KMT TEL1-PCM-BATT Operating Instructions Manual

KMT - Kraus Messtechnik GmbH

Gewerbering 9, D-83624 Otterfing, Germany,  08024-48737, Fax. [phone]
Home Page: http://www.kmt-telemetry.com, Email: [e-mail]

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“Gain and Auto Zero setting direct from Receiver Side!”

INSTRUCTIONS FOR QUALIFIED PERSONNEL ONLY!

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General Description

The TEL1-PCM single-channel telemetry system offers the easiest handling for the wireless transmission of strain gage signals
from rotating shafts. The very small encoder 35 x 18 x 12 mm with a weight of 13g. The transmitter (encoder) part is simply
mounted on the rotating shaft with a special fiber reinforced tape.

The data transfer between transmitter and receiver is digital. The powering of the transmission part by the TEL1-PCM BATT is
supplied by 6-9V battery.

Functional Description

The TEL1-PCM-BATT transmitter provides a pulse code modulated signal (PCM) to an induction winding around the shaft. The
magnetic field of this winding enables the inductive transmission of the signal from coil to pickup. From there the signal is
transferred by cable (5 m) to the receiver. The maximum distance between the transmitter coil and the pickup is 150mm.

The receiver unit offers a BNC connector at the front panel with analog outputs  10 V and a optional a digital output for PCM
interface ECIA100 (for notebooks) or IF16 (PCI Desktop). An LED bar indicator shows the actual level and a successful Auto
Zero calibration. Overload is indicated by the last LED´s in pos. or neg. direction of the bar graph. These OVL-LED´s operate in
peak-hold mode and are reset by pressing the overload switch.

Strain gage sensors (>=350 Ohm) in full- and half- bridge configuration can be directly connected to the transmitter. The
excitation is fixed to 4 Volt DC and the gain is set by the gain switch on the receiver side. An auto-zero (AZ) adjustment is
executed by pressing the AZ button on the front side of the receiver. The successful AZ operation is indicated by a yellow LED
in the middle of the LED bar indicator. The yellow LED flashes as long as the AZ is in progress. When the AZ completes the
LED continuously illuminates. A continued flashing of the yellow LED indicates some error in the AZ electronics. In this case
please contact the support of KMT. The AZ setting is stored in a Flash-RAM and thus is not lost during power-off. Use only
shielded sensor cable.

TEL1-PCM-BATT Set Contains:

Inductive PH-Pickup
with 5m cable

TEL1-PCM-BATT­DEC (Decoder)

Mounting tape
2x 25mm
Length 50meter

Ferrite tape
30mm x 3 meter
(isolate magnetic field
between shaft and coil)

Screw driver to
set the gain

Hexagon key to
activate the OLV
and AZ switch

TEL1-PCM-BATT-STG

(Encoder for strain gages)

DC-Power cable

CUL wire

0.5mm for coil

(Enamelled copper

wire)

6V Lithium battery CR-P2

not incl. in set!

Must be purchased in your

own country!

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Technical Data

TEL1-PCM-STG-BATT
Straingage: Full and 1/2 bridge >=350 Ohm,
Excitation: 4 VDC (fixed)
Gain: 250; 500; 1000; 2000; 4000; 8000 (select able from receiver side)

Gain

Resolution

Autozero range

250

12 bit

100%

500

12 bit

200%

1000

12 bit

400%

2000

12 bit

400%

4000

12 bit

400%

8000

11 bit

400%

Analog signal bandwidth: 0 - 1200 Hz (-3 dB)
Operating temperature: - 10 to + 80 °C
Sampling rate 6.944kHz
Dimensions: 35 x 18 x 12mm (without connectors)
Weight: 13 grams
Static acceleration: up to 1000g
TEL1 PCM BATT Powering: By battery 6-9V
Power consumption: 70mA
Housing: splash-water resistant (except the connector pins)

with female K type thermocouple connector

with solder pins for thermocouple

Analog signal bandwidth: 0 - 10 Hz (-3 dB)
Accuracy: +/-0.5 % (without sensor)
Operating temperature: - 10 to + 80 °C
Dimensions: 35 x 18 x 12mm (without th-connector)
Weight: each module 13 grams (with epoxy resin)
Static acceleration: up to 3000g

(housing not filled with epoxy resin)

Static acceleration: up to 10000g

(housing filled with epoxy resin and without solder pins

and external capacitor!)

Powering: Battery with 6-9V, Power consumption: 70mA
Housing: splash-water resistant IP65

(except the connector pins)

TEL1-PCM-TH-K - Select Gain 250!

At Gain 500 multiply the values x2, Gain 1000 with x4
Max. Voltage output at receiver is +10V!

°C

Calibrator

out (mV)

Output at receiver (DEC)

Normal

(V)

Min.

(V)

Max.

(V) 0 -1.203

0,06

0,01

0,11

50

0.820

0,50

0,45

0,55

100

2.893

1,00

0,95

1,05

150

4.935

1,50

1,45

1,55

200

6.935

1,98

1,93

2,03

250

8.950

2,46

2,41

2,51

300

11.005

2,98

2,93

3,03

350

13.090

3,45

3,40

3,50

400

15.194

3,95

3,90

4,00

450

17.313

4,46

4,41

4,51

500

19.441

4,96

4,91

5,01

550

21.573

5,47

5,42

5,52

600

23.702

5,99

5,94

6,04

650

25.822

6,49

6,44

6,54

700

27.926

6,99

6,94

7,04

750

30.010

7,49

7,44

7,54

800

32.072

7,99

7,94

8,04

850

34.110

8,46

8,41

8,51

900

36.123

8,94

8,89

8,99

950

38.110

9,42

9,37

9,47

1000

40.072

9,90

9,85

9,95

Calibrator OMEGA CA71S3, measure at a clamping
point temperature of 30°C (after 30 min run time)

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Front side Rear side

TEL1-PCM-DEC

Front side:

Analogue output: +/-10V via BNC (Optional 4-20mA)

(delay between analog IN/OUT 15mS constant!!)

Digital output for PCM Interface IF16 (ECIA100) OPTION
Gain setting : via screw switch
Auto Zero setting: via micro switch

Overload LED’s (Red ON) reset: via micro switch
Green LED’s: Bargraph +/-

Autozero LED:
Yellow ON- successful AZ
Yellow OFF- not successful AZ
if flashing, call support of KMT, error in EPROM
Green LED’s: Bargraph +/­SL LED: Red ON = if error of data transmitting
SL LED: Red Flashing = if the battery is empty
Power ON LED: Red ON = if power switch on

Rear side:

Output to Powerhead: via 6pol. Tuchel
Fuse LED: Flashing if fuse is defect
Powering: 10-30V DC (min. 24Watt), Input via 7pol. Tuchel

Switch: ON/OFF
Operating temperature: - 10 to + 70 °C
Dimensions: 200 x 105 x 44 (without connectors!)
Weight 950 grams
Static acceleration: upto 200g
System accuracy*: +/- 0.2 %

<*measure with gain 1000, 350ohm (0.1%) full bridge - test bridge!!>

TEL1-PCM-Pickup
Function:

Receiving PCM magnetic field in PCM modulated code Distance
between the transmitter coil and the pickup is 5-150mm
Output to TEL1-PCM-Decoder: Via 6pol. Tuchel Plug incl. 5m cable
Operating temperature: - 10 to + 80 °C

Dimensions: 53x66x30mm (without cable)
Weight: 200 grams (without cable!)
Housing: splash-water resistant IP65 (except connector).

Cable length standard 5m! Longer on request, but max. 50m!

Block diagram

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Transmitting Part:

Receiving Part:

Front

Auto Zero LED
ON = successful
OFF = Not successful

Analog output +/-10V

Negative Bargraph LED
With overload indicator

Strain gage connection

Power On LED

LED ON = Error data transmission
LED Flashing = Battery voltage lower 6V

Reset button of
overload indicator

AZ button

Gain switch

The pins for battery (e.g. CR-P2 1500mA)
Use only 6-9V battery
Red point = + pole for battery

Positive Baragraph LED
With overload indicator

Coil, depends of shaft diameter
4-25 parallel windings of 0.5 CUL wire,
see table for help.

Coil connection

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Rear

Pickup

Distance of 5-150mm

DC-Power cable

Power IN DC 10 – 30V

Data input from Pickup and
output to Powerhead

Power ON/OFF switch

PCM OUT for Interface

Flashing if fuse damage

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Pin Connection:

Note:

The Powerhead must be fixed in the middle of the coil in a distance from 5 to150 mm.

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Shaft Installation

2 layers of the special ferrite tape around the shaft

Fix with 2 layers of mounting tape around the shaft

Coil, depends of shaft diameter 4-25 parallel windings of

0.5 CUL wires, see table for help.

Solder the wires of the coil on the input pins of
TEL1-PCM-STG “COIL”

Strip the isolation from the end
of the wire with a skinning tool or
head up you soldering iron over
450°C to burn off the insulation
from the wire!

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hose clamps

Caution:

Fix TEL1-PCM module with at least 10 layers of the special mounting tape around the shaft. Depending on the
shafts RPM and diameter particular attention needs to be paid to the safe mounting of the components.

The manufacturer doesn’t accept liability for damages, which results from insufficient attachment of the

individual components.
The tape is only for test purposes, in order to test the electrical function of the units in the idle state of the shaft.

During the rotation test appropriate safety precautions should be taken.
The entire installation may be used only by authorized persons. By using tape for the attachment, it has to be
used in the direction of rotation of the shaft and the end has to be secured. Only non-elastic tapes (Fiberglas Tape)
with high tensile strength should be used for pre-fixing. Additionally, use hose clamps for final fixing!! The
individual components are to be distributed in such a way on the shaft that imbalances are avoided.

10 layers of the special mounting tape around the shaft.
We recommend aadditionally use of a hose clamps for
final fixing of the transmitter unit!!

Fix with 3 layers of mounting tape around the coil
and cables

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Find the correct amount of windings

The number of windings depends on several factors. The most important influential factors are the diameter, the materiel of the
shaft and the environment around the shaft. The table standing below will help you to find the right number windings for steel
shafts. The table below is a help to estimate the number of windings fast. To optimize your results you can try one winding
more or less.

Diameter (mm)

Windings

490

4

290 5 190 7 150 9 120

10

80

12

45

16

20

25

Optimum windings for steel shafts

0

100

200

300

400

500

600

0 5 10 15 20 25 30

windings

diameter

Coil, depends of shaft diameter 4-25 parallel windings of 0.5 CUL wire

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Attention

• Use only special lithium Battarys for rotating applications

• Use only shielded sensor cable

• When used on rotating shafts, all connections must be soldered.

• Mounting of the modules on a shaft must be first fixed with mounting tape (only for

prefixing) and then with additional steel strip!!!

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Kraus Messtechnik GmbH

Gewerbering 9, D-83624 Otterfing,  [phone], Fax. [phone] – Germany
Home Page: http://www.kmt-telemetry.com Email: [e-mail]

Konformitätserklärung

Declaration of Conformity

Declaration de Conformité

Wir

KMT - Kraus Messtechnik GmbH

We

Nous
Anschrift

Gewerbering 9, D-83624 Otterfing, Germany

Address

Adress

erklären in alleiniger Verantwortung, daß das Produkt

declare under our sole responsibility, that the product

declarons sous notre seule responsibilité, que le produit

Bezeichnung

Messdatenübertragungssystem

Name

Nom

Typ,Modell,Artikel-Nr., Größe

TEL1-PCM, TEL1-PCM-BATT

Type,Model, Article No.,Taille

Type, Modèle, Mo.d'Article,Taille

mit den Anforderungen der Normen und Richtlinien

fulfills the requirements of the standard and regulations of the Directive

satisfait aux exigences des normes et directives

108/2004/EG

Elektromagnetische Verträglichkeit EMV / EMC

DIN EN 61000-6-3 Ausgabe 2002-8 Elektromagnetische
Verträglichkeit EMV Teil 6-3 Fachgrundnorm Störaussendung

DIN EN 61000-6-1 Ausgabe 2002-8 Elektromagnetische
Verträglichkeit EMV Teil 6-1 Fachgrundnorm Störfestigkeit

und den angezogenen Prüfberichten übereinstimmt und damit den Bestimmungen entspricht.

and the taken test reports und therefore corresponds to the regulations of the Directive

et les rapports d'essais notifiés et, ainsi, correspond aux règlement de la Directive.

Otterfing, 27.04.2006

Martin Kraus

Ort und Datum der Ausstellung

Name und Unterschrift des Befugten

Place and Date of Issua

Name and Signature of authorized person

Lieu et date d'établissement

Nom et signature de la personne autorisée