Kistler 5073A Series Instruction Manual
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Kistler 5073A Series Instruction Manual

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ICAM – Industrial
Charge Amplifier for
Manufacturing
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Type 5073A...
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5073A_002-327e-04.23

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Summary of Contents for Kistler 5073A Series

  • Page 1 Instruction Manual ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A... ä 5073A_002-327e-04.23...
  • Page 3 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.

  • Page 4: Table Of Contents

    Contents     Contents Introduction ........................... 4     Enclosed CD ........................5     Important Notes ..........................6     For Your Safety ........................6     Electromagnetic Compatibility (EMC) ................6     Tips on Using this Instruction Manual ................6  ...
  • Page 5 Contents Opening the Project – 'Open Project ...' (Ctrl+N) ........... 35     7.4.2 Find/Connect Devices – ‘AutoScan’ ................ 36     7.4.3 Defining the Display Interface ..................37     7.4.4 Assigning a Channel to a Display Object ................38  ...

  • Page 6: Introduction

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

  • Page 7: Enclosed Cd

    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) ...

  • Page 8: Important Notes

    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.

  • Page 9: Nomenclature

    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.

  • Page 10: Software Upgrades And Updates

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     2.6 Software upgrades and updates Upgrades or updates for embedded software supplied by Kistler must be installed. Kistler accepts liability direct damage consequential damage caused by products with embedded software that is not up to date.

  • Page 11: Basics

    (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.

  • Page 12: Amplifier Variants

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     3.3 Amplifier variants The following key shows the available variants: Type 5073A    (opt.) Y0 1 channel/acquisition of 1 peak value 2 channels/acquisition of 2 peak values 3 channels/acquisition of 3 peak values...

  • Page 13: Optional Accessories

    Basics  IP67 cover for RS-232C, D-Sub 09 female, 65008385 connector  Operating Instructions  Calibration certificate With ICAM Type 5073A5xx  2 dust caps for sensor connection 3.5 Optional accessories Item No./ Type  RS-232C cable, l = 5 m, null modem, 1200A27 D-Sub 09 male, D-Sub 09 female ...

  • Page 14: Fundamentals

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

  • Page 15: Piezoelectric Measurement

    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.

  • Page 16: The Mathematical Model Of A Piezoelectric Measuring Chain

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

  • Page 17: The Industrial Charge Amplifier

    Fundamentals 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 U .
  • Page 18   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: ...

  • Page 19: Description Of Amplifier

    Description of amplifier 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 proportional output voltage. The output signals can be passed on to an industrial control system for monitoring, control and optimization of a production process.
  • Page 20 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     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.

  • Page 21: Block Diagram

    Description of amplifier 5.2 Block diagram Fig. 7: Block diagram of ICAM Type 5073A… 5073A_002-327e-04.23 Page 19...

  • Page 22: Power Supply, Control Inputs And Analog Outputs

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     5.3 Power supply, control inputs and analog outputs The D-Sub 15-pin male connector is used to connect to the power supply and to control the ICAM Type 5073A… during the industrial measurement process.

  • Page 23: Rs-232C Interface

    (for example, extension) cables without this crosslink. Crosslinking with the mini adapter is also necessary when using RS-232 adapters on USB connections. However, the Kistler Type 1200A89 or 1200A27 null modem cables do not need the mini adapter.

  • Page 24: Peak Value Acquisition

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     5.5 Peak value acquisition The ICAM 5073A... has peak value acquisition for measuring channels 1 ... 3. The fourth measuring channel does not have peak value acquisition. In the Type 5073A1xx … and Type 5073A3xx models, the peak signals are output as analog voltage on separate signal pins (see section 5.3 Power supply, control inputs and analog outputs).
  • Page 25 Description of amplifier Fig. 12: Method of operation of the 3 available peak modes. +peak, -peak and (peak-peak)/2   Peak memory can also be exported after the measuring cycle in Reset mode. The peak memory is reset at the start of the new cycle (see Fig.

  • Page 26: Setting Options - Configuration

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Fig. 13: Method of operation for peak value acquisition with programmed offset.   When offset is active, the peak value output indicates the offset signal immediately after the cycle has started.  5.6 Setting options –...
  • Page 27 There are two setting strategies for gain: Logically by measurement, as done by Kistler With this type of setting, the ratio between the mechanical variable to be measured and the amplifier output voltage is defined.

  • Page 28: Description Of The Individual Parameters

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Technical/physical With this type of setting, the ratio between the input charge and the output voltage is directly defined. Select 'pC' (picocoulomb) as the unit. The sensitivity is set to -1 [pC/pC].
  • Page 29 Description of amplifier value needs to be specified. This means that with Type 5073Axx2 variants only negative charges can be measured. Mechanical measuring range (Range 1/Range 2) The mechanical measuring range is used, together with the programmed sensitivity, to calculate the gain for the programmable amplifier (PGA), according to Formula 1 or Formula 2.

  • Page 30: Commissioning

    Type 1003 cleaning spray or white spirit.  Connect the cable to the sensor. We recommend using high-insulation, low-noise cables from the Kistler range. These are tested specifically for high insulation resistance, low noise and low unwanted (triboelectric) charge produced by friction.

  • Page 31: Connecting Rs-232C And D-Sub 15-Pin Male Connector

    Commissioning 6.1.2 Connecting RS-232C and D-Sub 15-pin male connector The parameters of the charge amplifier are set via the RS- 232C interface, whereas the power supply, control and analog output signals are taken via the D-Sub 15 connector. 6.1.3 Power supply and digital inputs The detailed pin allocation may be found in 5.3 Power supply, control inputs and analog outputs.

  • Page 32: Output Signals

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     lated power supply and inputs on the measurement system or insulated sensor. To avoid high noise on the signal, use shielded cables and the shortest possible wiring. It is recommended to separate the signal wiring from the power cables of other com- ponents in separate ducts.

  • Page 33: Manuware" Pc Software

    "ManuWare" PC software 7. "ManuWare" PC software The ManuWare PC software offers the following functionality:  Communication between the PC and the ICAMs, or other devices (such as Type 9238B… or Type 9337A… transmitters)  Setting of all parameters  Control of several devices via the serial interface (cycle control, range switching).
  • Page 34 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Installation menu starts up automatically (if not, start the "kistlersetup.exe" program manually) Fig. 19: Start screen of the installation routine You can select German or English, as required. ...

  • Page 35: Starting The Program

    "ManuWare" PC software 7.2 Starting the program ManuWare started Windows, under Start Menu>Programs>Kistler>ManuWare, clicking ManuWare program. Fig. 20: ManuWare splash screen   After the program starts up, the last project saved is automatically loaded and presented. The first time the program starts, a neutral project is loaded.

  • Page 36: Description Of The Program Interface

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     When the program is first started up, it may be necessary to select the menu language. The choice is currently between German and English. To select the language, go to the Tools>Options…...

  • Page 37: First Simple Measurement - Step By Step

    "ManuWare" PC software Any number of worksheets can be defined here. Graphic display objects (oscilloscope, XY plot, digital multimeter, etc.) can be positioned in them. Information frame The information frame contains different tabs containing device and system information. The current state of the individual devices or channels is displayed on the 'Status' tab.

  • Page 38: Find/Connect Devices - 'Autoscan

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     7.4.3 Find/connect devices – ‘AutoScan’ In order to be able to communicate with the connected devices, ManuWare must know which device type has been connected to which serial interface. This can be done manually, using the 'Add Device ...' function.

  • Page 39: Defining The Display Interface

    "ManuWare" PC software 7.4.4 Defining the display interface To run a test measurement, a graphic display must be set up for the relevant measuring channel. A graphic display object must be positioned on a worksheet in the display frame. In the current version, 3 different display objects are available.

  • Page 40: Assigning A Channel To A Display Object

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     7.4.5 Assigning a channel to a display object To display a measuring channel, it must be assigned to a display object. Dragging a measuring channel to a display object (cycle, oscilloscope or digital multimeter display object) makes this a very simple matter as well.

  • Page 41: Optimizing Measurement - Changing The Set Values

    "ManuWare" PC software  A hardware-driven external start on the measuring instrument (amplifier, transmitter) itself.  Software-driven, via the menu  Software-driven, via the tool bar  Software-driven via the 'SPACE' hotkey Fig. 27: Measurement can be directly started and stopped in 4 different ways with ManuWare 7.4.7 Optimizing measurement –...
  • Page 42 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     scale output (10 V). Measurement signal loading can be improved in the Properties dialog. In this case, the measuring range must be reduced. Fig. 29: The Properties dialog of an ICAM Type 5073A…. To obtain an output signal that is ten times larger, the range must be reduced tenfold, i.e., to 500 pC...

  • Page 43: Backup/Restore Functionality

    "ManuWare" PC software 7.5 Backup/restore functionality With the functions described above, ManuWare allows the settings of a device, or of an entire application to be backed- up and restored as required. The procedure is as follows: 1. After successful commissioning (see above), the running project is saved under a meaningful name (e.g., backup_project1_080512.mwproj).
  • Page 44 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     6. It is now possible either to send the data from ManuWare to the device or to read data from the device to ManuWare. In this case, the first option is chosen. 7.

  • Page 45: Maintenance And Diagnostics

    The sensor input connectors, particularly the Teflon insulators, must be kept absolutely clean. When cleaning, only use unadulterated cleaning agents, for example Type 1003 cleaning spray from Kistler or white spirit, on a clean, lint-free paper towel. 8.2 Loading new Firmware The ICAM has a flashloader that can be used to load the new firmware into the device as required.
  • Page 46 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...                 Fig. : Selecting the firmware version to be installed    The selection of the firmware to be installed is confirmed with 'Next >'. Fig.
  • Page 47 Maintenance and diagnostics Fig. 35: Selecting the interface to use    Now the device must be switched back on (Fig. 36). Fig. 36: Prompt to turn the device back on               Fig. 37: Once the device is switched on, the currently installed firmware version...
  • Page 48 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     together with the new firmware version to be installed    Press the 'Programming' button to load the new firmware version to the device. Fig. 38: Programming the new firmware is in progress  ...

  • Page 49: Drift

    In turn this is due to poor feedback capacitor insulation resistance. To rectify the defect, return the charge amplifier to the responsible Kistler sales center/distributor for repair. Input signal...

  • Page 50: Cause 2

    The zero of the charge amplifier input stage can be recalibrated if the problem persists. Send the amplifier to the responsible Kistler sales center/distributor to have this carried out. Output signal Output signal...
  • Page 51 Maintenance and diagnostics Fig. 42: Positive or negative drift of the output signal   Note Cause 3 is readily diagnosed by removing the sensor and sensor cable and connecting a charge calibrator for testing. 5073A_002-327e-04.23 Page 49...

  • Page 52: Technical Data

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     9. Technical data 9.1 Design variants Number of channels 1, 2, 3 or 4 4 charge inputs summed Special variant to 1 channel Input connector variants BNC, TNC Output signal variants –10 …...

  • Page 53: Current Output (Types 5073Axx2)

    Technical data Digitally adjustable offset (via RS-232C) ±1 Resolution of offset adjustment Error % meas. <±0,5 range Zero point offset <±30 Output noise signal 0.1 Hz … 1 MHz mVpp <30 with internally switchable LP filter mVpp <10 (10, 200, 3 000 Hz) In both cases without data transmission via the RS-232C interface Frequency range (–3 dB)

  • Page 54: Current Output Symmetrical (Types 5073Axx5)

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     9.5 Current output symmetrical (Types 5073Axx5) Output current range 12 ±8  Output impedance >2  Max. load Classification 4 mA corresponds –10 V 20 mA corresponds 10 V Hinweis 1: 12 mA corresponds 0 V The peak value is also output as voltage for...

  • Page 55: Peak Value Acquisition

    Technical data Group delay without low-pass filter μs <15 with 3 000 Hz low-pass filter μs <300 200 Hz low-pass filter <4 10 Hz low-pass filter <80 9.8 Peak value acquisition Error <±1,5 Zero point offset <±50 Rise time (0 … 99%) <0,35 Modes +Peak...

  • Page 56: Power Supply Voltage

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     9.10 Power supply voltage Supply voltage 18 … 30 Current consumption (without load, without current output, typically at 24 V) 1-channel device <125 (3 W) 2-channel device <167 (4 W) 3-channel device <210 (5 W) 4-channel device...

  • Page 57: Led Indicators

    Technical data 9.13 LED indicators Reset green, flashing Measure green, steady Overload red, flashing System error red, steady 9.14 Serial interface ANSI/EIA standard RS-232C Data bits Stop bits Parity none Handshake none Transmission speed Bits per 115 200 (fixed) second (baud rate) Max.

  • Page 58: Emc (To Conditions Of Directive 2014/30/Eu)

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     9.16 EMC (to conditions of Directive 2014/30/EU) Immunity EN 61000-6-1:2007 EN 61000-6-2:2005 EN 61326-1:2013 (Class A+B equipment) Interference EN 61000-6-3:2007 + A1:2011 EN 61000-6-4:2007 + A1:2011 EN 61326-1:2013 (Class A+B equipment)) Page 56 5073A_002-327e-04.23...

  • Page 59: Dimensions

    Technical data 9.17 Dimensions Fig. 43: Dimensions of ICAM Type 5073A… Type 5073Ax1x (BNC neg.) Type 5073Ax2x (TNC neg.)       5073A_002-327e-04.23 Page 57...

  • Page 60: Appendix

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     10. Appendix 10.1 Command set of RS-232C interface Interface parameters  Full parameter configuration and control of the Type Baud rate 115 200 baud 5073A... ICAM are possible with the command set Data bits described below.

  • Page 61: Feedback Structure

    Appendix 10.1.2 Feedback structure Fig. 45: Syntax of ICAM feedback. All return codes are sent as ASCII code 10.1.2.1 Command return codes Command Return Codes Unknown command Parameter outside permissible range Channel is not available Checksum error Device is measuring via external input Warning: change in the charge capacitor configuration 10.1.2.2 Event message...
  • Page 62 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Channel 4 Event Codes Charge amplifier overflow Remote Measure Remote Reset Remote Range 1 Remote Range 2 Page 60 5073A_002-327e-04.23...
  • Page 63 Appendix 10.1.2.3 Settings string Measure status: !9,p Reset Measure Selected range channel n:!13,p Range 1 selected Range 2 selected 5073A_002-327e-04.23 Page 61...
  • Page 64 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Full scale range 1/2 channel n:!18,p Floating Point Value without Exponent Sensitivity channel n: !19,p Floating Point Value without Exponent Filter configuration: !20,p 1 … 255 Cut-off frequency base (-3 dB) 0 = 10 Cut-off frequency multiplier (-3 dB)
  • Page 65 Appendix 107 grav μ 108 ft/s M.U. 17 V Jump correction channel n: !36,p Reset-measure jump correction off Reset-measure jump correction on Output offset channel n: !43,p -2048 … 2048 Output offset in steps of 1.171875 mV Overflow channel number: !60,p No channel in 'Overflow' 1 …...

  • Page 66: Command List

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     10.1.2.5 Digital inputs string 10.1.2.6 Min/Max values string 10.1.2.7 Instant values string 10.1.2.8 Init upload strings 10.1.3 Command list Command, Description Item./ Parameter Value/ Syntax index value range :8,p Selecting a measuring channel.
  • Page 67 Appendix according to the resolution of the Type 5073A... ICAM. :20,p Setting and activating/deactivating the low- Cut-off freq. 1 … 255 pass filter (fg= 1 … 20 000 Hz) base Cut-off freq. 0 … 3 (*10 Acknowledgement: exponent 0 Command acknowledgement Filter on/off, 0 = Filter off 3030...

  • Page 68: Examples Of Serial Communication

    ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     Return code: res. always 3 0 Behavior after 0 = deactivated after  restart restart 30,1,15,8,0 (event at start of 1 = activated after measurement) restart  -14; -14; -8;...
  • Page 69 Appendix :24,1 Unit Setting the unit 'Newton' (1) for the selected measuring channel 0  (Channel 1) with subsequent checking of the settings. :119 8,336,15612  :120 !9,0,!13,1,!13,1,!13,1,!13,1,!18,267665.9000,!18,1000000.0000, !18,1000000.0000,!18,1000000.0000,!18,1000000.0000,!18,10 00000.0000,!18,1000000.0000,!18,1000000.0000,!19,3.7360,!1 9,1.0000,!19,1.0000,!19,1.0000,!20,20000,0,0,1,!22,0,!22,0,!22, 0,!22,0,!24,1,!24,8,!24,8,!24,8,!36,0,!36,0,!36,0,!36,0,!43,+0,!43 ,+0,!43,+0,!43,+0,!60,0,!73,0,3 :19,3.736 Sensitivity Setting the sensitivity 0 :18,5000.0000 Measuring range 0...
  • Page 70 ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...     :69,3 Peak memory Reading out the peak memory (min./max. values). +0, +1126; Note: no CR+LF is sent after the values. :54 Digital inputs 30 Reading out the status of the digital inputs. ...

  • Page 71: Glossary

    Glossary 11. Glossary 11.1 Terminology Threshold The smallest change in the measurand that will result in a measurable change in sensor signal. In practice, the rule of thumb that the threshold is about twice to three times as large as the typical noise signal of a charge amplifier can be applied.
  • Page 72 Cable capacitance Capacitance, and therefore the length of the connecting cable, have no effect on the measuring result if special Kistler cables and Kistler charge amplifiers are used. Calibration certificate Document for sensors and devices stating the results of the factory calibration.
  • Page 73 Glossary Measuring range, charge amplifier In the ICAM, two independent measuring ranges can be set for each sensor connection. The entire setting range is available for each measuring range; the unit is M.U./10 V. Measuring range, sensor The range in which the quality of measurement within the specified tolerances is guaranteed.
  • Page 74 Reset Charge amplifier mode after the measuring cycle (see Reset/Measure mode). Quasistatic Describes the ability of Kistler sensors and charge amplifiers to undertake static short-term measurements or DC-similar measurements. RS-232C Serial interface of the ICAM. Used for cycle command or for parameter setting.

  • Page 75: Measurement Uncertainty

    Glossary Low-pass filter Electronically eliminates high-frequency interference signals and should normally be active. Triboelectricity Charge transfers caused by cable movements. Overload The maximum measurand value with which the sensor can be loaded without causing damage. It is a safety reserve rather than an extended measuring range.
  • Page 76 Laboratory charge amplifier 0,5 % Industrial charge amplifier Greater accuracy can be achieved with the following measures:  calibration by Kistler  calibration with a Type 5395A charge calibrator  limiting the temperature range Random errors, precision, reproducibility Precision or reproducibility is the extent of the conformity between independent measured values obtained under specified conditions.

  • Page 77: Ec Declaration Of Conformity

    EC Declaration of conformity 12. EC Declaration of conformity 5073A_002-327e-04.23 Page 75...

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