Gill WindMaster Pro User manual

WindMaster &
WindMaster Pro
Ultrasonic Anemometer
User Manual
Doc No. 1561-PS-0001
Issue 03
Gill Instruments Limited
Saltmarsh Park,
67 Gosport Street,
Lymington,
Hampshire.
SO41 9EG
UK
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Website: www.gill.co.uk

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Contents
Contents 2
1. FOREWORD 4
2. INTRODUCTION 4
3. PRINCIPLE OF OPERATION 5
Polar definition 6
U, V, and W axes definition 6
Effects of temperature, barometric pressure, rainfall and humidity 7
Measurement sequence 7
Signal processing 7
4. SPECIFICATION 8
5. PRE-INSTALLATION 9
5.1. Equipment supplied 9
5.2. Software 9
5.3. Options 9
5.4. Accessories 9
5.5. Packaging 9
5.6. Installation requirements 9
PC requirement 9
Other equipment 10
Connection 10
Power supply 10
6. INSTALLATION 11
6.1. Installation Guidelines 11
6.2. Bench system test 11
6.3. Cable type 11
6.4. Cable length 12
6.5. Connections 13
Cable assembly 14
Connector Pin & Conductor positions 15
Grounding (earthing) 17
6.6. Connection to a PC using RS 232 18
6.7. Connection to a PC using RS 422 18
6.8. Connection to a PC via a Power and Communications Interface 19
Environmental 19
PCI Electrical Power Requirements 19
Connector Pin and Cable Assignments for PCI 20
6.9. Networking using RS485 22
6.10. Mechanical installation 23
Location 23
Orientation 23
Alignment 23
Corrosion 23
Grounding (Earthing) 23
Cable strain relief 23
Flange mounting 24
Pipe mount adaptor 24
7. MESSAGE FORMATS 26
7.1. Mode 1– ASCII, UVW, Continuous 26
WindMaster Identification node address 27
Horizontal wind speed 27
Vertical wind speed 27
Units 27
Speed of Sound (SOS) 27

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Sonic temperature 27
Status 27
Analogue Inputs (Unit order option) 27
PRT (Unit order option) 27
Checksum 27
Output rate (not displayed) 27
7.2. Mode 2 – ASCII, Polar, Continuous (Default) 28
Horizontal wind direction 29
7.3. Mode 3 –ASCII, UVW, Polled. 29
7.4. Mode 4 –ASCII, UVW, Polled. 30
7.5. Mode 7 –Binary, Polar, Short 30
7.6. Mode 8 –Binary, UVW, Short 31
7.7. Mode 9 –Binary, Polar, Long 31
7.8. Mode 10 –Binary, UVW, Long 31
8. ANALOGUE INPUTS 32
8.1. Analogue Inputs 32
8.2. PRT input 32
8.3. Input Rates 32
9. ANALOGUE OUTPUTS 33
9.1. Output allocations 33
9.2. Output types 33
9.3. Voltage outputs 33
9.4. Current outputs 33
9.5. Scaling 33
9.6. Polar wind direction wraparound 33
9.7. Status 34
10. CONFIGURING 34
10.1. WIND software 34
10.2. Configuring using HyperTerminal 38
Setting up 38
Entering Configuration mode 38
Returning to Measurement mode 38
Checking the configuration 38
Changing settings 39
Command List 39
11. MAINTENANCE & FAULT-FINDING 45
11.1. Cleaning 45
11.2. Servicing 45
11.3. Fault-finding 45
11.4. Status (error) codes 45
11.5. Returning unit 46
12. TESTS 46
12.1. Bench test 46
12.2. Calibration 46
Standard calibration 46
Certified calibration 46
13. APPENDICES 46
13.1. Guarantee 46
13.2 Electrical Conformity 47
EC DECLARATION OF CONFORMITY ACCORDING 47

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1. FOREWORD
Thank you for purchasing a WindMaster or WindMaster Pro manufactured by Gill Instruments Ltd. The units have no
customer serviceable parts and require no calibration or maintenance. To achieve optimum performance we recommend
that you read the whole of this manual before proceeding with use.
Gill products are in continuous development and therefore specifications may be subject to change and design
improvements without prior notice.
The information contained in this manual remains the property of Gill Instruments and should not be copied or
reproduced for commercial gain.
2. INTRODUCTION
This manual describes the operation of both the WindMaster (1590-PK-020 + options) and WindMaster Pro (1561-PK-
020 + options). The instruments replace the previous WindMaster model (1086-PK-046) and WindMaster Pro (1352-
PK-001). Refer to appropriate manuals for these instruments.
The term 'WindMaster' is used in this manual as a general term for both the WindMaster and the WindMaster Pro; they
are robust three axis anemometers, with no moving parts.
The units of wind speed, output rate, and formats are all user selectable.
The WindMaster, constructed in aluminium and carbon fibre, can perform measurements in wind speeds up to 45 m/s.
The WindMaster Pro, constructed from marine grade stainless steel 316, can perform measurements in wind speeds up
to 65 m/s.
Options include up to four analogue input and four analogue output channels (12 or 14 bit resolution for WindMaster;
14 bit resolution for WindMaster Pro. A PRT input is also available (WindMaster Pro only).
Units may additionally be calibrated in a wind tunnel to ISO 16622, traceable to national standards.
WIND software is available free from the Gill website www.gill.co.uk. It is strongly recommended as it provides an
easy, user-friendly interface.

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3. PRINCIPLE OF OPERATION
Figure 1 Time of Flight details
The WindMaster measures the times taken for an ultrasonic pulse of sound to travel from an upper transducer to the
opposite lower transducer, and compares it with the time for a pulse to travel from lower to upper transducer.
Likewise times are compared between each of the other upper and lower transducers.
As Figure 1 shows, the air velocity along the axis between each pair of transducers can then be calculated from the
times of flight on each axis.
This calculation is independent of factors such as temperature.
From the three axis velocities, the wind speed is calculated, as either signed U, V, and W, or as Polar and W.
It can be seen from Figure 1 that the speed of sound in air can be calculated from the times of flight. From this the sonic
temperature can be derived from the formula TS1 = C12 / 403
Where
TS1 =Sonic temperature
C1 = Speed of sound
Note the formula does not account for the effect of Humidity
Figure 2 shows the direction and polarity of the U, V and W axes.

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Polar definition
The wind speed in the UV plane, with direction in degrees from 0 to 359 °, with respect to the Reference spar (which is
normally aligned to North).
U, V, and W axes definition
+U is defined as towards the direction in line with the north spar as indicated in the diagram.
+V is defined as towards the direction of 90°anti-clockwise from N / the Reference spar.
+W is defined as vertically up the mounting shaft.
Figure 2 U, V and W Axis Definition

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Effects of temperature, barometric pressure, rainfall and humidity
The calculated u, v and w components are independent of temperature, pressure, rainfall & humidity within the
operating parameters of the WindMaster.
The calculated sonic temperature/speed of sound should be corrected by the user for humidity to provide an indication
of ambient temperature.
Measurement sequence
The table shows the firing sequence of the transducers.
Measurement Sequence
The sample rate is automatically selected to either 32 or 40 Hz, depending on the output rate configured
Measurement
Period
Max 31ms (at 40Hz) or 25mS (at 32Hz) Next cycle
Ultrasonic
Measurement
Axis
1
(6ms Typical)
2 3 1 2
Transducer
Firing
L > U U > L L > U U > L L > U U > L L > U U > L L > U
etc
Analogue Input
Measurement
1, 2, 3 and 4 or PRT
Maths
Routine
Serial
Communications
Data from previous
measurement.
L > U Indicates lower to upper transducer firing.
U > L Indicates upper to lower transducer firing.
Analogue inputs and PRT are sampled synchronously at rates described in Para 8.3.
Signal processing
Instantaneous Sampling
The WindMaster can be configured to output the sampled data direct at the selected output rate without any averaging -
"Instantaneous Sampling". Alternatively data can be sampled at 32 or 40 Hz and averaged (see section 10.2 PX). This
applies for wind data and speed of sound. All samples are transmitted with a status code.
Retries Enabled
If this mode is selected, if a problem sample is detected, the unit will attempt another ultrasonic firing within the set
time parameters.
Calibration Enabled /Disabled
The on-board calibration (providing compensation for spar and transducer shadowing), can be disabled, returning the
unit to raw, uncorrected operation.

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4. SPECIFICATION
WindMaster WindMaster Pro
Outputs
Output rate 1, 2, 4, 8, 10, 16, 20, (32 option) Hz 1, 2, 4, 8, 10, 16, 20, 32 Hz
Sample rate (automatically selected) 32 or 40 Hz 32 or 40 Hz
Units of measure m/s, mph, KPH, knots, ft/min m/s, mph, KPH, knots, ft/min
Format UVW or Polar UVW or Polar
Averaging Flexible 0 - 3600 s Flexible 0 - 3600 s
Wind Speed
Range 0 - 45 m/s 0 - 65 m/s
Resolution 0.01 or 0.001 m/s 0.01 or 0.001 m/s
Accuracy (12 m/s) (Standard)* < 1.5% RMS < 1.5% RMS
Accuracy (12 m/s) (to special order)* # < 1.0 % RMS < 1.0 % RMS
Direction
Range 0 – 359.9°0 – 359.9°
Resolution 10 or 0.1010 or 0.10
Accuracy (12 m/s) (Standard)* 2°2°
Accuracy (12 m/s) (to special order)* # 0.5°0.5°
Speed of Sound
Range 300 -370 m/s 300 -370 m/s
Resolution 0.01 m/s 0.01 m/s
Accuracy < ±0.5% @ 20°C < ±0.5% @ 20 °C
Power requirement 9 -30 V dc, (55 mA @ 12 V dc)
(excluding analogue outputs)
9 -30 V dc, (55 mA @ 12 V dc)
(excluding analogue outputs)
Digital output
Protocol
(ASCII and Binary)
RS232, RS422, RS485
network up to 8 anemometers
RS232, RS422, RS485
network up to 8 anemometers
Baud rates 2400 - 57600 2400 - 57600
Analogue outputs (optional)
4 channels Resolution 12 or 14 bit Resolution 14 bit
Selectable range User selectable full scale wind speed User selectable full scale wind speed
Output type 0-20 mA, 4-20 mA, 0-5V, ±5V, ±2.5V 0-20 mA, 4-20 mA, 0-5V, ±5V, ±2.5V
Analogue inputs (optional)
Up to 4 single-ended
or 2 differential
Resolution 12 or 14 bit Resolution 14 bit,
plus PRT 100ohm (option)
Input range ±5 V ±5 V
Sonic temperature
Range -40 °C to +70 °C -40 °C to +70 °C
PRT
Resolution Not Applicable 0.01°C
Measurement Accuracy Not Applicable <±0.1 °C (-40 to +50°C)
Measurement Accuracy Not Applicable <±0.15°C (+50 to +70°C
General
Weight 1.0 kg 1.7 kg
Size 750 mm x 240 mm 750 mm x 240 mm
Environmental IP65 IP65
Operating temperature -40 °C to +70 °C -40 °C to +70 °C
Humidity < 5 % to 100 % < 5 % to 100 %
Precipitation Operation up to 300 mm / hour Operation up to 300 mm / hour
EMC Emissions BS EN 61000 - 6 - 3
Immunity BS EN 61000 - 6 - 2
Emissions BS EN 61000 - 6 - 3
Immunity BS EN 61000 - 6 - 2
* Accuracy specification applies for wind speed up to range maximum, and for wind incidence up to ±30 °from the horizontal.
# Custom calibration (to be specified when ordering, or unit can be returned for calibration) - Wind tunnel calibration is in
accordance with ISO 16622 and traceable to national standards.

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5. PRE-INSTALLATION
5.1. Equipment supplied
WindMaster or WindMaster Pro
Connector assembly comprising 31 way Clipper connector
Solder bucket pins
Sealing gland and washer
Installation kit Four M6 stainless steel nuts, bolts and shake-proof washers
User Manual (this document) on a CD.
5.2. Software
WIND software is available free at www.gill.co.uk , and is strongly recommended as it provides an easy, user-friendly
interface.
5.3. Options
Notes These options must be specified when ordering the WindMaster or WindMaster Pro.
See Section 4 Specification for more detail
WindMaster
WindMaster Pro
Four Analogue outputs 12 or 14 bit (specify) 14 bit
Four Analogue inputs 12 or 14 bit (specify) 14 bit
PRT input Not available Specify when ordering
Wind tunnel calibration,
traceable to national standards Specify when ordering * Specify when ordering *
* Units may be returned to Gill for Wind tunnel calibration.
5.4. Accessories
Item Part No
Travelling case - Portable protective case (WindMaster) 1210 - 30 -074
Travelling case - Portable protective case (WindMaster Pro) 1561 - 00 - 028
Spare 31 way Clipper connector 1561 - PK - 050
Spare 15m lead - one end free, other end fitted with Clipper pins 1561 - 10 - 018
Power Supply and Interface Unit (PCI) 1189 - PK - 021
Pipe mount adaptor 1561 - 30 - 025
5.5. Packaging
Whilst the WindMaster is being moved to its installation site, the unit should be kept in its packaging. All the packaging
should be retained for use if the unit has to be returned at any time.
Note that if the WindMaster is to be regularly moved around, a travelling case is available as an optional extra
5.6. Installation requirements
PC requirement
The new WIND software will operate with any PC with Windows software from Windows 98 onwards.
The PC must be fitted with a suitable interface to match the chosen communication format - RS232, RS422, or
RS485. Alternatively a Gill Power Supply and Interface (PCI) may be used to convert RS422/485 output to
RS232.

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Other equipment
Analogue inputs / outputs must be compatible with the options fitted to the WindMaster or WindMaster Pro.
See Sections 8 and 9
Connection
o The unit is fitted with a modified 31 way Clipper industrial plastic connector (shell size 3), and supplied with a
mating plug with solder bucket pins for installation by the user.
o The cable should be securely fixed with cable clamps or equivalent, so that the cable is not under stress at the
plug.
o There are restrictions on the maximum cable lengths for correct operation. See 6.4
o The cable should be routed up the inside of the mounting tube.
o See 6.3 for cable specification.
Power supply
o The WindMaster requires a DC supply of between 9 – 30 V DC.
o Typical current drain 55 mA @ 12 V (excluding analogue outputs)

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6. INSTALLATION
6.1. Installation Guidelines
As with any sophisticated electronics, good engineering practice should be followed to ensure correct operation.
 Always check the installation to ensure the WindMaster is not affected by other equipment operating locally,
which may not conform to current standards, e.g. radio/radar transmitters, boat engines, generators etc.
 Guidelines –
o Avoid mounting in the plane of any radar scanner – a vertical separation of at least 2m should be achieved.
o Radio transmitting antennas, the following minimum separations (all round) are suggested.
• VHF IMM – 1m
• MF/HF – 5m
• Satcom – 5m (avoid likely lines of sight)
 Use cables recommended by Gill. If cables are cut and re-connected incorrectly (perhaps in a junction box) then
EMC performance may be compromised if cable screen integrity is not maintained.
 Earth loops should not be created – wire the system in accordance with the installation guidelines.
 Ensure the power supply operates to the WindMaster specification at all times.
6.2. Bench system test
Note: Prior to physically mounting the WindMaster in its final location, we strongly recommend that a
bench system test be carried out to confirm the system is configured correctly, is fully functional and
electrically compatible with the selected host system and cabling (preferably utilising the final cable
length). The required data format, units, output rate, and other options should also all be configured at
this stage.
6.3. Cable type
An RS232 / RS422 compatible cable (as appropriate) should be used, with the number of twisted pairs matching the
application.
Generic description – Twisted pairs with drain wire, screened with aluminised tape, with an overall PVC sheath.
Wire size 7/0.2mm (24 AWG)
Gill 15m lead - A nine pair, 15metre lead, with one end free and the other end fitted with Clipper pins, is available as
an accessory from Gill, see 5.4 Accessories for part number.
The table shows some suitable manufacturers’ references; other manufacturers’ equivalents can be used.
No. of pairs Gill ref. Belden ref. Batt electronics ref.
9 026 - 02663 8774 91009
The cable allows for the connection of all: -
Power inputs
Digital data inputs and outputs
Analogue inputs
Analogue Outputs
Note: If PRT input option is selected customer must compromise on the number of enclosed inputs or outputs. If PRT is
connected you must sacrifice two analogue inputs or outputs.

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6.4. Cable length
The maximum cable length is dependent on the chosen communication format (RS232, RS422 or RS485), the baud
rate, and, to a lesser extent, on the cable type and the local electrical ‘noise’ level.
Communication format Baud rate Max. cable length
RS232 9600 6.5 m (20 ft) or if using Cat 5 cable see
manufacturers recommendations
RS422/485 9600 1 km (3200 ft)
Analogue outputs -
voltage
N/A 6.5 m (20 ft)
Analogue outputs - current N/A Resistance dependent (max 300 )
The table shows the typical maximum lengths at the given baud rates, using the recommended cable. If any problems of
data corruption etc are experienced, then a slower baud rate should be used. Alternatively, a thicker or higher
specification cable can be tried.

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6.5. Connections
Important
 Do NOT join any of the cores of the cable together.
Any cores not used should be isolated.
 Do NOT connect the unit’s analogue output 0V or power 0V to the screen or ground / earth.
 The integrity of the screen of each pair should be maintained throughout the cable run.
 Avoid long grounding loops.
For maximum lightning protection it is essential that the unit be properly grounded via its mounting base.
Function Remarks Pin No
TXA( -) Anemometer Transmit - 1
TXB (+) Anemometer Transmit + 2
RXB (+) Anemometer Receive + 5
RXA (-) Anemometer Receive - 6
Communications mode
Polarity sets comms mode:
Connect to V+ for RS232
Connect to 0V for RS422/485
If left unconnected unit will
default to RS422/485
4
Power V+ 9 – 30 V 11
Power 0V Use also for digital comms 0V 12
Analogue Output 1 8
Analogue Output 2 14
Analogue Output 3 9
Analogue Output 4 15
PRT Excitation + 19
PRT Excitation - 20
PRT Sense + 25
PRT Sense - 26
Analogue Input 1 27
Analogue Input 2 28
Analogue Input 3 29
Analogue Input 4 24
Analogue Grounds Use the most convenient pin 10, 16, 17
Screens Use the most convenient pin 3, 7, 21, 30, 31
Not connected 13, 18, 22, 23

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Cable assembly
Open the pack of parts (1561-PK-050) provided with the WindMaster.
Strip the cable and solder the contact pins to the cores (please note that the connector supplies the correct strain relief
for cables with an outside diameter of 6-12mm).
Put the parts on the cable in the order as shown below.
Whilst squeezing the red retainers in the direction of ARROW A, pull in the direction of ARROW B.
A
B
Your connector should now resemble the connector in the picture above.

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Insert each contact pin until you feel a slight click. If you have inserted the contact into the incorrect hole it can
be removed at this point by simply pulling it out. Please note there will be some resistance.
Continue to insert all of the contacts you require in accordance with the diagram below.
Connector Pin & Conductor positions
The drawing above shows the pin positions and the colour of the wire conductors, together with
position of conductor screens. This information must be used in conjunction with the information
shown in 6.5 connections. If the PRT option is selected you may have to sacrifice two analogue
inputs or outputs.

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Once all of the contacts are inserted push the red retainer into place.
NB. The retainer can only be pushed back into place if the contacts are fully engaged.
Fit the connector to the WindMaster so that you can now finish assembling the connector.
Screw the back-shell onto the connector until it is fully in place. Please note that the final rotations can be slightly
stiff
Screw the cable clamp into the back shell

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Now screw the cable-clamping nut into place
.
The connector can now be removed from the WindMaster.
Grounding (earthing)
To ensure correct operation, and for maximum protection against lightning, the anemometer MUST be correctly
grounded (earthed) via its mountings. Inadequate grounding will degrade anemometer performance, particularly in the
presence of radio frequency interference.
The unit MUST be connected to an appropriate grounding point with a minimum of 6mm² copper wire, via the M6 base
screws. The primary earth for the anemometer must be provided via the base screws and not via the cable screens.

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6.6. Connection to a PC using RS 232
Notes
1. Using RS232, the cable length for reliable operation is limited to 6.5m (20ft) @ 9600 Baud. See 6.4
2. For longer cable runs, we recommend using the WindMaster configured with RS422 output, and a RS422/232
converter at the PC. See 6.7
3. Ensure WindMaster is configured for RS232. See Section 10 Configuring
WindMaster
connector PC
Typical Serial connector
(9 Way ‘D’)
Signal names Pin nos. Cable
2 twisted pairs Signal names Pin nos.
TXA (-)
RXA (-)
1
6
RXD
TXD
2
3
Signal
comms
Ground
5
Comms Mode -
link to Power V+ (Pin 11) 4
Screen
(Use the most convenient pin)
3, 7, 21,
30 or 31
Screen and
Drain wires
Chassis
ground N/A
Power V+
Power 0V
11
12
+
–
DC Power
Supply
9 – 30V
6.7. Connection to a PC using RS 422
Notes
1. The PC must be fitted with an internal or external RS422 / RS232 converter.
2. Configure WindMaster for RS 422 by linking Comms Mode line (Pin 4) to 0V (Pin 12)
WindMaster connector PC with RS422/232
converter
Signal names Pin nos. Cable –twisted
pairs Signal names
TXB(+)
TXA(–)
2
1 RXB(+) RXA(–)
RXB(+)
RXA(-)
5
6 TXB(+) TXA(–)
Signal Ground
Screen
(Use the most convenient pin)
3, 7, 21,
30 or 31
Screen and drain
wires Chassis ground
Comms Mode
- link to Power 0V (Pin 12)
or leave unconnected
4
Power V+
Power 0V
11
12
+
–
DC Power
supply
9 – 30V

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6.8. Connection to a PC via a Power and Communications Interface
Dependent upon system requirements the WindMaster unit can be operated with the Power and Communications and
Interface unit (PCI), which can be ordered as an optional extra. Connect WindMaster via RS422 port; then connect
computer to RS232 port on PCI.
WindMaster 31 Way Connector PCI, 15 Way D Type Connector
Signal names Pin No’s Pin No’s Signal Names
TXB (+) 2 2 RXB (+)
TXA(–) 1 9 RXA (–)
RXB (+) 5 3 TXB (+)
RXA (–) 6 10 TXA(–)
SCREEN (Use the
most convenient
pin)
3, 7, 21, 30
or 31
1 SCREEN
COMMS MODE 4 4 DIGITAL 0V
- Link to Power
0V (Pin 12) or
leave unconnected
POWER V+ 11 5 POWER V+
POWER 0V 12 11 POWER 0V
Environmental
The Desktop PCI is intended for use in a protected environment and provides interfacing to a single anemometer.
RS232, and RS422 ports are provided. The PCI is not intended for outdoor use.
PCI Electrical Power Requirements
1) 100Vac - 120Vac, 10VA for the 115V switch position
2) 200Vac - 250Vac, 10VA for the 230V switch position
3) 9 - 30Vdc, 55mA excluding analogue outputs (anemometer)
8 - 15Vdc, 50mA max (interface)
3 fuses protect the unit:
1. Externally accessible 1 A (T) for 115/230v operation
2. Internally accessible 500 mA (T) AUX
500mA(T)ANEM

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Connector Pin and Cable Assignments for PCI
Anemometer connector - 15 way
Pin Designation
1 Screen
2 RS422_RXB (+)
3 RS422_TXB (+)
4 Digital 0V, Signal ground
5 Supply V+
6 Analogue output V1
7 Not used
8 Analogue output V2
9 RS422_RXA (-)
10 RS422_TXA (-)
11 Supply V-
12 Analogue output V4
13 Analogue 0V
14 Not used
15 Analogue output V3
DC Supply - 4 way
Pin Designation
1 Interface V+
2 Interface V-
3 Anemometer V-
4 Anemometer V+
RS232 Output - 9 way
Pin Designation
1 DCD
2 RX data
3 TX data
4 DTR
5 Signal Ground
6 DSR
7 RTS
8 CTS
9 RI
RS422 Input/Output - 9 way
Pin Designation
1 Not connected
2 Not connected
3 Not connected
4 RS422_RXA (-)
5 Signal ground
6 RS422_TXA (-)
7 RS422_TXB (+)
8 RS422_RXB (+)
9 Earth