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Binsfeld TorqueTrak 10K-LP User Manual

Torque telemetry system
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TorqueTrak 10K-LP
Torque Telemetry System
User's Guide
869501-9_F

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  • Page 1 TorqueTrak 10K-LP Torque Telemetry System User’s Guide 869501-9_F...

  • Page 3: Table Of Contents

    Table of Contents System Overview System Components Features and Controls RX10K Receiver Figure 1: Front view of the RX10K Figure 2: Rear panel of the RX10K TX10K Transmitter Figure 3: TX10K Transmitter RM10K Remote Control Figure 4: RM10K Remote Control Product Safety Installation Procedure Field Testing...

  • Page 4: System Overview

    System Overview The TorqueTrak 10K Torque Telemetry System utilizes proven digital RF technology to transmit a single data signal (most typically from a strain gage) a distance of 10 feet (3 meters) or more depending on the environment. Up to 16 systems can operate simultaneously on independent channels.

  • Page 5: System Components

    System Components A standard TorqueTrak 10K-LP Torque Telemetry System includes the following items: TX10K-LP Transmitter RX10K Receiver Receiver Antenna Element Receiver Antenna Magnetic Base with 25ft Cable RM10K Remote Control 110VAC-12VDC or 220VAC-12VDC Wall Plug Transformer 5-ft DB9 Cable 10-ft 4-Conductor Ribbon Cable...

  • Page 6: Features And Controls

    Features and Controls RX10K Receiver The RX10K Receiver features a simple keypad on the front panel for user configuration and adjustment. A two-line display indicates the operational status of the RX10K. The RX10K outputs the signal received from the TX10K Transmitter in three ways: 1) as text and graphics on the display, 2) as an analog voltage signal, and 3) as a digital data signal.
  • Page 7 ±10VDC and a maximum range of ±12VDC. The digital data signal is an RS-232 type signal for input to a PC “Com” port. See Appendix A for the pin out and protocol. Binsfeld Engineering Inc. Maple City, MI (+1) 231-334-4383 www.binsfeld.com Tested to Comply...
  • Page 8 User Parameter Selection and Adjustment The RX10K Receiver has seven user-configurable parameters. The parameter name and value are shown on the lower line of the display. Parameters are selected by scrolling through the parameter menu using the SELECT ◄► (left and right) arrow keys.
  • Page 9 Filter The Filter parameter allows the user to change the bandwidth of the output signal. It functions as a low pass filter, meaning frequencies above the selected value are attenuated. This allows the user to reduce the amount of high frequency data on the output signal (i.e., reduce noise) and effectively average the output value.
  • Page 10 Polarity The Polarity parameter allows the user to change the polarity of the output signal. +00000 -_ _ _ _ _ █ _ _ _ _ _+ olarity: ositive Gain The Gain parameter allows the user to adjust the gain or scale factor applied to the input signal and is reflected in the display output, the Voltage Output signal, and the digital (RS-232) output signal.
  • Page 11 The Transmitter constant (TX ) is 2.5V. The Gage Factor is const specified by the gage manufacturer but is typically about 2.0. See Appendix B for Full Scale torque and output scaling equations and sample calculations. Output Offset The Output Offset allows the user to adjust the offset or “move the zero”...

  • Page 12: Tx10K Transmitter

    Signal Processing The TX10K data signal is processed by the RX10K as follows: 1. Receive signal from TX10K 2. Check for errors and display if any detected 3. Check for simulated signal and apply if enabled 4. Apply Filter 5. Apply AutoZero 6.
  • Page 13 The TX10K can be configured even while it is installed (but not rotating) using the RM10K Remote Control. The TX10K has sixteen RF Channel settings and six Gain settings (500, 1000, 2000, 4000, 8000, and 16000). It can send low and high reference signals to the RX10K: internal precision shunt resistors simulate strain values that can be used to check calibration (refer to Appendix A for specifications).

  • Page 14: Rm10K Remote Control

    Fast flash (7 Hz) The input signal to the TX10K is out of range. Reducing the Gain will increase the input range and may eliminate this problem. NOTE: If the out-of-range condition is of a short duration, there may only be one or two flashes.
  • Page 15 Figure 4: RM10K Remote Control Battery Installation Slide the battery access cover on the back of the RM10K enclosure in the direction of the arrow to open. Remove the old battery if present. Install a new 9V battery and slide the cover back into place.
  • Page 16 key. When the TRANSMITTER ON key is pressed, the green SENDING light on the RM10K will come on for about 3 seconds. The desired function key must be pressed within this 3-second timeframe; otherwise the RM10K will revert back to normal (low infrared power) mode.
  • Page 17 GAIN ▲ Increases the gain setting of the TX10K. If the Transmitter Gain is already at the maximum value, the Status Indicator on the TX10K will flash only once, indicating the command was received but not carried out. GAIN ▼ Decreases the gain setting of the TX10K.

  • Page 18: Product Safety

    Multiple TX10K Transmitters When working with multiple TX10K Transmitters in close proximity, the Infrared Receivers may be intentionally covered with an opaque object in order to eliminate an inadvertent configuration change to an adjacent TX10K. Also, removing power (disconnecting the battery) or putting the TX10K in standby mode will prevent the RM10K from changing the configuration of a transmitter.

  • Page 19: Field Testing

    Field Testing Although the settings of the TX10K can be changed during operation of the system, it is best to determine the appropriate Transmitter Gain setting for a given application prior to installation. Refer to Appendix B for the relevant calculations. 1.
  • Page 20 NOTE: If testing will not begin for some time, use the RM10K Remote Control to put the TX10K in Standby mode to save battery life. The Status Indicator light will turn off. A fresh battery will last for several days in this mode. 4.

  • Page 21: Bench Testing

    Transmitter Gain setting, 2) apply a shunt resistor to balance the gage, or 3) replace the strain gage. For further assistance, contact Binsfeld Engineering Inc. 10. Scroll RX10K display to Filter parameter screen. Set the Filter to the desired level.
  • Page 22 3. Attach 9V Battery Connector to TX10K Transmitter (red to +PWR, black to –PWR). Attach BS900 Bridge Simulator to the TX10K terminals +/- EXC and +/- SEN to coincide with pins on BS900. Clip 9V battery to connector. 4. Slowly scroll through each RX10K channel until it matches TX10K channel setting (top line will quit flashing and bottom line will show the RF signal strength).

  • Page 23: Calibration

    It is recommended that the system be checked for calibration annually. If found to be out of specification, it can be returned to Binsfeld Engineering Inc. for calibration for a nominal fee ($170.00, price subject to change). - 21 -...

  • Page 24: Warranty And Service Information

    Binsfeld Engineering Inc. will not be liable for any special, indirect, incidental or consequential damages or loss, whether in contract, tort, or otherwise.

  • Page 25: Fcc Rules Part 15: Computing Devices

    FCC Rules Part 15: Computing Devices TRADE NAME: Torque Telemetry System COMPLIANCE TEST REPORT NUMBERS: B70309A1 Model: RM10K B70321A1 Model: RX10K B20817D1 Model: TX10K-LP COMPLIANCE TEST REPORT DATES: B70309A1 05/22/07 B70321A1 05/22/07 B20817D1 10/01/12 RESPONSIBLE PARTY (IN USA): Stephen Tarsa ADDRESS: 4571 W.

  • Page 26: Appendix A: Torquetrak 10K Specifications

    Appendix A: TorqueTrak 10K Specifications TX10K-LP-S Transmitter Power supply voltage 6 to 25 Vdc Power supply current Transmit mode 20mA (typ) @8Vdc 200mW (max) Standby mode 0.5mA (typ) @8Vdc 8mW (max) 9V Ultralife lithium battery life Transmit mode 48 hours (typ) Standby mode 2400 hours (est) Bridge excitation voltage...
  • Page 27 Sensor Input Range for Torque or Bending Full Bridge, 4 Active Arms TX10K Full Scale Full Scale System Gain (V/V) Gain Strain Input Setting (mV) (0.25x) (4.0x) (e) ±4000 ±20 2000 1000 ±2000 ±10 1000 4000 2000 ±1000 ±5 2000 8000 4000 ±500...
  • Page 28 RM10K Remote Control Power supply 9 V battery (supplied) Pulsed infrared frequency 38 KHz Transmission distance (line-of-sight) Normal mode 6 in (15 mm, typ) High power mode 10 ft (3 m, typ) Operating temperature range -20 to 60˚C (-4 to 140°F) (Battery-limited) Size 0.88"...
  • Page 29 Digital Output (Com) Specification The TT10K system includes a streaming digital output port on the rear panel of the RX10K Receiver. This output is RS-232 type data. A DB9 male-female cable is supplied for direct connection to a PC Com port. Pin out for the DB9 connector on the RX10K Data output Ground or common connection...
  • Page 30 TorqueTrak 10K Telemetry System with TX10K-LP-S Resolution 14 bits Sample transmission rate 2400 Hz Signal bandwidth 500 Hz (-3dB) Signal to noise ratio 60 dB (min) Signal delay 3.0 mS (typ) (transmitter input to voltage output) RF transmission distance 10 ft (3 m) line-of-sight (typ) Gain error 0.25%R (max) @ 25°C Gain drift...

  • Page 31: Appendix B: Calibration Calculations

    Appendix B: Calibration Calculations The equations in this Appendix define the relationship between the input signal to the TX10K Transmitter (typically from a strain gage) and the Full Scale output voltage of the TorqueTrak 10K System. The calculations are based on parameters of the device being measured (e.g.

  • Page 32: B1: Torque On Round Shafts

    Step 1: Calculate Full Scale Torque, T (ft-lb) The Full Scale Torque corresponds to a system output of 10 V. For a solid steel shaft, use the calculator on our website at www.binsfeld.com or use the simplified equation below: (1510.38 x 10 ft-lb/in...
  • Page 33 (shaft Outer Diameter, measured) = 3.000 inches GF (Gage Factor from gage package) = 2.08 (TX10K Gain setting) = 4000 (1510.38 x 10 ft-lb/in )(3.000 in) = 4,901 ft-lb (2.08) (4000) so 10 V output from the RX10K indicates 4,901 ft-lb of torque or 490.1 ft-lb/volt.
  • Page 34 In the example from Step 1 above, Full Scale Torque (T ) has been calculated to be 4,901 ft-lb. It may be convenient to scale the output so that 10 V indicates 5,000 ft-lb (1 V = 500.0 ft-lb). First, calculate the Scale Factor (Z): 4,901 ft-lb = Z = 0.9802 5,000 ft-lb...
  • Page 35 Alternatively, precision resistors can be placed in parallel with one arm of the bridge to simulate a torque load. The Tech Info section on our website (www.binsfeld.com) has a helpful Torque Strain Calculator to assist in determining the strain a given resistor value simulates.
  • Page 36 First, determine what the system output should be when applying the shunt resistance. In this case, Reference 1 (100 µe) is a good choice (20% of Full Scale). To calculate the calibrated output of the system, use the equation below: ε...

  • Page 37: B2: Axial Strain On Round Shafts

    B2: Axial Strain on Round Shafts Step 1: Calculate Full Scale Forces P (lb) that corresponds to the maximum system output of 10.0V. For a solid steel shaft, use this simplified equation: (145 x 10 lb/in (GF) (G For all other shafts use the more general equation: )()(E)(D )(GF)(2)(1+)(G const...
  • Page 38 Example: Given a solid steel shaft with (shaft Outer Diameter, measured) = 2.25 inches GF (Gage Factor from gage package) = 2.045 (TX10K Gain setting) = 4000 (145 x 10 lb/in )(2.25 in) = 89,739 lb (2.045) (4000) so 10 V output from the RX10K indicates 89,739 lb of force or 8974 lb/volt.

  • Page 39: B3: Single Grid (1/4 Bridge)

    B3: Single Grid (1/4 Bridge)  Step 1: Calculate Full Scale Strain, (inches/inch) that corresponds to the maximum system output of 10.0V. )(4)  )(GF)(G const Using the values listed in the table below, this equation reduces to: (16)  (GF)(G Legend of Terms Full Scale Strain (inches/inch;...

  • Page 40: Appendix C: Error Codes

    Appendix C: Error Codes Error Displayed Error Detected Tx Signal UnderRange The input signal to the TX10K is less than the minimum level Tx Signal OverRange The input signal to the TX10K is greater than the maximum level Rx Signal UnderRange The output signal of the RX10K is less than the minimum level Rx Signal OverRange...

  • Page 41: Appendix D: Strain Gage Application

    Appendix D: Strain Gage Application (Also refer to instruction bulletin B-127-12 provided with GAK-2- 200 Strain Gage Application Kit from Vishay Measurements Group, Inc., Raleigh, NC, 919-365-3800, www.measurementsgroup.com.) PREPARING THE SURFACE 1. A 3-inch square area will be used for gaging. Scrape off any paint or other coatings and inspect shaft for oil residue.
  • Page 42 PREPARING THE GAGE FOR MOUNTING 5. Using tweezers, remove one gage from its package. Using the plastic gage box as a clean surface, place the gage on it, bonding side down. Take a 6” piece of PCT-2M Mylar Tape and place it on the gage and terminal, centered. Slowly lift the tape at a shallow angle.
  • Page 43 7. Gage should now be positioned. Once again, lift the gage end of the tape at a shallow angle to the surface until the gage is free of the surface. Continue pulling the tape until you are approximately 1/8” – 1/4” beyond gage. Turn the leading edge of the tape under and press it down, leaving the bonding surface of the gage exposed.
  • Page 44 11. Immediately, using your thumb, apply firm pressure to the taped gage by rolling your thumb over the gage area. Hold the pressure for at least one minute. In low humidity conditions (below 30%) or if ambient temperature is below + 70...
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