Instruction
Manual
ICAM – Industrial
Charge Amplifier for
Manufacturing
Applications
Type 5073A...
ä
5073A_002-327e-04.23
Foreword
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.
© 2006 … 2023 Kistler Group. Kistler Group products are
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
info@kistler.com
www.kistler.com
5073A_002-327e-04.23
Page 1
Contents
Contents
1.
Introduction ................................................................................................................................... 4
1.1
2.
Important Notes ............................................................................................................................. 6
2.1
2.2
2.3
2.4
2.5
2.6
3.
General ............................................................................................................................ 17
Block Diagram ................................................................................................................. 19
Power Supply, Control Inputs and Analog Outputs ......................................................... 20
RS-232C Interface ........................................................................................................... 21
Peak Value Acquisition .................................................................................................... 22
Setting Options – Configuration ...................................................................................... 24
Description of the Individual Parameters.......................................................................... 26
Commissioning ............................................................................................................................ 28
6.1
6.1.1
6.1.2
6.1.3
6.1.4
7.
The measuring chain ........................................................................................................ 12
Piezoelectric Measurement .............................................................................................. 13
The Mathematical Model of a Piezoelectric Measuring Chain .......................................... 14
The Industrial Charge Amplifier ....................................................................................... 15
Description of Amplifier ............................................................................................................... 17
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
6.
Unpacking ......................................................................................................................... 9
Storage .............................................................................................................................. 9
Amplifier Variants ............................................................................................................ 10
Accessories Included ........................................................................................................ 10
Optional Accessories ........................................................................................................ 11
Fundamentals............................................................................................................................... 12
4.1
4.2
4.3
4.4
5.
For Your Safety .................................................................................................................. 6
Electromagnetic Compatibility (EMC) ............................................................................... 6
Tips on Using this Instruction Manual ................................................................................ 6
Nomenclature .................................................................................................................... 7
Disposal of Electronic Equipment ....................................................................................... 7
Software Upgrades and Updates ....................................................................................... 8
Basics ............................................................................................................................................. 9
3.1
3.2
3.3
3.4
3.5
4.
Enclosed CD ...................................................................................................................... 5
Installation ....................................................................................................................... 28
Connecting Sensors ......................................................................................................... 28
Connecting RS-232C and D-Sub 15-pin Male Connector ................................................ 29
Power Supply and Digital Inputs ...................................................................................... 29
Output Signals ................................................................................................................. 30
"ManuWare" PC Software ............................................................................................................ 31
7.1
7.2
7.3
7.4
7.4.1
Page 2
Installing "ManuWare" PC Software ............................................................................... 31
Starting the Program ....................................................................................................... 33
Description of the Program Interface ............................................................................... 34
First Simple Measurement – Step by Step ........................................................................ 35
Preparations..................................................................................................................... 35
5073A_002-327e-04.23
Contents
8.
7.4.2
Opening the Project – 'Open Project ...' (Ctrl+N) ................................................... 35
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.5
Find/Connect Devices – ‘AutoScan’ ........................................................................ 36
Defining the Display Interface .......................................................................................... 37
Assigning a Channel to a Display Object .......................................................................... 38
Starting and Stopping Measurement ................................................................................ 38
Optimizing Measurement – Changing the Set Values....................................................... 39
Backup/Restore Functionality ........................................................................................... 41
Maintenance and Diagnostics ...................................................................................................... 43
8.1
8.2
8.3
8.3.1
8.3.2
8.3.3
9.
Technical Data ..............................................................................................................................50
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
10.
Command Set of RS-232C Interface................................................................................. 58
Command Structure ......................................................................................................... 58
Feedback Structure ...........................................................................................................59
Command List ..................................................................................................................64
Examples of Serial Communication ................................................................................... 66
Glossary ........................................................................................................................................ 69
11.1
11.2
12.
Design Variants ................................................................................................................ 50
Charge Inputs................................................................................................................... 50
Voltage Outputs (Types 5073Axx1) ................................................................................. 50
Current Output (Types 5073Axx2)................................................................................... 51
Current output symmetrical (Types 5073Axx5) ................................................................ 52
Measuring Accuracy ......................................................................................................... 52
Dynamic Response of Signal ............................................................................................. 52
Peak Value Acquisition ..................................................................................................... 53
Climatic Operating Conditions ......................................................................................... 53
Power Supply Voltage ...................................................................................................... 54
Control Inputs (Bipolar Optocouplers) .............................................................................. 54
Connectors ....................................................................................................................... 54
LED Indicators .................................................................................................................. 55
Serial Interface .................................................................................................................. 55
Mechanical Data ..............................................................................................................55
EMC (to conditions of Directive 2014/30/EU) .................................................................. 56
Dimensions ..................................................................................................................... 57
Appendix ...................................................................................................................................... 58
10.1
10.1.1
10.1.2
10.1.3
10.1.4
11.
Inspections during normal operation ................................................................................ 43
Loading New Firmware .................................................................................................... 43
Drift.................................................................................................................................. 47
Cause 1 ............................................................................................................................ 47
Cause 2 ............................................................................................................................ 48
Cause 3 ............................................................................................................................ 48
Terminology ..................................................................................................................... 69
Measurement Uncertainty ................................................................................................ 73
EC Declaration of Conformity ....................................................................................................... 75
Total number of pages: 75
5073A_002-327e-04.23
Page 3
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
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 maintained.
Page 4
5073A_002-327e-04.23
Introduction
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
5073A_002-327e-04.23
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
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.
Page 6
5073A_002-327e-04.23
Important notes
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.
5073A_002-327e-04.23
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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 no liability for direct damage or
consequential damage caused by products with embedded
software that is not up to date.
Page 8
5073A_002-327e-04.23
Basics
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.
5073A_002-327e-04.23
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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
4 channels/acquisition of 2 peak
values
4 charging channels summed to 1
channel
BNC neg. connector (IP60)
TNC neg. connector (IP65)
Output signal voltage
-10 … ±10 V
Output signal current
4 … 20 mA (available for 1 and
2-channel versions only)
Output signal current symmetric
12 ±8 mA (available for 1 and
2-channel versions only)
With a fixed, customized time
constant; specify per channel
when ordering, incl.
high (>10 000 pC) or low (<10
000 pC) charge levels
For supply voltage
9 … 16 V (available for 1 and 2channel versions only)
1
2
3
4
5
1
2
1
2
5
488
489
3.4 Accessories included
The ICAM charge amplifier is supplied with:
Item No./
Type
65016033
D-Sub 15, female, IP40
with metalized cover and jackscrews
Null modem mini adapter (gender changer) 1489
D-Sub 09, male, D-Sub 09, female
ManuWare CD with
65016164
the ManuWare program
the latest firmware for all supported
devices
Flashloader programs for all supported
devices
Page 10
5073A_002-327e-04.23
Basics
IP67 cover for RS-232C, D-Sub 09 female,
connector
Operating Instructions
Calibration certificate
65008385
With ICAM Type 5073A5xx
2 dust caps for sensor connection
3.5 Optional accessories
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.
5073A_002-327e-04.23
Item No./
Type
1200A27
65016052
1500A41A5
1500A41Asp
1500A42A5
1500A42Asp
2867
1709
Page 11
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).
Fig. 1: Single-channel
amplifier
measuring
chain
with
charge
Key:
1 Sensor
2 Charge amplifier
3 Reset/Measure
4 Measurement signal
5 Signal evaluation
6 Power supply
Piezoelectric
sensor
Connecting cable
PLC
ICAM
Type 5073A…
Fig. 2: Example of a measuring chain
Page 12
5073A_002-327e-04.23
Fundamentals
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.
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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. 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:
Min
process variable
Xin
sensor measurand
Q
charge
Ua
amplifier voltage
UOffset
offset voltage
UOut
amplifier output voltage
S sensor
Udisplay displayed voltage
Xdisplay
displayed sensor measurand
Mdisplay displayed process measurand
Fig. 4:
Page 14
Xin
Min
k
Q
Xin
Mechanical system factor
(e.g., in force shunt or indirect
force measurement)
Sensor sensitivity as per
calibration certificate.
Sca
Charge amplifier transmission
factor
x
Display factor for the sensor
measurand
Ua
Q
Xdisplay
m
Uout
Mdisplay
Uout
Display factor for the process
measurand
Mathematical model of a piezoelectric measuring chain
5073A_002-327e-04.23
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 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 cutoff 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
5073A_002-327e-04.23
Page 15
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
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
Page 16
5073A_002-327e-04.23
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 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 designed for an industrial environment and mounting in the
immediate vicinity of sensors, for example right alongside a
machine tool.
5073A_002-327e-04.23
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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.
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
Measure
Reset
Overload
Fault
Page 18
LED
green, steady
green, flashing
red, flashing
red, steady
5073A_002-327e-04.23
Description of amplifier
5.2 Block diagram
Fig. 7: Block diagram of ICAM Type 5073A…
5073A_002-327e-04.23
Page 19
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.
Fig. 8: D-Sub 15-pin male connector; Exct/Control/Signal
out
Pin allocations for power supply, control inputs and analog
outputs of the D-Sub 15 male connector:
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Allocation
Output_Ch3
Output_Ch2
Output_Ch1 (or sum signal in case of
Type 5073A5…)
Output_Ch4
(or Peak_Ch3 in case of Type
5073A3...)
Peak_Ch2
Peak_Ch1
Common Control
Measure
Exct. GND
Signal GND
+Exct. 18 … 30 VDC
Range_Ch4
Range_Ch3
Range_Ch2
Range_Ch1
With the four-channel version of the ICAM Type
5073A4xx, the peak value can be output for the first two
channels only.
Page 20
5073A_002-327e-04.23
Description of amplifier
5.4 RS-232C interface
The ICAM can be incorporated into a control system or
connected to a PC for parameter setting via the RS-232C
interface. Measuring ranges, peak memories and offsets
can be configured with the ManuWare PC software (see
section 7 "ManuWare" PC software). A low-pass filter can
be connected and measurement set to Reset/Measure. It is
also possible to export the latest measured values, or the
peak memory, via the serial interface. The measured values
of a single, selectable channel can be output continuously.
Pin allocations of the RS-232C serial interface, D-Sub
09 female connector:
Pin
1
2
3
4
5
6
7
8
9
Allocation
NC
RxD
TxD
NC
Exct. GND
NC
NC
NC
NC
Fig. 9: D-Sub 9-pin female connector, RS-232C
To control an amplifier with a PC or a controller via an
RS-232C interface, a null modem cable is required, which
crosslinks pin 2 and pin 3. This ensures that the transmitter
communicates with the receiver (and vice versa) on a single
line in each case. The Type 1489 mini adapter must also be
used in the connection for standardized (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.
TxD:
RxD:
GND RS (Exit. GND):
f (female):
Transmit data
Receive data
Signal ground
Socket
m (male):
Connector
Fig. 10: Connection of null modem cable with crosslinking
of pin 2 and pin 3
5073A_002-327e-04.23
Page 21
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). In the Type 5073A4xx model, only
the peak signals of channels 1 and 2 are run to a separate
pin due to lack of space. The peak value of channel 3 can
only be read out digitally in the 4-channel model. The
fourth measuring channel does not have peak value
acquisition.
There are three different peak modes (+peak, -peak,
(peak-peak)/2), which can be set individually for each
channel (see
Fig. 12
The analog outputs of peak value acquisition are executed
as voltage outputs. This is also the case when normal signal
outputs are executed as current outputs.
Peak outputs have a delay time of max.
0.35 ms (see Fig. 11).
Fig. 11: The maximum rise time of the peak output (in the
event on an FS jump on the charge input) is
0.35 ms
Page 22
5073A_002-327e-04.23
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. 12).
The detected peak value corresponds to the absolute signal
peak, i.e., it includes the programmed offset voltage (see
Fig. 13).
5073A_002-327e-04.23
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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 – configuration
The ICAM Type 5073A… has various device-specific and
channel-specific setting options. All the parameters can be
set in two different ways:
With the ManuWare setup software (standard; for
description, see section 7 "ManuWare" PC Software)
Directly by serial commands over the RS-232C interface
(for description see 10.1 Command set of RS-232C
interface)
The device and setting options in ManuWare can be found
in the device-specific Properties dialog.
Drivers for Labview Version 7.1 are available but are not
maintained further.
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5073A_002-327e-04.23
Description of amplifier
Fig. 14: The device-specific Properties dialog in ManuWare
shows at a glance all the properties that can be
set
All the setting options and display fields are described
below. Please note that it is always advisable to check all
the fields from top to bottom and set them to suit the
application requirements.
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. To do this, it is necessary to know the sensor
sensitivity, or the system sensitivity.
First select a unit (e.g., [N]). Then set the sensor sensitivity
S in pC/N, for example. The minus sign is fixed and can
not be inverted. The measuring ranges ('Range 1' and
'Range 2') are now set directly in [N]. During operation,
this value then corresponds to an output signal of 10 V.
The transfer function is
Formula 1: Transfer function, applied logically
measurement, as done by Kistler
U out
5073A_002-327e-04.23
Q
FSO
S Bereich_x
[V]
by
[10V]
[pC]
[pC] [M.U.]
[M.U.]
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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]. The minus sign is fixed and can not be
inverted. The measuring ranges ('Range 1' and 'Range 2')
are now set directly in pC. During operation, this value
then corresponds to an output signal of 10 V. The transfer
function is
Formula 2: Transfer function, technical/physical application
U out Q ( 1)
FSO
Bereich_x
[pC] [10V]
[V] [pC]
[pC]
[pC]
5.6.1 Description of the Individual parameters
Channel
The channel to be set or displayed is selected here. Use the
button on the right to copy the current channel settings to
the other channels.
Unit
The unit being used is set here. This setting has no
technical function on the charge amplifier, but makes
setting the amplifier easier.
The following units are available:
N, kN, p/grf, kp/kgf, bar, kPa, MPa, M.U., grav, m/s2, Nm,
Ncm, pC, με, mm, A, V, lbf, psi, lbf-in, lbf-ft, pC, grav,
ft/s2
The abbreviation M.U. means 'mechanical unit' and can be
used to represent other units.
Once the unit is selected, the sensitivity and the measuring
range are also defined in the chosen unit.
The unit setting has no technical function for
measurement. This setting is merely stored in a memory
register, where it is available to the host systems (such as
ManuWare), and can be digitally accessed for interpreting
the measured values.
Sensitivity
The sensitivity of the sensor being used is specified here.
This figure can be found on the calibration certificate
included with the sensor. If the connected sensors are used
in a force shunt, or for indirect force measurement, system
sensitivity must be determined by an in-situ calibration.
Sensitivity is used, together with the set (programmed)
measuring range, to calculate the gain for the
programmable amplifier (PGA), according to Formula 1 or
Formula 2.
The sensitivity of piezoelectric sensors is usually expressed
negatively. This is why the minus sign in the ICAM
5073A… is already predefined, so that only a positive
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5073A_002-327e-04.23
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.
Scale factor (m) (only displayed in ManuWare)
This factor allows the amplifier output signal to be correctly
interpreted. For the exact function of m, see section 4.3
The Mathematical Model of a Piezoelectric Measuring
Chain.
Charge measuring range
The activated measuring range converted to a charge is
specified in the charge measuring range field. This value
allows you to quickly check the range in which the charge
amplifier is being operated. By comparing range 1 and
range 2, it is possible to check whether or not the charge
capacitors have to be switched between the two ranges.
Full-scale output
Full-scale output in the ICAM Type 5073A… is always 10
000 mV
Output offset (Uoffset)
The output offset can be adjusted between –1 000 … +1
000 mV. This results for Type 5073Axx2 in
–1.6 ... +1.6 mA and Type 5073Axx5 in –0.8 ... +0.8 mA
Offset.
Peak
The peak detector can be activated and configured. The
choice is between Off, +peak, -peak and (peak-peak)/2.
Low-pass filter (cut-off frequency)
A low-pass filter can be activated for all the measuring
channels together. Cut-off frequencies of 10 Hz, 200 Hz
and 3 000 Hz are available.
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
6. Commissioning
6.1 Installation
Follow the safety precautions in section 2.1 during
installation, commissioning and operation.
The ICAM charge amplifier has IP60 or IP65 protection to
EN60529 and is designed for industrial use under the
operating conditions specified in section 9.16.
Protect the amplifier inputs and outputs against dirt
and never touch the connector contacts with your
fingers. Put the supplied covers on if a connection is
not being used.
6.1.1 Connecting sensors
Depending on the version, one, two, three or four sensors
can be connected to the ICAM charge amplifier.
The extremely high input insulation of the charge
amplifier means the signal or charge input has to be
protected against dirt. Clean the connector contacts
with a clean, lint-free paper towel and 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. If the cable is moved
during operation, it should not be suspended over
spans exceeding 30 ... 50 cm.
Connect the sensor cable to the BNC or TNC jack of the
industrial charge amplifier.
+
+
S
Page 28
-
EMC and ground loops
Piezoelectric sensors are normally designed
so that one of the electrodes is on the sensor
case. When it is installed, the sensor is usually
grounded by the metal structure (safety). If
the sensor is not insulated when it is installed,
a resultant ground loop could cause
interference. A low-impedance and at the
same time low-inductance connection
between instrument case and sensor (largearea copper braiding, ribbon cable) usually
provides good results.
5073A_002-327e-04.23
Commissioning
6.1.2 Connecting RS-232C and D-Sub 15-pin male connector
The parameters of the charge amplifier are set via the RS232C 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. Power is
supplied between +Exct. 18 ... 30 VDC pin 11 and Exct.
GND pin 9 as ground.
+24 Volt
0 Volt
12 ... 15 Range_Ch1 ... 4
8
Reset/Measure
7
Common Control
SPS
PLC
+24 Volt
0 Volt
5073A..
Exct. 18 ... 30 VDC
Exct. GND
11
9
Fig. 15: Power supply with electrical isolation to PLC
11 Exct. 18 ... 30 VDC
9 Exct. GND
12 ... 15 Range_Ch1 ... 4
8
Reset/Measure
7
Common Control
5073A..
+24 Volt
0 Volt
1
SPS
PLC
0 Volt
+24 Volt
Fig. 16: Power supply without electrical isolation to PLC
One digital input is available for Measure, and four
for channel selective measuring range switching. Without
switching, the ICAM is in Reset mode and all
channels are in measuring range 1.
The logic of the control inputs can be determined by
switching the Common Control pin ('Exct/Control/Signal
Out' connector, pin 7). (Common Control = 0 V
corresponds to 'Active High'; Common Control = Vcc
corresponds to 'Active Low')
In industrial environments other loads with strong backscattering to the power supply are sometimes used. The
following actions could help to reduce the noise level on
the measured signal. Make sure the amplifier grounding is
done properly. It is recommended to separate the signal
ground from the power ground by using galvanically insu-
5073A_002-327e-04.23
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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 components in separate ducts. Finally, use a separate power
supply unit and if necessary, a mains filter.
Fig. 17: Block diagram of the control inputs
The Measure control input always acts on all channels
simultaneously. Each measuring range can be chosen with
a separate signal.
6.1.4 Output signals
The common reference ground of the analog outputs and
peak memories of all channels is Signal GND pin 10.
It is advisable to use a shielded cable for the connection.
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"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).
Display of the current device status, and of all digital
inputs, in real time
Graphical representation of measurement data with a
reduced data rate for commissioning a measuring chain
Scaling measuring channels to known measurands
(support for determining system sensitivity)
Backup and Restore of the set values.
ManuWare is universal software and supports, as well as
ICAM, other industrial sector products such as transmitters.
An individual interface can be defined for the configuration
and display of an entire measuring system. Any number of
ICAMs can be supported simultaneously.
Fig. 18: The ManuWare setup and test software is included
on the CD, free of charge
7.1 Installing "ManuWare" PC software
Below is a description of how to install ManuWare PC
software on a PC:
Place the 'ManuWare' CD-ROM, item
7.643.035 (SAP 65016164), in the CD or DVD
drive of your PC. Once the CD is inserted, the
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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.
To install ManuWare on your computer, select the
second menu item 'Install ManuWare'.
Follow the instructions of the Installation Wizard.
Once installed, ManuWare is ready to start up for the
first time.
As an alternative to the regular installation, which requires
administrator rights (because of registry entries),
ManuWare can also be installed by manually copying the
program folder from the CD to the computer. To start the
program, run manuware.exe or a link to it.
To work with ManuWare, the program can also be started
directly from the CD, or from a memory stick. When
starting from the CD, please note that the last
configuration is not automatically saved, and that no data
can be written to the CD.
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"ManuWare" PC software
7.2 Starting the program
ManuWare is started in Windows,
Menu>Programs>Kistler>ManuWare, by
ManuWare program.
Fig. 20:
under Start
clicking the
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.
Fig. 21: The first time the program starts, a neutral project
is loaded
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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… menu and then to the 'Language'
tab. The newly selected language will be active the next
time you start the program.
7.3 Description of the program interface
The principal sections of the ManuWare program interface
are the navigation frame, the graphic display frame and the
information frame. There are also the familiar Windows
areas, such as a title bar, menu bar, tool bars and status
bar.
Fig. 22: ManuWare main window - The dotted blue lines
show how the window is divided into frames
Navigation frame
The 'Project Explorer', which lists the devices in a project,
can be found here. The following functions are also
possible: configuring devices and channels, activation for
measurement; software range switching, device status
overview.
Graphic display frame
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"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. Warnings, error messages and/or the entire protocol
between ManuWare and the connected devices (if
required) are listed on the 'Messages' tab.
7.4 First simple measurement – step by step
7.4.1 Preparations
Three conditions must be met in order to carry out a simple
measurement (such as commissioning a measuring chain):
1. ManuWare must be installed on the PC.
Proceed exactly as described in the installation instructions
on the installation CD.
2. The measuring chain (or chains) to be checked must be
installed on your system and switched on.
Instructions on how to do this can be found in the
operating instructions for your sensors, amplifiers or
transmitters. Take particular care to ensure that the sensor
mounting is mechanically correct, that the sensor is firmly
connected to the charge amplifier with a high insulation
connecting cable, and that the power supply, signal and
control lines are properly connected to the charge
amplifier.
3. The amplifiers or transmitters of the measuring
chain(s) must be connected to the PC.
In the ICAM Type 5073A… , this is done via the RS-232C
interface. The COM ports on the PC can be used directly
or the COM ports of a USB serial hub can be used.
7.4.2
Opening the project – 'Open Project ...' (Ctrl+N)
The first time you start ManuWare, a new empty project
called Project1 is opened. If a current project already exists,
you can use the 'Open Project ...' function to open a new
empty project at any time. If the existing project has not
already been saved, you will, of course, first be asked if
you want to save it.
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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. However, the
device type and the relevant interface must be known.
The ‘AutoScan’ function is an extremely convenient
alternative, which in practice will probably become the
norm. The first time you start ManuWare, or after you
open a new project, simply click on the ‘AutoScan’ button,
and ManuWare will automatically scan all the existing
COM ports for defined devices (currently Types 5073A...,
9238A... and 9337A...).
The devices found will immediately be listed in the Project
Explorer. The devices are listed as soon as they are found,
with the device search running for a set period of time in
the background (approx. 10 s). The hourglass cursor is
displayed during this time . Once the time-out expires, a
message is displayed, Scanning Completed.
Fig. 23: Once the automatic scan is complete, the devices
found are displayed in the Project Explorer,
and the completion of the search is indicated
by a dialog box
The detected devices (and/or their measuring channels) are
now ready for measurement.
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"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. These are located in the display objects bar on
the right side of the screen.
Cycle display object
This display object is only updated once measurement
is complete (Reset). It is ideal for representing twochannel measurements (force/displacement, torque/
angle, etc.). So it is primarily useful for representing
ComoNet results. A measurement indicator and a zoom
function (drag the mouse with the Ctrl key pressed) are
available. Several channels can be represented at the
same time in the cycle display object.
Oscilloscope display object
This display object shows the measurement signal as a
function of time. It is updated in real time. It is
particularly suitable for an initial check of the
measuring channels.
Digital multimeter display object
With this display object, the measured signals can be
represented in real time numerically, and as a bar chart.
Display objects can be positioned on a worksheet by using
Drag-and-Drop with the mouse.
Fig. 24: Display object positioning example: an oscilloscope
object is created on the worksheet using Dragand-Drop with the mouse
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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.
Fig. 25: A measuring channel is assigned to a display object
using Drag-and-Drop
The display object key reveals which measuring channels
are assigned to a display object.
Fig. 26: The displayed measuring channels are shown in
the key below the graph
7.4.6 Starting and stopping measurement
When the measuring instruments are integrated in a
project and a measurement data display has been set up,
an initial test measurement can be started. There are 4
options:
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"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 – changing the set values
Once an initial measurement has been performed, a
measurement could look like this:
Fig. 28:
An initial measurement is not always perfectly
loaded. Loading of such a measurement needs
to be tuned.
The measurement shown in Figure 28 is poorly loaded. The
useful signal (<0.5 V) is too small in relation to the full
5073A_002-327e-04.23
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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
To program the addressed device with the changed
parameters, the values must be sent to the device by
pressing 'Send'. Use 'Load' to load the parameters from
the device to the dialog. In this example, the measurement
looks like this after optimization:
Fig. 30: A measurement with optimum loading
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"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 backedup 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).
2. A restore becomes necessary if the parameters of a device
are unintentionally changed, or if a device fails
(replacement). Both situations are identical as far as the
application (i.e., ManuWare) is concerned.
3. Make sure that the device concerned is switched on.
4. When the backed-up project is loaded in ManuWare, the
connected devices are linked. The link can also be made
manually if the device has since been connected to a
different interface or if the device is defined in the project
as not connected.
5. When the Properties dialog is displayed, ManuWare
detects that the parameters in the device and in the project
are different. This is shown by a message below the
synchronization bar: Parameter Sets are Different!
Fig. 31: If the parameters in the project and in the device
are different, this is shown by a message in the
Properties dialog
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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. Once the parameters have been sent to the device, the
device is returned to exactly the same state as it was
when the backup was made.
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Maintenance and diagnostics
8. Maintenance and diagnostics
8.1 Inspections during normal operation
Periodic maintenance can be limited to visual inspections of
the outside of the case and the cable connection. The case,
cables and connectors must not have any visible damage.
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. This requires a
PC and the software with the firmware files. The latest
firmware with flashloader can be downloaded from our
website: www.kistler.com.
The flashloader can also be started directly from
the included ManuWare CD.
Fig. 32: The flashloader start screen
Choose a language to proceed to the next screen.
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
Fig. 33: Selecting the firmware version to be installed
The selection of the firmware to be installed is
confirmed with 'Next >'.
Fig. 34: Prompt to switch off the device
The next step is to switch off the device (Fig. 34). This
is confirmed with 'Next >'.
Now the interface is selected, to which the ICAM Type
5073A… is connected. This is confirmed with 'Next >'.
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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 is displayed,
5073A_002-327e-04.23
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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
Once programming is completed, the ICAM Type
5073A… must be switched off and on again to
activate the new firmware.
Fig. 39: Reprogramming successfully
device must be restarted
completed.
The
Press 'Finish' to close the flashloader.
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Maintenance and diagnostics
8.3 Drift
The gradual zero point shifting of the output signal during
a measuring cycle is called drift. The maximum drift is
specified as ±0.05 pC/s at 25°C (see section 9.4). Any
significantly higher value can be due to one of the
following causes:
8.3.1 Cause 1
The output signal drops exponentially towards zero. It is
caused by the insulation resistance in the charge amplifier
feedback being too low. 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
Input signal
Input signal
t
t
Measurement
inactive
Measurement
inactive
Measurement
active
+
Measurement Measurement
inactive
active
+
+
Input offset
Output signal
-
Measurement
active
Output signal
t
t
t
-
t
Output signal
Fig. 40: Exponential drift of the output signal during the
measuring cycle
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
8.3.2 Cause 2
The signal at the output drifts linearly in the positive or
negative direction. This may be caused by a faulty input
operational amplifier. To rectify the defect, return the
charge amplifier to the responsible Kistler sales
center/distributor for repair.
Output signal
+
+
+
t
t
t
-
-
-
Output signal
Output signal
Fig. 41: Linear drift of the output signal during the
measuring cycle
8.3.3 Cause 3
Depending on the polarity of the offset voltage on the
amplifier input, the drift can be in the positive or negative
direction. It is caused by the insulation resistance at the
input of the charge amplifier being too low. It may,
however, also be due to insufficient sensor insulation
resistance. The insulation of the sensor cable and the
sensor (but not the input resistance of the
charge amplifier) can be measured with a Type 5493
insulation tester. Dirty amplifier input, sensor and cable
connectors and sockets must be cleaned or replaced. 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
+
+
+
t
t
Output signal
Page 48
-
-
-
t
Output signal
5073A_002-327e-04.23
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.
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
9. Technical data
9.1 Design variants
Number of channels
1, 2, 3 or 4
Special variant
4 charge inputs summed
to 1 channel
Input connector variants
BNC, TNC
mA
–10 … 10
4 … 20
Measuring range
pC
±100 … ±1 000 000
Low charge level
pC
±100 … ±10 099
High charge level
pC
±10 100 … ±1 000 000
Time constant
s
100 000 (long)
Drift at 25 °C
pC/s
<±0,05 (Type 5073A1...)
Output signal variants
V
9.2 Charge inputs
Note: Above the threshold of ±10 099 pC,
switching the measuring range without
measuring errors is only possible in RESET status.
<±0,05 (Type 5073A2...)
<±0,07 (Type 5073A3...)
<±0,09 (Type 5073A4...)
Drift at 0 ... 60 °C
pC/s
<±0,5 (Type 5073A1...)
<±0,5 (Type 5073A2...)
<±0,7 (Type 5073A3...)
<±0,9 (Type 5073A4...)
9.3 Voltage outputs (Types 5073Axx1)
Output voltage
V
–10 … 10
Maximum output current
mA
±5
Output impedance
10
Output voltage limit
V
>±11
Page 50
5073A_002-327e-04.23
Technical data
Digitally adjustable offset (via RS-232C)
V
±1
Resolution of offset adjustment
mV
2
Error
% meas.
range
<±0,5
Zero point offset
mV
<±30
mVpp
<30
mVpp
<10
kHz
0 … 20
kHz
0 … 2
Output noise signal
0.1 Hz … 1 MHz
with internally switchable LP filter
(10, 200, 3 000 Hz)
In both cases without data transmission via the
RS-232C interface
Frequency range (–3 dB)
Charge range <10 000 pC (pos. or neg.)
Charge range between 10 000 and
100 000 pC (pos. or neg.)
In both cases without data transmission via the
RS-232C interface
9.4 Current output (Types 5073Axx2)
Output current range
mA
4 … 20
Output impedance
>2
Max. load resistance
500
Correlation
4 mA corresponds to 0 V
20 mA corresponds to 10 V
Note 1:
The peak value is always output as a voltage,
even in current output devices.
Note 2:
Current outputs are only available for single and
two-channel variants (Types 5073A1x2 and
5073A2x2)
Note 3:
Only negative charges can be measured,
inversion is not possible.
Error
% meas.
range
<±1
Zero point offset
mA
<±0,3
Frequency range (–3 dB)
Charge range <10 000 pC (pos. or neg.)
Charge range between 10 000 and
100 000 pC (pos. or neg.)
kHz
0 … 10
kHz
0 … 2
5073A_002-327e-04.23
Page 51
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
9.5 Current output symmetrical (Types 5073Axx5)
Output current range
mA
12 ±8
Output impedance
>2
Max. load
500
Classification
4 mA corresponds –10 V
20 mA corresponds 10 V
Hinweis 1:
The peak value is also output as voltage for
devices with current outputs.
12 mA corresponds 0 V
Note 2:
Current outputs are only available for the single
and dual channel versions (Type 5073A1x5 and
5073A2x5).
Error
% Measuring
range
<±1
Zero offset
mA
<±0,15
Frequency range (–3 dB)
Charge range <10 000 pC
(pos. or neg.)
kHz
0 … 10
Charge range between 10 000 und
100 000 pC (pos. or neg.)
In both cases without data transfer via RS-232C
interface.
kHz
0 … 2
Repeatability
% meas.
range
<±0,05
Reset/Measure jump
pC
<±2
Hz
10/200/3 000
or
switched off
9.6 Measuring accuracy
9.7 Dynamic response of signal
Butterworth low-pass filter
(cut-off reference –3 dB; 5th order)
Page 52
5073A_002-327e-04.23
Technical data
Group delay
without low-pass filter
with 3 000 Hz low-pass filter
200 Hz low-pass filter
10 Hz low-pass filter
μs
μs
ms
ms
<15
<300
<4
<80
Error
%
<±1,5
Zero point offset
mV
<±50
Rise time (0 … 99%)
ms
<0,35
9.8 Peak value acquisition
Modes
+Peak
–Peak
(Peak-Peak) 2
To the new measuring cycle
(MEASURE)
Reset (reset to 0 V, or offset voltage)
Max. output current
mA
±5
Output impedance
10
Note:
The detected peak value corresponds to the
absolute signal peak, i.e., includes the
programmed offset voltage
9.9 Climatic operating conditions
Operating temperature range 1)
Minimum/maximum temperature
Max. relative humidity
2)
°C
0 … 60
°C
–40/80
%
60
1)
non-condensing
2)
Device ready for operation, but differences in technical data possible/non-condensing
5073A_002-327e-04.23
Page 53
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
9.10 Power supply voltage
Supply voltage
VDC
18 … 30
Current consumption (without load, without
current output, typically at 24 V)
1-channel device
2-channel device
3-channel device
4-channel device
mA
mA
mA
mA
<125 (3 W)
<167 (4 W)
<210 (5 W)
<250 (6 W)
Note:
At startup and reprogramming of the amplifier
a momentary increase of power consumption by
50 % may occur.
9.11 Control inputs (Bipolar Optocouplers)
Response voltage
VDC
2.4 … 30, bipolar
Current consumption
mA
0,3 … 6,2
ms
ms
<9
<90
Reset
'Measure'
switching and reset time
Q <±10 000 pC
Q <±1 000 000 pC
de-energized state
Scope
'Range II'
switching time
de-energized state
scope
Common to all channels
ms
<2
Range I
each channel switchable individually
Type
Type
BNC neg. (IP60)
TNC neg. (IP65)
Power supply, control inputs, signal outputs
(connector 'Exct/Control/Signal Out')
Type
D-Sub 15-pin pos.
(IP40; IP67 with connected
special connector, item no. 65016052)
Serial Interface
Type
D-Sub 9-pin neg.
(IP40; IP67 with cover,
item no. 65008385)
9.12 Connectors
Sensors (connector 'Sensor x')
Type 5073Ax1x
Type 5073Ax2x
Page 54
5073A_002-327e-04.23
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
8
Stop bits
1
Parity
none
Handshake
none
Transmission speed
Bits per
second
(baud rate)
115 200 (fixed)
Max. cable length
m
5
Max. input voltage, continuous
V
<±20
Max. voltage between case and protection
ground
Vrms
<±20
Vibration resistance
(20 … 2 000 Hz, duration 16 mins., cycle 2
mins.)
gp
10
Shock resistance (1 ms)
g
200
9.15 Mechanical data
Case material
Weight
5073A_002-327e-04.23
Aluminum, pressure diecast
grams
360 (4-channel device)
Page 55
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
Technical data
9.17 Dimensions
Fig. 43: Dimensions of ICAM Type 5073A…
Type 5073Ax1x (BNC neg.)
5073A_002-327e-04.23
Type 5073Ax2x (TNC neg.)
Page 57
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
10. Appendix
10.1 Command set of RS-232C interface
Interface parameters
Baud rate
Data bits
Stop bits
Parity
Flow control
115 200 baud
8
1
none
none
Full parameter configuration and control of the Type
5073A... ICAM are possible with the command set
described below. The measurement results can also be
continuously transmitted (streamed) to the serial interface.
The protocol architecture is defined in the syntax diagrams
below. The data is transmitted using a simple ASCII
protocol.
10.1.1 Command structure
Fig. 44:
Page 58
Command syntax. All commands are sent as
ASCII code
5073A_002-327e-04.23
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
0
OK
1
Unknown command
2
Parameter outside permissible range
6
Channel is not available
7
Checksum error
18
Device is measuring via external input
24
Warning: change in the charge capacitor
configuration
10.1.2.2 Event message
Channel
5073A_002-327e-04.23
1
Channel 1
2
Channel 2
4
Channel 3
Page 59
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
8
Channel 4
Event Codes
Page 60
4
Charge amplifier overflow
8
Remote Measure
80
Remote Reset
60
Remote Range 1
61
Remote Range 2
5073A_002-327e-04.23
Appendix
10.1.2.3 Settings string
Measure status: !9,p1,
p1 0
1
Reset
Measure
Selected range channel n:!13,p1,
5073A_002-327e-04.23
p1 1
Range 1 selected
2
Range 2 selected
Page 61
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
Full scale range 1/2 channel n:!18,p1,
p1
Floating Point Value without Exponent
Sensitivity channel n: !19,p1,
p1
Floating Point Value without Exponent
Filter configuration: !20,p1, p2, p3, p4,
p1 1 … 255
Cut-off frequency base (-3 dB)
p2 0 = 100
Cut-off frequency multiplier
(-3 dB)
1 = 101
2 = 102
3 = 103
Filter on/off; filter order
p3 0 = filter off
5 = 5th order
p4 1 = Butterworth
Filter type
Peak detector channel n: !22,p1,
p1 0
Off
1
+Peak
2
-Peak
3
(peak-peak)/2
Unit channel n: !24,p1,
Page 62
p1 1
N
9
grav
101 lbf
2
kN
10
m/s2
102 psi
3
p / grf
11
Nm
103 lbf-in
4
kp /kgf
12
Ncm
104 lbf-ft
5
bar
13
pC/mV
105 pC/mV
5073A_002-327e-04.23
Appendix
6
kPa
14
μ
107 grav
7
MPa
15
mm
108 ft/s2
8
M.U.
16
A
17
V
Jump correction channel n: !36,p1,
p1 0
Reset-measure jump correction off
1
Reset-measure jump correction on
Output offset channel n: !43,p1,
p1 -2048 … 2048
Output offset in steps of
1.171875 mV
Overflow channel number: !60,p1,
p1 0
1…4
No channel in 'Overflow'
Number of channel with 'Overflow'
Continuous data transmission status: !73,p1, p2, p3,
p1 0
3
p2 3
Continuous data transmission disabled
Continuous data transmission disabled at
≈200 Hz
Data format ±xxxxx;
Value in mV; 7 digits
p3 0
Current status not saved in permanent
flash memory
1
Current status saved in permanent flash
memory
10.1.2.4 Identification String
5073A_002-327e-04.23
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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,
Syntax
:8,p1,p2
Description
Item./
index
1
2
reserved
Channel no.
1
Status
1
Measuring
range number
Measuring
range
:9,p1
Selecting a measuring channel. The
subsequent commands relate to this
channel.
Reset/Measure
:13,p1
Selecting the measuring range
:18,p1
1
Setting the measuring range in mechanical
units (e.g., N, μ, etc.; mechanical value for
10 V output signal).
The setting relates to the currently chosen
measuring range and measuring channel.
Note: (measuring range x sensitivity) must
lie within the range 100 … 1 000 000 pC.
The programmed value is rounded
according to the resolution of the Type
5073A... ICAM.
1
Setting the sensitivity
(in pC/M.U.).
The setting relates to the currently chosen
measuring channel.
Note: (measuring range x sensitivity) must
lie within the range 100 … 1 000 000 pC.
Only positive values are accepted. These are
always interpreted by the amplifier as
negative sensitivity.
The programmed value is rounded
:19,p1
Page 64
Parameter
Sensitivity
Value/
value range
always 0
1…4
1 = measure
0 = reset
1/2
0.0100 …
100 000 000.0000
(4 decimal places);
Floating point but
not exponential
format.
0.0100 …
10,000.0000
(4 decimal places);
Floating Point but
not exponential
format; positive
values only, without
sign
5073A_002-327e-04.23
Appendix
:20,p1,p2,p3,p4
:22,p1
:24,p1
according to the resolution of the Type
5073A... ICAM.
Setting and activating/deactivating the low- 1
pass filter (fg= 1 … 20 000 Hz)
2
Acknowledgement:
3
0
Command acknowledgement
3030 Actual cut-off frequency after
4
rounding.
Adjustable cut-off frequencies:
7 (6) … 13 (13)
140 (130) … 260 (260) Hz
2 000 (2 000) … 20 000 (20 000) Hz
The actual values set are given in brackets.
The rounding differences are system
dependent. The setting should always be
verified by reading back the setting string
(:119 and :120).
1
Setting peak mode
:43,p1
Setting the mechanical unit
1
N
9
grav
2 kN
10 m/s2
3
p / grf 11 Nm
4
kp /kgf 12 Ncm
5
bar
13 pC/mV
6
kPa
14 μ
7
MPa
15 mm
8
M.U.
16 A
17 V
Setting the offset voltage
:54
Querying status of digital inputs
:69,p1
:72,p1
:73,p1,p2,p3
1 … 255
Peak mode
0 = off
1 = +peak
2 = -peak
3 = (peak-peak)/2
1 … 17, 101 … 108
0 … 3 (*10x)
0 = Filter off
5 = Filter on/5th
degree
1 = Butterworth
(only option)
1
Unit
1
Offset voltage -2048 … +2048
(always with sign
in steps of
1.171875 mV and 4 digits; voltage
limitation at ±1.00 V)
101 lbf
102 psi
103 lbf-in
104 lbf-ft
105 pC/mV
107 grav
108 ft/s2
Return code:
Bit 1 'Measure' input (0 = Reset)
Bit 2 'Channel 1 range' input (0 = R1)
Bit 3 'Channel 2 range' input (0 = R1)
Bit 4 'Channel 3 range' input (0 = R1)
Bit 5 'Channel 4 range' input (0 = R1)
Other bits = 0
Returned as decimal value (in ASCII)
Querying peak values (min, max) of the
currently selected channel (with :8,0,x)
Return code: ±xxxxx,±xxxxx; (in mV)
Current measured value of the selected
channel (with :8,0,x)
Return code: ±xxxxx; (in mV)
Continuous data transmission for the
selected channel (during MEASURE only)
5073A_002-327e-04.23
Cut-off freq.
base
Cut-off freq.
exponent
Filter on/off,
filter degree
Filter type
-
1
res.
always '3'
1
res.
always '3'
1
On/Off
0 = deactivate
3 = activate
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ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
:119
:120
:123
:124
Return code:
0
30,1,15,8,0 (event at start of
measurement)
-14; -14; -8; etc.
(measured values in mV)
Initialize reading of the settings
Return code:
'8, number of chars., check number'
e.g., 8,331,15381
Send current settings
Return code, see section 'Settings string'
Initialize reading of the ID string
Return code:
'8, number of chars., check number'
e.g., 8,43,2079
Send current ID string
Return code, see section 'Identification
String'
2
3
res.
Behavior after
restart
always 3
0 = deactivated after
restart
1 = activated after
restart
-
-
-
10.1.4 Examples of serial communication
The example below was carried out with a Type 5073A411
ICAM with factory settings.
:119
8,337,15612
:120
!9,0,!13,1,!13,1,!13,1,!13,1,!18,1000000.0000,!18,1000000.000
0,!18,1000000.0000,!18,1000000.0000,!18,1000000.0000,!18,1
000000.0000,!18,1000000.0000,!18,1000000.0000,!19,1.0000,!
19,1.0000,!19,1.0000,!19,1.0000,!20,20000,0,0,1,!22,0,!22,0,!2
2,0,!22,0,!24,8,!24,8,!24,8,!24,8,!36,0,!36,0,!36,0,!36,0,!43,+0,!
43,+0,!43,+0,!43,+0,!60,0,!73,3,3
Settings query
Settings query with command combination :119 - :120.
For structure of the settings string, see section 'Settings string'
:123
8,43,2079
:124
&1,5073A411,&2,1637155,&3,42008,&4,01.17,&0
ID query
ID query with command combination :123 -:124
For structure of ID string see section 'Identification String'
:9,1
0
Operate
Starting measurement with 'Operate'.
:9,0
0
Reset
Stopping measurement with 'Reset'.
:8,0,1
0
Selecting a measuring channel
Selected measuring channel 1 for measuring channel-specific
settings.
Page 66
5073A_002-327e-04.23
Appendix
:24,1
0
: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
Unit
Setting the unit 'Newton' (1) for the selected measuring channel
(Channel 1) with subsequent checking of the settings.
:19,3.736
0
Sensitivity
Setting the sensitivity
:18,5000.0000
0
:119
8,334,15508
:120
!9,0,!13,1,!13,1,!13,1,!13,1,!18,4974.2070,!18,1000000.0000,!1
8,1000000.0000,!18,1000000.0000,!18,1000000.0000,!18,1000
000.0000,!18,1000000.0000,!18,1000000.0000,!19,3.7360,!19,
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
:8,0,3
0
:18,5000.0000
0
:8,0,4
0
:18,15000.0000
0
:13,2
0
:18,7500.0000
0
:119
8,326,15259
:120
!9,0,!13,1,!13,1,!13,1,!13,2,!18,4974.2070,!18,1000000.0000,!1
8,1000000.0000,!18,1000000.0000,!18,4998.7790,!18,1000000
.0000,!18,14993.8900,!18,7499.3900,!19,3.7360,!19,1.0000,!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
Measuring range
Setting the measuring range for the selected measuring channel
(Channel 1) and the active range (Range 1) with subsequent
checking of the settings. The set value (e.g., 5000.0000) is
adapted to the possible amplifier resolution (e.g., 4974.2070).
:8,0,3
0
:22,1
0
5073A_002-327e-04.23
Selecting Channel 3
Setting the measuring range of Channel 3/Range 1 to 5000.0000
Selecting Channel 4
Setting the measuring range of Channel 3/Range 1 to
15000.0000
Selecting Range 2 (of Channel 4)
Setting the measuring range of Channel 3/Range 2 to 7500.000
Checking the settings with :119 - :120
Peak detector
Selecting measuring channel 3 and activating the peak detector
(+peak). This function only relates to analog peak output. In the
microprocessor, only min. and max. values are acquired in all
three peak modes. When peak mode is deactivated, no min./max,
values are acquired.
Page 67
ICAM – Industrial Charge Amplifier for Manufacturing Applications Type 5073A...
:69,3
+0, +1126;
Peak memory
Reading out the peak memory (min./max. values).
Note: no CR+LF is sent after the values.
:54
30
Digital inputs
Reading out the status of the digital inputs.
30d = 11110b (channels 1-4 to range 2; measure input to reset)
:20,200,0,5,1
0
:119
8,324,15181
:120
!9,0,!13,1,!13,1,!13,1,!13,1,!18,4974.2070,!18,1000000.0000,!1
8,1000000.0000,!18,1000000.0000,!18,4998.7790,!18,1000000
.0000,!18,14993.8900,!18,7499.3900,!19,3.7360,!19,1.0000,!19
,1.0000,!19,1.0000,!20,195,0,5,1,!22,0,!22,0,!22,1,!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
LP filter
Setting the LP filter to cut-off frequency 200 Hz adjusts the ICAM
setting by rounding. As the rounding in the ICAM 5073A... is
relatively approximate in many cases, it is advisable to read back
the actual status. In this case, 200 Hz is specified and 195 Hz
effectively set.
:72,3
+1287;
Current measured value (Polling Mode)
The current measured value can be queried with command :72,3.
The measured value of the currently selected measuring channel is
returned in mV.
Note: no CR+LF is sent after the values.
:73,3,3,0
0
30,1,15,8,0
+20; +68; +115; +175; +222; +264; +312; +353; +389;
+431; +472; +508; +550; +585; +621; +651; +680; +710;
+734; +758; +781; +805; +817; +829; +835; +841; +841;
+841; +829; +799; +770; +710; +639; +544; +437; +324;
+187; +86;30,1,15,80,0
:73,0,3,0
0
Continuous data transmission
Continuous data transmission is activated and deactivated with
command :73…. After 'Measure' (here externally hardwaredriven), the measurement data of the currently selected channel
are continuously transmitted. Approx. 200 values are transmitted
per second. The transmission ias in [mV].
:43,+0853
0
:119
8,327,15328
Offset voltage
The offset voltage for the currently selected measuring channel is
set with command :43,…. This occurs in increments of 1.171875
mV. Although values between -2084 and +2048 are accepted,
the maximum output voltage is ±1 V (853 increments).
:120
!9,0,!13,1,!13,1,!13,1,!13,1,!18,4974.2070,!18,1000000.0000,!1
8,1000000.0000,!18,1000000.0000,!18,4998.7790,!18,1000000
.0000,!18,14993.8900,!18,7499.3900,!19,3.7360,!19,1.0000,!19
,1.0000,!19,1.0000,!20,2000,0,5,1,!22,0,!22,0,!22,1,!22,0,!24,1,
!24,8,!24,8,!24,8,!36,0,!36,0,!36,0,!36,0,!43,+0,!43,+0,!43,+853,
!43,+0,!60,0,!73,0,3
Page 68
5073A_002-327e-04.23
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. This value can, however, only be achieved
in dynamic measurements, whereas with quasistatic
measurements, drift and environmental influences are
limiting factors.
Output signal
Voltage signal on the charge amplifier output between 0
… ±10 V. Passed to an industrial controller to monitor,
control and optimize the production process.
Reset/Measure mode
(also Reset/Operate) Operating mode of the ICAM. In
Reset, the ICAM clears the charge in the charge amplifier.
The output signal is 0 Volts. Contingent on the system,
however, rapid changes in a possible input signal can
appear at the output and disappear instantly. In Measure
(Operate), the input charge in the charge amplifier is
converted to an adequate output voltage.
Operating temperature
The range of ambient temperatures in which the sensor is
to be operated. The specified, temperature-dependant
tolerances only apply within this range. The sensor may
suffer irreversible damage as a result of higher
temperatures.
Channel
Input for the charge signals of a sensor.
Channel copy.
Coulomb
Unit of electric charge.
1 coulomb corresponds to 1 ampere second (1 C = 1 As).
Drift
Unwanted changes in the output signal independent of the
measurand, as a function of time.
Natural frequency
The frequency of free (not induced) oscillations of the
entire sensor. In practice, the generally lower natural
frequency of the entire mounting determines the frequency
behavior.
Clear Error = Delete error
The displayed communication error between the ICAM and
the configuration PC is reset.
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FS = Full Scale
Full Scale. Full-scale output. The difference in the output
signal between the zero and end points of the measuring
range.
Flashloader
Software for installing firmware updates for the ICAM.
Negative feedback capacitor
Electronic component in the charge amplifier; must be
discharged
after
each
measuring
cycle
(see
Reset/Measure).
ICAM
Industrial Charge Amplifier for Manufacturing applications.
Insulation resistance
The electrical resistance of a sensor, a cable or the input of
a charge amplifier, measured between the signal lead and
the connection ground.
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.
Calibration
Sensor calibration.
Calibrated measuring range
Measuring range or part of measuring range for which the
sensor has been calibrated. Thanks to the high linearity of
quartz crystal sensors, the sensitivity of a given measuring
range can usually also be used for smaller measuring
ranges. In unusual measuring arrangements and/or if ultraaccurate measurements are required, it is advisable to run a
calibration with the sensor mounted. In applications with a
force shunt, it is mandatory to run a calibration with the
sensor installed.
Channel
Input for the charge signals of a sensor.
Charge signal
Output signal in picocoulomb (pC) of a piezoelectric sensor
without an integrated charge amplifier.
Charge amplifier
The part of a measuring chain that converts the sensor
charge signal into a proportional voltage signal.
Load
The parameters saved in the ICAM are transferred to the
configuration PC (see Send).
Local
Mode adopted by the configuration PC while not
connected to the ICAM.
LP filter
Low-pass filter
Measure (also Operate)
Charge amplifier operating mode, see Reset/Measure
mode.
Ground insulation
Electrical resistance of a sensor between the signal lead and
ground or the electrical resistance of a charge amplifier
between the connector screen and ground.
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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. This range is
regarded as the binding maximum range.
Measurand
The physical variable, state or characteristic that is being
measured, such as, force, torque, etc.
Measuring chain
Interconnection of several individual components for
measurement purposes. Measuring chains usually consist
of sensors and amplifiers, in conjunction with
data acquisition, indicating, evaluation and recording
equipment (e.g., PC, printer).
M.U. = Mechanical Unit
Mechanical unit, dependent on the type of sensor being
used and the measuring task, for example [N] for force.
Null modem cable
Cable connecting ICAM and control system or PC, which
crosslinks pins 2 and 3.
Offset
A reproducible zero error at the input of the amplifier that
can be eliminated by specifying an offset voltage.
Operate
Measure (see Reset/Measure mode).
Output
Voltage output
Output Scale = transmission factor
Corresponds to the measured value in an output voltage of
one volt; the unit is M.U./V.
Overload
The ICAM receives more charge from the sensor than it
can accept. The measurement results are falsified. This
status is eliminated by a reset. The measuring range can
usually be increased.
Parameter set
A file containing the settings and parameters for an
application.
Configuration PC
A PC with configuration software, connected to the ICAM
to make settings and assign parameters.
Configuration software
Software for making settings and assigning parameters to
the ICAM.
Configuration (parameter setting)
Setting measuring ranges, peak memories, offset, etc., for
the ICAM channels.
Peak
Analog output for querying the maximum value during
measurement.
pC (picocoulomb)
1 picocoulomb = 10-12 coulomb. See "coulomb".
Piezoelectric
A characteristic of quartz crystals that generate a
proportional, electric charge when exposed to mechanical
load.
Polarity
An increase in compression force produces a negative
charge in the sensor that is converted to a positive output
signal in the charge amplifier. Correspondingly, a tensile
force produces a positive charge, which produces a
negative output signal.
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Range
Measuring range
Remote = remote controlled
Operating mode in which there is a connection between
the configuration PC and the ICAM.
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.
Degree of protection
Protection of electrical equipment by suitable cases, covers,
etc., to EN60529. The degree of protection is indicated by
IP (International Protection), followed by two digits. The
first digit stands for the degree of protection against
contact and ingress of solid bodies, the second for the
degree of protection against the ingress of water. IP65, for
example, indicates complete protection against contact, as
well as the ingress of dust and water projected from all
directions (water jets).
Select Range
Selecting the measuring range.
Send
The set parameters are transferred to the charge amplifier
(see Load).
Sensitivity
Sensor sensitivity.
Sensor
A system that produces a definite change in the output
signal as a function of the change in the measurand acting
upon it.
Sensor sensitivity
The nominal value or the calibrated value stated in the
calibration certificate of the change in signal produced by
the sensor per change in measurand.
Scaling
The output voltage per unit of the measurand on the
analog or monitor output of a charge amplifier.
Power supply
The necessary power for the electronics, supplied in the
ICAM via the 15-pin D-Sub connector.
Peak memory
Stores the peak value of the sensor signal for each channel.
In the version with four channels, only peak memories of
the first two channels are available.
Disturbance variable
Forces, moments and environmental influences (e.g.,
temperature) acting on the sensor, which the sensor does
not acquire as a measurand and which produce an output
signal (error). Example: an additional bending moment
acting on a force sensor.
Summing amplifier
ICAM amplifier variant, where the charge signals from up
to four connected sensors are added together and output
via one channel.
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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. The characteristics specified on the calibration certificate are no longer
guaranteed at overload. However, measurements during
overload usually produce useful measured values.
Crosstalk
A signal at the output of a sensor that is produced by a
measurand acting on the sensor which is different from the
measurand assigned to this output. For example, when a
load in the Fy direction produces an Fz signal in a 3component sensor.
utilities.vi
File with user-specific settings.
V = Volt
Unit of electric voltage.
LabView driver
Driver for National Instruments LabView software that
integrates the configuration software into a separate
LabView application.
Time constant
The time constant describes the behavior of a high-pass filter
(RC element) and represents the period of time after which
the signal has fallen to 1/e of the output value. The time
constant depends on the measuring range selected on the
charge amplifier. Possible values vary from approx. 0.01 s in
the most sensitive range to approx. 100 000 s in the least
sensitive range. The largest possible time constant must be
selected for quasistatic measurements. The time constant
allows the measuring error to be estimated in relation to the
measuring duration. Detailed information on time constants
and sensitivity ranges can be found in the Instruction
Manual for your charge amplifier.
Cycle control
An industrial application process, usually controlled by a
PLC.
11.2 Measurement uncertainty
Systematic errors, accuracy
Accuracy is the extent of the conformity between the
measured value and the true value of the measurand. In a
piezoelectric measuring chain, it is determined by
numerous systematic errors, such as:
sensor linearity
sensor hysteresis
crosstalk from other measurands
charge amplifier linearity
disturbance variables (forces, moments)
disturbance variables (environmental influences,
such as temperature)
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measurement period
etc.
With a measuring chain consisting of sensor, cable and
charge amplifier, experience shows that the accuracy
achieved is about 1 ... 2% of the measuring range. This
value does not include errors due to influence quantities
from external sources acting on the measuring chain, for
example due to mechanical adaptation of the sensor and
environmental influences. For maximum accuracy, we
recommend calibrating application-specific measuring
ranges.
Measurement uncertainty of charge amplifiers
Measurement uncertainty may be derived from the
combined random and systematic errors quantified as a
variance. With charge amplifiers, this is largely dependent
on the type. The following typical values apply:
Laboratory charge amplifier
Industrial charge amplifier
0,2 ... 0,5 %
0,5 %
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.
Repeatability
Repeatability is understood to mean "serial precision", i.e.,
the conformity between several measured values in
succession under largely unchanged conditions.
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EC Declaration of conformity
12. EC Declaration of conformity
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