Kistler 5073A212 Owner's manual

Instruction

Manual

ICAM – Industrial

Charge Amplifier for

Manufacturing

Applications

Type 5073A...

ä

5073A_002-327e-04.23

Foreword

5073A_002-327e-04.23 Page 1

Foreword

Thank you for choosing a Kistler quality product

characterized by technical innovation, precision and long

life.

Information in this document is subject to change without

notice. Kistler reserves the right to change or improve its

products and make changes in the content without

obligation to notify any person or organization of such

changes or improvements.

protected by various intellectual property rights. For more

details visit www.kistler.com. The Kistler Group includes

Kistler Holding AG and all its subsidiaries in Europe, Asia,

the Americas and Australia.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

[email protected]

www.kistler.com

Contents

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Page 2 5073A_002-327e-04.23

Contents

1.Introduction ................................................................................................................................... 4

1.1Enclosed CD ...................................................................................................................... 5

2.Important Notes ............................................................................................................................. 6

2.1For Your Safety .................................................................................................................. 6

2.2Electromagnetic Compatibility (EMC) ............................................................................... 6

2.3Tips on Using this Instruction Manual ................................................................................ 6

2.4Nomenclature .................................................................................................................... 7

2.5Disposal of Electronic Equipment ....................................................................................... 7

2.6Software Upgrades and Updates ....................................................................................... 8

3.Basics ............................................................................................................................................. 9

3.1Unpacking ......................................................................................................................... 9

3.2Storage .............................................................................................................................. 9

3.3Amplifier Variants ............................................................................................................ 10

3.4Accessories Included ........................................................................................................ 10

3.5Optional Accessories ........................................................................................................ 11

4.Fundamentals ............................................................................................................................... 12

4.1The measuring chain ........................................................................................................ 12

4.2Piezoelectric Measurement .............................................................................................. 13

4.3The Mathematical Model of a Piezoelectric Measuring Chain .......................................... 14

4.4The Industrial Charge Amplifier ....................................................................................... 15

5.Description of Amplifier ............................................................................................................... 17

5.1General ............................................................................................................................ 17

5.2Block Diagram ................................................................................................................. 19

5.3Power Supply, Control Inputs and Analog Outputs ......................................................... 20

5.4RS-232C Interface ........................................................................................................... 21

5.5Peak Value Acquisition .................................................................................................... 22

5.6Setting Options – Configuration ...................................................................................... 24

5.6.1Description of the Individual Parameters .......................................................................... 26

6.Commissioning ............................................................................................................................ 28

6.1Installation ....................................................................................................................... 28

6.1.1Connecting Sensors ......................................................................................................... 28

6.1.2Connecting RS-232C and D-Sub 15-pin Male Connector ................................................ 29

6.1.3Power Supply and Digital Inputs ...................................................................................... 29

6.1.4Output Signals ................................................................................................................. 30

7."ManuWare" PC Software ............................................................................................................ 31

7.1Installing "ManuWare" PC Software ............................................................................... 31

7.2Starting the Program ....................................................................................................... 33

7.3Description of the Program Interface ............................................................................... 34

7.4First Simple Measurement – Step by Step ........................................................................ 35

7.4.1Preparations ..................................................................................................................... 35

Contents

5073A_002-327e-04.23 Page 3

7.4.2 Opening the Project – 'Open Project ...' (Ctrl+N) ................................................... 35

7.4.3 Find/Connect Devices – ‘AutoScan’ ........................................................................ 36

7.4.4Defining the Display Interface .......................................................................................... 37

7.4.5Assigning a Channel to a Display Object .......................................................................... 38

7.4.6Starting and Stopping Measurement ................................................................................ 38

7.4.7Optimizing Measurement – Changing the Set Values ....................................................... 39

7.5Backup/Restore Functionality ........................................................................................... 41

8.Maintenance and Diagnostics ...................................................................................................... 43

8.1Inspections during normal operation ................................................................................ 43

8.2Loading New Firmware .................................................................................................... 43

8.3Drift .................................................................................................................................. 47

8.3.1Cause 1 ............................................................................................................................ 47

8.3.2Cause 2 ............................................................................................................................ 48

8.3.3Cause 3 ............................................................................................................................ 48

9.Technical Data .............................................................................................................................. 50

9.1Design Variants ................................................................................................................ 50

9.2Charge Inputs ................................................................................................................... 50

9.3Voltage Outputs (Types 5073Axx1) ................................................................................. 50

9.4Current Output (Types 5073Axx2) ................................................................................... 51

9.5Current output symmetrical (Types 5073Axx5) ................................................................ 52

9.6Measuring Accuracy ......................................................................................................... 52

9.7Dynamic Response of Signal ............................................................................................. 52

9.8Peak Value Acquisition ..................................................................................................... 53

9.9Climatic Operating Conditions ......................................................................................... 53

9.10Power Supply Voltage ...................................................................................................... 54

9.11Control Inputs (Bipolar Optocouplers) .............................................................................. 54

9.12Connectors ....................................................................................................................... 54

9.13LED Indicators .................................................................................................................. 55

9.14Serial Interface .................................................................................................................. 55

9.15Mechanical Data .............................................................................................................. 55

9.16EMC (to conditions of Directive 2014/30/EU) .................................................................. 56

9.17 Dimensions ..................................................................................................................... 57

10.Appendix ...................................................................................................................................... 58

10.1Command Set of RS-232C Interface ................................................................................. 58

10.1.1Command Structure ......................................................................................................... 58

10.1.2Feedback Structure ........................................................................................................... 59

10.1.3Command List .................................................................................................................. 64

10.1.4Examples of Serial Communication ................................................................................... 66

11.Glossary ........................................................................................................................................ 69

11.1Terminology ..................................................................................................................... 69

11.2Measurement Uncertainty ................................................................................................ 73

12.EC Declaration of Conformity ....................................................................................................... 75

Total number of pages: 75

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 4 5073A_002-327e-04.23

1. Introduction

The quality precision Kistler product you have chosen is

characterized by a high level of technical innovation and

built to last.

The Type 5073A... ICAM charge amplifier (Industrial

Charge Amplifier Manufacturing) converts the charge

signal from the piezoelectric sensor into an output voltage

proportional to the mechanical input quantity. Depending

on the version, up to four sensors can be connected, which

can monitor an industrial production process.

Most important performance features at a glance:

 Wide, variable measuring range from ±100 ... ±1 000 000

pC

 Two independent and variable measuring ranges per

channel; switchable online

 Adjustment in sealed case via serial interface

 Executable PC software for configuration 1)

 LED for visualizing the current operating status

 ICAM versions for degrees of protection IP60 and IP65

 Integrated peak value memory

Please take the time to thoroughly read this Instruction

Manual. It will help you with the installation, maintenance,

and use of this product.

Kistler offers a wide range of measurement products and

turnkey solutions:

 Quartz crystal sensors for measuring force, torque,

strain, pressure, acceleration, shock, vibration and

structural noise

 Piezoresistive pressure sensors and transmitters

 Measuring amplifiers, indicators and calibrators

 Electronic control, monitoring and evaluation systems,

as well as software for specific measurement

applications

 Data transmission modules (telemetry)

Kistler also develops and produces complete measuring

solutions for engine, vehicle, manufacturing, plastics and

biomechanics applications.

1) Drivers for Labview Version 7.1 are available but not maint-

ained.

Introduction

5073A_002-327e-04.23 Page 5

Our product and application brochures will provide you

with an overview of our product range. Detailed data

sheets are available for almost all products.

If you need additional help beyond what can be found

either online or in this manual, please contact

Kistler's extensive support organization. Your regional

Kistler sales center or distributor will gladly provide expert

advice – even for application-specific problems.

1.1 Enclosed CD

A CD containing the following is attached inside this

Instruction Manual:

 ManuWare setup and test software, incl. online Help

files (HTML, can also be printed out)

 Flashloader program and firmware of all devices

supported by ManuWare

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 6 5073A_002-327e-04.23

2. Important notes

Please follow the following instructions, which are intended

to ensure your safety when working with the ICAM Type

5073A… and guarantee a long, trouble-free service life.

2.1 For your safety

The device left the factory in a perfectly safe condition. To

maintain this condition and ensure safe operation, follow

the directions and warnings in this Instruction Manual and

on the device.

Also follow local safety regulations governing the handling

of electrical and electronic equipment.

If it has to be assumed that the amplifier can no longer be

operated safely, switch it off and secure it to ensure it

cannot be switched on again inadvertently.

Safe operation is no longer possible

 if the equipment is visibly damaged,

 if it is not working properly,

 after prolonged storage under adverse conditions,

 after being severely impacted in transit.

If any of the above indicate that safe operation is no longer

ensured, the device must be immediately sent to the

responsible Kistler sales center or distributor for repair.

2.2 Electromagnetic compatibility (EMC)

The ICAM Type 5073A… charge amplifier is manufactured

in conformity with CE requirements. It meets the

electromagnetic compatibility safety requirements to EN

61000-6-2 (Immunity) and EN 61000-6-3 (Interference).

2.3 Tips on using this instruction manual

We always recommend that you read the entire Instruction

Manual. However, if you cannot spare the time and are

already familiar with Kistler charge amplifiers, you can limit

yourself to reading the sections containing the information

you currently require.

Important notes

5073A_002-327e-04.23 Page 7

Keep this Instruction Manual in a safe place where it is

readily accessible at all times. Please ask the responsible

Kistler sales center or distributor for a replacement copy if it

is lost. A copy of this Instruction Manual can also be

downloaded from our website www.kistler.com.

Modifications (conversion, retrofitting, etc.) to the amplifier

generally also result in changes to the Instruction Manual. In

this case, please ask the responsible Kistler sales center or

distributor about the options for updating your

documentation.

2.4 Nomenclature

The following table explains the nomenclature and

abbreviations used in this Instruction Manual:

Explanation

M.U. Mechanical Unit,

depending on the type of sensor used, for

example:

pressure in bar

force in N or kN

strain in 

pC pico Coulomb = unit of electric

charge

1 pC = 10-12 C or 1 C = 1 As

V Volt = unit of electric voltage

1 V = 1 000 mV

FS Full Scale = full scale value

2.5 Disposal of electronic equipment

Old electronic equipment must not be disposed of in

domestic or residual waste. For disposal at end of life,

please return this product to an authorized electronic

waste disposal service or contact your nearest Kistler

sales office.

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 8 5073A_002-327e-04.23

2.6 Software upgrades and updates

Upgrades or updates for embedded software supplied by

Kistler must be installed.

Kistler accepts no liability for direct damage or

consequential damage caused by products with embedded

software that is not up to date.

Basics

5073A_002-327e-04.23 Page 9

3. Basics

3.1 Unpacking

Check all the device packaging for damage in

transit. Report such damage to the freight forwarder and

the responsible Kistler sales center or distributor.

Please check the included accessories before

commissioning the device (see section 6). Please contact

the responsible Kistler sales center or distributor if there is

anything missing.

3.2 Storage

Take the following safety precautions if prolonged storage

is envisaged.

 The temperature must lie in the range –40°C to 80°C.

 Cover the sensor connections with a non-shorting dust

cap.

 The surroundings should be as dry as possible.

 If possible the amplifier should be stored in its original

packaging until used.

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 10 5073A_002-327e-04.23

3.3 Amplifier variants

The following key shows the available variants:

Type 5073A    (opt.) Y0

1 channel/acquisition of 1 peak

value 1

2 channels/acquisition of 2 peak

values 2

3 channels/acquisition of 3 peak

values 3

4 channels/acquisition of 2 peak

values 4

4 charging channels summed to 1

channel 5

BNC neg. connector (IP60) 1

TNC neg. connector (IP65) 2

Output signal voltage

-10 … ±10 V 1

Output signal current

4 … 20 mA (available for 1 and

2-channel versions only)

2

Output signal current symmetric

12 ±8 mA (available for 1 and

2-channel versions only)

5

With a fixed, customized time

constant; specify per channel

when ordering, incl.

high (>10 000 pC) or low (<10

000 pC) charge levels

488

For supply voltage

9 … 16 V (available for 1 and 2-

channel versions only)

489

3.4 Accessories included

The ICAM charge amplifier is supplied with:

Item No./

Type

 D-Sub 15, female, IP40

with metalized cover and jackscrews

 Null modem mini adapter (gender changer)

D-Sub 09, male, D-Sub 09, female

 ManuWare CD with

 the ManuWare program

 the latest firmware for all supported

devices

 Flashloader programs for all supported

devices

65016033

1489

65016164

Basics

5073A_002-327e-04.23 Page 11

 IP67 cover fo

r

RS-232C, D-Sub 09 female,

connector

 Operating Instructions

 Calibration certificate

With ICAM Type 5073A5xx

 2 dust caps for sensor connection

65008385

3.5 Optional accessories

Item No./

Type

 RS-232C cable, l = 5 m, null modem,

D-Sub 09 male, D-Sub 09 female

 D-Sub 15, female, IP67, with M20x1.5

lifting screws for cable diameters 6 ... 12

mm

 D-Sub 15 female, IP40, with pigtail, l = 5

m

 D-Sub 15 female, IP40, with pigtail ,

length to order

(Lmin = 1 m/Lmax = 10 m)

 D-Sub 15 female, IP65, with pigtail, l = 5

m

 D-Sub 15, female, IP65, with pigtail,

length to order

(Lmin = 1 m/Lmax = 10 m)

 Converter, USB 1.1 to RS-232C,

D-Sub 09 male, USB 1.1

 Adapter, TNC pos. – BNC neg.

1200A27

65016052

1500A41A5

1500A41Asp

1500A42A5

1500A42Asp

2867

1709

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 12 5073A_002-327e-04.23

4. Fundamentals

4.1 The measuring chain

The typical measuring chain consists of a piezoelectric

sensor with charge output, a charge amplifier and a system

for cycle command, data acquisition and data evaluation.

In industry, cycle command functionality is usually

implemented with a programmable logic controller (PLC).

Fig. 1: Single-channel measuring chain with charge

amplifier

Key:

1 Sensor

2 Charge amplifier

3 Reset/Measure

4 Measurement signal

5 Signal evaluation

6 Power supply

Piezoelectric

sensor

Connecting cable ICAM

Type 5073A…

PLC

Fig. 2: Example of a measuring chain

Fundamentals

5073A_002-327e-04.23 Page 13

4.2 Piezoelectric measurement

Sensors

Piezoelectric sensors directly convert mechanical quantities,

such as force, pressure and acceleration, into an electric

charge. This charge is proportional to the force acting on

the quartz crystal in the sensor. The sensitivity of the

sensors is given in pC/M.U.

Fig. 3: Force F on the piezoelectric sensor

Notes on piezoelectric measurement

When working with piezoelectric instruments, please note

that these differ from other familiar electrical measuring

instruments. The applicable criteria are different from those

for conventional current or voltage measurement, for

example. When unpacking the sensors and the special

cables ensure that their connectors remain clean and dry, in

order to maintain their high insulation resistance. In

particular, the Teflon insulator of all connector pairs in the

input circuit must be kept absolutely clean and must not be

touched with your fingers. Only use unadulterated

cleaning agents, for example 1003 cleaning spray from

Kistler or white spirits, on a clean, lint-free paper towel.

High insulation sensor cables

Only high insulation, low noise sensor cables, as per Kistler

data sheets 1631C_000-346 and 1601B_000-352, may be

used for connecting the sensors. Normal commercial

coaxial cables generate triboelectricity as a result of

movement, which would falsify the measurement result.

Connecting piezoelectric sensors in parallel

When several sensors are connected in parallel, the

charge amplifier measures the sum of all charges. For

example, the four quartz force links of a measuring

platform can be connected in parallel in order to measure

the total force.

Polarity

Kistler defines polarity in such a way that an increase in

compressive force in a force sensor produces a negative

charge. The charge amplifier inverts the sensor signal and in

this case generates a positive output voltage. The charge

amplifier does not offer an option for additional signal

inversion.

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 14 5073A_002-327e-04.23

Measuring range

We recommend setting the widest measuring range at

the start of measurement or for very intermittent

operation. Normal overdriving by overly-large charge

signals does not damage the charge amplifier. If the

amplifier is overdriven by a factor of more than 10, the

charge can produce an unacceptably high voltage. The

amplitude of the voltage depends on the input charge, the

total input capacitance (sensor and cable) and the range

capacitor.

Measure mode

The major advantage of the charge amplifier principle is

that even quasistatic measurement can be carried out

perfectly. Static measurement is limited by the finite time

constant in the negative feedback circuit, as well as by drift

effects (for example, input current) in the charge amplifier.

4.3 The mathematical model of a piezoelectric measuring chain

The mathematical model of a piezoelectric measuring chain

looks like this:

M

in

process variable

X

in

sensor measurand

Q charge

U

a

amplifier voltage

U

Offset

offset voltage

U

Out

amplifier output voltage

U

display

displayed voltage

X

display

displayed sensor measurand

M

display

displayed process measurand

in

M

X

k

Mechanical system factor

(e.g., in force shunt or indirect

force measurement)

in

sensor

X

Q

S

Sensor sensitivity as

p

er

calibration certificate.

Q

U

S

a

ca



Charge am

p

lifier transmission

factor

out

display

U

X

x

Dis

p

lay factor for the sensor

measurand

out

display

U

M

m

Dis

p

lay factor for the

p

rocess

measurand

Fig. 4: Mathematical model of a piezoelectric measuring chain

Fundamentals

5073A_002-327e-04.23 Page 15

4.4 The Industrial charge amplifier

In this context it should be noted that the term "charge

amplifier" does not mean a device that amplifies a charge

Q1 to a value Q2. We use it in the sense of a device for

converting the charge Q into a voltage Ua. A charge

amplifier is therefore a charge-to-voltage converter. It

employs the circuit principle of the integrator. Its key

components are an operational amplifier with very high

internal gain and extremely high input insulation (Rg) as well

as a high-precision, low-loss negative feedback capacitor

(Cg).

Fig. 5: Equivalent circuit diagram of charge amplifier with

charge source

The following approximate formula is adequate for

calculating the voltage signal in most cases:

Ua = -Q/Cg

At the end of each measuring cycle the negative feedback

capacitor is discharged by means of the Reset command

and the output signal is set to zero in order to prevent zero

drift during measurement. The insulation resistance of the

negative feedback capacitor Cg determines the lower cut-

off frequency of the charge amplifier according to the

formula

fu = 1/(2 · Rg · Cg)

The negative feedback capacitor can also be discharged

according to a time constant. This option is available on

request.

Very stringent requirements are imposed on the stability,

low input current and high input insulation of such an

integrator, as the charges to be measured are often just a

few pC. As a result of the high charge sensitivity and high

input resistance, the sensitivity to noise is also relatively

high.

In industrial applications, the sensitivity to interference can

be reduced if the charge amplifier is mounted as close as

possible to the sensor. The signal can then be processed

further away, as the output circuit of the charge amplifier is

low resistance and hence insensitive to interference. Due to

ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...

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Page 16 5073A_002-327e-04.23

the typically metallic shielding of the sensors, cables and

amplifiers, as well as options regarding the grounding

concept, piezoelectric measuring chains from Kistler can

generally achieve high resistance to interference.

In summary, an industrial charge amplifier should have the

following properties:

 Compact

 Robust, sealed housing

 Remote-controlled measurement start and stop

 Low-voltage power supply

 Several measuring channels

 Quick and easy parameter setting

 Adaptable to suit special measuring tasks

Description of amplifier

5073A_002-327e-04.23 Page 17

5. Description of amplifier

5.1 General

The charge signal coming from the piezoelectric sensor is

converted by the ICAM Type 5073A… (Industrial Charge

Amplifier Manufacturing) charge amplifier into a

proportional output voltage. The output signals can be

passed on to an industrial control system for monitoring,

control and optimization of a production process. During

the process, the amplifier is controlled via digital inputs and

a serial interface.

Models are available with the same case and bolt

pattern but one, two, three or four channels, each of

which accommodates one sensor.

The Type 5073A5xx ICAM has an integrated summing

amplifier to which up to four sensors can be connected

via the input channels. The amplifier operates like a

single-channel version, where the individual charges of all

four channels are summed into a total charge.

Note therefore, for example, that depending on the total

charge of all the channels, the frequency response can

also change.

The charge input is protected against static discharge and is

ground-isolated. It is allowed to have a potential difference

of up to 4 volts relative to the output or supply voltage.

The ICAM has a rugged pressure diecast aluminum case.

With a wide voltage input range from 18 ... 30 VDC and

degree of protection up to IP60/65, the amplifier is desig-

ned for an industrial environment and mounting in the

immediate vicinity of sensors, for example right alongside a

machine tool.

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Page 18 5073A_002-327e-04.23

Fig. 6: ICAM Type 5073A...

The ICAM parameters are set with ManuWare PC

software. Virtually any measuring range can be set. For

each sensor connection, two measuring ranges are

available that can also be switched during measurement.

However, for technical reasons this is only permitted

between ±100 to ±10 100 pC and ±10 100 ... ±1 000 000

pC, as otherwise measuring errors will occur. With the

stored peak value, the optimum measuring range can be

determined and hence the highest resolution set. An offset

can be configured for each channel. A low-pass filter can

also be connected. Its cut-off frequency is always valid for

all channels.

Only two peak memory outputs are available on the

version with four channels.

The LED indicates the operating mode of the industrial

charge amplifier. If the ICAM is in Measure mode, the LED

is constantly green. Flashing green indicates Reset mode.

The LED flashes red if the amplifier has been overloaded,

i.e., if the sensor has generated more charge than the

ICAM can accept based on the preselected measuring

range. This can lead to measuring errors. A reset restores

the original state, i.e., the charge amplifier output is set to

zero. The LED is constantly red if the ICAM is faulty.

ICAM mode LED

Measure green, steady

Reset green, flashing

Overload red, flashing

Fault red, steady

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Kistler 5073A212 Owner's manual

Kistler 5073A212 Owner's manual

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