Kaman KDM-8200 User Manual

KDM-8200

• EuroCard • Noncontacting • Displacement

Measuring System

Instruction Manual

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.

********

Warranty

Kaman Precision 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 Extreme Environm ent Sy stems data

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 there under 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

sheets.

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Customer Service Information

Should you have any questions regarding this product, please contact an applications engineer at Kaman Precision Products Operations 719-635-6979 or fax 719-634-8093

through our web site at:

www.kamansensors.com.

Service Information

. You may also contact us

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

Customer Service/Repair Kaman Precision Products Operations

860-632-4442

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Table of Contents

WARRANTY CUSTOMER SERVICE INFORMATION INTRODUCTION

Welcome…………………………………………………………………………………… 10 Cautions and Safeguards…………………………………………………………………… 10 Using this Manual………………………………………………………………………….. 11 Icon Directory………………………………………………………………………………. 11

PART 1: WHAT IS THE KDM-8200?

System Technology………………………………………………………………………... 14 System Configurations………………………………………………..……………………. 15

PART 2: GETTING STARTED

Inventory and Set-up………………………………………………………………….……. 18

PART 3: THE EQUIPMENT

Series 8000 Enclosures……………………………………………………………………. 22 EuroCard Module…………………………………………………………………………... 25 Optional Function Modules………………………………………………………………... 25 System Modifications……………………………………………………………………… 25 Power Supply………………………………………………………………………………. 25 Wiring……………………………………………………………………………………… 26 Sensors Specification………………………………………………………………………. 27 Measuring Range…………………………………………………………………………... 27 Sensor Mounting…………………………………………………………………………… 28 Conductive vs. Nonconductive……………………………………………………………. 28 Simulated vs. Application Fixture…………………………………………………………. 28 Conductive Materials in the Measuring Area……………………………………………… 28 Surface Mounting………………………………………………………………………….. 29 Flush Mounting…………………………………………………………………………….. 29 Target Material…………………………………………………………………………….. 30 Target Size…………………………………………………………………………………. 30 Target Thickness…………………………………………………………………………… 31 Other Considerations………………………………………………………………………. 31

PART 4: CALIBRATION

Factory Calibration………………………………………………………………………… 34 Dimensional Standards…………………………………………………………………….. 34 Offset………………………………………………………………………………………. 34 Sensitivity………………………………………………………………………………….. 35 When is the System Fully Calibrated?……………………………………………………... 35 Calibration Controls……………………………………………………………………….. 35 Test Points…………………………………………………………………………………. 35 Zero Control……………………………………………………………………………….. 36 Gain Control……………………………………………………………………………….. 36 Linearity……………………………………………………………………………………. 37 The Three Calibration Methods……………………………………………………………. 37 Full Scale Calibration Procedure…………………………………………………………... 38 Alternate Bipolar Output Calibration……………………………………………………… 40 High Accuracy Band Calibration Procedure………………………………………………. 40

PART 5: APPENDICES

A. Glossary………………………………………………………………………………... 43 B. System Modifications………………………………………………………………….. 47 C. Troubleshooting………………………………………………………………………... 51

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Introduction

Welcome

Cautions and Safeguards

Using this Manual

Icon Directory

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Introduction

Welcome Welcome to the Series 8000 by Kaman – a family of precision EuroCard,

noncontact displacement measuring systems designed to solve a wide variety of position measurement problems.

This instruction manual is a valuable part of your precision measurement toolbox.

It is intended to simplify your use of the KDM-820 you are new to Kaman systems or a veteran user.

In addition to the precision measuring channels, other special function modules,

such as a summation/comparator, and voltage to current converter are available. Each is described thoroughly in its supplemental instruction manual.

The information in this manual contains everything you need to know to optimize

system performance. Any optional function cards you choose will come with their own instruction manual to supplement the information contained here. If after reviewing this manual you need additional information or assistance specific to your application, please call us a (800) 552-6267.

Cautions This information contains important cautions and safeguards associated and with the use of the KDM-820 Safeguards working with the system.

• To protect against risk of electrical shock, do no 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.

• Do not let power cords or sensor cables hang where someone might trip

on them.

• Unplug all power supplies before attempting to make any system

modifications.

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

• Be careful not to break the glass on the display module.

0 system. Please read the list carefully before

0 measurement system whether

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Introduction

Using this Our goal is to have you taking measurements as quickly and easily as Manual possible regardless of your familiarity with our systems. This is a do-it-yourself

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 1: An introduction to our technology, system configuration, and chassis enclosure.

• PART 2: System inventory and set-up.

• PART 3: Detailed considerations and explanations of system

operation and configuration.

• PART 4: Calibration

• PART 5: Appendices containing a glossary, supplementary

material on troubleshooting and system modifications.

All users, despite their level of expertise, should do the following before attempting to use the KDM-820

• Familiarize yourself with the icons defined below. They will appear

throughout the manual.

• Inventory the system.

• Refer to Part 3: EQUIPMENT on sensors and targets, and Part 4

CALIBRATION for a detailed discussion of the considerations involved

in making the right choices for your specific application.

Icon A variety of symbols, called icons, appear throughout this instruction Directory 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 ................................ Provides additional information about the

step you are performing.

TROUBLESHOOTING ... Tells you what to do when the system isn’t

functioning properly.

0 system.

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Part I

WHAT IS THE KDM-8200?

System Technology

System Configuration

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What is the KDM-8200?

System What is the KDM-8200? Kaman Instrumentation’s KDM-8200 family of Technology 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,

which 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.

TARGET

CABLE CAPACITANCE

REF COIL ACTIVE COIL

SYNCHRONOUS DEMODULATOR

COARSE LINEARITY

ZERO ADJUST

LOG AMP

CONVERTER

OUTPUT

AMP.

ANALOG

VOLTAGE OUT

FINE

LINEARITY

GAIN

ADJUST

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 high the analog output.

Reference

Reference Plane

Target Target

Plane

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What is the KDM-8200?

System The figure below shows a block diagram of the system configuration. Configuration Every system contains an electronics oscillator / demodulator and a sensor.

TEST POINTS

FRONT PANEL

OSCILLATOR

STAGE

POWER

CONDITIONING

STAGE

CONTROL

STAGE

CONTROL

SENSOR DRIVE

STAGE

+/- 15 Vdc Input Power

Analog Output

To Sensor

EURO

CONNECTORS

CALIBRATION

CONTROLS

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Part 2

GETTING STARTED

Inventory and Set-Up

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Getting Started

Basis System 1. Your KDM-8200 system consists of these basic components:

A. Sensor(s) and cable(s) B. EuroCard modules C. User manual D. Accessory kit

Options 2. Depending upon the configuration of your KDM-8200 system or options you have ordered, you might also have any of these items:

A. A EuroCard chassis with integral power supply B. An MCD 8000 display module C. Special function modules D. Micrometer calibration fixture

Module 3. All modules (except NEMA configurations) have the following Identification identification:

P/N 853479-001 S/N XXXXX-XX-XX SENSOR XXX XXXXXX

Connecting 4. Your Series 8000 system comes configured to you specifications. Sensors However, you will need to connect sensors and cables yourself.

Connect sensors to module using the A and B connectors located on the rear of the chassis. Sensors with model numbers ending in a “1” use connector “A”; sensors with model numbers ending in “2” or “M” use both connectors. An exception is the .5U2, which only has one connector that connects to “A”.

PART NUMBER

SERIAL NUMBER

GENERIC SENSOR TYPE

CONFIGURED AS “MASTER” OR “SLAVE”

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Getting Started

Connecting 5. The KDM-8200 operates from a +/- 15 VDC power source. If your system External was no configured with a power supply; you will need to provide an external Power Supply power source. Using 24 AWG or heavier insulated wires, connect +V to Pins

2A and 2C, -V to Pins 6A and 6C, and ground to Pins 10A and 10C on the

Kaman power bus. All Series 8000 racks have a power supply, except for customerspecial configurations.

Connecting power to any other than the specified pins may cause damage to the 8200 and / or power source.

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

7. Set the target in place for calibration

8. 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.

9. 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.

In rack configurations, all measuring channels must be synchronized. In Kaman-supplied racks, the master is the left most measuring channel (slot position one); all others are slave modules. Because of system wiring requirements, removing any module will disable all modules to the right of the removed module. See APPENDIX B for synchronization instructions.

If you have purchased a Kaman EuroCard chassis, power supply, display, or function card, see the appropriate user manual for specific information.

If you have more than one sensor or measuring channel in close proximity, you may require synchronization. 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.

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