visilab AK50 User manual

1
AK50AK50
AK50AK50
AK50
PROCESS MOISTURE LOGGER FOR ON-PROCESS MOISTURE LOGGER FOR ON-
PROCESS MOISTURE LOGGER FOR ON-PROCESS MOISTURE LOGGER FOR ON-
PROCESS MOISTURE LOGGER FOR ON-
LINE OPERATIONLINE OPERATION
LINE OPERATIONLINE OPERATION
LINE OPERATION
2018-09
USER'S MANUAL
Model 6S
AK50 - Infrared Measurement and Analysis
Copyright (c) 2018 Visilab Signal Technologies Oy
Made in Finland
Manual printed in Pukkila, Finland
PART #700181
Unit information:
Model & Rev: AK50 Rev:
Serial number:
Firmware V
PCB's:
Adjusted:
Service Interval (hours):
The embedded software version V2.09S and later support all the features mentioned in this manual.
The PC program referred to in this manual is IRMA7Basic which follows each meter. It can also
always be downloaded from our web site to upgrade at no cost. A license for the Advanced and
Profiler programs is now a standard with the AK50 meter.
Visilab Signal Technologies OyVisilab Signal Technologies Oy
Visilab Signal Technologies OyVisilab Signal Technologies Oy
Visilab Signal Technologies Oy
Address: Tel.:
Sepäntie 4 [phone] www.visilab.fi
FI-07230 Monninkylä Y 0631208-0 ALV Rek.
FINLAND VAT FI 06312080 Mäntsälä Reg. 365.258 e-mail: [email protected]

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
2
CONDITIONS OF GUARANTEE, COPYRIGHT NOTICE AND LIABILITIES OF THE MANU-
FACTURER
The manufacturer (Visilab Signal Technologies Oy) grants a guarantee of two years for the buyer of
AK50 moisture meter from the date of purchase. The guarantee covers all faults and misalignments
which are in the equipment at the moment of purchase including those which appear during the
guarantee period. The manufacturer is liable of repairing the instrument without cost to the buyer. The
manufacturer can ship a new instrument of equivalent value and status if considered as a better
solution than repairing. The buyer is liable of paying the freight costs to the factory of the faulty unit.
The unit must not be sent to the manufacturer without a permission from the manufacturer. Units sent
without a permission will be repaired at the cost of the buyer.
The guarantee does not cover wearing parts, like batteries, lamps or motors. The guarantee does not
cover faults caused by errors or neglects of the user nor those faults which are caused by deliberate
damaging. The guarantee does not cover faults caused by incorrectly installed cables or conduc-
tors. The guarantee does not cover any damages to the user or to any third party independently of
the way how the instrument has been used. The guarantee does not cover faults caused by natural
phenomena like lightnings or floods, nor user errors like dropping or hitting the unit. The guarantee
is void if the unit is sold to any third party. All faults which are not covered will be repaired at the cost
of the buyer.
If opening of the instrument has been attempted at those parts which are not intended for the user,
the manufacturer can refuse to repair or service the instrument. Then the instrument will be shipped
back to the buyer at the cost of the buyer. Such parts are the light source, the optical head and parts
on the electronics boards. The instrument can be opened only strictly according to the instructions
in this manual and should not be disassembled unnecessarily. Also, if some parts can not be opened
with a reasonable force, they should be left to avoid any damage.
Copyright (c) 1994 - 2018 Visilab Signal Technologies Oy, All Rights Reserved
Visilab Signal Technologies Oy reserves all rights to changes and modifications in the looks,
specifications, optical and electronic design, electronic and software interfaces and computer
programs, and also the right to change the retail prices of the instrument or its parts without any notice
to present or potential customers. All copyrights and design rights belong to Visilab Signal Technolo-
gies Oy. The PC programs, which have been sold to the buyer, can be used and copied freely for his
own use but can not be sold to any third party.
The manufacturer is not responsible for any casualties, damages or accidents which the user has
caused directly or indirectly with this AK50 instrument, either to himself or to any third party,
independent on the instrument being used correctly or not.
Important warnings are highlighted in this manual with red color.
Recommendations are in blue and important instructions are in brown.

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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EC Declaration of Conformity
We
Visilab Signal Technologies Oy
Sepäntie 4
FI-07230 Monninkylä
FINLAND
declare that the
AK50 AND IRMA-7 model D Process Moisture Loggers
meets the intent of the EMC directive 89/336/EEC. Compliance is based on the following harmonized
standards:
Emissions:
EN 50 081 part 2 (industrial environment):1993 referring to :
EN 55 011 radiated, Class A, Group 1
EN 55 011 conducted, Class A, Group 1
Immunity:
EN 50 082 part 2 (industrial environment):1992 referring to (both radiated and
conducted fields):
EN 61000-4
IEC 1000-4
ENV 50140
ENV 50141
ENV 50204
I certify that the apparatus identified above conforms to the requirements of Council Directive 89/
336/EEC.
---------------------------------------------------------
Henrik Stenlund
managing director
5th May 1997
Note for users:
When the apparatus identified above is connected by someone to become a part of an industrial
control system, he is also responsible for the EMC compatibility of the resulting system. He is also liable
of providing the necessary optical or galvanic isolations for signals and transient absorbers for other
lines to conform to the EMC directives.
The meters and the power source apparatus have been individually tested according to DIN
VDE0701 and DIN VDE0702 for electrical safety.

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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EC Declaration of Conformity
We
Visilab Signal Technologies Oy
Sepäntie 4
FI-07230 Monninkylä
FINLAND
declare that the products which are put on the EU market:
Portable Surface Moisture Logger, model A, AK30 and its derivatives
AK50 On-line Moisture Logger, also model AK40 and IRMA-7 model D and all
derivatives thereof
meet the intent of the RoHS directive 2002/95/EC and the WEEE directive 2002/96/EC. Compliance is
based on the following.
The instruments belong to Category 9 "Monitoring and Control Instruments" of the WEEE directive and
thus are not required to fulfill the said directives.
I certify that the apparatus identified above conforms to the requirements of Council Directives 2002/
95/EC and 2002/96/EC.
---------------------------------------------------------
Henrik Stenlund
managing director
10th February 2017
Note:
In spite of the fact that the products are not required to fulfill the directives, we make every effort to
comply with the directives in practice. When the Category 9 is moved to be covered the same
requirements as other categories do, we are ready to certify that these products comply with the
directives.

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Contents
1. Introduction and Taking into Use...7
Connecting the Cables and Starting the Meter...7
Mechanical Assembly of the Meter...17
Cabling...17
Testing...18
2. Basic Features of the Instrument...19
Result of Measurement...19
Operating Characteristics...20
Calibration and Material Libraries...23
3. Use of the Instrument...25
Menus and Settings...25
AN IMPORTANT NOTICE:...25
3.1. Data Series...27
Memory Banks...28
Burst Mode...28
3.1.2. Manage Menu...29
Typing in Data...30
3.2. Calibration menu...30
General Information about Calibration...31
SCALE Calibration or Scaling...32
Execution of SCALE Calibration / Scaling...33
Coefficient Setting for Scaling...33
MULTI Calibration...33
Performing MULTI Calibration with Samples of Different Moisture Levels...35
Performing MULTI Calibration when Working with a Climatic Chamber and a Balance...36
Adjusting a Table...36
The Procedure for Adjusting...37
Scaling the Output Voltage...39
Standardization Menu...40
3.3. Tables Menu...40
3.4. Profibus DP Menu...42
3.5. Service Menu...42
3.6. Selection of Filtering...43
3.7. Unit Menu...44
3.8. Communications Menu...45
3.9. COMPOSER...46
3.10. Keys Available in the Measuring State...46
Other Keys Available in Measuring State...47
Hints for Use...48
Notices for Measuring...48
Appendix 1. Servicing...50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Appendix 2. Jumper Plugs...51
Appendix 3. Definition of the Data Transmission Protocol...53
Appendix 4. Technical Specifications of the Moisture Meter (Rev. 6S only)...58
Appendix 6. Graphs of Features of AK50, Rev. 6S...65
Appendix 8. Troubleshooting the Meter...67
A. Symptom: No moisture signal to the PC data collection system, no contact in either packet protocol
mode nor in keyboard mode with the IRMA7Basic program....67
B. Symptom: No moisture signal to the Profibus DP data collection system, the Master is not able to
find the slave...67
C. Symptom: No moisture signal from the voltage output but the PC program and Profibus DP work all
right and moisture readings are correct....68
D. Symptom: The moisture signal is incorrect....68
E. Symptom: The autotimer starts running when the meter is turned on....69
G. Symptom: The moisture signal is zero....69
Appendix 9. Mechanical Installation of the Meter...70
Distance...70
Angles...70
Mounting...71
Index...74

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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1. Introduction and Taking into Use
We congratulate you for your decision of becoming a user of AK50 process moisture logger. It has
been designed to withstand rough use in harsh environments and to offer you as much surface
moisture information of your process as possible having also a great variety of useful features. Our
intent has been to offer you a unique instrument serving you reliably for several years. To utilize all
features in this product we recommend that you read the whole of this manual and also other
manuals shipped with this unit. This manual covers model's revision 6. The older revisions are no longer
manufactured. Refer for more details in the appendices 1 to 6. Refer to the mechanical drawings in
this chapter.
AK50 is a very fast process surface moisture transmitter for requiring conditions in paper machines and
other comparable applications. Its true moisture measurement speed is 100 Hz. That speed can be
exploited in different ways. One can acquire the latest moisture value into some control system in
digital form either via the RS232/485 serial port (typically a PC) or via Profibus DP fieldbus (max 12
Mbauds RS485). The moisture signal can be read also in analog voltage form (0...+10 V, +/-5 V or 0...+5
V corresponding to 0...100% moisture, selectable and scalable). Moisture can be sampled and
collected to the unit's own battery backed data memory at regular intervals from 10 ms to 32000 s.
The data can later be retrieved from the memory as a data series. One external trigger line is
available for starting either continuous sampling or a preset Batch (1 to 4096 samples). The meter is
equipped with an infrared thermometer for reading the web temperature.
AK50 is taken out of its package carefully and it should be inspected for any damage during shipping.
If any damage is visible, contact the manufacturer or the representative from which the unit was
bought. Note that in spite of being designed to rough conditions it is still a sensitive optical instrument
and it should be handled with care. Avoid any mechanical and thermal shocks to the meter!
Especially sensitive is the light source motor which is easily damaged if it is being subjected to sharp
shocks.
The following items should be available:
1. AK50 instrument
2. Program on a USB stick
3. User's manual (this)
4. Connection cables with connectors and a power source unit -PS
5. Serial cable for PC operation
6. PC program user's manual
7. Profibus DP user's manual
8. galvanically isolated USB-to RS232 converter plug with a USB-B cable
9. Vortec tube
10. Other optional items ordered
If something is missing, inform your dealer and he will ship any missing parts. The instrument is ready
to use after connecting the cables and power.
Connecting the Cables and Starting the Meter
Notice that the cable connector in AK50 may have a cap which protects them against dirt. It must
be opened by turning anti-clockwise. Also the connector on the cable end may have a protecting
cap. The connectors are splash water proof. To keep them that way for the operating life of the
instrument we ask the user to handle them carefully and to avoid too much force while opening or

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1A. Assembly of electrical cables in AK50 for use via RS232 with a PC or a
terminal and Profibus DP simultaneously. The drawing is not to scale. The wire posi-
tioning may vary on the distribution box. The box is just an example of connecting
the cables into your process measurement system and for initial testing. The sec-
ond screw terminal for analog output is functional too. Its signal contents can be
selected.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1B. Assembly of electrical cables in AK50 for use via Profibus DP only.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1C. Assembly of electrical cables in AK50 for use via RS232 at 9600/38400/
115200 bauds with a PC or a terminal only. The drawing is not to scale.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1D. Assembly of electrical cables in AK50 for use via RS485 with a PC or a
terminal only at 9600 bauds. The drawing is not to scale.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1E. Assembly of electrical cables in AK50 for use via RS485 with a Local Area
network (LAN) PC only. The PC works as a network Master. Note that all the AK50
meters to be attached to the LAN need to be configured for quiet booting (ser-
vice menu 5 - option 7). Each slave has to have its own address (communication
menu 8 - option 1). No two slaves can have the same address.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1F. Assembly of electrical cables in AK50 for use with external analog data
acquisition systems. The cable carries the trigger input line which is optionally used
for starting the autotimer. The trigger line is normally open and only momentarily
closed for action. You can use optoswitches or mechanical switches for this. Also
TTL level logic can be applied. In that case, note the ground polarity of the trigger
input lines. Refer to model -PS power supply unit's operating guide for details.
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1G. Assembly of electrical cables for use with LAN232 networking unit. Each
slave is wired normally with its own distribution box. The RS232 lines are used for
LAN232. The Profibus DP network can be used freely as can each voltage output
and trigger line. Any of the slaves can be any product of Visilab supporting the
packet protocol, like AK50, AK40 etc.
AK50
AK50
AK50
AK50
AK50
AK50
AK50
AK50

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1H. Assembly of electrical cables for AK50 without the -PS module by using a local power supply

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Figure 1I. Assembly of electrical cables for AK50 with the -PS module

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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closing. Else the sealing rings, threads or contact pins may be broken down or lost. Refer to Figures
1A to 1I for various cable connections in typical applications. In practice, there are more possible
combinations than these but are self-evident as all of the interfaces can be used simultaneously.
The cables are connected as follows. The big connector goes to the instrument connector and the
other end of the cable is in the power supply. To separate the RS232/485 and Profibus DP cables from
each other, they are marked correspondingly on the power supply panel. The box has a D9
connector for the PC serial cable and another for the Profibus DP. Note that to obtain the maximum
operating speed 12 Mbauds for the Profibus, you have to provide your own Profibus DP compatible
fieldbus cable for connecting
directly into the instrument. The supplied cable will support operation
to at least 1.5 Mbauds. Refer to the -PS User's Guide for proper locations of each connector on the
panel.
The RS232 cable is connected to the -PS and its other end is plugged into your PC's serial port
COM1...COM255 whichever is available either as such or via a galvanically isolated USB-RS232
adapter (delivered). It does have the connector of proper size (subD9). The power adaptor is placed
to the mains connection (230 V 50 Hz or any other local standard). Turn on AK50. If the instrument
refuses to operate, check the cables again. If you are certain that everything has been done in a
correct way, contact your local representative or the factory to get some help. You can use the
indicator lights on the USB-RS232 adapter to diagnose if any traffic is in the cable at all. If none, then
the port you are using in the PC program is not correct or the adapter is not properly installed.
To get a better view of connecting the cables in your final process control system, we have supplied
a schematic (Appendix 5.). Your control/data acquisition system may be based either on RS232/485
(a PC), Profibus DP fieldbus or standard analog voltage output. The bus lines, voltage output and
trigger lines are optically isolated for safe operation in difficult conditions in industrial control systems.
The connector type presently in use is ITT Cannon Trident TNM IP65 classified with shell size 14. The
codes for the parts used are: Standard receptacle 12 pins TNM14-12SKT STD192993-0033 TNMOS14-
0012S1L, standard plug TR1412PMS1NB 192922-1270. The pin numbering is the same as in the
schematic (from 1 to 12). The socket for the receptacle is T3P20FC1LX (crimp type) of 20 AWG and
gold plated. The corresponding pin is T3P20MC1LX (crimp) 20 AWG gold plated. You can use any
other fully compatible parts when necessary.
Mechanical Assembly of the Meter
AK50 moisture meter is assembled in the following way for a fixed position in on-line systems. Refer to
Appendix 9 for details.
Cabling
When assembling to a traverse crossing the web, you should have cables that resist repeated
bending in coiling and they should be especially designed for that purpose. The cables should be
resistant to the conditions prevailing at the site of assembly. If either the Profibus DP or the RS232/485
cable is not used, you can leave its connector cap closed. If pressurized air is required, use a pressure
regulator and standard tubing to connect to the quick connector. The air flow should be of the order
of one liter / second to keep the meter's optical surfaces dry in moist conditions. If the surrounding
temperature is high (>+35C), extra air flow is recommended to keep the optical head of the
instrument cool (clearly below +50C). At high ambient temperatures (>+30C), you should use cool
air flow with thermally insulated tubing for it. It is the user's responsibility to arrange proper cooling
for the meter. The guarantee does not cover damages caused by overheating.The recommended
operating temperature would be from +25 to +35 C for best results measured (as the optical head
temperature).

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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Anchor the electrical cables so that the connectors are not mechanically supporting them and the
connectors are thus protected against repeated bending. That applies for the air tubing too. Support
the air tubing along with the electrical cables if possible. Do not apply high pressures into the air line!
The air flow resistance is low, a small pressure difference is sufficient in most cases.
Testing
For installing the PC program, refer to the PC program user's manual. Test your communication link
as instructed there. After a successful test you can be assured that your AK50 will serve you for several
years with minimal service. For troubleshooting, refer to Appendix 8.
Figure 2D. Pictures of AK50, without and with the nose box

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
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2. Basic Features of the Instrument
Result of Measurement
The moisture value the meter indicates has a unit which is either a percent relative to the total or dry
weight of the material or it is the water density in the material. The practical moisture range (total
percentage) is 0..70%. With some materials the range can go up to 80%. The instrument has been
designed to give reliable values throughout this range. The internal noise is very low at moistures
below 10% and increases somewhat at higher levels. The repeatability (depends on the model, see
specifications) of the instrument is within +/-0.2% below 10% moisture. Typically it is much better. The
absolute accuracy depends on the calibration for the material. The calibration generates a group
of points on a balance-% vs meter signal plot. AK50 places segments of line onto this plot from one
point to another thus linearizing the original meter response curve. The sampling rate for moisture
values is 100 Hz and the PC display in keyboard mode is updated about twice/s. The light source
applied in the instrument has a lamp with a radiating power of the order 2 W. Of this the material
under test receives typically 20 to 50 mW approximately. That does not cause any notable warming
up or drying effects in most materials if they are static. No effects are detectable in moving webs.
AK50 is now available as revision 6S. The earlier revision 5KLN with 400 Hz sampling will be available
for a short time but is considered obsolete. The latest enhanced and new features are in the follow-
ing.
zz
zz
zNew ultrastable technology is taken into use with a new kind of optics and signal process-
ing. It will ensure absolute stability in difficult conditions with ultralow annual drift of the mois-
ture reading (Rev 6S and upwards)
Other recent advances in this model (6S):
zz
zz
zThe internal Signal Quality variable is now available outside the meter as an analog volt-
age and in digital format too, both in Profibus DP and RS232. It indicates three things affecting
directly to the quality of the moisture signal: Light source power output, dirty glasses, too high
temperature in the optical head.
zz
zz
zThere is now a Fault Diagnosis feature in the Advanced PC program checking some of the
important variables in the moisture meter to decide what is wrong if anything.
zz
zz
zAn extra digital filter is added to the meter and it can optionally be taken into use. It is a
very slow filter useful in conveyor measurements and in paper machine measurements when
the signal needs to reflect the average reading and not the momentary changes. The filter
strength can also be varied.
zz
zz
zThe second analog signal can now be selected as any signal: Moisture, web tempera-
ture, head temperature, Signal Quality or Extra temperature, just like the first channel does.
zz
zz
zautomatic rejection of weak moisture signal in dark surface conditions or at very reflective
targets. The meter offers zero as output after detecting this kind of conditions. The response
time is about 50 ms and independent on the digital filter used
zz
zz
zan optional wireless connection to the meter's power supply
zz
zz
za reduced sensitivity to angular changes of the target surface
zz
zz
za reduced sensitivity to edges of cut material production lines
zz
zz
za reduced noise level, especially in requiring high-speed web measurements
zz
zz
zlong distance versions of the meter are now available with working distances up to 400
mm or longer
zz
zz
zan enhanced immunity against external water vapor
zz
zz
zan enhanced immunity against external infrared sources, like heaters
zz
zz
zthe power supply unit -PS has a connector for a standard optical sensor for arranging a
triggering to incoming product batches or edges of piecewise products

PROCESS SURFACE MOISTURE METER, REV. 6S USER'S MANUAL
20
zz
zz
zthe RS232/Bluetooth/RS485 supports now speeds up to 115200 bauds in addition to the
earlier 9600/38400 bauds. Notice that cables over 5 m are not tolerated.
zz
zz
zan optional wireless connection to the meter's power supply using Bluetooth with up to
100 m of working range
zz
zz
za new secure memory system protecting better the internal configuration data and pa-
rameters against shocks and external disturbances. The data is saved to a nonvolatile memory
and read at bootup. The original data is not used except when someone wants to change a
setting. The changes can be made preferrably from the PC programs at highest level. One
may do them in the Keyboard mode in text format but needs to pay attention to the remarks
in the section 3.4.
zz
zz
zstatus flags are added for monitoring both the meter and the web, like a web break
indicator which also has an optional indicator light on the front panel in addition to the status
bits available via digital interfaces.
zz
zz
zthe optical head's sensitive parts are all enclosed into a hermetically sealed container to
prevent any effects of water or dust contamination
zz
zz
zthe PC program is called IRMA7Basic. It operates in Windows 10/8/7 and future versions.
It has a great number of features just like the older software did. The program Advanced is an
extended version it supporting the use of several meters at the same time. It has also other
interesting and useful special features.
Please note that the manufacturer reserves all rights to change specifications without advance
notification and to make manufacturing and design choices for each unit delivered in order to
offer the best possible meter for each application. The current specifications will be given to the
buyer.
Operating Characteristics
AK50 is equipped with a keyboard and display simulating software for any standard PC for portable
field use. With them the user can e.g. modify instrument settings and acquire data. The latest moisture
value is updated on the display when in the measuring state without extra operations. The instrument
has five sample memories (memory banks) which may contain up to 4096 + 4096 samples. The
autotimer may fill this memory at user's control and may operate at any sampling interval between
14 ms and 32000 s. The autotimer can also operate in Batch mode to collect only a predetermined
number of samples into one Batch. The Batch sampling can be repeated at will. Single moisture
samples are saved into the data series by pressing the key "s" (in Keyboard mode. It is the key "t" in
the graphic mode). There is an electrical trigger line for sending a starting command (a falling
voltage edge) for the autotimer (see Appendix 5.). The Autotimer has an indicator light on the meter's
panel being lit when it is on for easy visual synchronization of measurements.
The collected data series can be uploaded to a PC or it can be browsed in the meter. Also statistics
can be calculated easily. Nonvolatile memory is used for saving all settings and the data series
independent of disconnecting the power. The material under test can be quickly selected from a
calibration library of up to 100 materials. The calibration table is then immediately in use.
The data series can be managed with the memory banks as either a long contiguous Series (4096
points max.) or as four smaller (1024 points max.). All the banks are completely independent of each
other. Statistics calculation and e.g. the data transfer of series is handled completely within one bank
at a time without affecting the others.
For field operation, there is a web temperature autotimer available. It has a fixed 1 second interval
and it uses its own memory bank of 1024 points maximum. Its statistics can be evaluated afterwards
and the data series collected can be copied to the regular Bank4 for further processing in PC. Refer
to Fig. 3 for a sketch of the data flow in the moisture meter.