Solartron metrology Bicm series Manual

BICM

(Boxed Inline Conditioning Module)

user leaet

Index

501651 Issue 13

Index

Section Title Page

Index . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.0 Introduction . . . . . . . . . . . . . . . . . 2

2.0 Technical Specification . . . . . . . . . . . . . . . 3

3.0 Operational and Set-Up Guide - BICM Kit . . . 6

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . 6

3.2 Screen Connection . . . . . . . . . . . . . . . . . 8

3.3 Gain Adjustment . . . . . . . . . . . . . . . . . . . 10

3.4 Offset . . . . . . . . . . . . . . . . . . . . . . . . 10

3.5 Set Up Using Fixed Value Resistors . . . . . 11

3.6 Gain Set Up Procedure . . . . . . . . . 13

3.7 Offset Set Up Procedure . . . . . . . . . 14

4.0 The Case . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.0 The "Why Doesn't it Work Guide" . . . . . . 17

6.0 Application Notes . . . . . . . . . . . . . . . . . . . . 18

6.1 Transducer Installation . . . . . . . . . . . . . . . . 18

6.2 Example 1 . . . . . . . . . . . . . . . . . . . . . 22

6.3 Example 2 . . . . . . . . . . . . . . . . . . . . . 23

Return Of Goods

Solartron Sales Offices

501651 Issue 13

1.0: Introduction & Glossary

The Boxed Inline Conditioning Module (BICM) is an electronics module that may be used with a wide range of LVDT transducers. Layout and size are

designed to allow the BICM to be easily fitted inline with the transducer cable and installed with the minimum of effort (or changed if ready connected to a

transducer)

The BICM output may be set for a full scale range up to ±10 VDC, offset facilities are provided. The BICM is either powered from a bipolar ±15 VDC supply

or a unipolar ±24 VDC supply depending on product type.

BICM - Boxed Inline Conditioning Unit

Gain - The output voltage per mm of transducer stroke

Offset - The output voltage when the transducer core is at null

P.C.B. - Printed Circuit Board

NPV - Nearest Preferred Value. A resistor selected from a standard range of value

(E24, E48, etc.) that is closest to the required value

BICM kits are supplied for user connection to an LVDT transducer.

1.0: Introduction

2.0: Introduction

501651 Issue 13

Standard BICM IP67 BICM

Bipolar Supply Unipolar Supply Bipolar Supply

Power Requirement

Voltage ±15 V ±1.5 V 24 V ±2.4 V ±15 V ±1.5 V

Current ±15 mA nominal 30 mA nominal ±15 mA nominal

Transducer Excitation

Primary Voltage 2 Vrms nominal

Primary Frequency 15 kHz typical

Primary Current 10 mA nominal

Signal Input

Input Voltage Range Up to 2.5 Vrms

Input Load Resistance 100 kW

2.0: Technical Specication

501651 Issue 13

Standard BICM IP67 BICM

Bipolar Supply Unipolar Supply Bipolar Supply

Signal Output

Voltage Output Up to ±10 V

Current Output 11 mA

Output Ripple <14 mVrms

Output Offset 100%

Temp Co. Gain <0.03% FRO / oC

Temp. Co. Offset <0.025% FRO / oC

Warm up Time 15 minutes recommended

Linearity 2(electronics only) <0.1% FRO

Bandwidth (-3 dB) 3250 Hz typical

1Other frequencies are available on request.

2The electronics has a specification of <0.1%, the overall linearity is dominated by the transducer.

3Other bandwidths available on request.

2.0: Technical Specication

501651 Issue 13

Standard BICM IP67 BICM

Bipolar Supply Unipolar Supply Bipolar Supply

Environmental

Operation Temperature Range 0 - 70 oC

Storage Temperature Range -20 to +85 oC

IP Rating IP40 IP67

Mechanical and Connections

Connections Solder pad or factory fit Factory fit only

Enclosure Size 98.5 x 30.5 x 13.0 mm 73.0 x 20.6 mm

Weight 30 g 75 g

Material ABS 400 Series Stainless Steel

Cable Lengths

All specification limits assume a nominal 3 m cable length between transducer and BICM. The BICM can be mounted up to 10 m from the transducer, but

this may result in reduced performance. Not all transducers can cope with long cable lengths. Cable from the BICM to the processing unit or display should

be limited to 100 m.

2.0: Technical Specication

501651 Issue 13

3.1: Introduction

The BICM kit is supplied with a selection of potentiometers and an output cable allowing users to connect LVDT sensors and set up to their own

requirements. Connections are made to the BICM PCB as shown in Fig. 3.1A or Fig. 3.1B below depending on the PCB version.

The BICM output is adjustable for GAIN and OFFSET. See the specification for range of adjustments possible.

Gain is sometimes called span or range. This control will affect the output voltage at the full transducer stroke. Adjusting the control clockwise will increase

the output.

Offset is sometimes called DC shift or zero shift. This control may be used to zero the output if mechanically nulling the transducer is not convenient or

can provide as much as 100% offset to enable the output to be unipolar ie. 0V to 10 V for full transducer stroke. Adjusting the control clockwise will make

output more negative.

Adjustment is by means of trimmer potentiometers (also called variable resistor or pots). The BICM will accept fixed value resistors in place of

potentiometers.

The BICM is designed to accept the following types of potentiometer or resistor:-

Potentiometer - Standard 3/8in square top adjust type potentiometer, see Fig. 3.1 (ie. Bourns 3299 type). The BICM kit comes complete with four

potentiometers.

Resistors - 1/4W MRF4 style.

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

501651 Issue 13

Fig. 3.1A Connections to PCB - 105186 (Bipolar or Unipolar)

Fig. 3.1B Connections to PCB - 103766 (Bipolar only)

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

Yellow

SEC2

SEC1

Green

White

Screen

Primary

Blue

Red

I/O CONNECTIONS

PRI1

PRI2

Screen

VOUT

-15 V

+15 V

Power

Supply

Output

Signal

SEC2

SEC1

Green

White

Screen

Primary

Blue

Red

TRANSDUCER CONNECTIONS

I/O CONNECTIONS

PRI1

PRI2

Screen

VOUT

-15 V

+15 V

Power

Supply

Output

Signal

Yellow

White

Green

Blue

Red

0V (Signal

white

)

Secondary 2 Green

0V Supply

Green

+15 V Bipolar

+24 V Unipolar

Red

Vout Yellow

Gain Offset

+R4

-R4

RV2RV1

Secondary 1 White

Primary Exc 2 Red

Primary Exc1 Blue

-15V Bipolar only

Blue

Screen

501651 Issue 13

3.2: Screen Connection

The screen connection is arranged so that the transducer cable screen and I/O cable screen is connected and that some cable strain relief is

provided whilst setting up the board. Screens are not connected to 0V on the PCB. Screen and 0V may be connected on the PCB by using a wire

link or at the user connection end, for example at the PSU, but it all depends on the installation requirements.

Colours are for Solartron MACH 1 5 kHz Series transducers. Check individual transducer data sheets before connecting.

If a different polarity output is required secondary connections may be reversed. See application notes.

Centre Tap (CT), yellow wire, connection not required. Ensure no loose wires.

3.2 Screen Connection

Fit the potentiometers in the positions indicated in Fig. 3.3. The table below gives suggested values for use with some solartron LVDT's. Once fitted

the set up procedure can be followed to give the required output.

3.0: Operational and Set-Up Guide - BICM Kit

FIG 4.2 SCREEN CONNECTION

3.0: Operational Guide

501651 Issue 13

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

TRANSDUCER POTENTIOMETER VALUE (ohms)

GAIN OFFSET

B2.5 100K 5K

B5.0 50K 10K

B10 100K 5K

B15 100K 5K

B25 100K 5K

B50 50K 10K

B100 50K 10K

Fig. 3.3 Component Installation

Top View

Side View

Fit this way round

FIG 5.1 COMPONENT INSTALLATION

Transducer

Connection

End

501651 Issue 13

3.3. Gain Adjustment

Gain adjustment is best done before offset adjustment. If an OFFSET potentiometer has been fitted then set this to the mid position.

GAIN SETUP PROCEDURE

1) Adjust the potentiometer to the approximate mid position, about 12 full turns from either end.

2) Adjust the LVDT core position to give 0V output.

3) Move the core to a full scale position either inwards (+ve output) or outwards (-ve output). Adjust the potentiometer value to give the required

full scale output voltage such as + or -10 V. Adjusting the control clockwise will increase the output.

4) Return the core to the null position and check the output. Repeat steps 2 & 3 as required.

3.4. Offset

Any offset required is set by simply adjusting the OFFSET potentiometer until the required positive or negative offset is achieved. Adjusting the

control clockwise will make the output more negative.

Example:- Output required is 0V to +8 V for full transducer stroke (fully out to fully in). Set the gain for an output of 0V ±4 V then apply an offset

of +4 V.

Applying the required offset can sometimes be difficult if the gain is not correctly set. The application notes may help.

If no offset is required it is best not to fit the OFFSET potentiometer.

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

501651 Issue 13

3.5. Set Up Using Fixed Value Resistors

Fit the components into the positions shown in Fig 3.4 once component values have been determined using the set up procedure.

The term nearest preferred value (NPV) is used throughout. This is a resistor selected from standard ranges (E24,E48 etc) that most closely

matches the value required.

Two resistors (in series) may be fitted to allow for more accurate calibration of gain and offset. If only one resistor is required a wire link is fitted

in place of the second resistor.

Gain adjustment is best done before offset adjustment. If an OFFSET potentiometer is fitted, set this to the mid position. If a resistor is fitted,

temporarily disconnect this.

If an offset is to be applied take this into account when setting the gain.

Example:- Output required is 0V to +10 V for full transducer stroke (fully out to fully in). Set the gain for an output of 0V ±5 V then apply an

offset of +5 V.

Some suggested start values for resistors are shown in the table below. If the transducer being used is not in the list then start with an arbitrary

value such as 50 Kohms.

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

501651 Issue 13

TRANSDUCER APPROXIMATE RESISTOR VALUE (ohms)

GAIN OFFSET (+ or -5V)

B1.5 85K 20K

B2.5 61K 13K

B5.0 40K 7K5

B10 70K 15K

B15 52K 11K

B25 51K 11K

B50 39K 7K5

B100 25K 4K3

Fig 3.4 Resistor Positions

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

501651 Issue 13

3.6. Gain Set Up Procedure

If this procedure is to be used to determine the value of potentiometer required perform up to step (6). The potentiometer value will be the NPV

greater than the resistor value determined.

1) Temporarily connect a variable resistance (such as a decade box) to the board as in

Fig. 3.5(a). Set the resistor to an initial value as shown in the table.

Fig 3.5 Temporary Resistor Connections - Gain

2) Move the core to a full scale position either inwards (+ve output) or outwards (-ve output). Adjust the potentiometer value to give the

required full scale output voltage such as + or -10 V.

3) Move the core to the full scale position. Adjust the variable resistor value to give the required full scale output voltage such as + or - 10 V.

4) Return the core to the null position and check the output. Repeat steps 2 & 3 as required.

5) If a single resistor is to be fitted, fit a NPV fixed resistor to position R1. Fit a wire link to position R2. If two resistors are to be used for a more

accurate calibration see step (6)

3.0: Operational and Set-Up Guide - BICM Kit

Resistance

Box

Resistance

Box

(a)

(b)

3.0: Operational Guide

501651 Issue 13

6) Fit a NPV fixed resistor that is just below the value required to position R1. Reconnect the temporary variable resistor to position R2, see Fig 3.6(b).

7) Repeat steps 2 & 3, moving the core between the null position and the full scale position adjusting the variable resistor as necessary to achieve the

required output.

8) Substitute a NPV fixed resistor for the temporary variable resistor position R2.

3.7 Offset Set Up Procedure

It is assumed that the gain has been set up consistent with the overall required result.

1) Set the transducer core to the null position. If this cannot be determined mechanically then, with no OFFSET resistors connected, adjust the core

position for a 0V output.

2) Connect temporary SOT or variable resistors (leads to be kept as short as possible) as shown for the required polarity offset. Fig. 3.6(a) for a positive

offset and Fig. 3.6(b) for a negative offset.

Fig 3.6 Temporary Resistor Connections - Offset

3.0: Operational and Set-Up Guide - BICM Kit

Resistance

Box

(a)

(b)

POSITIVE OFFSET

NEGATIVE OFFSET

Resistance

Box

3.0: Operational Guide

501651 Issue 13

3) Adjust the variable resistance until the required offset is achieved.

4) If a single resistor is to be fitted, fit a NPV fixed resistor to position +R4 or -R4 . Fit a wire link to position R3. If two resistors are to be used for a more

accurate calibration see step (5).

5) Fit a resistor with NPV that is just below the required value to position +R4 or -R4.

Re-connect the temporary variable resistor to position R3.

6) Repeat steps 1 & 3, moving the core between the null position and the full scale position adjusting the variable resistor as required to achieve the

required output.

7) Substitute the temporary variable resistor for a fixed resistor of the nearest preferred value.

3.0: Operational and Set-Up Guide - BICM Kit

3.0: Operational Guide

501651 Issue 13

The BICM case comprises two identical halves which are simply clamped around the PCB and connecting cables. Four self tapping screws are used to

secure the halves together.

Please note each half has a step along the side. The case halves will only mate correctly one way round.

DO NOT OVER TIGHTEN THE SCREWS when reassembling the case.

The strain relief blades in each half of the case may be removed if not required.

If enhanced environmental protection is required it is recommended that a suitable adhesive/sealant is applied to all edges of the case before assembly.

A suitable potting agent may also prove effective.

Fig 4.1 Case Assembly

4.0: The Case

Strain Relief

Blades

501651 Issue 13

This is not an exhaustive list of problems but may help cure some of more common problems.

FAULT CONDITION POSSIBLE CAUSE OF FAULT

NO OUTPUT Power supply

Is it connected correctly?

Is it turned on?

Is there at least ±13.5 VDC at the power supply pads of the bipolar or +21.6 V for unipolar BICM?

Transducer

Is it connected correctly?

Is the transducer functional (perform continuity tests)?

SUPPLY CURRENT HIGH Power supply (see NO OUTPUT)

Transducer

Core not in transducer?

Short on primary connection?

Short on secondary connection?

Is the transducer functional (perform continuity test)?

Is the primary drive to transducer correct (compare with specification)?

Output load

Is the output shorted or wrong load?

INSUFFICIENT OUTPUT Power supply

Is there at least ±13.5 VDC at the power supply pads of the bipolar or +21.6 V for unipolar BICM?

Is there a proper 0V connection?

Transducer

Is the transducer core able to move the required amount?

Setup

Is gain and offset set correctly?

Have the components been fitted properly (any dry joints)?

WRONG POLARITY OUTPUT Transducer

Secondary connection wrong way round (swap white and green wires).

Set up

Voltmeter/indicator connected wrong way round.

5.0: The "Why Doesn't it Work Guide"

501651 Issue 13

6.1. Transducer

The MACH 1 5 kHz Series range of Transducer coil assemblies are designed for protection against dust and water to IP66, making them suitable for use

in harsh environments. Designed to be rugged and yet still cost effective, these devices offer the Customer all the attributes associated with LVDT’s. A

variety of combinations and accessories are available as options.

6.1.1. Introduction

The MACH 1 5 kHz Series range of transducers operate on the LVDT principal, where movement of a core inside the transducer body is detected by a

differential change in output on two secondary coils, the primary coil(s) being energised by an appropriate AC signal. With the core in a central position,

the coupling from the primary to each secondary is equal and opposite and therefore cancel out, thus the resultant output voltage is zero. As the core

is displaced further into one secondary, its voltage increases proportionally and the other secondary voltage decreases, hence the output changes in

magnitude and phase in proportion to movement in either direction from null.

The red and white connections are in phase for inward movement (ie. towards the cable end).

The output signal depends on both core movement and energisation voltage and is expressed as a sensitivity in mV output / V energising / mm travel.

6.1.2. Installation

LVDT transducers generally are a reliable and proven technology that is well established in all areas of manufacturing and control industries. The majority

of the associated problems experienced with their application and use are totally avoidable, particularly if sufficient thought is given during the initial design

stages of equipment, to the positioning and clamping methods employed for these feedback elements.

LVDT’s being of inductive nature are susceptible to some degree to the influence of magnetic fields and therefore should be positioned well away from

electric motors, relays and permanent magnets, where this is not possible then magnetic shielding should be considered as an alternative.

Clamping of the coil assembly should be carefully considered, some example methods are shown overleaf. Ideally the body of the transducers should be

clamped centrally in a pinch or yoke type clamp, manufactured from a low conductivity, non-magnetic material, if this is not possible then the introduction

of a non-metallic bush between body and clamp is a preferred alternative.

6.0: Application Notes

501651 Issue 13

6.1.2. Installation (continued)

Irrespective of clamping method care must be taken not to overtighten retaining screws as distortion of the body may prove damaging to the integrity of the

transducer and adversely affect the geometry of the installation.

If the LVDT is to be mounted on equipment subject to high ”g” then dependent on the direction of these forces, it may be advantageous to consider end to

end clamping in preference to over body clamping.

The magnetic core supplied with each transducer has been manufactured and heat treated to achieve the optimum magnetic performance, any subsequent

handling of the core which results in stress being imparted will render the calibration void, this includes overtightening of the core during installation onto its