Sensormate QE1008-W User manual

Wireless magnet mount strain sensors
QE1008-W
Magnet-extensometer with press on strain gauge and wireless transmission
Operation Manual
SWISS MADE QUALITY

SENSORMATE AG
Steigweg 8
CH-8355 Aadorf TG
Switzerland
Tel. [phone]
Fax [phone]
Email: [email protected]
www.sensormate.ch
Preface
Dear Customer
Sensormate AG would like to thank you most sincerely for choosing a sensor system
from the QE1008-W product series.
This operation manual is intended for sales partners, customers and skilled service
personnel.
We seek to ensure that the product works to your full satisfaction. Adherence to this
operation manual ensures optimum function and service life of the QE1008-W sensor
system.
The graphics and photos in this operation manual are purely schematic examples.
Your product may look di󰀨erent to what is illustrated.
We are continually improving our products. If you should have any questions concerning
your product or this operation manual, please contact our Customer Service department
or visit our homepage.
Original language: German

WEEE Information
“Attuazione della direttiva 2012/19/UE sui
riuti di apparec¬chiature elettriche ed elett-
roniche (RAEE)”
Il simbolo del cassonetto barrato riportato sull’ap-
parecchiatura o sulla sua confezione indica che
il prodotto alla ne della propria vita utile deve
essere raccolto separatamen¬te dagli altri riuti.
La raccolta differenziata della presente ap-pa-
recchiatura giunta a ne vita è organizza¬ta e
gestita dal produttore.
L’utente che desideri disfarsi dell’apparec-chi-
atura dovrà quindi contattare il produt¬tore per
ricevere indicazioni sul sistema da quest’ultimo
adottato per consentire la rac¬colta separata
dell’apparecchiatura giunta a ne vita.
L’adeguata raccolta differenziata per l’avvio
successivo dell’apparecchiatura dismessa al
riciclaggio, al trattamento e allo smaltimento
ambientalmente compatibile contribuisce ad
evitare possibili effetti negativi sull’ambiente e
sulla salute e favorisce il reimpiego e/o riciclo dei
materiali di cui è composta l’ap¬parecchiatura.
“Implementation of Directive 2012/19/EU on
waste electrical and electronic equip¬ment
(WEEE)”
The symbol showing a crossed-out wheeled bin
on equipment or its packaging indicates that the
product must be collected separately from other
waste at the end of its useful life.
The manufacturer is responsible for organ¬ising
and managing the separate collection of this
piece of equipment at the end of its useful life.
Users wishing to dispose of the equipment must
therefore contact the manufacturer to obtain inst-
ructions from the same on how to have the equip-
ment collected separately at the end of its useful
life.
By collecting the disused equipment sepa¬rately,
it can be recycled, treated or disposed of in an
environmentally friendly manner, thus helping to
prevent the environment and public health from
being affected negatively and enabling reuse and/
or recycling of the materials forming the same
equipment.
„Umsetzung der Richtlinie 2012/19/EU über
Elektro- und Elektronik-Altgeräte (EEA)“
Das Symbol der durchgekreuzten Mülltonne auf
dem Gerät oder der Geräteverpackung weist da-
rauf hin, dass Sie das Produkt am Ende seines
Lebenszyklus separat entsor¬gen müssen.
Die Getrenntsammlung dieses Geräts an seinem
Lebenszyklusende wird vom Her¬steller organi-
siert und besorgt.
Der Nutzer, der das Gerät entsorgen möchte,
muss sich daher an den Hersteller wenden,
um Auskunft über seine Vorgehensweise zur Ge-
trenntsammlung des Geräts an dessen Lebens-
zyklusende zu erhalten.
Die entsprechende Getrenntsammlung für die
anschließende Zuführung des Altgeräts zum
Recycling, zur Wiederaufbereitung und zur
umweltverträglichen Entsorgung trägt dazu bei,
negative Auswirkungen auf die Umwelt und die
Gesundheit zu unterbinden und begünstigt die
Wiederverwendung und/oder das Recycling von
Werkstoffen, aus denen das Gerät besteht.
“Transposition de la Directive 2012/19/UE re-
lative aux déchets d’équipements électriques
et électroniques (RAEE)”
Le pictogramme de la poubelle barrée, gu¬rant
sur l’équipement ou sur son emballage, indique
que le produit en n de vie doit être traité séparé-
ment des autres déchets.
Le ramassage sélectif de cet équipement en n
de vie est organisé et géré par le constructeur.
Tout utilisateur qui souhaiterait se débarras¬ser
de l’équipement devra donc contacter le const-
ructeur pour obtenir des informations concernant
la méthode adoptée pour per¬mettre le ramassa-
ge sélectif de l’équipe¬ment en n de vie.
Un ramassage sélectif correct, en vue de l’ache-
minement de l’équipement vers des opérations
de recyclage, de traitement et de mise au rebut
respectueuses de l’environne-ment, contribue
à réduire les impacts poten-tiellement néfastes
sur l’environnement et la santé, outre à favoriser
la réutilisation des matériaux/composants dont
l’équipement est constitué.
DE EN
FR IT

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Inhalt
1. Intended use 6
2. Basic safety regulations 7
2.1. Explanation of symbols 7
2.2. Basic safety regulations 7
2.3. Organisational measures 7
3. Liability and warranty 8
3.1. Area of application 8
3.2. Exclusion of liability and warranty 8
4. Product description 9
4.1. Introduction 9
4.2. Scope of delivery 10
4.3. Technology 11
5. Technical data 12
6. Terminology 15
7. Mounting and installation 16
7.1. Mounting for bending compensated tie bar strain measurement 16
8. Operation and control 20
8.1. Sensor QE1008-W 20
8.2. Wireless receiver QE1008-W-G 21
8.3. Activating the system 22
8.4. QE Booster 23
8.5. Application software 24
8.6. Measuring the tie bar strain distribution 25
8.7. Measuring the tie bar bending (tie bar crack detection) 26
8.8. Assigning a QE1008-W sensor 27
8.9. New assignment of all QE1008-W sensors 29
9. Troubleshooting 31
10. Maintenance of QE1008-W sensors 32
10.1. Inspection 32
10.2. Servicing 33
11. Accessories and spare parts 34
12. Technical support 34
13. Service and repairs (RMA) 35
14. Notes 37

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1. Intended use
This product has been built according to the latest technology and certied safety
regulations.
This product is intended exclusively for the dened purpose
(→ see Chapter 4) and services (→ see Chapter 5).
Any other use or usage beyond this scope is not regarded as the intended use.
Use for the intended purpose includes reading, understanding and adhering to the
operation manual.

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2. Basic safety regulations
The details given here do NOT replace the regulations of the machine manufacturer.
They are a minimum requirement for the safe use of the system.
2.1. Explanation of symbols
2.1.1. Notes
Information for the optimum operation and service life of the product.
Non-observance can lead to malfunctions and damage to the
product or accessories.
2.2. Basic safety regulations
• Basically, the general accident prevention regulations and safety-related legislations
of the relevant country/region must be observed.
• Use this product only if it is in a perfect technical condition. Use it correctly while
keeping in mind the safety aspects and hazards detailed in the operation manual. In
particular, malfunctions which can a󰀨ect safety, must be eliminated immediately.
The manufacturer shall not be responsible for any damages that may result thereby.
The user shall bear full responsibility.
• Work to be carried out must be completed in accordance with local legislation and
implementary provisions. If instructions in this operation manual di󰀨er from the
statutory requirements, please follow the more restrictive option. If these provisions
contradict each other, please contact your sales partner or Customer Services at
Sensormate AG before starting work.
2.3. Organisational measures
The operation manual must always be readily available with the product.

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3. Liability and warranty
3.1. Area of application
The area of application of the QE1008-W sensors is described in Chapter 1 (Intended
use) and Chapter 5 (Technical data).
3.2. Exclusion of liability and warranty
Exclusion of liability and warranty arises:
• If the QE1008-W is used outside of the specied area of application
(see Chapter 1).
• If the notes and instructions in this manual are not observed.
• If the QE1008-W and its associated equipment are not operated correctly.
• If the QE1008-W is not serviced or is serviced incorrectly, including the use of non-
prescribed spare parts.
• If unapproved accessories and components are used without written approval from
Sensormate AG, which could directly or indirectly a󰀨ect the QE1008-W sensors and
associated accessories.
• If any kind of modication is made to the products supplied by Sensormate AG.
• Sensormate AG shall not be liable for any consequential damage caused by the
incorrect handling of its products.

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4. Product description
4.1. Introduction
The double magnet strain measurement sensors QE1008-W are used for accurate
force and strain measurements on ferromagnetic surfaces. The use of two QE1008-W
sensors enables the system to take exact measurements of bending compensated
tie bar strains. The compact design and simple installation also o󰀨er a wide variety of
di󰀨erent applications.
Each sensor has a strain gauge signal amplier. Data is transmitted wirelessly to the
wireless receiver which is connected to the PC. The supplied software shows the
received measurement data in real-time. The data can be saved and opened using an
Excel program.
Sensor (transmitter)
Receiver with computer
Machine
Display software

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4.2. Scope of delivery
Example with 8 + 1 sensors (order code: QE1008-W-09)
01 USB stick includes: – Instructions
– Software
– Brochures
02 8 sensors incl. rechargeable batteries
03 Charger with 2x connection cables for the charge bars
04 1x replacement sensor (optional)
05 Wireless receiver (Host)
06 Repair kit
07 2 x charge bars
08 Operation manual under the foam insert
01
02
03
05
07
06
08
04

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4.3. Technology
Two strong magnets press the strain gauge of the patented sensor QE1008-W onto the
material to be measured.
The strain gauge is located under the foil between the two magnets. The magnets press
the strain gauge that strongly onto the surface that transmission through friction occurs.
The surface strains are hereby transmitted directly onto the strain gauge which creates
the same e󰀨ect of an applied strain gauge (bonding).
The individual sensors can be used for applications such as strain measurements on tie
bars with di󰀨erent diameters to stress analyses on at surfaces.
The press-on technology of the QE1008-W enables the high-precision measurement of
strains with quick and reliable mounting, thus reducing the idle time of the machine to a
minimum.
Examples of applications
• Bending compensated tie bar strain measurement
• Tie bar strain distribution on presses (acc. to EUROMAP #7)
• Clamping force measurement on columns
• Measurement on at surfaces
• Replacement of bonded strain gauges
The advantages of this system
• Very high accuracy: <0.5% absolute (like a bonded strain gauge)
• Used for tie bar diameters 45... >1000mm
• Bending compensated measurement
• Reliable and accurate also on at surfaces
• Supplied display software with option to save in CSV le format
• Digital and direct tie bar-related display of force in kN, tons, US-tons or µε
• No cables
• Easy to mount and remove
• Very compact design (suitable for skilled service personnel)
• Minimum space requirements and protected as all accessories are stored in a
practical carrying case.
• No more dirty cables in the machine bed

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5. Technical data
QE1008-W (Sensor)
Strain gauge type Foil (GF = 2.0)
Bridge resistance 350Ω
Measuring range ± 800με
Output signal for radio transmission IEEE 802.15.4TM
Signal range 30...100m
Sensitivity tolerance ± 0.2%
Transverse sensitivity 0.9 ± 0.2 %
Accuracy < ± 0.5% FS
Linearity < ± 0.5% FS
Hysteresis < ± 0.5% FS
Repeatability < 0.2% FS
Supply voltage when charging 6.2VDC (max. 6.5VDC)
Power consumption when charging 325mA
Ambient temperature 5...65°C
Storage temperature 0...65°C
Overload capability unlimited
Type of protection IP40
Material: Housing Aluminium
Material: Cover Plastic
Weight 530g

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Dimensions in [mm]
Dimensions of QE1008-W

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QE1008-W-USB-G (receiver)
Dimensions in [mm]
Dimensions
Transmission module
Frequency 2.405-2.480 GHz (ISM band)
Safety record standard IEEE 802.15.4TM
TX performance 0dBm / 1 mW (max.)
Range 30...100m
(dependent on operational environment)
Main functions: – Hardware CSMA-CA
– Hardware safety-related (AES-128)
The transmission module is FCC (USA), IC (Canada), ETSI (Europe) and TELEC
(Japan) certied. The MAC address is always unique and burnt into the hardware.

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6. Terminology
Terms Explanation
DMS Strain gauge
FS = Full Scale Calibrated measuring range
Accuracy Combined errors for linearity and hysteresis
Linearity Delta of signal curve to straight line "zero point - FS"
Hysteresis Delta of signal curve "load/relief"
Repeatability Dispersion of signal for multiple measurements
Tons Metric ton: 1t = 9.81kN
US-tons American ton: 1 US-tons = 1.1023t
µε = micro strain 1 µε = strain of 1µm/m
Full scale
kN
Signal load
Delta = Linearity
Linearity
0
µε
Delta = Hysteresis
Signal relief
Signal load
Full scale
Hysteresis
kN
0
µε

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7. Mounting and installation
These sensors are precision instruments with a resolution of 0.001mm.
The devices must therefore be handled with great care. This instruction
manual must be read and observed by every user.
7.1. Mounting for bending compensated tie bar strain measurement
7.1.1. Preparation
The sensors must always be placed in pairs onto a tie bar (1.1&1.2), (2.1&2.2) etc.
Position
The distance between the sensor and clamping
plate must be at least once the diameter of the tie bar so
that the deformation of the tie bar can be measured
evenly and correctly.
Surface
Oil and other surface contamination, or paint which
has been applied, must be removed at the site of
installation.
Sensor
Check the charge of the current batteries
(see Chapter 8 „Operation and control“)..
Check the foil on the sensor for signs of damage.

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7.1.2. Positioning the sensor
1. Turn both knurled nuts so that they are ush with the end of the threaded rod.
2. The long edge of the sensor must be placed onto the surface to be measured and
then tilted. The magnets pull the sensor onto the tie bar.

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3. If the magnets do not automatically jump onto the measuring surface, press down
the knurled nuts one after the other. The magnets should now jump onto the tie bar.
The attraction force of the magnets is now optimal.
–The sensor on the tie bar may only be moved fractionally.
–The magnets have ground guides. Make sure that both sides of
the guide rest on the tie bar!
4. The contact force can be increased by tightening the knurled nut. (usually not
necessary.)
If a magnet jumps back, the knurled nut has been tightened too much, thereby
making the spring tension too big. Loosen the knurled nut to relieve the tension of
the spring.
–The sensor must make proper contact and be stable.
–The sensor must not move when shaken slightly.

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5. Remove the 2nd sensor from the carrying case and complete steps 1 to 4.
–The sensor must be positioned parallel to the tie bar!
–The 2nd sensor pair must be placed exactly opposite (180°) and
parallel to the 1st sensor at the same position!
Correct!
Incorrect!
Not 180° opposite
Incorrect!
Not at same position

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8. Operation and control
8.1. Sensor QE1008-W
LED status
Button function
Using the sensors in a new environment a new assignment as described
in chapter 8.7 should be done.
Normal operation:
LED green: on LED red: o󰀨 → Receiver search
LED green: ashing LED red: o󰀨 → Ready
(connected to receiver)
LED red: on LED green: on or ashing → Rechargeable battery virtually empty
LED red: ashing LED green: on or ashing → Strain gauge damaged
Special displays:
Both LEDs ash alternately → Sensor is in logon mode for
assignment
LED green: o󰀨 LED red: ashing → Sensor not assigned to receiver
→ reassign
Switching on QE1008-W sensor Press button for ~1 second
Switching o󰀨 QE1008-W sensor Press button for ~1 second
Logon mode for assignment Press button for ~5 seconds until the LEDs
ash alternately
Deleting assignment Press button for ~10 seconds until red LED
ashes
01 Knurled nut
02 Steel spring
03 Charging socket 6VDC
04 Slot number
05 LEDs red and green (status displays)
06 Button
07 Aerial
06
03
01
02
05
07
04