HKS Sensors Series S3 Technical Data EN User manual

Brand
HKS
Model
Sensors Series S3 Technical Data EN
Type
User manual
Sensors
HKS-Prozesstechnik GmbH
Heinrich-Damerow-Str. 2
D-06120 Halle / Saale
Tel. +49 (0)345 68309-0
Fax +49 (0)345 68309-49
info@hks-prozesstechnik.de
www.hks-prozesstechnik.de
for measuring of welding data
Technical data /
operating instructions
sensors of the series S3
Process sensors
P 1000-S3 / P1500UP-S3/
Wire feed sensors
DV25 M-S3 / DV25 ST-S3 /
DV25 UP-S3 / DV25UP/K-S3
Gas sensor
GM30L10B-S3
calibration certificates
CE - declaration
Konformitätserklärung
nach DIN EN ISO/IEC 17050
Hersteller / Adresse
manufacturers name /aderess:
HKS-Prozesstechnik GmbH
Heinrich-Damerow-Str. 2
D-06120 Halle
Deutschland / Germany
Produkte / Modell:
Products / model
µQAS-S3
S3-Modul
WeldScanner S3
WeldAnalyst S3
ThermoProfilScanner
Prozesssensoren / process sensors:
P100-S3, P1000-S3; P 1500-S3; P100K-H-S3
Gassensor / gas sensors: GM30L10B-S3
Drahtsensoren / wire sensors:
DV25M-S3; DV25ST-S3; DV25UP-S3;
DV25UP/K-S3
Einsatzgebiet:
Designation:
Geräte zur Schweißdatenüberwachung
welding monitoring systems
Die genannten Produkte wurden auf Basis der
technischen Spezifikation und in Übereinstimmung
mit allen relevanten Standards und Vorschriften
gefertigt, wobei insbesondere folgende Standards
berücksichtigt wurden:
The listed products have been manufactured
according to the technical specifications of the
product and conform in all respects to the relevant
standards and regulations. The following standards
were taken into account particularly:
EN 55022 - Störaussendung / transient emissions
EN 61000-6-2 - Störfestigkeit / interference resistance
Ort / location: Halle / Saale
Datum / date: 19.05.2016
Geschäftsführer / CEO
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Straße 2, D-06120 Halle/Saale,
Tel. +49 345 683090, Fax: +49 345 6830949, www.hks-prozesstechnik.de
Process sensors
P100-S3 / P1000-S3 / P1500UP-S3
Calibrated special measuring instrument for the measuring
of
welding current
welding voltage
Suitability
for all arc welding processes
complete capable for TIG / plasma
Process sensor P1000-S3
Process sensor P 1500 UP-S3
with separate current transformer
Process sensor P 1000
with wire feed sensor, gas sensor and adapters
1. welding voltage adapter +
2. welding voltage adapter -
3. welding cable (trough the opening)
4. speed sensor
5. WeldQAS / WeldScanner
6. wire feed sensor
7. gas flow sensor
8. reserve
Impact
galvanic isolation of the process signals for further
processing of the measuring signals safety
measuring current: Signal change
over hall effect transducers
measuring voltage:
galvanic isolation by HF-filter und special buffer
amplifier
Installation
1. Put the welding cable trough the opening of the
process sensor. Pay attention to the current direction
given on the process sensor.
2. Attach the welding voltage via the enclosed cable
adapters at the sockets of the current source
and connect the measuring cables with the connections
for plus and minus pole at the process sensor.
3. The corresponding sensors can be attached to the
labelled sockets for the wire feed-, gas and speed
measurement.
Anschlüsse
2016- 02- 12
2
Prozesssensoren P1000-S3, P1500-S3
pin assignment
Pin
definition
pin assignment front side
connection to
WeldQAS-S3
________________________
__
appropriate mating-connector:
HUMMEL M23
7.106.400.000 und
7.001.919.104
1
welding current 0 … +/-10 V
2
welding current GND
3
welding voltage 0…+/-10 V
4
welding voltage GND
5
gas signal 0… +/- 10 V
6
Gas signal ground
7
reserve signal 0… +/- 10 V
8
reserve signal GND
9
wire signal A 10…30V
10
wire signal B 10…30V
11
wire signal GND
12
speed signal A 10…30V
13
speed signal B 10…30V
14
speed signal GND
15
supply 9 - 36V
16
supply 9 – 36 V
17
supply 0 V
18
supply 0 V
19
sensor control-signal
pin assignment front side
connection to
gas sensor GM30L10B-S3
and RESERVE
________________________
appropriate mating-connector:
Binder series 680
09-0317-00-05
alternative
09-0305-00-03
1
supply +12 V (optional +24 V)
2
GND signal
3
signal (0…10V)
4
GND supply
5
NC
connection for wire feed
sensors
DV 25M-S3 and DV 25ST-S3
and measuring of the welding
speed
_______________________
appropriate mating-connector:
Binder series 680
09-0309-00-04
1
rotery encoder signal A
(impulse +10…30 V)
2
rotery encoder signal B
(Impulse +10…30 V)
3
GND rotary encoder
4
supply + 24 V
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Straße 2, D-06120 Halle/Saale,
Tel. +49 345 683090, Fax: +49 345 6830949, www.hks-prozesstechnik.de
* Both sensors are optionally available as "fast" variant with a voltage bandwidth of 100 kHz.
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welding method
MIG/MAG, WIG, EH
for all power sources
UP and stud welding
supply
9…36 V DC, max. 10 W
operating temperature
0…40 °C
relative humidity
80 % without condensation
dimensions (H x B x T)
120 x 120 x 105 mm (ohne Steckverbinder)
weight
1 kg
0,7 kg (without current transformer
separate current
transformer
S 1500 (for P1500UP-S3)
dimension
weight
200 x 120 x 90 mm
1 kg
electrical connection
19–pole M23
measuring method
current-compensated Hall effect
transducer
direct Hall effect transducer
maximum opening
for welding cable
Ø 40 mm
105 x 37 mm
transducer screwed
effective range
current
voltage
current
voltage
nominal current
+/- 300, 500, 1000 A
+/- 100 V
+/- 1500, 2000, 3000 A
+/- 100 V
accuracy
+/- 1%
+/- 1 %
+/- 2 %
+/- 1 %
bandwidth /
100 kHz
20 kHz /
100 kHz
(fast)*
10 kHz
20 kHz /
100 kHz (fast)*
exit
0 … +/- 10V
0 … +/- 10V
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Str. 2, D-06120 Halle
Tel. +49 345 68309-0, Fax +49 345 68309-49, email [email protected] , http://www.hks-prozesstechnik.de
Process sensors P100K-H-S3
for resistance and CD-welding 2017-19-04
Special instrument for the measurement of
welding current
AC, DC, MF, resistance welding and
capacitor discharge welding
welding voltage
Versions
P100K-H-R-DC/MF
for all resistance welding methods
P100K-H-CD
for all CD-methods
Process sensor P100K-H-S3
+
-
with current transformer and pin welding gun
Mode of operation
galvanic isolation of the process signals for the further safe
signal processing
current measurement:
signal conversion via current measuring coil (Rogowski coil)
high accuracy by self-adjusting, offset calibration and
temperature compensation
automaticly choosing AC- or DC- Mode
no manual reset of the sensor before the measurement is
required because of the intelligent self-synchronizing
mechanism
voltage measurement:
via special galvanic isolated amplifier
Installation
The Rogowski-coil is attached around the current path
and connected to the process sensor to measure
current flow.
Connect the welding plug with the cable, plus (red) and
minus pole (black) to the process sensor.
Distance and force sensors can be connected optionally.
Functionality
The sensor is starting after connection of the supply
voltage with a initialisation adjustment which takes
around 60 seconds. In that time there is no
measurement.
Afterwards the sensor will waits for a current break of at
least 0.2 seconds to synchronize the measurment.
The DC-measurement is limited to 20 seconds to ensure
the high accuracy measurements.
If the sensor exceeds the measuring limits there will be
a automatic resynchronisation.
connections, displays and control elements
Indication
The state of the sensor is indicated by its both LED’s. The following table shows the possible states
of the sensor.
system active
(LED green)
AC/DC mode
(LED orange)
state of the sensor
flash (0,5 Hz)
off
Initialisation of the sensor starts
on
flash (short long)
The sensor needs an interruption in the current flow
for the synchronization of the DC measurement.
on
off
Sensor is ready for measurement
on
flash (1 Hz)
Sensor in AC-mode
on
on
Sensor in DC-Mode
flash alternately
DC measurement over 20 seconds or
measuring over the measuring limit
flash (10 Hz)
-
Internal error
Operation
By pushing the reset button the output signal will be resettet to zero.
Holding the reset button for longer then 3 seconds will force the sensor to restart and reinitialize.
1 welding voltage -
2 welding voltage +
3 measuring device
4 force sensor – pin
5 distance sensor - pin
6 current sensor - pin
7 reset-button
8 LED current mode (AC / DC)
9 LED system status
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Str. 2, D-06120 Halle
Tel. +49 345 68309-0, Fax +49 345 68309-49, email [email protected] , http://www.hks-prozesstechnik.de
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Process sensor P100K-H-R-DC/MF
Process sensor P100K-R-AC
Process sensor P100K-CD
welding method
Resistance welding (P100K-R-AC; P100K-R-DC/MF))
capacitor discharge welding (P100K-CD)
dimensions
sensor
120 x 105 x 120 mm (L x W x H)
current transformer
current coil (Rogowski- coil) Ø max. 100 mm
(for bigger required diameters please contact us)
weight
sensor 700 g; current transformer 500 g
supply
+ 9V – 36 V DC, 3 W
electrical connection
19-pole M 23: connection for distance- and force measure
measuring method
current: current coil (Rogowski-coil);
voltage: isolating amplifier
effective range
current
AC: +/- 20, 30, 60, 80, 100 kA
DC, MF: +/- 20, 30, 60, 100 kA (drift <1% from upper range value URV/20 s)
Accuracy for 20, 30, 60 kA: 1,5 % from upper range value (URV) within the
measure time of 20 s (exactly class for high-precision applications
according to DIN EN ISO 17657-2 / DIN EN ISO 17657-3 in contact with QAS-
monitoring system)
max. slope control speed at different upper range values
20 kA 30 A / µs
30 kA 45 A / µs
60 kA 90 A / µs
80 kA 120 A / µs
100 kA 150 A / µs
(for quicker slop control please contact us)
low level-Band with: 8 kHz (-3dB)
measure time: AC endless, DC until 20 s (for longer measure times please contact us)
voltage
resistance R : max. 10 V
capacitor KES/CD: max. 300 V
accuracy: +/- 1 % from upper range value
Setting time: 30 µs
Input impedance: 1,2 kΩ
band with: 80 kHz (-3dB)
working temperature
15 °C bis 40 °C
reference temperature
20 °C
relative air humidity
45 bis 75 % without condensation
safety regulations
DIN 100
Standards (norms)
for current measure according to DIN EN ISO 669:2013-02
output
+/- 10 V
pin assignment
Pin
definition
pin assignment front side
connection to
WeldQAS-S3
________________________
appropriate mating-connector:
HUMMEL M23
7.106.400.000 und
7.001.919.104
1
welding current 0 … +/-10 V
2
welding current GND
3
welding voltage 0…+/-10 V
4
welding voltage GND
5
gas signal 0… +/- 10 V
6
Gas signal ground
7
reserve signal 0… +/- 10 V
8
reserve signal GND
9
wire signal A 10…30V
10
wire signal B 10…30V
11
wire signal GND
12
speed signal A 10…30V
13
speed signal B 10…30V
14
speed signal GND
15
supply 9 - 36V
16
supply 9 – 36 V
17
supply 0 V
18
supply 0 V
19
sensor control-signal
pin assignment front side
connection to
force sensor
and distance sensor
________________________
appropriate mating-connector:
Binder series 680
09-0317-00-05
alternative
09-0305-00-03
1
supply +24 V
2
GND signal
3
signal (0…10V)
4
GND supply
5
NC
connection to Rogowski-coil
assignment of the 2-pole
connector
1
exit Rogowski-coil
2
exit Rogowski-coil
Connection to RESET-pin
assignment of the 4 pole
M 18 connector
order-number: 413-7516
at RS Components
1
2
normally open contact for RESET
(GND)
3
normally open contact for RESET
4
+5 V output (100 mA)
The operations at Reset pin are only allowed to
activate by a potential separated signal (relay
with closing contact).
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Straße 2, D-06120 Halle/Saale,
Tel. +49 345 683090, Fax: +49 345 6830949, www.hks-prozesstechnik.de
0 2 . 1 1 . 2 0 1 6
Wire feed sensors
DV25M-S3 / DV25ST-S3 / DV25UP-S3 DV25UP/K-S3
Calibrated special measuring instruments for measurement of
wire feed speeds while welding
for calibration tasks
Suitability
for wire size of 0,8 – 5 mm, depending on type
Attention!
DV25 M for TIG / Plasma – cold wire measurements
only with plastics rolls applicable
wire feed sensor DV 25 ST in use
wire feed sensor DV 25 M in use
Impact
Scanning of the wire speed via an especially
developed role mechanism directly at the wire
a rotary encoder changes the wire feed speed into a impulse
consequence proportional to the feed
Installation
The wire sensors should be placed nearby the wire feed
gear.
DV25M-S3 via magnet leg and universal joint
DV25ST-S3 via mandrel (in different sizes available)
(see picture next page)
DV25UP-S3 via mandrel
DV25UP/K-S3 via mandrel
wire feed sensor DV25 UP
deduces with process sensor P 1500 UP
and separate current transformer
wire sensor DV25 UP/K
2
Drahtsensoren
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wire size (Ø mm):
0,8 … 2 mm
0,8 …1,8 mm
2 … 5 mm
2…3 mm
output frequency in Hz at 5 m/min // at 25 m /min
732 // 3660
732 // 3660
303 // 1515
427 // 2133
attachment :
magnet leg
mandrel
mandrel
mandrel
dimensions in mm / weight in kg
85x60x35 / 0,5 kg
60x60x50 / 0,5 kg
170x120x70 / 1,0 kg
130x70x70 / 0,8 kg
option TIG: Ausführung für HF (TIG / plasma)
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pin assignment
Pin
definition
pin assignment front side
connection
4-pole M18-connector
Binder series 680
09-0309-00-04
1
wire feed signal A
(impulse +10…30 V)
2
wire feed signal B
(impulse +10…30 V)
3
GND
4
supply 10 … 30 V
Adapter Type -No.
(other on request)
A
in mm
B
Ø in mm
C
Ø in mm
D
in mm
11
44
20
13,1
8
12
16
12
21
50
12,9
22
48
16,9
23
35
11,7
24
35
12,9
HKS-Prozesstechnik GmbH, Heinrich-Damerow-Straße 2, D-06120 Halle/Saale,
Tel. +49 345 683090, Fax: +49 345 6830949, www.hks-prozesstechnik.de
6 N o v e m b e r 2 0 1 4
Gas sensor
GM30L10B-S3
Calibrated measuring instrument for the
measurement of
gas flow rates
Suitability
used for all in welding and cutting
technology non-combustible gases
Impact
The sensor provides a voltage at
his exit, which is linearly
dependent on the mass flow of the
gas flowing trough the sensor.
It is based on the principle of the
cooling of a heated sensor
element which is exposed to the
gas current.
The bigger the gas flow the bigger
the cooling, which is converted into
the output signal.
gas sensor deduces with process sensor
Installation
The GM 30 L 10 B is installed about to the gas pipe that the gas pass trough the sensor in the showed
direction on the type label. The sensor has to be attached horizontally and as close as possible nearby
the torch.
Installation draft (measurements in mm)
2
Gassensor GM30L10B-S3
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all non-combustible welding gases
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of the built-in sensor
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pin assignment
pin
definition
pin assignment front side
connection
5-pole M-18 connector
Binder series 680
09-0317-00-05
1
1
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V
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r
r
s
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4
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5
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.
.
c
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.
.
kind of gas
signal=5V =>flow rate
accuracy
calibration factor
min/l
%
V
l min/
Ar
30,0
+/- 3%
6,00
He
as real gas calibrations only
N2
21,4
+/- 5%
4,28
O2
21,2
+/- 5%
4,24
CO2
15,3
+/- 5%
3,06
82% Ar + 18% CO2
25,6
+/- 5%
5,12
92% Ar + 8% CO2
27,9
+/- 5%
5,58
98% Ar + 2% CO2
29,4
+/- 5%
5,88
92% Ar + 8% O2
29,0
+/- 5%
5,80
95% Ar + 5% O2
29,4
+/- 5%
5,88
97% Ar + 3% O2
29,6
+/- 5%
5,92
30% Ar + 70% He
helium mixture as real gas calibrations only
50% Ar + 50% He
70% Ar + 30% He
80% Ar + 20% He
95% Ar + 5% He
65% Ar + 35% H2
26,4
+/- 5%
5,28
90% Ar + 10% H2
28,9
+/- 5%
5,78
94% Ar + 6% H2
29,3
+/- 5%
5,86
97,5% Ar + 2,5% H2
29,7
+/- 5%
5,94
98% Ar + 2% N2
29,8
+/- 5%
5,96
80% N2 + 20%H2
21,4
+/- 5%
4,28
90% N2 + 10%H2
21,4
+/- 5%
4,28
86% Ar + 12% CO2 + 2% O2
26,7
+/- 5%
5,34
96% Ar + 3% CO2 + 1% O2
29,0
+/- 5%
5,80
75% Ar + 15% CO2 + 10% He
26,2
+/- 5%
5,24
81% Ar + 18% He + 1% CO2
29,7
+/- 5%
5,94
60% Ar + 38% He + 2% CO2
29,4
+/- 5%
5,88
75% Ar + 20% He + 5% H2
29,8
+/- 5%
5,96
88% Ar + 10% He + 2% N2
29,8
+/- 5%
5,96
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HKS Sensors Series S3 Technical Data EN User manual

Brand
HKS
Model
Sensors Series S3 Technical Data EN
Type
User manual
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