KMT T1-PCM-IND 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
T1 1- -P PC CM M- -I IN ND D
D
Di ig gi it ta al l 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
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
O
Op pe er ra at ti in ng g I In ns st tr ru uc ct ti io on ns s
•Easy to assemble and operate
•Distance up to 30mm (Range)
•Strain gage sensors (>=350 Ohm)
•Powering of transmitter part inductive
•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
•Signal bandwidth 0…1200Hz (-3dB)
•Gain: 250-500-1000-2000 or 1000-2000-4000-8000
•Output +/-10V
•16 bit ADC
•Output 4-20mA (Option)
•Digital transmission realized inductively
•System accuracy <0.2%
INSTRUCTIONS FOR QUALIFIED PERSONNEL ONLY!

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General description
The T1-PCM-IND single-channel telemetry system offers the easiest handling for the wireless transmission of strain gage
signals from rotating shafts. The encoder 35x24x14mm with a weight of 16g. The transmitter (encoder) part is simply mounted
on the rotating shaft with a special fiber reinforced tape.
The data transfer between transmitter and receiver is digital. The powering of the transmission part by the T1-PCM-IND is
inductive!.
Functional description
The T1-PCM-IND transmitter provides a pulse code modulated signal (PCM) to an induction winding around the shaft. The
magnetic field of this winding enables the inductive transmission of the signal from coil to pickup. From there the signal is
transferred by cable (5 m) to the receiver. The maximum distance between the transmitter coil and the pickup/powerhead is
30mm.
The receiver unit offers a BNC connector at the front panel with analog outputs 10 V and optional a current output of 4-20mA
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 plug-In bridge in 4 steps (250-500-1000-2000 or 1000-2000-4000-8000).
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. The yellow LED flashes as long as the AZ is in progress. When the AZ completes the
LED continuously illuminates. The AZ setting is stored in a Flash-RAM and thus is not lost during power-off.
T1-PCM-IND set contains:
Inductive Pickup/Powerhead
with 5m cable
T1-PCM-DEC
(Decoder)
Mounting tape
2 x 25mm x 50m
Ferrite tape - 30mm x 3 meter
(isolate magnetic field between
shaft and coil)
DC-Power cable
Hexagon key to
activate AZ switch
T1-PCM-STG-(IND)
(Encoder for strain gages)
CUL wire
0.5mm for coil
(Enamelled copper
wire)

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Technical data transmitting part:
T1-PCM-STG
Strain gage: Full and half bridge >=350 Ohm,
Excitation: 4 VDC (fixed)
Gain: 250-500-1000-2000 standard
1000-2000-4000-8000 on request!
Gain and Sensitivity
Gain 250 = +/-10mV/V
Gain 2000 = +/-1.250mV/V
Gain 500 = +/-5mV/V
Gain 4000 = +/-0.625mV/V
Gain 1000 = +/-2.5mV/V
Gain 8000 = +/-0.3125mV/V
AZ: Auto Zero calibration (via AZ button from receiver side)
Analog signal bandwidth: 0 - 1200 Hz (-3 dB)
Operating temperature: - 10 to + 80 °C
Resolution 16bit
Scanning rate 6.41 kHz
Static acceleration: up to 3000g
Powering: inductive
Dimensions: 35x24x14mm, weight 16g
Housing: splash-water resistant IP65 (except the connector pins)
T1-PCM-Pt100
Pt100 thermo sensor
Measurement range -50 to 250°C or -50 to 500°C (select by jumper)
Analog signal bandwidth: 0 - 10 Hz (-3 dB)
Operating temperature: - 10 to + 80 °C
Resolution 16bit
Scanning rate 6.41 kHz
Static acceleration: up to 3000g
Powering: inductive
Dimensions: 35x24x14mm, weight 16g
Housing: splash-water resistant IP65 (except the connector pins)

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Dimensions Encoder - T1-PCM-STG
Draw about 1:1
Weight 16 gram

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Technical data receiving part
Front Rear
T1-PCM-DEC
Analogue output: +/-10V via BNC output 1200Hz
(delay between analog IN/OUT 1.8mS constant!!)
Optional add. 4-20mA output to the analog output
Auto Zero setting: via AZ button
Autozero LED:
Yellow ON- successful AZ
Yellow OFF- not successful AZ
if flashing, call support of KMT, error in EPROM
SL LED: Red ON = if error of data transmitting
SL LED: Red Flashing = distance to far
Power ON LED: Red ON = if power switch on
Output to Powerhead: via 6-pol. Tuchel
Fuse LED: Flashing if fuse is defect
Powering: 10-30V DC (min. 24Watt), Input via 7-pol. Tuchel
Switch: ON/OFF
Operating temperature: - 10 to +70 °C
Dimensions: 75 x 105 x 105 (without connectors!)
Weight 750 grams
Static acceleration: up to 200g
System accuracy*: +/- 0.2 %
<*measure with gain 1000, 350ohm (0.1%) full bridge - test bridge!!>
T1-PCM-Pickup/Powerhead (standard version)
Function: Receiving inductive PCM modulated data from the coil of
the T1-PCM-STG unit
Inductive frequency is 60kHz
Distance between the transmitter coil and the pickup is 5-30*mm
Output to T1-PCM-Decoder: Via 6-pol. Tuchel plug incl. 5m cable
Operating temperature: - 10 to +80 °C
Dimensions: 53x66x30mm (without cable)
Weight: 200 grams (without cable!)
Housing: splash-water resistant IP65 (except connector).
Cable length standard 5m! Optional 10 or 15m
*(depend of shaft diameter!)
Optional top-hat rail clip

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Pin connection & block diagram
Caution:
The Powerhead must be fixed in the middle of the coil in a distance from 5 to 25 (35)mm.
Don’t introduce any metal parts between or near the Powerhead and the shaft.
Don’t mix T1-PCM and Tel1-PCM parts together!
There are not compatible!
At high RPM we recommend to solder
the GAIN jumper! On the back side of
PCB are solder bridges what can use
instead of jumper!

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Mounting example of power head / pickup:
Right installation
Wrong installation, head position is 90° wrong to the coil and will not work!
Ideal distance 10mm

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Receiving part:
Front
Rear
Analog output +/-10V
Power ON LED
AZ button
Power ON/OFF switch
Top-hat rail mounting clip
(Option!)
Flashing if fuse damage
Yellow ON- successful AZ
Yellow OFF- not successful AZ
If flashing, call support of KMT,
error in EPROM
LED ON = Error data transmission
LED Flashing =Distance between Coil
and Pickup is too
far away
Data input from Pickup and
output to Powerhead
Power IN DC 10 –30V
LEMO Plug for 4-20mA
(at 4-20mA option only!)
Pin 1= grey = 4-20mA
Pin 2 = black = GND
+10V = 20mA
0V = 12mA
-10V = 4mA
Add. 4-20mA output (Option)

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Receiving part - dimensions:
Weight: 0.750 kg

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Pin connection cable:
Pickup / Powerhead
Standard version for distance of 5-30*mm
*(depend of shaft diameter!)
DC-Power cable

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Shaft installation
2 layers (layer by layer) of the special ferrite tape around
the shaft
Fix with 2 layers of mounting tape around the shaft
Coil, depends of shaft diameter 5-18 parallel windings of
0.5 CUL (Enamelled copper wire) wires, see table for help.
Fix with 2 layers of mounting tape around the coil

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Caution:
Fix T1-PCM-STG module with at least 10 layers 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 hose clamps for final fixing!! The individual
components are to be distributed in such a way on the shaft that imbalances are avoided.
We recommend add. use a steel hose clamps for final fixing!!
We recommend soldering all pins of the T1-PCM-STG!
10 layers of the special mounting tape around the shaft.

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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. The table below is a help to estimate the number of windings fast. To optimize your results you can try one
winding more or less.
.
Diameter
(mm)
Windings
(+/-1)
max. distance with
(30mm) Powerhead
Ferrite tape
no. of layers
recommend capacitor
(Type MKT or MKS 250V)
1000
5
10mm
2
without built-in 220nF, only with external 68nF (specify at order
500
5
18mm
2
without built-in 220nF, only with external 100nF (specify at order)
500
3
5mm
2
with built-in 220nF (is standard in housing)
Not recommend for large diameters!!!!
300
5
22mm
2
with built-in 220nF (is standard in housing)
210
6
23mm
2
with built-in 220nF (is standard in housing)
160
7
23mm
2
with built-in 220nF (is standard in housing)
130
8
30mm
2
with built-in 220nF (is standard in housing)
90
11
30mm
2
with built-in 220nF (is standard in housing)
60
13
30mm
2
with built-in 220nF (is standard in housing)
30
14
30mm
2
with built-in 220nF (is standard in housing)
20
18
30mm
2
with built-in 220nF (is standard in housing)
Take note:
The typical distance between powerhead and coil is about 10mm!
At 10mm you have the lowest power consumption at the T1-PCM-DEC.
(At 5mm additional inductive power will flow in to the steel shaft and the T1-PCM-DEC will warm up!)
You can check it easy with an ampere meter at the power input of decoder!
Typical power consumption e.g. at 12V = 0.9-1.0A
Coil, depends of shaft diameter 5-18 windings of 0.5 CUL wire

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T1-PCM-IND
Following must be considered at the mounting of the inductive power head
Example of mounting
Magnetic
field
Shaft with CUL
wire Coil
Don’t use for mounting any kind metal
in this area (25-30mm)! Otherwise
magnetic energy will flow in the metal
and decrease the distance between
power head and coil (on shaft)!
25-30mm
Wrong!!! Mounting (only if metal) plate cover the active area of
inductive head

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Powerhead / Pickup - distances (coil / head)
All distance are only „up to“ and can change a little, depens of diameters!
(typical shaft diameter 20-50mm)
PH-PU-Standard & XL
+/-10mm Z
10-25mm standard,
at XL 10-35mm X
+/-10mm Y
From center cross out
PH-PU-N25
+/-10mm Z
10-25mm X
+/-10mm Y
PH-PU-XL100Z
+/-50mm Z
10-30mm X
+/-10mm Y

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

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Dimensions Powerhead / Pickup (Standard and XL) draw

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Dimensions Powerhead / Pickup (CRS at standard and XL) draw
CRS = cable rear side out!

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Dimensions Powerhead / Pickup (N25) draw

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Dimensions Powerhead / Pickup (XL100-Z) draw