KMT TEL1-PCM-HS-BATT User manual

KMT - Kraus Messtechnik GmbH
Gewerbering 9, D-83624 Otterfing, Germany, 08024-48737, Fax. [phone]
Home Page: http://www.kmt-telemetry.com, Email: [e-mail]
T
TE EL L1 1- -P PC CM M- -H HS S- -B BA AT TT T
U
Us se er r M Ma an nu ua al l
D
Di ig gi it ta al l H Hi ig gh h D Da at ta a R Ra at te e T Te el le em me et tr ry y S Sy ys st te em m f fo or r S St tr ra ai in n
G
Ga ag ge e a an nd d I IC CP P A Ap pp pl li ic ca at ti io on ns s o on n R Ro ot ta at ti in ng g S Sh ha af ft ts s
“Gain and Auto Zero setting direct from Receiver Side!”
Easy to assemble and operate
ICP current 4mA, Gain selectable to: 2-4-8-16
For strain gages or IPC sensors
Digital transmission realized inductively
Strain gage sensors (>350 Ohm)
Distance up to 50mm
Full- and half bridge configuration
No influence through radio frequency
Excitation fixed 4 Volt DC
Many systems can operated at the same time
Auto-Zero adjustment - Setting receiver side
Signal bandwidth 0…50kHz (Scanning rate 104kHz)
Gain: 250-8000 - Setting receiver side
Output +/-10V and digital for interface (Option)
External shunt calibration
System accuracy <0.2%
INSTRUCTIONS FOR QUALIFIED PERSONNEL ONLY!

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General Description
The TEL1-PCM-HS-BATT single-channel high data rate telemetry system offers the easiest handling for the wireless
transmission of strain gage signals from rotating shafts. The encoder 62x27x13mm with a weight of 30g. The transmitter
(encoder) part is simply mounted on the rotating shaft with a special fiber reinforced tape.
Powering of the transmission part is via battery 6-9V or optional inductive power supply. The digital data transfer between
transmitter and receiver is realized inductively.
Functional Description
The TEL1-PCM-HS-BATT transmitter provides a pulse code modulated signal (PCM) to an induction winding around the shaft
(max. diameter 500mm, other on request!). The magnetic field of this winding enables the inductive transmission of the signal
to the pickup coil. From there the signal is transferred by cable (5 m) to the receiver. The maximum distance between the
transmitter coil and the pickup is 50mm. (with standard head)
The receiver unit offers a BNC connector at the front panel with analog outputs 10 V and a optional a digital output for PCM
interface ECIA100 (for notebooks) or IF16 (PCI Desktop). An LED bar indicator shows the actual level and a successful Auto
Zero calibration. Overload is indicated by the last LED´s in pos. or neg. direction of the bar graph. These OVL-LED´s operate
in peak-hold mode and are reset by pressing the overload switch.
Strain gage sensors (>350 Ohm) in full- and half- bridge configuration can be directly connected to the transmitter. The
excitation is fixed to 4 Volt DC and the gain is set by the gain switch on the receiver side. An auto-zero (AZ) adjustment is
executed by pressing the AZ button on the front side of the receiver. The successful AZ operation is indicated by a yellow LED
in the middle of the LED bar indicator. When the AZ completes the LED continuously illuminates. A continued flashing of the
yellow LED indicates some error in the AZ electronics. In this case please contact the support of KMT. Additional to the AZ
you have the possibility to calibrate the bridge by external shunt. (+ and -). The AZ setting is stored in a Flash-RAM and thus is
not lost during power-off. Use only shielded sensor cable.
TEL1-PCM-HS-BATT set contains:
Inductive Pickup
with 5m cable
TEL1-PCM-HS-BATT-DEC
(Decoder)
Mounting tape
25mm and 50mm
Length 50meter
Ferrite tape
30mm x 3 meter
(isolate magnetic field
between shaft and coil)
CU wire, 0.5mm
for coil (insulated
with lacquer)
DC-Power cable
Screw driver to
set the gain
Hexagon key to
activate the OLV
and AZ switch
6V Lithium
battery
TEL1-PCM-HS-STG-(BATT)
(Encoder for strain gages)

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Technical Data - rotating part
TEL1-PCM-HS-BATT-STG
Strain gage: Full and 1/2 bridge >350 Ohm,
Excitation: 4 VDC (fixed)
Gain: 250; 500; 1000; 2000; 4000; 8000 (selectable from receiver side)
Sensitivity STG Module Input vs Decoder Output
Gain 250 = 4mV/V
Gain 2000 = 0.500mV/V
Gain 500 = 2mV/V
Gain 4000 = 0.250mV/V
Gain 1000 = 1.0mV/V
Gain 8000 = 0.125 mV/V
The max. output is +/-10V
Shunt Cal: Via external resistor for positive and negative calibration
AZ: Auto Zero calibration (selectable from receiver side)
Analog signal bandwidth: 0 - 50 kHz (-3 dB)
Sampling rate 104 kHz
Operating temperature: - 10 to + 80 °C
Dimensions: 62 x 27 x 13mm (without connectors)
Weight: each module 30 grams
Static acceleration: up to 3000g
Powering: Battery 6-9V, Power consumption 70mA at 6V
Optional additional inductive powering
TEL1-PCM-HS-BATT-ICP
For all ICP sensors
Curren: 4mA(fixed)
Gain: 1; 2; 4; 8; 16; 32 (selectable from receiver side)
Gain
Resolution
250 = 1 at ICP
12 bit
500 = 2 at ICP
12 bit
1000 = 4 at ICP
12 bit
2000 = 8 at ICP
12 bit
4000 = 16 at ICP
12 bit
8000 = 32 at ICP
11 bit
Analog signal bandwidth: 3 - 50000 (-3 dB)
Sampling rate 104 kHz
Operating temperature: - 10 to + 80 °C
Dimensions: 62 x 27 x 13mm (without connectors)
Weight: each module 30 grams
Static acceleration: up to 3000g
Powering: Battery 6-9V, current consumption 80mA at 6V
Optional additional inductive powering

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Technical Data - static part
Front Rear
TEL1-PCM-HS-BATT-DEC
Front side:
Analogue output: +/-10V via BNC
Digital output for PCM Interface IF16 (ECIA100) OPTION
Gain setting : via screw switch
Auto Zero setting: via micro switch
Overload LED’s (Red ON) reset: via micro switch
Green LED’s: Bargraph +/-
Autozero LED:
Yellow ON- successful AZ
Yellow OFF- not successful AZ
if flashing, call support of KMT, error in EPROM
Green LED’s: Bargraph +/-
SL LED: Red ON = if error of data transmitting
SL LED: Red Flashing = if distance to far
Power ON LED: Red ON = if power switch on
Rear side:
Output to Powerhead: via 5pol. Tuchel
Fuse LED: Flashing if fuse is defect
Powering: 10-30V DC, Input via 7pol. Tuchel
Switch: ON/OFF
Operating temperature: - 10 to +70 °C
Dimensions: 200 x 105 x 44 (without connectors!)
Weight 950 grams
Static acceleration: up to 200g
System accuracy (without sensor): +/- 0.2 %
TEL1-PCM-HS-Pickup
Function: Receiving inductive magnetic field in PCM modulated
code
Distance between the transmitter coil and the pickup is 50mm
Output to TEL1-PCM-HS-BATT Decoder via 5pol. Tuchel plug incl.
5m cable. Cable length standard 5m, optional 20m
Operating temperature: - 10 to +80 °C
Dimensions: 45x60x25mm (without cable)
Weight: 400 grams (with 5m cable!)
Housing: splash-water resistant IP65 (except connector).

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Transmitting Part:
Strain gage connection
The pins for battery
+6-9V and GND
Coil connection
Inductive coil
Battery

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Block diagram:
Note: The Powerhead must be fixed in the middle of the coil in a distance from 5 up to 50 mm.

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Receiving Part:
Front
Rear
Auto Zero LED
ON = successful
OFF = Not successful
Analog output +/-10V
Negative Bargraph LED
With overload indicator
Power On LED
LED ON = Error data transmission
LED Flashing = Battery voltage lower 6V
Reset button of
overload indicator
AZ button
Gain switch
Power In DC 10 –30V
Data input from Pickup head
Power ON/OFF switch
PCM OUT for Interface
(Option!)
Flashing if fuse damage
Positive Baragraph LED
With overload indicator

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Pin connection cable:
Pickup
Distance of 5-100mm
DC-Power cable

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Shaft Installation
1.)
2.)
3.)
4.)
5.)
6.)
Mount 2 layers of the special ferrite tape around the
shaft. (each layer seperatly, without overlap!)
Coil, depends of shaft diameter 4-25 parallel
windings of 0.5 CUL wires (see table for help)
Fix with 2 layers of mounting tape around the shaft
Fix with 3-4 layers of mounting tape around the shaft

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7.)
8.)
9.)
10.)
steel hose clamps
Caution:
Fix TEL1-PCM-HS-STG-BATT module with at least 10 layers (width 50mm) of the special mounting tape
around the shaft. Depending on the shafts RPM and diameter particular attention needs to be paid to the
safe mounting of the components.
The manufacturer doesn’t accept liability for damages, which results from insufficient attachment of the
individual components.
The tape is only for test purposes, in order to test the electrical function of the units in the idle state of
the shaft.
During the rotation test appropriate safety precautions should be taken.
The entire installation may be used only by authorized persons. By using tape for the attachment, it has
to be used in the direction of rotation of the shaft and the end has to be secured. Only non-elastic tapes
with high tensile strength should be used for pre-fixing. Additionally, use a steel hose clamp for final
fixing!! The individual components are to be distributed in such a way on the shaft that imbalances are
avoided.
10 layers of the special mounting tape (width 50mm)
around the shaft.
We recommend add. use a steel hose clamp for final fixing!!
Solder the wires of the coil on the pins of TEL1-
PCM-HS-STG “2x Coil”

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Find the correct amount of windings
The number of windings depends on several factors. The most important influential factors are the diameter, the materiel of the
shaft and the environment around the shaft. The table standing below will help you to find the right number windings for steel
shafts. Thetable below is a help to estimate the number of windings fast. To optimize your results you can try one winding
more or less.
Windings
Diameter (mm)
8
600
8
500
9
250
10
125
11
80
12
40
13
20
Optimum windings for steel shafts
0
100
200
300
400
500
600
0 2 4 6 8 10 12 14
windings
diameter
Coil, depends of shaft diameter 4-25 parallel windings of 0.5 CUL wire

Version 2012-10 Technical Data are subject to change without notice!
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Kraus Messtechnik GmbH
Gewerbering 9, D-83624 Otterfing, [phone], Fax. [phone] –Germany
Home Page http://www.kmt-gmbh.com Email: [e-mail]
Konformitätserklärung
Declaration of Conformity
Declaration de Conformité
Wir
KMT - Kraus Messtechnik GmbH
We
Nous
Anschrift
Gewerbering 9, D-83624 Otterfing, Germany
Address
Adress
erklären in alleiniger Verantwortung, daß das Produkt
declare under our sole responsibility, that the product
declarons sous notre seule responsibilité, que le produit
Bezeichnung
Messdatenübertragungssystem
Name
Nom
Typ,Modell,Artikel-Nr., Größe
TEL1-PCM-HS-BATT
Type,Model, Article No.,Taille
Type, Modèle, Mo.d'Article,Taille
mit den Anforderungen der Normen und Richtlinien
fulfills the requirements of the standard and regulations of the Directive
satisfait aux exigences des normes et directives
108/2004/EG
Elektromagnetische Verträglichkeit EMV / EMC
DIN EN 61000-6-3 Ausgabe 2002-8 Elektromagnetische
Verträglichkeit EMV Teil 6-3 Fachgrundnorm Störaussendung
DIN EN 61000-6-1 Ausgabe 2002-8 Elektromagnetische
Verträglichkeit EMV Teil 6-1 Fachgrundnorm Störfestigkeit
und den angezogenen Prüfberichten übereinstimmt und damit den Bestimmungen entspricht.
and the taken test reports und therefore corresponds to the regulations of the Directive
et les rapports d'essais notifiés et, ainsi, correspond aux règlement de la Directive.
Otterfing, 27.04.2006
Martin Kraus
Ort und Datum der Ausstellung
Name und Unterschrift des Befugten
Place and Date of Issua
Name and Signature of authorized person
Lieu et date d'établissement
Nom et signature de la personne autorisée

Version 2012-10 Technical Data are subject to change without notice!
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KMT - Kraus Messtechnik GmbH
Gewerbering 9, D-83624 Otterfing, Germany, 08024-48737, Fax. [phone]
Home Page http://www.kmt-gmbh.com, Email: [email protected]om
I
In nd du uc ct ti iv ve e p po ow we er r s su up pp pl ly y
A
As ss se em mb bl li in ng g i in ns st tr ru uc ct ti io on ns s f fo or r
T
TE EL L1 1- -P PC CM M- -H HS S- -B BA AT TT T

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Inductive power supply set
Picture shows standard Inductive Power Supply for diameter up to 300mm
Mounted on shaft
25 and 50mm mounting tape
to fix coil on shaft
Power supply for power head
DC Power cable
IND-PWR AC/DC module
Input: AC from coil
Output 6.5VDC 100mA
CU wire 0.5mm
Ferrite tape
30mmx3m
Power Head with cable

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Installation of coil for inductive powering on shaft
Attach for electromagnetic insulation “Ferrite Tape”
- 2 x layers Ferrite-Tape around the shaft
- Fixed with 2 layers mounting tape
Wind the 0.5 mm enameled copper wire around the
shaft:
- 4-25 windings for 500-20mm diameter
Other diameter on request!
Note: “The inductive load of the IND-PWR AC/DC
module and the capacitor in the Power Head must be in
resonance to get the optimal transmission. The
inductive load of the shaft depends of diameters,
material and number of windings. ”
To find the optimal transmission try one winding more
ore less. The LED on the Inductive Power module will
help to find the best configuration. The distance
between powerhead and the coil is 3-10mm.
Control the output voltage and move the powerhead in
the max distance to the coil.
The minimum Output voltage must be 6,5 V!
Fix all with 2-3 layers around the coil with mounting
tape.

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Diameter (mm)
Windings
Fine adjustment capacitor
parallel to coil
We recommend a capacitor decade e.g
100pF .... 11,111 µF
1000
4-5
100-200nF (Type MKT or MKS 250V)
490
4-5
100-200nF (Type MKT or MKS 250V)
290
5
100-200nF (Type MKT or MKS 250V)
190
7
---
150
9
---
120
10
---
80
12
---
45
16
---
20
25
---
0
200
400
600
800
1000
1200
0 5 10 15 20 25 30
Diameter mm
Windings
Optimum windings for steel shafts
Magnetic field
100-200nF

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The pins “AC IN” are the AC power input from the coil.
On the pins “+6.5” and “GND“ you get a stabilized
output voltage of 6.5V DC. The control LED will lights
up, as soon as the power head is switched on and at
the right position - close enough to the coil on the shaft.
The max. load current on the DC output is 100mA.
The AC/DC converter will use instead battery pack!
Never use any battery together with the IndPwr!´
Installation of the power head for inductive powering
Connect the power head on the “AC Out” socket of the
power box and then the DC power cable on the “DC In
10-30V” socket. The two banana plugs have to be
connected to a DC power source with red on +10-30V
DC and black on 0V.
You should mount the power head at a fixed location
that it’s as free as possible from vibration influences.
The center of the coil should be in the same horizontal
position as the center of the power head. The distance
is optimal in the range between 3 and 10mm. (depends
of shaft and current consumption)
If the red LED of the AC/DC converter lights up, the
position of the power head is OK.
Power head
Control LED
AC IN
6,5 DC OUT
Power head
IND-PWR AC/DC module
Inductive coil
Power supply
for power head

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Fixing of IND-PWR AC/DC module and TEL1-PCM-HS-BATT
Fix all modules with at least 10 layers of the special mounting tape around the shaft.
According to the shafts RPM and diameter it’s particularly paid attention to safe mounting of the components.
Add. use hose clamps for final fixing!!
The manufacturer doesn’t accept liability for damages, which results from not sufficiently attachment of the
individual components. The provided cable harness and the tape are only for test purposes, in order to test the
electrical function of the units in the idle state of the shaft.
During the rotation test appropriate safety tools are to be attached.
The entire installation may be used only by authorized persons. By using tape for the attachment, it has to be
used in the direction of rotation of the shaft and the end has to be secured against removing. Only non-elastic
tapes with high tensile strength have to be used for pre-fixing. Add. use hose clamps for final fixing!!
The individual components are to be distributed in such a way on the shaft that imbalances will avoid.
Connection IND-PWR AC/DC module and TEL1-PCM-HS-BATT
To avoid transmitting error, the mounting distance between Inductive Power Head and
Inductive Pickup Head must be at least 100mm.

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Following must be considered at the mounting of the inductive
power head
Example of mounting plate,
Magnetic
field
Shaft with
Cu wire Coil
Don’t use for mounting any kind metal
in this area (25-30mm)! Otherwise flow
magnetic energy in the metal also and
degrease the distance between power
head and coil (on shaft)!
25-30mm
Wrong!!! Mounting plate cover the active area of inductive head

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Dimensions Powerhead
66
Cable length 5m
Optional 10...20m
30
Drill d= 4,3mm
10
43
53
33
33mm
66