SyncroCraft Sonic Meter SM1000 User manual

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Sonic Meter
SM1000
Operating Manual
2-00, 1-11, Rev 1.1
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SyncroCraft, LLC
SyncroCraft, LLCSyncroCraft, LLC
SyncroCraft, LLC
16225 CAMINO DEL Sol
LOS GATOS, CA 95032
TELEP ONE 408-438-0597
[e-mail]
Important: Do not attempt to operate this instrument without completely
reading this manual and understanding the correct operating procedures.
For online technical support and further information refer to our web site at
www.sonicmeter.com
www.sonicmeter.comwww.sonicmeter.com
www.sonicmeter.com
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Table of Contents
1. Safety
1.1 Batteries
1.2 Charger
1.3 Meter
1.4 Probe
1.5 Electromagnetic Compatibility
2. Introduction
3. Description
3.1 Sonic Meter
3.2 Keypad
3.3 LCD display
3.4 1meter cable
3.5 Sonic Meter probe
3.6 Battery Charger
3.7 Batteries
4. Operation
4.1 Changing the batteries
4.2 Resetting the circuit breaker
4.3 Powering up the meter
4.4 Options
4.5 Battery capacity
4.6 Real time reading
4.7 Averaged reading
4.8 Setup
4.9 Powering off the meter
4.10 How to take measurements
5. Appendices
A. Specifications
B. Troubleshooting
C. Parts List
D. Warranty
E. Calibration sheet
1. Safety:
1.1 Batteries:
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The Sonic Meter SM1000 is powered by 4 AA Nickel Metal Hydride (NiMH) batteries
rated at 1300mAh. The meter is fault protected against reverse polarity via a resetable
circuit breaker. The meter ships with 8 AA batteries. The 4 AA batteries in the meter
were charged at the time of shipping. The other 4 AA batteries are not charged.
CAUTION: Shorting the batteries (positive terminal connected to negative
terminal) is extremely dangerous and could cause serious injury. Extreme caution
should be used when handling and charging the batteries.
Do not store meter for long periods with the batteries installed. When disposing of
batteries follow all state and local laws.
1.2 Charger:
The battery charger is powered by 120Volts AC at 60Hrz. Use of charger with any other
voltage input will damage the charger and could cause serious injury.
1.3 Meter:
The Sonic Meter’s housing is not waterproof. If the meter becomes immersed in water
do not attempt to use it. Do not attempt to repair it. Return the meter to SyncroCraft for
authorized repair.
1.4 Probe:
The probe attaches to one end of the 1 meter co-axial BNC cable. The other end of the
BNC cable that connects to the meter. Never attempt to remove or install the probe or
cable while the meter is powered. Attempting this could cause voltage surges,
possibly damaging the probe or meter.
1.5 Electromagnetic Compatibility:
The Sonic Meter SM1000 complies with EN 61326-1:1997. The meter is CE approved.
Important: The Sonic Meter SM1000 is not designed for use as a medical device.
Important: Never operate the Sonic Meter SM1000 and probe in areas where high
voltage potentials are not properly contained.
NOTE: Please read and understand the entire manual before operating the Sonic Meter
SM1000 .
2. Introduction:
The Sonic Meter SM1000 quantifies the ultrasonic pressure output of a liquid filled
ultrasonic cleaning tank. If a tank’s ultrasonic output is diminished, the quality of the
parts and the processes that follow the production may drift from the original
specification. The Sonic Meter is designed to help maintain process stability of
ultrasonic cleaners by quantifying the tanks output during scheduled calibration intervals.
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Ultrasonic cleaners utilize a transducer attached to the tank’s exterior. The transducer
outputs pulsating mechanical energy at high frequencies (ultrasonic), which cause the
liquid in the tank to agitate.
The agitation at this high frequency level is what gives ultrasonic cleaners their cleaning
ability. As the liquid becomes agitated, a phenomenon known as cavitation takes place.
Cavitation is the almost instantaneous formation and implosion of small bubbles and
cavities in the cleaning liquid.
As the liquid cavitates, the minute bubbles and the coincident implosions cause the
surrounding liquid to impinge forcefully upon the surface areas of the part being cleaned.
The force that the liquid applies to the area of the part is commonly referred to as the
scrub-force.
This scrub-force action takes place throughout the tank. However, the scrub-force can
vary significantly due to the placement of the tank’s transducer and the constructive and
destructive interference caused by the shape of the tank and parts being cleaned.
These process variations in scrub-force throughout the tank can be referred to as hot or
cold spots in the liquid. Hot and cold spots are locations of high and low intensity scrub-
force relative to a mean value scrub-force. These process variations can significantly
alter the cleanliness or integrity of the parts being cleaned. Some parts may not have
been thoroughly cleaned for the next process, or the stresses due to the cleaning action
may have altered the integrity of the parts. With the Sonic Meter these process variation
can be minimized.
With the Sonic Meter’s slender probe, operators can probe ultrasonic cleaners to
pinpoint areas of optimum intensity in which to place each part. The Sonic Meter’s
displays the intensity variations. Parts could be varied in their z-height or their x and y
positions via an adjustable array fixture. The operator can determine the location for
each part so that all parts are placed in regions of the same specified pressure range
(scrub-force). Or several readings could be taken and averaged to determine the mean
value scrub-force of a particular cleaner.
The Sonic Meter SM1000 measures scrub-force in units of pounds per square inch
(psi). The SM1000 works with tanks that use frequencies in the range of 0-500kHz.
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3. Description:
Figure 1
Figure 1 shows the main components of the Sonic Meter SM1000 .
3.1 Sonic Meter:
The Sonic Meter SM1000 is packaged in an industrial T-shaped housing. The housing
is made of hard anodized aluminum. The housing is splash proof (not waterproof).
3.2 Keypad:
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Figure 2
Figure 2 shows the designations of the keypad’s four keys.
The keypad utilizes membrane keys with a color mylar overlay. There are four keys that
control the meter:
Scroll Up: Color designation is yellow. Used for scrolling up through the menu choices
and increasing input values.
Scroll Down: Color designation is yellow. Used for scrolling down through the menu
choices and decreasing input values.
Power ON/Scroll Right: Color designation is green with “1”. Used for powering on the
meter, for selecting a specific menu choice and for scrolling right when changing input
values.
Power OFF/Scroll Left: Color designation is red with “0”. Used for powering off the
meter, for returning back to the previous menu and for scrolling left when changing input
values. By holding this key the meter will always return to the main Options menu
from any other menu.
3.3 LCD Display:
The LCD is a character based, high contrast display made up of 4 lines by 20 characters.
Information is displayed in a menu driven format where selections are made by scrolling
to the desired selection point with the keypad.
3.4 1 meter cable:
The 1m BNC cable connects the meter to the probe.
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Never attempt to remove or install the probe or cable while the meter is powered on.
Surges in voltage could damage the probe or meter.
3.5 Sonic Meter Probe:
The probe is made of 304 stainless steel with a BNC connector at the top of the probe and
the sensing transducer at the bottom. Each probe has a unique sensitivity value associated
with the sensing transducer. The sensitivity value is input into the meter’s memory via
the keypad. The top of the probe is engraved with a serial number that distinguishes it
from other Sonic Meter probes. For example, if an operator were to switch the probe
from the meter with another probe, the operator would need to power off the meter,
switch the probes, power up the meter and then go into the Setup menu and change the
probes sensitivity. This procedure is explained in detail in section 4.8.
3.6 Battery charger:
The battery charger can only be used to charge Nickel Metal Hydride (NiMH) type
rechargeable batteries. Do not attempt to charge NiCd batteries or mix other
batteries with NiMH batteries.
The battery charger should only be powered by 120 Volts AC at 60 Hz. The plug type is
UL.
3.7 Batteries:
The Sonic Meter SM1000 ships with 8 AA Nickel Metal Hydride (HiMH) batteries.
The meter use 4 AA NiMH batteries rated 1.2V/1300mAh or higher. The batteries
should reach full charge in 6hrs.
Do not attempt to charge these batteries on any other charger than the unit shipped
with the meter.
4. Operation:
4.1 Changing the Batteries
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Figure 3
Figure 3 shows how the 4 AA batteries are removed.
With a Phillips screwdriver, unscrew the flathead screw from the back of the meter. Lift
the battery cover out from the meter. Remove the 4 AA NiMH batteries, and replace
with 4 charged batteries. Make certain that you replace the batteries into their sockets
with the correct polarity. The polarity is clearly marked on the bottom of each battery
socket. Reinstall the battery cover with the retaining tab positioned first in the bottom of
the meter before securing the cover.
If the batteries are installed with the incorrect polarity, one of three situations will be
evident:
1. One of the 4 batteries was installed with the incorrect polarity.
Observation: The meter will power on, but the battery percentage will not be
displayed, and keypad keys will not function. Reinstall the battery correctly.
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2. Two or three batteries were installed with the incorrect polarity.
Observation: The meter will not power on. Reinstall the batteries correctly.
3. All four batteries were installed with the incorrect polarity.
Observation: The 0.63Amp circuit breaker will disengage power. The meter will not
power on. Remove all four batteries. Reset the circuit breaker. Reinstall the
batteries correctly.
4.2 Resetting the circuit breaker
Figure 4
Figure 4 shows the circuit breaker located at the bottom of the meter just below the
battery housing.
Remove the battery cover. With a small screwdriver, push the small white tab of the
circuit breaker to the right. A small click will sound when the reset tab has been moved
all the way to the right. The circuit breaker is now reset.
The most probable reason for setting off the circuit breaker would be incorrectly installed
batteries.
4.3 Powering up the meter
Options: Batt.=100%
→1. Real time reading
2. Averaged reading
3. PowerOFF / etup
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Figure 5
Press and release the green Power ON key to power up the meter as shown in Figure 5.
Note: Before taking measurements, wait approximately 1 minute after powering up
the meter. Waiting 1 minute allows the probe to come to full charge.
4.4 Options menu (main menu)
The Options menu will appear on the LCD after powering up the meter as shown in
Figure 5. The Options menu displays the batteries capacity and 3 option selections: 1.
Real time reading; 2. Averaged reading; 3. PowerOFF / Setup.
4.5 Battery capacity
The battery’s capacity is displayed in percent. As the battery decreases in voltage, this
value decreases. For NiMH batteries, this value will gradually drop until about 40%.
After this point, the NiMH batteries drop off quickly. With continuous use, the meter
will run approximately 8 hours
4.6 Real time reading
In Figure 5, the Options menu displays the selection arrow at the 1st position. Note: the
1st position (Real time reading) is always the default position of the selection arrow when
entering the Options menu.
With the selection arrow still at the 1st position, press and release the green Right Scroll
key as shown in Figure 5.
The following screen will appear on the LCD as shown below in Figure 6.
Figure 6
The real time pressure (psi) is displayed along with the operator’s specified Low and
High range limits as shown above in Figure 6.
The Low and High range limits are input into the meter’s non-volatile memory at the
Setup stage, which will be explained in section 4.8 Setup.
Pressure=###.##psi
Low <
<<
< ###.##psi
High >
>>
> ###.##psi
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The Low range limit indicator is a “<” symbol that is displayed in the upper left-hand
corner. Refer to Figure 7. This indicator appears when the pressure reading is less than
the acceptable Low range limit value XXX.XXpsi. At 0.00psi this symbol is not
displayed.
For example: If the Low range limit is <15.00psi and the actual pressure reading
=14.99psi, then the Low range limit indicator “<” will be displayed in the upper left-hand
corner of the LCD as shown below in Figure 7.
Figure 7
The High range limit indicator is a “>” symbol that is displayed in the upper right-hand
corner. Refer to Figure 8. This indicator appears when the pressure reading is less than
the acceptable High range limit value XXX.XXpsi.
For example: If the High range limit is >25.00psi and the actual pressure reading equals
25.01psi, then the High range limit indicator “>” will be displayed in the upper right-hand
corner of the LCD as shown below in Figure 8.
Figure 8
Return back to the Options menu at anytime by pressing and releasing the red Left scroll
key as shown below in Figure 9.
Figure 9
<
<<
<
Pressure= 14.99psi
Low <
<<
< 15.00psi
High >
>>
> ###.##psi
Options: Batt.=100%
→1.Real time reading
2. Averaged reading
3. PowerOFF / etup
Pressure= 25.01psi
>
>>
>
Low <
<<
< ###.##psi
High >
>>
> 25.00psi
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4.7 Averaged readings
Figure 10
At the Option menu, scroll down to 2nd position as shown above in Figure 10. If the
meter is not at the Option menu press and hold the red Scroll Left key.
With the selection arrow at the 2nd position, press and release the green Scroll Right key
to select the Averaged reading option. The following menu will appear as shown below
in Figure 11.
Figure 11
The first line displays the real time pressure. The real time pressure is displayed so that
the operator can position the probe in the cleaner before taking an averaged reading.
Below the real time pressure, the Averaged readings menu displays 3 selections: 1. Begin
readings; 2. Samples= XX; 3. Interval=XX.XXsec.
Selection 1 will initiate the averaging of the pressure based on the number of pressure
reading samples and the time interval. Selections 2 will allow the user to select the
number of samples. Selection 3 will allow the user to select the time interval between
samples.
Before taking an average reading of the pressure, selections 2 and 3 will need to be setup.
Start by changing the Samples value. Press the yellow Scroll Down key once so that the
selection arrow is on 2. If you passed selection 2, you can either press the yellow Scroll
Up key or keep pressing the Scroll Down key until the selection indicator is at selection 2
as shown below in Figure 12
Figure 12
Options: Batt.=100%
1. Real time reading
→2. Averaged reading
3. PowerOFF / etup
Pressure=###.##psi
→1. Begin readings
2. amples=##
3. Interval=##.##sec
Pressure=###.##psi
1. Begin readings
→2. amples=##
3. Interval=##.##sec
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With the selection indicator at the 2nd position, press and release the green Scroll Right
key. An underscored flashing cursor will appear in the rightmost ones digit of the
Samples value as shown above in Figure 12.
The number of samples can range from 0 to 40.
With the cursor still in the ones digit, use the yellow Scroll Up or Scroll Down buttons to
change this number. When the desired ones digit is set, press and release the red Scroll
Left key once. The underscored cursor will now be positioned in the tens digit as shown
below in Figure 13. Once again, use the Scroll Up or Scroll Down keys to change this
number.
Figure 13
When the desired number is set for the tens digit, press and release the red Scroll Left key
once to return the selection arrow to the 2nd position. The value will automatically be
saved in non-volatile memory.
To set the time interval between sampling, scroll down to the 3rd position with yellow
Scroll Down key as shown below in Figure 14
Figure 14
With the selection indicator at the 3rd position, press and release the green Scroll Right
key. An underscored flashing cursor will appear in the rightmost hundredths digit of the
Samples value as shown in above Figure 14.
The time interval between samples can range from 0.01 to 99.99 seconds.
Figure 15
Pressure=###.##psi
1. Begin readings
→2. amples=10
3. Interval=##.##sec
Pressure=###.##psi
1. Begin readings
2. amples=10
→3. Interval=##.##sec
Pressure=###.##psi
1. Begin readings
2. amples=10
→3. Interval=##.28sec
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With cursor still in the hundredths digit, use the yellow Scroll Up or Scroll Down buttons
to change this number. When the desired hundredths digit is set, press and release the red
Scroll Left key once. The underscored cursor will now be positioned in the tenths digit
as shown above in Figure 15. Once again, use the Scroll Up or Scroll Down keys to
change this number. Repeat this step for the ones and tens digits. When the desired
number is set for the ones and tens digits, press and release the red Scroll Left key once
to return to the selection arrow at the 3rd position. The value will automatically be saved
in non-volatile memory.
When the number of samples and time interval parameters are set to the desired values,
scroll up to the 1st position (Begin readings) by pressing and releasing the yellow Scroll
Up key twice. To execute the averaging process, press and release the green Scroll Right
key once. The following screen prompt will appear as shown below in Figure 15. This
screen will remain for the duration of the averaging. The index (number of samples) of
the average will count down each of the readings and be displayed in the upper left-hand
corner as shown below in Figure 16.
Figure 16
After the averaging process has been completed, the following screen will display the
average pressure value as shown in Figure 17.
Figure 17
To return to the averaging screen press the red Scroll Left key once. To return to the
options screen, press the red Scroll Left key again.
4.8 Setup
From the Options menu, scroll down to the 3rd option as shown below in Figure 18.
Figure 18
With the selection indicator at the 3rd position, press and release the green Scroll Right
key. The Setup menu will appear as shown below in Figure 19.
#
* Averaging Data *
Average = ###.##psi
←exit
Options: Batt.=100%
1. Real time reading
2. Averaged reading
→3. PowerOFF / etup
Instrument etup:
→1. Limits
2. Median
3. Probe etup
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Figure 19
Options 1 and 2 are used for setting up the low and high range limits that were explained
in section 4.6. The low and high range limits are calculated as follows:
low range = median(value) – limits(value)
high range = median(value) + limits(value)
Example: median = 25, limits = +5. The low and high range limits will be 20 and 30 psi,
respectively.
Now setup the limits. With the selection indicator at the 1st position, press and release the
green Scroll Right key.
The following limits setup screen will appear as shown in below in Figure 20.
Figure 20
The cursor will appear underscored and flashing in the hundredths position of the “New
Value”. By using the yellow Scroll Up/Down keys, each digit can be changed. To move
to the next digit use the red Left Scroll key. The cursor can always be moved to the
previous digit by using the green Right Scroll key. After the last digit (hundreds) has
been set, push the red Left Scroll key once to return to the Setup menu. Values are
automatically saved.
Now setup the median. At the Setup menu, with the selection indicator at the 2nd
position (Median), press and release the green Scroll Right key.
The following median setup screen will appear as shown in below in Figure 21.
Figure 21
Use the same procedure to setup the median as was previously used for setting up the
limits.
Old value=XXX.XXpsi
Enter a new limit:
New value=XXX.XXpsi
To exit scroll left
Old value=XXX.XXpsi
Enter a new median:
New value=XXX.XXpsi
To exit scroll left
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Now setup the probe.
Each probe sold with each Sonic Meter has a unique sensitivity value. Because of this,
the probe sensitivity value will have to be changed whenever the probe is switched among
meters or a probe has been replaced due to damage. If this is not done, the accuracy of
the measured value will change by a small amount. The serial number of each probe is
engraved at the top of the probe. The sensitivity and serial number for each probe is
recorded in the Calibration sheet located in Appendix E. If more than two meters are
used at the same location, occasionally check to make sure the probes are matched with
their corresponding meters.
At the Setup menu, with the selection indicator at the 3rd position (Probe), press and
release the green Scroll Right key.
The following median setup screen will appear as shown in below in Figure 22.
Figure 22
Use the same procedure to setup the probe sensitivity as was previously used for setting
up the limits and median. Refer to Appendix E for the probe’s sensitivity value.
4.9 Powering off the meter
From the Options menu, scroll down to the 3rd position as shown in Figure 23.
Figure 23
Press and hold the red Left Scroll key. A slight click will sound, and the LCD will go
blank. The meter is powered off.
Old value=XXX.XXpsi
Enter sensitivity:
New value=XXX.XXpsi
To exit scroll left
Options: Batt.=100%
1. Real time reading
2. Averaged reading
→3. PowerOFF / etup
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4.10 How to take measurements
Follow the manufacturer’s operating procedures before operating ultrasonic cleaners: set
the proper degas and temperature settings.
Quick real time scrub-force readings:
The real time reading mode allows for a quick estimate of the scrub-force at a particular
point. This is useful for checking scrub-force levels during the process of cleaning
Begin probing the tank with the meter in real time reading mode. Notice the fluctuations
in the readings. The readings usually fluctuate + 3 psi for most tanks.
Average scrub-force:
For precise scrub-force readings set the meter in averaged reading mode. Averaged
reading mode is useful for determining the scrub-force levels of a particular point or the
tanks overall scrub-force output
For a good starting point set the number of samples to 10, and the interval to 1 second.
These settings will average 10 samples over a 10second period.
With the meter still in averaged reading mode, take 8 to 10 readings throughout the tank.
Make sure to hold the probe steady while taking each average. Write down each reading.
Then average these readings to get an overall scrub-force value for the tank.
Factors that determine the tanks scrub-force output:
Scrub-force levels can vary by as much as +10psi each time a different set of
measurements is taken.
The factors that determine this variance are:
•Degas time
•Tank temperature
•Part geometry
•Probe position
Degas the tank according to the manufacturer’s specifications. The degas time is usually
15-20 minutes
Some tanks have a heat setting so that temperature can be controlled. Follow the
manufacturer’s specifications. Usually by the time the tank is degassed, the temperature
has stabilized.
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Part geometry: the shape of a part can cause a change in the scrub-force output. The
part’s shape can cause constructive and destructive interference to the scrub-force output
Probe position is critical. Within in only a few millimeters, the scrub-force can vary
significantly (this variance differs by tank type). This is due to nodes of high and low
pressure that develops within the liquid. For the highest level of precision, the probe
should be held in some type of fixture that allows for x, y and z positions.
5. Appendices:
A. Specifications
Bandwidth: 0-500kHz
Pressure reading: 0-130psi, error < 1.5%. Determined over the entire working
range.
Temperature Operating Range: -65 to 250 F or –55 to 120 C
Performance: Real time reading samples pressure every 50msec. Averaged reading
can sample 0-40 readings at sample intervals of 10msec to 99.99sec.
Accuracy: The Sonic Meter SM1000 uses a 12bit ADC to digitize the analog
signal coming from the probe’s transducer. The accuracy of the meter is +0.03psi.
Battery life (hours): The Sonic Meter SM1000 consumes current at a rate
150mA/hour. The NiMH batteries are rated at 1300mAh. For continuous use, the
meter will run approximately 8 hours before batteries will need to be recharged.
B. Troubleshooting
Meter fails to power on:
1. Batteries need to be recharged.
2. Batteries were improperly installed. (refer to section 4.1)
3. Circuit breaker has tripped. (refer to section 4.1 and 4.2)
4. Circuit fault unknown (return to SyncroCraft)
Meter fails to power off:
1. Circuit fault unknown (return to SyncroCraft)
Pressure reads zero when tanks are on:
1. Cable has a line break.
*measure impedance of cable: 1-5ohms acceptable
*replace cable if impedance is above 5 ohms
2. Probe fault unknown (return to SyncroCraft)
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