MTI Instruments Accumeasure 563 Owner's manual

Type
Owner's manual
MTI Instruments Technical Manual 7001-0003
Revision 1.3 April 28, 2017
Accumeasure AS-563-PA
Capacitance Sensor Amplifier
Single Channel Board Unit-Single Ended Probe
Users Manual
MTI Instruments Incorporated
325 Washington Avenue Extension, Albany, New York 12205 USA
Phone: (518) 218-2550 or 800-342-2203 (USA Only) Fax: (518) 218-2506
Web: www.mtiinstruments.com Email: sales@mtiinstruments.com
This page was intentionally left blank
MTI Instruments Technical Manual 7001-0003
Revision 1.3 April 28, 2017
i
Revision History
Rev 1.0 .............. Release.
Rev 1.1 .............. Fixed linearity chart example. Updated Master-Slave section. Added optional parts
section. Added typical sensitivity chart. Updated board dimensions and drawings.
Delete extra output spans. Changed to new official MTI part number scheme for
manuals (previous number was 7000-0405).
Rev 1.2 ............. ECN 3976
Rev 1.3 ............. ECN 5609
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WARRANTY
Seller warrants to the Purchaser that equipment to be delivered hereunder which is of Seller's own
manufacture will be free from defects in material or workmanship and will be of the kind and quality
designed or specified in the contract. Any parts of the equipment which have been purchased by Seller
are warranted only to the extent of the original manufacturer's warranty.
This warranty shall apply only to defects appearing within 1 year from the date of shipment by Seller. If the
equipment delivered hereunder does not meet the above warranty, and if the Purchaser promptly notifies
Seller, Seller shall thereupon correct any defect, including nonconformance with the specifications, either,
at its option, by repairing any defective or damaged parts of the equipment, or by making available at
Seller's plant necessary repaired or replacement parts. No allowance will be make for repairs or
alterations made by others without Seller's written consent or approval. Seller assumes no responsibility
for damage caused by improper installation or by operation in violation of its rated operating condition,
intentional or otherwise, or by improper handling or maintenance. The liability of Seller under this warranty
(except as to title), or for any loss or damage to the equipment whether the claim is based on contract or
negligence, shall not in any case exceed the cost of correcting defects in the equipment as herein
provided and upon the expiration of the warranty period of all such a liability shall terminate. The foregoing
shall constitute the exclusive remedy of the purchaser and the exclusive liability of the Seller.
The foregoing warranty is exclusive and in lieu of all warranties, whether written, oral, implied or statutory
(except as to title). There are no warranties which extend beyond those expressly stated in this contract.
FCC NOTICES
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the manufacturer’s instruction manual, may cause interference with radio and television
reception. This equipment has been designed as a Class A digital device of the FCC rules. These limits
are designed to provide reasonable protection against harmful interference in a commercial installation.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment
does cause harmful interference, which can be determined by turning the equipment off and on, you are
encouraged to try to correct the interference by one or more of the following measures:
Relocate the instrument with respect to the other device.
Plug the instrument into a different outlet so that the instrument and the other device are on
different branch circuits.
If necessary, consult a representative of MTI Instruments, Inc. You may find the following booklet helpful:
FCC Interference Handbook, 1986, available from the U.S. Government Printing Office, Washington, D.C.
20402, Stock No. 004-000-00450-7.
Information in this manual is subject to change without notice.
© 2013 MTI Instruments
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Revision 1.3 April 28, 2017
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TABLE OF CONTENTS
WARRANTY .................................................................................................................................................. II
FCC NOTICES .............................................................................................................................................. II
TABLE OF CONTENTS ............................................................................................................................... III
1.1 ACCUMEASURETM AS-563 SYSTEM DESCRIPTION ............................................................................. 1
1.2 AS-563 PROBE AMPLIFIER SPECIFICATIONS ..................................................................................... 2
1.3 PROBE SPECIFICATIONS .................................................................................................................. 3
1.4 TYPICAL LINEARITY PLOT .................................................................................................................. 3
1.5 TYPICAL VOLTAGE VS GAP (DISPLACEMENT) CURVE......................................................................... 4
1.6 RECEIVING INSPECTION PROCEDURE ............................................................................................... 4
1.7 RETURN SHIPMENT PROCEDURE ...................................................................................................... 5
1.8 OPTIONAL ACCESSORIES ................................................................................................................. 5
2 OPERATING PRINCIPLES ................................................................................................................... 6
3 INSTALLATION INSTRUCTIONS ......................................................................................................... 8
3.1 POWER REQUIREMENTS .................................................................................................................. 8
3.2 BOARD DIMENSIONS ...................................................................................................................... 10
3.3 CONNECTIONS .............................................................................................................................. 12
3.3.1 Connectors .............................................................................................................................. 12
3.3.2 Signal Connections .................................................................................................................. 12
3.3 CONTROL SWITCHES AND JUMPERS ............................................................................................... 15
3.3.1 OFFSET ................................................................................................................................... 15
3.3.2 GAIN ........................................................................................................................................ 15
3.3.3 JUMPERS ................................................................................................................................ 15
4 DISPLAYS ........................................................................................................................................... 17
5 PROBES ............................................................................................................................................. 17
5.1 PROBE MOUNTING ......................................................................................................................... 17
5.2 PROBE CABLES ............................................................................................................................. 18
6 TARGET .............................................................................................................................................. 19
6.1 ELECTRICAL REQUIREMENTS ......................................................................................................... 19
7 CALIBRATION .................................................................................................................................... 20
7.1 PROBE AMPLIFIER FACTORY CALIBRATION ..................................................................................... 20
7.2 PROBE AMPLIFIER SITE CALIBRATION ............................................................................................. 20
7.2.1 Recommended Equipment ...................................................................................................... 21
7.2.2 Full Calibration Procedure ....................................................................................................... 21
8 PUSHED AMPLIFIERS AND PROBES .............................................................................................. 22
9 CONDUCTIVE TARGET THICKNESS MEASUREMENTS ................................................................ 23
9.1 THICKNESS MEASUREMENT PROCEDURE ....................................................................................... 23
9.2 ADDITIONAL CONSIDERATIONS FOR THICKNESS MEASUREMENTS .................................................... 24
10 MASTER-SLAVE OPERATION ...................................................................................................... 25
11 TROUBLESHOOTING .................................................................................................................... 26
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LIST OF FIGURES
Figure 1: Linearity Plot ................................................................................................................................... 3
Figure 2: Typical Voltage vs Gap Curve ........................................................................................................ 4
Figure 3: Capacitance Probe Physics ........................................................................................................... 6
Figure 4: Card Test Points, Adjustment Points, Jumpers, and Connectors .................................................. 9
Figure 5: Dimensioned Board Outline (inches) ........................................................................................... 11
Figure 6: Overall Wiring Diagram ................................................................................................................ 14
Figure 7: Master-Slave Operation Connections .......................................................................................... 25
Figure 8: Card Test Points, Adjustment Points, Jumpers, and Connectors (Reference) ............................ 29
LIST OF TABLES
Table 1: Power Connections ......................................................................................................................... 8
Table 2: Jumper Positions for Standard AS-563-PA Operation .................................................................. 16
Table 3: Standard Probe Cable Characteristics .......................................................................................... 18
Table 4: Troubleshooting Guide .................................................................................................................. 28
Table 5: Jumper Positions for Standard AS-563-PA Operation (Reference) .............................................. 30
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1 INTRODUCTION
1.1 AccumeasureTM AS-563 System Description
The AccumeasureTM System AS-563, single channel board unit is a high-precision capacitance probe
amplifier that works with standard or custom MTII Single Ended non-contact probes to measure the
position of grounded metallic targets. For measurement to ungrounded or semi-metallic targets, MTII also
makes an Accumeasure™ System AS-562, single channel amplifier for use with MTII proprietary Push-
Pull style non-contact capacitance probes.
Both the Accumeasure™ AS-562 and Accumeasure™ AS-563 boards output an analog voltage from the
board that is proportional to the gap between a probe and the target. For ease of customer installation, the
output signal and the power supply connections are provided on both the board edge connector and a
miniature, quick disconnect header.
The probes measure displacement from the probe face to the target, and are connected to the amplifier
with special low-noise coaxial cable. The cable outer shield is electrically driven to cancel cable parasitic
capacitance and ensure the highest possible linearity.
An internal 4-pole Butterworth low-pass filter removes unwanted high-frequency noise for the best
resolution possible. Optional filter cutoff frequencies of 10Hz, 500Hz, 1kHz, 2kHz and 5kHz are available.
The primary calibration produces an analog output proportional to the probe range divided by 10 volts. For
a probe with a 1.27-mm (0.050 inch) range and a 10V full-scale output, the analog output is 0.127mm per
volt (5 mils per volt).
CAUTION
The AS-563-PA boards have circuitry that is sensitive to Electrostatic Discharge (ESD). Use proper
ESD techniques when handling this product.
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1.2 AS-563 Probe Amplifier Specifications
The following specifications are listed for the “Standard” configuration (MTII P/N: 7500-6709) with 1X
push. Contact the factory for specifications of other versions.
Measurement Range1: 0-12.5mm (0.500inch)
Resolution2: (0.000423xBandwidth Hz +1.2) x 0.00002 x FSR
Linearity3: ±0.02% FSR
Repeatability4 ±0.01% FSR
Frequency Response (Factory Selectable): DC-5kHz
Warm-up Up time 1 Hour
Temperature Stability: ±0.01% FSR/ºC
Time Stability5 ±0.01% FSR/100 hours
Output Signal6: 0 to 10VDC
Power: ±15VDC (20mV AC ripple), 3.9W
Operating Temperature: 4 to 40ºC (40 to 100ºF)
Storage Temperature: -15 to 65ºC (5 to 150ºF)
Dimensions (LxWxH)7: 239.27x99.95x21.54mm (9.42x3.94x0.85”)
Mass : 0.198g (0.437lbs)
1 Dependant on probe type selected.
2 100-5kHz. Equivalent to 0.00167% FSR @500Hz RMS.
3 After 100hours site acclimation, warm up, 20ºC,100kPa,50% (Temperature, Pressure, Humidity).
4 After 100hours site acclimation, warm up, 20ºC,100kPa,50% (Temperature, Pressure, Humidity).
5 After 100hours site acclimation, warm up, 20ºC/100kPa/50% (Temperature, Pressure, Humidity).
6 Signal Proportional to probe gap.
7 Includes connectors which extend beyond the PCB.
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1.3 Probe Specifications
Temperature Rating: Standard Probes: -130 to 200ºC (-200 to 390ºF)
Probe Connector (if equipped): -65 to 85ºC (-85 to 185ºF)
Cable: -130 to 200ºC (-200 to 390ºF)
Cable Termination at Amplifier: -65 to 165ºC (-85 to 330ºF)
High-temperature, Cryogenic, and Vacuum compatible probes
are available. Contact the factory.
Accuracy: ±0.05% of range when calibrated to a known standard.
Probe Cable Interchangeability: Accurate within ±0.5% of range without recalibration
Pressure Rating: Standard, 1400kPa (200psig). Higher pressure probes available.
Contact factory.
Cable Length: 2.5m (8.2ft)
Construction: 304 stainless steel standard. Lower coefficient of thermal
expansion designs available. Contact factory
1.4 Typical Linearity Plot
During factory calibration, adjustments are made to drive the 10%, 50%, and 90% FSR output to 0% error.
Data is then taken at 10% intervals to verify that the linearity of the matched card and probe pair will be
within specifications. A typical plot is shown below.
Linearity Error (max)
-0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
0.00 0.05 0.10 0.15 0.20 0.25
Displacement (mm)
%FSR
Figure 1: Linearity Plot
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1.5 Typical Voltage vs Gap (Displacement) Curve
Typical Volts vs Displacement
(250um Range Probe)
0
50
100
150
200
250
0 1 2 3 4 5 6 7 8 9 10
Output V
Gap (Displacement) um
Figure 2: Typical Voltage vs Gap Curve
Where 0um gap is the probe touching the target and 250um is the maximum range of the probe.
1.6 Receiving Inspection Procedure
The AccumeasureTM System AS-563 single channel board unit is shipped from MTII fully assembled and
packed in a cardboard carton with foam supports to guard against shipping damage. Upon receipt,
perform the following procedure before using the unit to perform dimensional measurements:
1) Inspect the exterior of the shipping carton. Note any obvious damage. If shipping damage is
evident, file a claim with the carrier.
2) Remove the amplifier board from the shipping carton. Inspect the board for any signs of damage.
3) Apply ±15 Volt DC power to the board in accordance the wiring information provided in the Power
Requirements” section.
4) With the probe cable not attached to the probe BNC connector input of the amplifier and the
OFFSET INDICATOR LED unlighted, the voltage on the Output Signal Cable BNC connector
should be close to +12 Volts DC.
5) If any problems were found with the Output Signal Cable voltage, contact MTII at 1-518-218-2550.
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1.7 Return Shipment Procedure
Contact MTI Instruments, Inc. at 1-518-218-2550 to receive return authorization prior to shipping the
instrument. Reference the instrument's name, model and serial numbers on all correspondence. Be sure
to include a brief description of the reason for the return. Place the instrument in the original shipping
carton (if available) and forward prepaid to:
MTI Instruments, Inc.
Supervisor of Manufacturing
325 Washington Avenue Extension
Albany, NY 12205-5505
Mark "RMA" and the RMA number (if a number is issued) on the outside of the box. If the original packing
materials are not available:
1) Wrap the instrument in plastic or heavy paper.
2) Place packing material around all sides of the instrument and pack it in a cardboard carton.
3) Place instrument and inner container in a sturdy cardboard carton or wooden box.
1.8 Optional Accessories
The following optional accessories available for purchase from MTI Instruments. Contact your authorized
MTI Instruments representative for availability and pricing.
MTI# Comment
7500-6508 P3 OEM Wiring Harness without synchronization wire.
7500-6508A P3 OEM Wiring Harness with synchronization wire.
2100-1801 P2 Mating Connector, PCB Mount, Thru Hole.
2100-1702 P2 Mating Connector, Drilled Hole Mount, Ribbon Cable.
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2 OPERATING PRINCIPLES
AccumeasureTM System measurement technology is based on the principle of parallel plate capacitor
measurement. The electrical capacitance formed between an AccumeasureTM probe and a target surface
varies as a function of the distance (gap) between these two surfaces. This function can be stated as:
Figure 3: Capacitance Probe Physics
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The AccumeasureTM System measures the electrical impedance of the capacitance between a sensing
electrode in the probe and a ground-referenced target. The magnitude of the impedance is proportional to
the reciprocal of the capacitance value as defined by the equation below:
C
Zc
1
where:
is proportional to the frequency at which the capacitance measurement is performed.
Substituting the equation for capacitance into the impedance equation shows that the impedance is directly
proportional to the gap value D, as shown in the following equation:
A
D
ZC
e
The AccumeasureTM probe amplifier produces a DC voltage that is linearly proportional to the average value
of the probe gap impedance, and an AC voltage variation from the DC voltage that is directly proportional to
the amplitude of the target vibration. The amplifier electronic circuitry eliminates the effects of both the probe
cable capacitance and the stray capacitance at the edge of the probe sensing area that could cause non-
linearity of the gap and vibration measurements.
The standard probe cable length is 2.5m (8.2ft) and standard full scale gap probes from 25um to 5mm
(0.001 to 0.200 inches) are available. Custom cable lengths from 300mm to 15m (1 to 50ft) and custom
probes from 12.5um to 12.7mm (0.0005 to 0.5 inches) can be used with the AccumeasureTM probe
amplifier. Contact the factory for details on custom cables and/or probe lengths.
A summing amplifier is present in the dual-channel model (System AS-563-2) to produce the sum or
difference of two gap proportional voltages. This function is ideal for target thickness measurements (see
Conductive Target Thickness Measurements).
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3 INSTALLATION INSTRUCTIONS
3.1 Power Requirements
The AccumeasureTM System AS-563 single channel board unit requires a maximum of 0.130 Amperes DC
from a +15 Volt DC and from a 15 Volt DC power supply. Two power and signal connectors are provided
on the edge of the circuit board, and a power cable with an un-terminated, labeled end is shipped with
each board. Caution should be exercised when applying power to this board since there is no fuse
protection on the board. On the P3 connector only, reverse power supply line protection is provided
through the use of diodes in series with the supply lines. However, it is recommended that each of the
supply lines to this unit be current limit protected with a 0.25Ampere fuse. It is also recommended that the
power supply voltages be tested for the correct voltage values and polarities on the power cable plug
provided with the board before the plug is connected to the board for the first time in an installation.
A power On/Off switch is not provided with the single channel board unit, so the probe amplifier will be
operational whenever there is DC voltage on the power supply cable. Refer to Figure 4: Card Test Points,
Adjustment Points, Jumpers, and Connectors for the location of the P2 edge connector and the P3
auxiliary power supply and signal connector on the circuit board. DC power can be supplied to the
terminals of either the P2 connector or the P3 connector to operate the board. Power connections to the
P2 and P3 connector pins are made to:
Power Pins
+15Volts DC
Power Common
-15 Volts DC
Analog Common
P2 Connector
24 and 25
4,28,30
26
1-21 odd pins
P3 Connector
1
2
3
5
Table 1: Power Connections
Note: Power Common and Analog Common are connected together on the AccumeasureTM AS-563 single
channel board unit. However, separate wires should be connected from these pins to the ±15 Volt power
supply common.
CAUTION
The card edge connector (P2) is not protected by fuses and does not have overvoltage nor reverse
voltage protection.
The OEM connector (P3) is not protected by fuses and does not have overvoltage protection but it does
have reverse polarity protection.
Ensure the power supply connections and the supply voltages are correct before applying power to the
board. Applying improper power to the AS-563-PA card may damage the card and void any warranty.
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P3-Power and Signal Connector
(Molex 70553-0006)
1) +15VDC POWER (RED)
2) POWER GROUND (BLK)
3) -15VDC POWER (GRN)
4) SIGNAL (BLU)
5) SIGNAL GROUND (BRN)
6) NC
7) SYNC (VIO/WHT)
OFFSET INDICATOR LED
OFFSET CONTROL SWITCH
R28-GAIN
R42-WIDE RANGE OFFSET
R43-NARROW RANGE OFFSET
CH A - SENSOR
CONNECTOR
(BNC)
TP9
TP2 TP3TP1
P2 - BOARD EDGE
CONNECTOR
JP14
JP2
Figure 4: Card Test Points, Adjustment Points, Jumpers, and Connectors
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3.2 Board Dimensions
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Figure 5: Dimensioned Board Outline8
8 Note that the front potentiometer screw dials, LED, Switch, and BNC extend outside the outline of the board
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3.3 Connections
3.3.1 Connectors
3.3.1.1 P2 (the board edge connector) has 1.27mm (0.050”) gold plated copper with a 2.54mm
(0.100”) pitch. The board is 1.6mm (0.062) thick. The edge connector has a key feature.
The recommended mating connector is EDAC 395-050-520-202 (MTI# 2100-1801) or
equivalent.
3.3.1.2 P3 is the recommended connector for OEM applications. P3 is populated with a Molex
70553-0006 connector. The mate is Molex 50-57-9407. MTI can provide a cable assembly,
part number 7500-6508 (standard) or 7500-6508A (includes synchronization wire). Contact
MTI Instruments or their authorized representative for information on ordering this cable.
3.3.2 Signal Connections
3.3.2.1 P2 Pinout
1 Signal GND 2 Sync
3 Signal GND 4 Power Common
5 Signal GND 6 Master Osc Enable
7 Signal GND 8 NC
9 Signal GND 10 NC
11 Signal GND 12 NC
13 Signal GND 14 NC
15 Signal GND 16 NC
17 Signal GND 18 NC
19 Signal GND 20 NC
21 Signal GND 22 NC
23 NC 24 +15VDC
25 +15VDC 26 -15VDC
27 NC 28 Power Common
29 NC 30 Power Common
31 NC 32 Signal
33 NC 34 Aux Out
35 NC 36 Reserved
37 NC 38 NC
39 NC 40 NC
41 NC 42 NC
43 NC 44 Ext Osc
45 NC 46 NC
47 NC 48 NC
49 NC 50 NC
P2
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3.3.2.2 P3 Pinout
1 +15VDC
2 Power Common
3 -15VDC
4 Signal
5 Signal GND
6NC
7 Sync
P3
The AccumeasureTM AS-563, single channel probe amplifier board unit requires five sets of external
connections for operation:
1) Sensor cables
2) The target and probe fixture ground connection
3) The gap output Signal (referenced to Signal GND)
4) The DC power
5) The master/slave control signal
The sensor cable should be connected to the BNC connector on the amplifier board. The BNC connector
is labeled CH A SENSOR. (see Figure 4: Card Test Points, Adjustment Points, Jumpers, and
Connectors).
A target ground wire is required with the AccumeasureTM AS-563 single channel probe amplifier board
unit and a ground connection to the probe fixture is also required. The probe fixture ground and target
ground connection should be returned to the board unit through the power supply ground connection wires
attached to either connector P2 or P3 (see Figure 4: Card Test Points, Adjustment Points, Jumpers, and
Connectors).
CAUTION
The outer shell of the sensor BNC connector on the front board edge are driven at the probe carrier
voltage and cannot be grounded. Also, the shield integrity of the probe cable cannot be broken. If the
probe cable is damaged, it is recommended that it be replaced rather than repaired.
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The gap output signal is available from the either pin 32 of the P2, board edge connector, or from pin 4
of the P3, power supply and signal connector (Figure 4: Card Test Points, Adjustment Points, Jumpers,
and Connectors).
The output impedance of the amplifier that drives the gap output signal cable is 50. This impedance is
included in the output signal circuit to ensure signal stability. The cable that is provided with the board unit
is designed to be compatible with the P3 power supply and signal connector. This cable should be used
for the best performance of the unit.
Additional cable lengths may be added to the gap output signal connector at the end of this cable. It is
recommended that a good quality coaxial cable, with the shield connected to analog common be used for
the extension. Up to a length of 30meters (100 feet) can be used to connect to other equipment.
DC power is provided to the AccumeasureTM AS-563 board unit through the power supply and signal
cable that is provided with the board. This power cable should be connected to the P3 connector on the
rear edge of the board. See Figure 4: Card Test Points, Adjustment Points, Jumpers, and Connectors for
the location of P3. Power can also be provide to the board through pins on the P2, board edge connector.
See Figure 4: Card Test Points, Adjustment Points, Jumpers, and Connectors for the power supply pin
locations on the P2 connector.
The master/slave signal provides the capability of synchronizing the sine wave carrier signal frequencies
of multiple probe amplifier board units to minimize the output noise of the units. A square wave sync
signal is transmitted from the master board unit to the slave board units to set the slave board unit carrier
frequency to be in frequency and phase synchronization with the master. Jumpers are used to set each
board to be either a master or a slave. For single channel units, no cable connection is required and the
board jumpers are set to a master condition. A master/slave signal connection is available on both the
P2, board edge connector, and the P3, power supply and signal connector. Refer to MASTER-SLAVE
OPERATION for a more detailed description of the master/slave signal operation.
-15VDC
Power Common
+15VDC
Power Supply
Readout
1 (+15VDC)
2 (Power Common)
3 (-15VDC)
4 (Signal)
5 (Signal Common)
6 (NC)
7 (Sync)
P3 CHA BNC
Probe
Probe Holder
Target
AS-563 Card
Figure 6: Overall Wiring Diagram
CAUTION
The output impedance of the gap output signal connection is 50. Attachment of the Signal Output cable
to any electronic instrument (meter, display, computer, or analog-to-digital converter) with an input
impedance of less than 50k will results in a calibration error of greater than 0.1% of the full scale probe
range. A total instrument load impedance on the Signal Output cable greater than 100k recommended.
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MTI Instruments Accumeasure 563 Owner's manual

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