter 4-blade helicoid
polypropylene propeller, 29.4 cm air
passage per revolution
Distance Constant 2.7 m (8.9 ft.) for 63% recovery
Threshold Sensitivity 1.0 m/s (2.2 mph)
Transducer Centrally mounted stationary coil,
2K Ohm nominal DC resistance
Output Signal 0 to 1.00 VDC over specified range
Model No.
Suffix Range
M 0 to 50 M/S
P 0 to 100 MPH
N 0 to 100 KNOTS
K 0 to 200 KILOMETERS/HOUR
WIND DIRECTION (AZIMUTH) SPECIFICATION SUMMARY
Range 360° mechanical, 355° electrical
(5° open)
Sensor Balanced vane, 38 cm (15 in)
turning radius.
DampingRatio 0.3
Delay Distance 1.3 m (4.3 ft) for 50% recovery
Threshold Sensitivity 1.1 m/s (2.4 mph) at 10° displacement
DampedNatural
Wavelength 7.4 m (24.3 ft)
UndampedNatural
Wavelength 7.2 m (23.6 ft)
Transducer Precision conductive plastic potentio-
meter, 10K ohm resistance (±20%),
0.25% linearity, life expectancy 50
million revolutions, rated 1 watt at
40°C, 0 watts AT 125°C
Output Signal 0 to 1.00 VDC for 0 to 360°

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aspecial anti-staticplastic.It isimportant thatthemounting postbe
connected to a good earth ground. There are two ways this may
beaccomplished.First,theWindMonitormaybemountedonametal
pipewhich isconnectedtoearthground. Themounting pipeshould
not be painted where the Wind Monitor is mounted. Towers or
masts set in concrete should be connected to one or more
grounding rods. If it is difficult to ground the mounting post in this
manner, the following method should be used. Inside the junction
boxthe terminallabeled EARTHGNDisinternallyconnectedtothe
anti-static mounting post. This terminal should be connected to an
earth ground (Refer to wiring diagram).
Initial installation is most easily done with two people; one to adjust
the instrument position and the other to observe the indicating
device. After initial installation, the instrument can be removed and
returned to its mounting without re-aligning the vane since the
orientation ring preserves the wind direction reference. Install the
Wind Monitor following these steps:
1.MOUNT WIND MONITOR
a) Place orientation ring on mounting post. Do Not tighten
band clamp yet. Orientation ring may be omitted when
portable tripod is used.
b) Place Wind Monitor on mounting post. Do Not tighten band
clamp yet.
2.CONNECTSENSORCABLE.
a) Refer to wiring diagram located at back of manual.
3. ALIGN VANE
a) Connect instrument to indicator.
b) Choose a known wind direction reference point on the
horizon.
c) Sighting down instrument centerline, point nose cone at
reference point on horizon.
d) While holding vane in position, slowly turn base until
indicator shows proper value.
e) Tighten mounting post band clamp.
f) Engage orientation ring indexing pin in notch at instrument
base.
g) Tighten orientation ring band clamp.
CALIBRATION
The Wind Monitor is fully calibrated before shipment and should
require no adjustments. Recalibration may be necessary after
some maintenance operations. Periodic calibration checks are
desirable and may be necessary where the instrument is used in
programs which require auditing of sensor performance.
Accurate wind direction calibration requires a Model 18112 Vane
AngleBenchStand.Beginby connecting the instrument to a signal
conditioning circuit which has some method of indicating a wind
direction value. This may be a display which shows wind direction
values in angular degrees or simply a voltmeter monitoring the
output. Orient the base so the junction box faces due south.
Visually align the vane with the crossmarkings and observe the
indicator output. If the vane position and indicator do not agree
within 5°, it may be necessary to adjust the potentiometer coupling
inside the main housing. Details for making this adjustment appear
intheMAINTENANCE,POTENTIOMETERREPLACEMENT,outline,
step 7.
It is important to note that, while the sensor mechanically rotates
through 360°, the full scale wind direction signal from the signal
conditioning occurs at 355°. The signal conditioning electronics
must be adjusted accordingly. For example, in a circuit where 0 to
1.000 VDC represents 0° to 360°, the output must be adjusted for
0.986VDCwhentheinstrumentisat355°.(355°/360°X1.000volts
= 0.986 volts).
Wind speed calibration is determined by propeller pitch and the
output characteristics of the transducer. The calibration formula
relating propeller rpm to wind speed is shown below. Standard
accuracy is ±0.3 m/s (0.6 mph). For greater accuracy, the sensor
must be individually calibrated in comparison with a wind speed
standard. Contact the factory or your supplier to schedule a NIST
(National Institute of Standards & Technology) traceable wind
tunnel calibration in our facility.
To calibrate wind system electronics, temporarily remove the
propeller and connect an Anemometer Drive to the propeller shaft.
Applythecalibrationformulatothecalibratingmotorrpmandadjust
theelectronics fortheproper value.For example,withthe propeller
shaft turning at 3600 rpm adjust an indicator to display 17.6 m/s
[3600 rpm x .0049 (m/s)/rpm = 17.6 m/s].
Details on checking bearing torque, which affects wind speed and
direction threshold, appear in the following section.
CALIBRATION FORMULAS
Model 05103V Wind Monitor w / 08234 Propeller
WIND SPEED vs PROPELLER RPM
05103VM m/s = 0.00490 x rpm
05103VN knots = 0.00952 x rpm
05103VP mph = 0.01096 x rpm
05103VK km/h = 0.01764 x rpm
WIND SPEED vs 0-1 VDC OUTPUT
05103VM m/s = mV x 0.05
05103VN knots = mV x 0.10
05103VP mph = mV x 0.10
05103VK km/h = mV x 0.20
WIND DIRECTION vs 0-1 VDC OUTPUT
DEGREES = mV x 0.36
MAINTENANCE
Given proper care, the Wind Monitor should provide years of
service. The only components likely to need replacement due to
normal wear are the precision ball bearings and the wind direction
potentiometer. Only a qualified instrument technician should per-
form the replacement. If service facilities are not available, return
the instrument to the company. Refer to the drawings to become
familiar with part names and locations. The asterisk * which
appearsinthefollowingoutlinesisareminderthatmaximumtorque
on all set screws is 80 oz-in.
POTENTIOMETER REPLACEMENT
The potentiometer has a life expectancy of fifty million revolutions.
As it becomes worn, the element may begin to produce noisy
signals or become non-linear. When signal noise or non-linearity
becomes unacceptable, replace the potentiometer. Refer to ex-
ploded view drawing and proceed as follows:
1.REMOVEMAINHOUSING
a) Unscrew nose cone from main housing. Set o-ring aside for
later use.
b) Gently push main housing latch.
c) While pushing latch, lift main housing up and remove it from
vertical shaft bearing rotor.

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2.UNSOLDERTRANSDUCERWIRE
a) Remove junction box cover, exposing circuit board.
b) Remove screws holding circuit board.
c) Unsolder three potentiometer wires (white, green, black),
two wind speed coil wires (red, black), and earth ground
wire (red) from board.
3.REMOVEPOTENTIOMETER
a) Loosen set screw on potentiometer coupling and remove it
from potentiometer adjust thumbwheel.
b) Loosen set screw on potentiometer adjust thumbwheel and
remove it from potentiometer shaft extension.
c) Loosen two set screws at base of transducer assembly and
remove assembly from vertical shaft.
d) Unscrew potentiometer housing from potentiometer mount-
ing & coil assembly.
e) Push potentiometer out of potentiometer mounting & coil
assembly by applying firm but gentle pressure on potentio-
meter shaft extension. Set o-ring aside for later use.
f) Loosen set screw on potentiometer shaft extension and
remove it from potentiometer shaft.
4.INSTALLNEW POTENTIOMETER
a) Place potentiometer shaft extension with o-ring on new
potentiometer (Gap0.040") andtightensetscrew*. Regrease
o-ring if necessary.
b) Push new potentiometer into potentiometer mounting & coil
assembly.
c) Feed potentiometer and coil wires through hole in bottom
of potentiometer housing.
d) Screw potentiometer housing onto potentiometer mounting
& coil assembly. Apply a small amount of silicone sealant on
threads.
e) Gently pull transducer wires through bottom of potentiom-
eter housing to take up any slack. Apply a small amount of
silicone sealant around hole.
f) Installtransducer assemblyonvertical shaftallowing 0.5mm
(0.020")clearancefrom vertical bearing.Tightenset screws*
at bottom of transducer assembly.
g) Place potentiometer adjust thumbwheel on potentiometer
shaft extension and tighten set screw*.
h) Place potentiometer coupling on potentiometer adjust
thumbwheel. Do Not tighten set screw yet.
5.RECONNECTTRANSDUCER WIRES
a) Using needle-nose pliers or a paper clip bent to form a small
hook, gently pull transducer wires through hole in junction
box.
b) Solder wires to circuit board according to wiring diagram.
Observe color code.
c) Secure circuit board in junction box using two screws
removed in step 2b. Do not overtighten.
6.REPLACE MAIN HOUSING
a) Place main housing over vertical shaft bearing rotor. Be
careful to align indexing key and channel in these two
assemblies.
b) Place main housing over vertical shaft bearing rotor until
potentiometer coupling is near top of main housing.
c) Turn potentiometer adjust thumbwheel until potentiometer
coupling is oriented to engage ridge in top of main housing.
Set screw on potentiometer coupling should be facing the
front opening.
d) Withpotentiometercouplingproperlyoriented,continuepush-
ing main housing onto vertical shaft bearing rotor until main
housing latch locks into position with a “click”.
7. ALIGN VANE
a) Connect excitation voltage and signal conditioning electron-
ics to terminal strip according to wiring diagram.
b) With mounting post held in position so junction box is facing
due south, orient vane to a known angular reference. Details
appear in CALIBRATION section.
c) Reach in through front of main housing and turn potentiom-
eter adjust thumbwheel until signal conditioning system
indicates proper value.
d) Tighten set screw* on potentiometer coupling.
8.REPLACE NOSECONE
a) Screw nose cone into main housing until o-ring seal is
seated. Be certain threads are properly engaged to avoid
cross-threading.
FLANGE BEARING REPLACEMENT
If anemometer bearings become noisy or wind speed threshold
increases above an acceptable level, bearings may need replace-
ment. Check anemometer bearing condition using a Model 18310
Propeller Torque Disc. If necessary, bearings are replaced as
follows.
1.REMOVEOLD BEARINGS
a) Unscrew nose cone. Set o-ring aside for later use.
b) Loosen set screw on magnet shaft collar and remove
magnet.
c) Slide propeller shaft out of nose cone assembly.
d) Remove front bearing cap which covers front bearing.
e) Remove both front and rear bearings from nose cone
assembly. Insert edge of a pocket knife under bearing flange
and lift it out.
2.INSTALL NEW BEARINGS
a) Insert new front and rear bearings into nose cone.
b) Replace front bearing cap.
c) Carefully slide propeller shaft thru bearings.
d) Place magnet on propeller shaft allowing 0.5 mm (0.020")
clearance from rear bearing.
e) Tighten set screw* on magnet shaft collar.
f) Screw nose cone into main housing until o-ring seal is
seated. Be certain threads are properly engaged to avoid
cross-threading.
VERTICAL SHAFT BEARING REPLACEMENT
Vertical shaft bearings are much larger than the anemometer
bearings. Ordinarily, these bearings will require replacement less
frequently than anemometer bearings. Check bearing condition
using a Model 18331 Vane Torque Gauge.
SincethisprocedureissimilartoPOTENTIOMETERREPLACEMENT,
only the major steps are listed here.
1. REMOVE MAINHOUSING.
2. UNSOLDER TRANSDUCERWIRESANDREMOVE
TRANSDUCER ASSEMBLY. Loosen set screws at base of
transducer assembly and remove entire assembly from
vertical shaft.
3. REMOVE VERTICAL SHAFT BEARING ROTOR by sliding it
upward off vertical shaft.
4. REMOVE OLD VERTICAL BEARINGS AND INSTALL NEW
BEARINGS. When inserting new bearings, be careful not to
apply pressure to bearing shields.
5. REPLACE VERTICAL SHAFT BEARING ROTOR.
6. REPLACE TRANSDUCER&RECONNECT WIRES.
7. REPLACE MAINHOUSING.
8. ALIGN VANE.
9. REPLACE NOSECONE.
*Max set screw torque 80 oz-in

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WARRANTY
This product is warranted to be free of defects in materials and
construction for a period of 12 months from date of initial pur-
chase. Liability is limited to repair or replacement of defective item.
A copy of the warranty policy may be obtained from R. M. Young
Company.
CE COMPLIANCE
This product has been tested and shown to comply with European
CE requirements for the EMC Directive. Please note that shielded
cable must be used.
Declaration of Conformity
Application of Council Directives:
89/336/EEC
Standards to which Conformity is Declared:
EN 50082-1 (IEC 801-2, 3, 4)
Manufacturer's Name and Address:
R. M. Young Company
Traverse City, MI, 49686, USA
Importer's Name and Address:
See Shipper or Invoice
Type of Equipment:
Meteorological Instruments
Model Number / Year of Manufacture:
05103V/1996
I, the undersigned, hereby declare that the equipment
specified conforms to the above Directives and Standards.
Date / Place:
Traverse City, Michigan, USA January 8, 1996
DavidPoinsett
R & D Manager, R. M. Young Company