Kaman KD-2300 User Manual

Instruction Manual

KD-2300

Noncontacting Displacement Measuring System

EC DECLARATION OF CONFORMITY

This apparatus, when installed and operated per the manufacturer’s recommendations, conforms with the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of the member states relating to Electromagnetic Compatibility, as required by the Technical Construction File Route to Conformity.

This certificate has been issued in accordance with the conditions of regulation No. 53 of U.K. Statutory Instruments 1992 No: 2372 – The Electromagnetic Compatibility Regulations.

********

DO NOT MAKE ANY MODIFICATIONS TO CABLE LENGTH, SENSOR

OR CALIBRATED TARGET MATERIALS WITHOUT PRIOR

CONSULTATION WITH A KAMAN APPLICATION ENGINEER

*********

Contents

Introduction 1

Welcome....................................................................................................................................1

Customer Service Information....................................................................................................2

Warranty 7A...............................................................................................................................3

Cautions and Safeguards............................................................................................................4

Using this Manual......................................................................................................................4

Icon Directory............................................................................................................................5

Application Information.............................................................................................................6

Part I: What is the KD-2300? 7

System Technology....................................................................................................................7

System Configuration.................................................................................................................8

Part II: Getting Started 9

Basic System..............................................................................................................................9

Module Identification.................................................................................................................9

Connecting the Sensors..............................................................................................................9

Connecting External Power Supply..........................................................................................10

Part III: The Equipment 13

Operating Principle* ................................................................................................................13

Specifications...........................................................................................................................13

Accessories...............................................................................................................................14

Sensor Options......................................................................................................................... 15

Sensor Specification.................................................................................................................16

Measuring Range......................................................................................................................17

Sensor Mounting......................................................................................................................17

Conductive vs. Nonconductive.................................................................................................17

Simulated vs. Application Fixture............................................................................................18

Conductive Materials in the Measuring Area...........................................................................18

Surface Mounting.....................................................................................................................19

Flush Mounting........................................................................................................................20

Target Material.........................................................................................................................21

Target Size ...............................................................................................................................21

Target Thickness......................................................................................................................22

Other Considerations................................................................................................................22

KD-2300 Instruction Manual Contents •••• i

Part IV: Calibration 23

Factory Calibration..................................................................................................................23

Calibration Interval..................................................................................................................23

Dimensional Standards............................................................................................................23

Offset .......................................................................................................................................24

Sensitivity ................................................................................................................................24

When is the System Fully Calibrated?.....................................................................................24

Calibration Controls.................................................................................................................25

Zero Control.............................................................................................................................25

Gain Control ............................................................................................................................26

Linearity...................................................................................................................................26

The Three Calibration Methods...............................................................................................26

Full Scale Calibration Procedure...............................................................................27

Bipolar Output Calibration Procedure.......................................................................28

Alternate Bipolar Output Calibration.........................................................................30

High Accuracy Band Calibration...............................................................................31

Appendix A: Glossary 33

Glossary...................................................................................................................................33

Appendix B: System Modifications 35

Maximum Sensitivity (Gain Control)....................................................................................... 35

Zero Control Sensitivity...........................................................................................................35

Synchronization of Multiple Units...........................................................................................36

Appendix C: Troubleshooting 38

Checklist for Basic Troubleshooting........................................................................................38

Symptoms and Causes..............................................................................................................39

Contents •••• ii KD-2300 Instruction Manual

Introduction

Welcome

Welcome to the Series 2300 by Kaman — a family of precision, noncontact displacement measuring systems designed to solve a wide variety of position measurement problems.

Kaman Precision Product’s MULTI-VIT (MULTI-purpose Variable Impedance Transducer) Displacement Measuring System Model KD2300 series is a non-contacting linear proximity measuring system. This easy-to-use system makes precision static and dynamic measurements of metal targets and thickness measurements of nonconductive material backed by metal.

The simplicity and versatility of the KD-2300 solves process control, product design, inspection of metal objects, and quality control applications that require accurate and stable measurements.

This instruction manual is a valuable part of your precision measurement toolbox. It is intended to simplify your use of the KD2300 measurement systems whether you are new to Kaman systems or a veteran user.

The information in this manual contains everything you need to know to optimize system performance. If after reviewing this manual you need additional information or assistance specific to your application, please call us at (719) 635-6979.

KD-2300 Instruction Manual Introduction •••• 1

Customer Service Information

Should you have any questions regarding this product, please contact an applications engineer at Kaman Precision Products | Measuring 719-635-6979 or fax 719-634-8093 our web site at:

www.kamansensors.com.

. You may also contact us through

Service Information

In the event of a malfunction, please call for return authorization:

Customer Service/Repair Kaman Precision Products | Measuring

860-632-4442

2 •••• Customer Service Information KD-2300 Instruction Manual

Kaman Products Standard

Limited Warranty

Products of Kaman Precision Products are warranted to be free from defects in materials and workmanship when installed and operated in accord with instructions outlined in the instruction manual.

Kaman Precision Products's obligation under this warranty shall be limited to repair or replacement (at the discretion of Kaman Precision Products) of the defective goods returned to Kaman's plant within one (1) year from date of shipment. Extreme environment sensors are limited to the maximum operating temperature as specified within the most current Kaman Measuring Systems Extreme Environment Systems data sheets.

This warranty is valid except when the products have been subject to misuse, accident, negligent damage in transit or handling, or operation outside the conditions prescribed in the data sheet or instruction manual. This will be determined by Kaman Precision Products personnel.

In no event shall Kaman be liable for incidental or consequential damages, including commercial loss, resulting from any article sold under this Agreement.

In the event Buyer fails to limit to Kaman's warranty set forth above, any express or implied warranty Buyer may make with respect to any product of which any article sold thereunder is a component, Buyer shall indemnify and hold Kaman harmless from any and all liability, costs and expenses to which Kaman may be subjected as a result of Buyer's failure to so limit its express or implied warranties.

THIS WARRANTY IS EXCLUSIVE AND IS MADE IN LIEU OF ALL OTHER WARRANTIES; AND THOSE IMPLIED WARRANTIES, INCLUDING SPECIFICALLY THE WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY LIMITED TO ONE (1) YEAR DURATION.

NO MODIFICATION OR ALTERATION OF THE FOREGOING WARRANTY AND LIMITATION OR REMEDIES PROVISIONS SHALL BE VALID OR ENFORCEABLE UNLESS SET FORTH IN A WRITTEN AGREEMENT SIGNED BY KAMAN AND THE BUYER.

Kaman Precision Products Warranty No. 7A

KD-2300 Instruction Manual Service Information •••• 3

Cautions and Safeguards

This information contains important cautions and safeguards associated with the use of your KD-2300 system. Please read the list carefully before working with the system.

• To protect against risk of electrical shock, do not place the system

module in water.

• Do not operate with a damaged power cord.

• Do not let power cords or sensor cables touch hot surfaces.

• Unplug all power supplies before attempting to make any system

modifications.

• Do not expose system modules to excessive heat or moisture.

Using this Manual

Our goal is to have you taking measurements as quickly and easily as possible regardless of your familiarity with our systems. This is a do-ityourself manual, allowing you to work and learn at your own pace, depending upon the amount of background information you need to complete each step. You can find as much or as little information as you need:

• Part I: An introduction to our technology and system configuration.

• Part II: System inventory and set-up.

• Part III: Detailed considerations and explanations of system operation

and configuration.

• Part IV: Calibration.

• Appendices: Glossary, supplementary material, troubleshooting, and system

modifications.

4 •••• Service Information KD-2300 Instruction Manual

All users, despite their level of expertise, should do the following before attempting to use the KD-2300 system:

• Familiarize yourself with the icons defined below. They will

appear throughout the manual.

• Inventory the system.

• Refer to Part III: EQUIPMENT on sensors and targets and Part

IV: CALIBRATION for a detailed discussion of the considerations involved in making the right choices for your specific application.

Icon Directory

A variety of symbols called icons appear throughout this instruction manual to call your attention to information requiring special consideration. The chart below details what the icons look like and how they will be used.

CAUTION Describes actions that can damage either the

system or endanger the person using it.

ADVISORY Describes situations that could impact the

measurement and utility of the product. However,

an advisory does not affect the system or person.

NOTE

are performing.

TROUBLESHOOTING

functioning properly.

Provides additional information about the step that you

Tells you what to do when the system isn’t

KD-2300 Instruction Manual Service Information •••• 5

Application Information

The system speeds gaging and precision measurements by eliminating

errors caused by “feel”. It uses modern electronics (eddy current

operating principle) to replace LVDT’s, air gages, capacitance systems,

dial indicators, and micrometers.

Applications include precision displacement (proximity) measurements

of shafts, plates, foils, and other ferrous and non-ferrous metal targets.

Environments that have oil, dirt, and humidity between the sensor and

target will not affect the system accuracy. The system output has high

noise immunity (low impedance).

As a non-conductive medium between a sensor and a metal target

doesn’t affect a calibrated system, the thickness of non-conductive

materials (i.e. rubber, plastic, insulation, wood) can be measured when

the material is against metal. If the non-conductive material is moving,

the sensor can be mounted on a rider or shoe and look through to the

metal reference target.

The electrical zero can be offset up to half of the measuring range;

therefore, + and - deviation from a nominal can be obtained.

Long term stability, resolution and thermal stability improve

exponentially as the operating gap between the sensor and target

decreases. Therefore, in extremely critical applications, the first half of

the measuring range permits the best performance.

6 •••• Service Information KD-2300 Instruction Manual

Part I: What is the KD-2300?

System Technology

Kaman Precision Products’s KD-2300 family of displacement measuring systems uses inductive technology to determine the position of a target relative to the system sensor.

An AC current flows through the sensor coil, generating an electromagnetic field that radiates out from the sensor. As the conductive target enters this field, the sensor induces a current flow; it produces a secondary opposing field, reducing the intensity of the original. This opposing electromagnetic field results in an impedance variation in the sensor coil.

The sensor coil makes up one leg of a balanced bridge network. As the target changes position within the sensor field, the bridge network senses impedance changes in the sensor coil and passes the information on to signal conditioning electronics for conversion to an analog voltage. This voltage is directly proportional to target displacement.

SYNC HR ONOU S DEMODULATOR

COARSE LI NEARITY

CABLE CAPACITANCE

REF COIL ACTIVE COIL

TARGET

KD-2300 Instruction Manual Part I: What is the KD-2300? •••• 7

ZERO ADJUST

LOG AMP

CONVERTER

OUTPUT

AMP .

V OLTAGE OU T

ANALOG

FINE

LINEARITY

ADJUST

GAIN

Nonconductive materials intervening between the sensor and target have little or no effect on system output. Because of this, environmental contaminants, such as oil, dirt, humidity, and magnetic fields, have virtually no effect on system performance. The function of a noncontact displacement measuring system is to monitor the position of a target relative to some reference plane. The magnitude of the analog output is dependent upon the relative position of the target within the sensor’s electromagnetic field—the farther the sensor is from the target, the higher the analog output.

Reference Plane

System Configuration

The figure below shows a block diagram of the system configuration.

Every system contains an electronics oscillator / demodulator and a

sensor.

CALIBRATION

CONTROLS

Zero Gain Linearity (Coarse or Fine)

OSCILLATOR

STAGE

Target Target

POWER

CONDITIONING

STAGE

CONTROL

STAGE

CONTROL

STAGE

Reference Plane

± Vdc input

System V out

SENSOR DRIVE

CONNECTORS

TO SENSOR

8 •••• Part I: What is the KD-2300? KD-2300 Instruction Manual

Part II: Getting Started

Basic System

Your KD-2300 system consists of these basic components:

• Sensor(s)

• Cable(s)

Depending upon the system, the standard sensor cable

length may be increased in increments of 5 feet (1.55 m) up to a maximum of 30 feet (9.15 m) on special order basis.

• Oscillator/ Demodulator

• User manual

• Accessory kit

Module Identification

All modules have the following identification:

a. Model number b. Serial number

Your Series 2300 system comes configured to your specifications. However, you will need to connect sensors and cables yourself.

Connecting the Sensors

Connect sensors to oscillator/ demodulator using the connector located on the front of the electronics.

The model KD-2300 family consists of a sensor, a signal conditioning electronics, and a separate interconnection cable when not integral with the sensor. The signal conditioning electronics with each system model has been designed to provide optimum performance with its sensor, cable length, and target material (magnetic or non-magnetic); therefore,

1. Sensor cable length and type should not be altered.

2. Sensors are interchangeable only with others of the same type and cable length (with slight calibration adjustment). See CALIBRATION PROCEDURE.

3. The proper target material must be used.

KD-2300 Instruction Manual Part II: Getting Started •••• 9

Connecting External Power Supply

The KD-2300 operates from a ± 15 Vdc power source. If your system was not configured with a power supply, you will need to provide an external power source.

The Kaman Model P-34XX power supplies are recommended, although 15 Volt regulated supplies are satisfactory. Use 24 AWG or heavier insulated wires.

Connecting power to any other than the specified pins may cause

damage to the 2300 and / or power source. Output connections to

voltmeter, recorder, or oscilloscope should be made as noted in Figure 1.

1. Mount the sensor in its application fixture in either a surface or flush mount.

2. Set the target in place for calibration.

3. Zero, Gain, and Linearity (Coarse and Fine) potentiometers are located on the control panel on the front of the module. You can adjust these using a screwdriver.

4. Determine whether your calibration will be full scale, bipolar output or high accuracy band. Proceed to the appropriate page for full instructions on the method you require.

All users, refer to Part 3: THE EQUIPMENT. Fixture conductivity, conductive objects within sensor range, sensor diameter, and shielded vs. unshielded sensor types are all determining factors of how the sensor should be mounted.

Using a simulated fixture for mounting during calibration can affect the adjustments for each channel. Whenever possible, use your application fixture during calibration.

If you have more than one sensor or measuring channel in close proximity, you may require sychronization. See Appendix B for more information.

With a thorough knowledge of calibration controls and accurate application of the calibration procedures described in Part 4: CALIBRATION, you can achieve optimum results. Deviations or shortcuts can result in operator-induced errors and may complicate, rather than solve your measurement problems.

10 •••• Part II: Getting Started KD-2300 Instruction Manual

WIRING DIAGRAM USING TWO SEPARATE 15 V LINEAR POWER SUPPLIES

15 V

Supply

15 V

Supply

user

supplied

DVM,

Recorder,

user

supplied

Oscilloscope,

Computer Interface

+ Output

- Output

1 2 3 4 5 6

+ 15 Vdc (Positive supply input) Ground (Common supply input)

- 15Vdc (Negative supply input) + Output

- Output (Common with ground) No connection (Sync output)

Figure 1

KD-2300 Instruction Manual Part II: Getting Started •••• 11

+ 30 hidden pages