Microcell Calibration

7/27/2019 Microcell Calibration

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Kistler-Morse'

KM 0441.CAL.16-01

Bolt-OnMicrocell' SensorCalibrationWithoutMovingMaterial: SimulatorMethodINTRODUCTIONThemethod fcalculatingaterialweightescribednthisdoqrmentrovidesrelativelyasyway oestab-lishhescaleactor f hesignal rocessorithoutmoving aterialnto routof hevessel. lso, heckscanbemadehroughouthe nstallationrocessoen-sure hat hewiringserror-freend hat hesensorsare nproper orkingrder. heK-M ignal roces-sorswithwhichhisprocedureanbeperformedare he904XC,11,924,954,000/1020,1200112201240, nd he1700/130.

Theproceduresperformedsinga K-M estmeter.voltmeter nda potentiometeranbe used nplaceoftheK-M estmeter.

Theblockdiagrams escribe ictoriallyowKistler-MorseBolt-OnMicrocell roducts ork.Theyprovideanoverview f the effects f themechanicaltructure,sensitivityf thesensors, nd he unction f thesignalprocessorn a bolt-onmeasurementystem.

TECHNICAL DESCRIPTIONOF ABOLT-ONMICROCELL SENSORMEASUREMENTSYSTEMTheblockdlagramsn Figures hrough providetechnical escriptionf theworking equencef a Bolt-OnMicrocell easurementystem.As shownn Figure , he otalweight f thematerialand hevesselholdinghematerialWrornu) ombineto putstress n hevessel upport tructure'Whenanexcitationoltage l 12 Vdc sappliedo theMicrocellsensor rr:ay y hesignal rocessor,he sensor rray'outputs voltage roportionaltohematerial lusa@nstant flset oltage r avoltage roportionaltohedeadweight l thevessel. hesignal rocessorreceiveshevoltage utputrom he sensor rray' ub-tracts hezerooffsel, pplies scaleactor, ndprovidesome ypeof display' hezerooffset f thesignal rocessorubtractsut heoffset oltageves-selweight r nstalledensor rrayoffset)'Whenadigitalsignalrocessors used,he ransducerutput(eo)s convertedo a numericalvaluecount) eloresubtraclinghezerootfset.Figure shows nly hematerialweightWLL) uttingstress nthevessel upport tructure. 12Vdcexcita-tionvoltages appliedo theMicrocellensor rray

NOTE

' Noto:'Arraymang any utrbe. ol Microll ocnoo cqtnoctcdnpilall'l b awrage ho;En:;a'ttt i"J'lrlo".t i+port r*nterr, i.q.venicalootutms'hodzontaloattB'andrhitl. Page1


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a bExcitiationr-'-.+5Vdc Vdcl ll l

Wu + Wol

WtornlFigure4. BlockDiagramof a Boft-OnMicrocellAnay WorkingSequencewithouta Signal Processor.

order. hismethod lsoprovides way oretrievenlormationt imeswhenmaterialcannot emovedorcalibrationue o plantscheduling,tc.NOTETheaccuracyof this calculationcan-not be predicted becausecatwallcs,overheadpipes, etc. can affect theperformance f thesensors.The en-sor array takes heseeffects nto ac-count, but the effects cannot befactored into the equations and2.

An accuratecalibrationac-tor canbeachieved,owever,by enteringa roughnumberatfirst and hencontinuingotune hatfactoroveraperiodof time. See UNINGTHESCALE FACTOR or thisprocedure.)ConnectingheTestEquipmentotheSignalProcessorThissection escribesow o connecthe estequipmento hesignalprocessor.operlormthisprocedureouwillneed voltmeter,10- o20-turn2K-10K)otentiometer,nd wo esis-tors,or K-M estmeter.Followhisprocedureo connectheequipmentto yoursignal rocessor.1. Dlsconnecthesensor rrayrom hesignalprocessor.2. AnalogSlgnalProcessors. igure il-lustrates ow o wire heK-M estmeterothe erminal lock.Refero hesignalprocessor anualor the specifc erminalblock ocation.) igure illustratesow oconnecthepotentiometer,esistors,ndvoltmetero the erminal lock.Chooseheligurehat llustratesourequipmentndwire hesignal rocessorsshown.

Figure5. SubtractingOutthe Afset Voftage.

Figure6.Bloc| Diagramof a MicrocellSensorArray WorkingSequencewithOtfset VoftageSubtncted Out.

SignalProcessor-+\

Figure7. BlockDiagramf aBolt-OnMicrocellMeasurementystemWorking equence ithOf-fsetVoltage eroedOut.

EO ELL

Wr_r_

a

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PCB nSignalProcessorK-MTestMeter

Figure .K-MTestMeterWiredo anAnalogSignalProcessor.3. DlgltalSlgnalProcessors.igure0 llustrates

howo @nnectheK-Mestmetertohe erminalblock.Referlohesignal rocessoranualforthespecificterminalblockocation.)igure 1 l-lustratesow o @nnecthepotentiometero heterminallock. hoosehe igurehat llustratesyour quipmentndwirehesignal rocessorsshown.4. Proceedo henext ectionoperformhecalibra-tionprocedure.

Set UpProceduresor AnalogSlgnalProcessorsThe911,924,and954 Level ndicatorsisplay er-centages, aveZeroCalibrate nd SpanCalibratepotentiometers,nduse he sameset upprocedure.

Figure9. Voftmeter ndPotentiometerWired o anAnalogSignalProcessor.Page4

PotentiometerRo 2K ohrr 5K ohrn, d 10K ohmR-2.5 uNOTE: Ushg R- 2.5 Re will rctinft. yoltaor tango at lho pcaonfptrFlt crrtPd to +/'ap|orimably lV wttidr b th. ra,rt r. th. t rEp ol . Mictoll mot

PCB nSignalProcessorK-MTestMeter

Figure10.K-M TestMeterWiredo a DigitalSignalProcessor.The904XCTransmitteretupprocedures he samebutusesan ammeternstead f a displayo indicatetheoutput.Thesetupproceduresordigital ignal rocessorsrecompletelyifferentrom hosedescribedn hissec-tion. f youhavea digital ignal rocessor,kip hissec-tionand ollowheproceduresnSetUp Proceduresfor DlgitalSlgnalProcessors.

911,924,and 954 Level lndlcatorsWith he estequipmenlonnected,lollowhisproce-dure o calculateheweight t thematerial nd o setupyouranalog ignal rocessor.

Processor.

R R p Ra

PotenfdmeterRp 2K ohm, 5K ohrn, ot 1OK hmR-2.5tuNOTE: Using R. 2.5 Rpwill tsuknlhe voltap ange at hs potenlbmaaor utput o +/-app.dimtdy lV whidt b th6 m at lho rdgc ol a Mbr@ll snsol


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1. lf youareusingmetern heSlMlpotentiometern2. Turn hedialontiometerntil0nsor.3. LocateheZerosor. f necessary,manualforot o

TurnhepotvnalprocessorThemaximunvessels henumbersner(eu-) f hes

material eightsappliedo the sensors. or hesakeof example,hisprocedure illuse150 ons(Full-ScaleLL 150 ons). heequationooks

4.5.

E q .1:ull-Scaleeu lmV/psi.t/Arq= 85.7 n2equationooks

E q .2Full-Scaleu

l usinga K-M estmeter, ut he estthe SIMULATEnode.f youareusinganeter ndvoltmeter,kip hisstep.dialon he K-M estmeter r poten-until0mV sappliedo hesignalproces-p ZeroCalibrateot n hesignalproces-cessary,efero the signal rocessororpot ocation.potwitha smallscrewdriverntilthesig-rssor isplay eads0%.imummaterial eighthatwillbe n hethe ull-scaleive-load eight Wu-). hiss neededo calculatehevottage utputnesensor rraywhen hemaximum

sakeof example,hisprocedure illt(Full-ScaleLL 150 ons). heequlike his:150 2000lb/ton mV

A* x Fsi - =r-uUseTable or hecorrect alueol n

6. Forthe akeof example, ewillsay,andmV/psi 90mV/1000 si.Theetlikehis:300,000lb

Bt? i.'-Full-Scaleu = 315mV

x f,l|# -F

VesselType SensorArray ApproxlmateSensltivltyMaxlmumAllowableVoltageOutput

Leg-SupportedVessel

Leg-SupportedVessel

Beam-SupportedVessel

Skirt-SupportedVessel

NOIES1.Theaboveah2.Aluminumicr3. Stainlessteel

Vertical -lnchMountedon theFlangeVertical -inchMountedon theFlangeVertical -inchMountedL on heWebIVertical -lnchMountedI on theWebII| 2-lnch hearMountI| 3-lnchShearMountI| 3-lnchRosette rrayI| 2-lnchBack-to-I BackAnaV| 3-lnchBack-to-I BackAnay

es refer o 1018 arbon te,ocell ensors avea sensitiMicrocell ensors avea st

60mV/1000si90 mV/1000si60mV/1000 si90 mV/1000si

60 mV/100090 mV/100060 mV/100060 mV/100090 mV/1000

rl Microcellsensorsvityof 2.57 imes hernsitivityl 0.67 imes

765mV765mV765 mV765mV765mV765mV510mV765mV765mV

above alues.;the above alues.

Table1.MicrocellSensorMillivoltOutput s.PSl. Page


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7.r .

9.

Turn he dialon heK-M estmeter rpoten-tiometer ntil315mV s appliedo the signalprocessor.Turn he SpanCalibrateotwitha smallscrewdriverntil he signal rocessorisplayreads100%. heSpanCalibrates nowset.Thesignal rocessor ill read100%when hesensorarrayoutputs 15mV which epresentsull-scaleweight150 ons).DisconnectheK-M est meter r vollmeter ndpot rom hesignal rocessorndconnecthe sen-sor array.

10. lf thevesselsempty,hepercentageisplayed ythe signal rocessor hen he sensor nay scon-nected epresenlshe offset oltage. urn heZeroCalibrate otuntilthesignal rocessorisplays0o/olo eroout he offsetvoltage.TheZeroCalibrates nowset.lf there s materialn he vessel,hepercentagedisplayed y he signal rocessor il lbe a com-bination f the otfset oltage ndmaterialweight.Tozeroout heolfset oltage,lumheZeroCalibrate otuntilthesignal rocessorisplaysthepercentagef materialn hevessel. Loweringa ropewitha weightattachednto hevessel s acommonmethod f locatingmaterialevelanddeterminingercentage.)t thevessel ontainshalfof what sconsideredo be ull-scaleive-loadweight,um heZeroCallbrate otuntilthesignalprocessor isplays 0%.

904XCTransmltterWithhe est quipmentonnecled,ollowhis roce-dure o calculateheweight f thematerial nd o setupyour904XCTransmitter.

lf youareusinga K-M estmeter, ut he estmeter n heSIMULATE ode. f youareusingapotentiometerndvoltmeter,kip hisstep.Turn he dialon heK-M estmeter rpoten-tiometer ntil0 mV s appliedo the signalprocessor.

1 .

2.

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8.

lf youareusinga K-M estmeter, onnect n am-meteroTB2 the4-20mAoutput).f youareusinga voltmeter,isconnectt romTB1,set t o readmilliamps,ndconnectt o TB2.LocateheZeroCalibrateot n he signal roces-sor. f necessaryefer o thesignal rocessormanualorpot ocation. urn hepotwitha smallscrew-driverntiltheammetereads mA.Themaximum aterialweightha twillbe n hevessels he ull-scaleive-loadeightWr_l).hisnumbers neededo calculatehevoltage utput(eu-)of the sensor naywhen hemaximummaterial eightsappliedo the sensors. or hesakeof example,hisprocedure illuse150 ons(Full-ScaleLL 150 ons). heequationookslike his:

150 2000 bAon E q . 1= Full-ScaleltUseTable or hecorrect alueof mV/psi.For hesake f example, ewillsayAsq= 85.7 nzandmV/psi 90 mV/1000 si.Theequationookslike his:

mVX psleq

6.

9.

300,000b8r7 ilz-Full-Scalet-t. 315mVTurn hedialon heK-M es lmeter ntil '15mV sappliedo the signal rocessor.f youareusingavollmeter ndpot, econnecthevoltmetero thetestpointandpotentiometerndset t o readmil-livolts. urn hedialon hepotuntil 15mV sap-plied.Disconnecthevoltmeter,et t to readmilliamps,andconnectt o TB2again.Witha K-M estmeter,heammeterhould tillbe nplace.)Turn heSpanCalibrateotwitha smallscrewdriverntil20 mA sdisplayed.heSpanCalibrates nowset.The904XCwilloutput 0mAwhen hesensor rray utputs 15mV,which ep-resentsull-scaleeight150 ons).DisconnectheK-M estmeter rpotentiometerfrom hesignal rocessorndconneclhesensorarray.

E q .290 mVx ffi- = Full-scaleu


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10. f tnevessels empty,hecurrent utput y he sig-nalprocessor hen he sensor rray sconnectedrepresentshe offsetvoltage.Tum heZeroCalibrateotuntiltheammeter isplays rnAtozeroout heoffset oltage. heZeroCalibratesnowset.lf there smaterialn hevessel,hecurrent utputdisplayed y heammeter il lbe a combinationlthe oflset oltage ndmaterialweight.ozeroouttheoflset oltage,um heZeroCalibrate otuntilthe ammeter isplayshe number f milliampshatrepresentshearnount f materialn hevessel.(Lowering ropewilh aweightattachednto hevessel s a comrnonmethod f locatingmatedallevelanddetermininghepercentagef materialin hevessel.)f thevessel ontains alfol what sconsideredo be ull-scaleive-load eight,urntheZeroCalibrateotuntiltheammeter isplays12mA.

SetUpProceduresor DigitalSignalProcessorsTheprocedureor calculating aterialweightndset-tingup hesignal rocessoriffersoreachsignalprocessor.ollowhesetupprocedurehatpertainsoyourparticularignal rocessor.lf youhavean analog ignalprocessor,isregardhissection nd ollow heproceduresn SetUp Proce-dures or AnalogSlgnalProcessors.1000/120WelghtndlcatorsThe1000 nd1020Weightndicatorsave built-involtmeterhatallowsou oreadhemVoutput f hesensor rray. herelorevoltmetersnotnecessarybuta K-M estmeter rpotentiometerFigures0and11)are equiredosimulatehevoltageutput f hesensor rray.Wilh he estequipmentonnec{edo he1000/1020,ollowhisProcedure.1. lf youareusing K-M estmeter,ut he estmetern heSIMULATErode.fyouareusingpotentiometer,kiP hissteP.2. Hold ownheGREENeyandpressheREDkey oaccesshedouble-digitunction ode' hedisplay il l ead1'1'.

3. Press heREDkeyuntil 44'appears n hedis-play.nadditiono '44',thevoltage utput l thesensor nay s disPlaYed.4. Tum hedialon heK-M astmeter rpoten'tiometerntil0mV s disPlaYed.5. Hold he REDkeydown.Thedisplaywillscrolltotheendol thedoubledigitunctions ndbeginscrollinghroughhesingle-digitunctions' topatFunction "SetLo SPan".6. Press heBLUE ey o accesshe"setLo span"nrcde.Use heYELLOW ey o scroll p or heGREEN ey o scrolldownntilthe isplayeads"0",or anycombinationfzeros. ressheBLUEkeyagaino enter hisvalue.7, Press heREDkey wice o get o Function "Set

Zero".8. PressheBLUE ey o accesshe"SelZero"mode.Use heYELLOW ey o scroll por theGREEN ey o scrolldownntilthe isplayeads"0",or anycombinationl zeros'PressheBLUEkeyagaino enter heParameter.9 Hold heRED eydown. hedisplay il lscrolltotheendof the singledigitunctions nd eturnothe"WeightDisPlaY"node'10 . Themaximum aterialweightha twillbe n hevessels he ull-scaleive-loadeightWll)'Thisnumbers neededo calculatehevoltage utput(er-r-)f hesensor naywhen hemaximummaterial eights appliedo thesensors' or hesake l example,hisprocedureil luse150 onsas ull-scaleive-loadeightFull-Scale,'ys 150tons).Theequationooksike his: E q . 1

150x 2000 b/ton mVX ttl- = Full-Scaleu

UseTable1 or hecorrect alueof mV/psi'11. For hesakeof example,ewillsayAeq 85'7 n2andmV/psi 90 mV/1000 si.Theequationookslike his: Eq.2300,000Ib

85.7 n" x ##k = Futl-scaleurFull-Scaleu = 315mV

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12. Turn hedialon heK-M estmeteror poten-tiometer ntil315mV sappliedo thesignalprocessor.13 . HolddownheGREEN eyandpressheREDkey o relurno thedouble-digitunctions gain.14 . PressheRED eyuntil'44'appearsn hedis-play.15. Turn hedialon heK-M estmeleror poten-tiometer ntil315mVappears n hedisplay.16. Hold he REDkeydown.Thedisplaywiilscrolttotheendof thedouble-digitunctions ndbeginscrollinghroughhe singledigitunctions. topatFunction which sthe"SetHi Span" unction.17 . PressheBLUE ey o a@esshe SetHiSpan"mode.Use he YELLOW ey o scrollup or theGREEN ey o scrolldownuntilthedisplayeads150.0 or300,000). ressheBLUE eyagainoenter he value.18. Hold he HEDkeydown.Thedisptay iilscroil otheendof thesingle-digitunctions nd eturnothe"WeightDisplay' node.19. Disconnecthe K-M estmeter r voltmeter ndpot rom hesignal rocessorndconnecthe sen-sorarray.

lf the vesselsempty, erform teps 1 hrough24. l there s materialn he vessel, kipSteps21through 4 andcontinue ithSteps25 hrough 8.20. Theweight isplayed y hesignal rocessorwhen hesensor rray sconnectedepresentsthe weight f the vessel nd/or noffset oltage.Tozeroout he hisvoltage, se he REDkey oscrolltoFunction "SetZeto".21. Pressn. gLue key o a@esshe

"SetZero,,mode.Use heYELLOW ey o scroll portheGREEN ey o scrolldownuntil he disptay eads"0".

22. PressheBLUE ey o enterheparameter.23. Use he REDkey o scrollto he"WeightDisplay"mode.

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24 [ tnere s materialn hevessel,heweight is-played y hesignal rocessorsa combinationfthe vesselweight, nd/or ffset oltage, ndmaterial eight. ozeroout hisvoltage, se heREDkey o scrolltoFunction "SetZero',.

25. Presshe BLUE ey o accesshe',Set ero,'nucde. se heYELLOW ey o scroll p or theGREEN ey o scrolldownntilthe isptayeadsthe estimated eight f the materialn hevessel.26. PressheBLUE ey o enterheparameter.27. Use heRED ey o scrolltohe WeightDisplay,,mode.

1200/1220/1240 Batch Controt tersThe1200,1220,and1240BatchControllersaveabuilt-in oltmeterhatallows ou o read he mVoutputol thesensotaray.Therelore voltmeters notneces-sarybuta K-M esl meter rpotentiometerFigures 0and11)are requiredo simulatehe voltage utput fthesensor rray.With he estequipmentonnectedolhe 120011220/1240,ollowhisprocedure.1. ll youareusinga K-M estmeter, ut he estmetern heSIMULATE ode.f youareusingpotentiometer,kip hisstep.2. Presshe FUNCTN eyand enler zZ"to accessthe Units f Measure ode.PressheENTER eyto get he lashing ursor nd he current nitofmeasure.

PressheSCROLL Pkeyor SCROLL OWNkey o selecthe desired nitol measure. resslheENTER ey o save our election.Presshe FUNCTN eyandenter 82"to accessthe Calibrate flsetmode.Presshe ENTER ey,the displaywill readGROSSollowed ya weightvalue ndACTUALollowed y a weight alue.

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5. PressheACCESS ey,an access ode,and heENTER ey l necessaryo geta flashing ursor.6. Press he CLEAR ey o clear heweight alue ifany) hat ollowsACTUAL n hedisplay. ressthe ENTER eyand he GROSSweight aluewill

alsoclear.7. Presshe FUNCTN eyandenter 81"to accessthe Calibrate panmode.Presshe ENTER ey .and he displaywill read:

CALIBRATEPANBY ADD]NGWT.8. Dial n0 mVon heK-M estmeter rpotandpress he ENTER eyagain.When his s done,the signal rocessor ill read he 0 mV nputsig-naland hedisplaywillread:

ADDMATER]ALANDRESS NTER.9. Themaximummaterialweighthatwillbe n hevessels he ull-scaleive-load eight Wt-l). hisnumbers neededo calculatehevoltage utput(er-r-)l thesensor rraywhen hemaximummatedalweights appliedo thesensors. or hesakeof example,hisprocedure il luse150 onsas ull-scaleive-load eight Full-Scale LL=150 ons).Theequationooks ike his: E q . 1

150x 2000 b/ton = Full-ScaleltUseTable for hecorrect alueof mV/psi.

10. Fqrthe ake fexample, e willsayAeq 85.7in2andmV/psi=90 mV/1000 si.Theequationlooks ike his: Eq.z

fuq x #

x ffi, =Fuu-scaleu-Full-Scaleu-= 315mV

11. With he estmeter rpot,dial n hevoltagehatyoucalculatedo be hechangen he outputofthesensors hen hevessel ontainshe ull-scale ive- oadweight.12. Press heENTER ey o enterthis alueand hedisplaywill read:TOTAL DDEDWEIGHTandaweight alue.13. Press heCLEAR ey o clear heexisting eightvalue. Page

14. Enterhevalue epresentinghe ull-scaleive-loadweight.15. PressheENTER ey o save hevalueomemory.hedisplay il l etumo heDisplayWeightmode.16 . DisconnectheK-M estmeter rvoltmeterndpot rom he signal rocessorndconnecthe sen-sorarray. hedisplaywillreada combinationf of-fsetvoltage ndmaterialweight,f here s materialin hevessel.17. Tozeroout heoflset oltage,eturno Function82 Calibrate ffset. hedisplay illread:GROSSlollowed y hematerialndvesselweighlndACTUALOOOON.18. Estimatehematerialweightn hevessel. hisnumber il lbe 0 il theres nomaterialn heves-sel.Asyouenterha tvaluehenumber illappearalterACTUALon hedisplay. hevaluehat ol-lowsGROSS n hedisplay il l emain n-changed.19 . PressheENTER ey o save hevalue nmemory.hedisplaywillbrieflyeadSCALEOF-FSETSETand hen eturno theWeightDisplaymode. t his ime hevalueollowing ROSS nthedisplay il l eadheweight alueustentered.

TUNINGTHE SCALEFACTORIt wasstatedn he ntroductionhatsetting p hescale actorbycalculatingtsvalue s notas accurateasa calibrationrocedurehatusesmaterialmove-ment.Thissection xplains ow ocalculate djustmentso thescale actor hatwill mprovehesystemcalibrationccuracy.ScaleFactorAdiustmentlf oneor moreweight amples anbeweighed itha.separatecale, nadjustmento thescale actor anbe calculateds ollows:Adjustmentactor Adfl = ? Trueweight Eq'gs

i Indicated eight


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Onescenariowouldbe toweighan empty ruckon atruckscale.Fillthe ruckwithmaterialfromhe vesselrndweighhe truckagain.Subtrac{ut heweight frhe ruck o get he material eight.Observehe signalprocessor eforeand atter illing he truck o seehowmuchmaterialweight as renrlvedrom he vessel.Thematerialweightbtained y usinghe scalesthe"TrueWeight" in heabove ormula. he lndicatedWeight" n he ormulas heweight btainedrom hesignalprocessor. heAdjustment ac{or AdF) stheratioof the twoweights.Calculatinghe newscale actors doneas ollows:

NewScaleFactor AdFx old ScF Eq'4NewScaleFactor AdFx Full-Scale UL Eq. 5OldFull-Scaleu_

NewScaleFactor Full-Scale u- Eq.6W Fuu-G['eeLLEquatinghe ight-handides l Eqs. and5yields:

NewFull-scaleLL otdFull-scateu- Eq'7AOr

SeeEq. 1 for OldFull-ScaleLL.

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Now nlerhisnew alue f ull-scaleu_ y ollowingtheentire rccedureutlinedneither etUpProc+dure orAnalogSlgnalProcessorsr SetUpProcedure or DlgltalSlgnalProcessorshich recedethissection.

SummarySfepsTheollowingteps ummarizeheproceduredescribedbove.1. Set heZeroCalibratef thesignal rocessor itha 0 mV nput rom he simulator.2. Adjust he scaleactorusinghe newly alculated

lull-scale LL s he nputo thesignal rocessorlrom hesimulator.ollowhe SpanCalibrationprocedure.3. Re-zerohesignalprocessoryconnectinghesensor nay nputand ollowingheZeroCalibrate rocedure.

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Microcell Calibration