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Home Noncontact Displacement Measuring System User’s Manual 1.23 (31.24) .984 (24.99) Copyright © 1998 PART NO: 860135-001 Rev. B Kaman InstrumentationOperations 3450 North Nevada Avenue Colorado Springs, CO 80907 www.kamaninstrumentation.com or 719-635-6979 PIN SIGNAL 2 SWITCH 3 SWITCH 4,7 V IN 5 COMM 9 V OUT KD 2440 KAMAN 2.357 (59.9) 1.902 (48.3) Instrumentation This apparatus, when installed and operated per the manufacturer’s recommendations, conforms with the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of the member states relating to Electromagnetic Compatibility. Please refer to the KD-2440 Declaration of Conformity or contact Kaman Precision Products for details. .610 (15.5) Home • • • • KD-2440 Unit The KD-2440 system consists of three subassemblies: the sensor with integrated cable, the signal conditioning electronics module, and the power and output cable. The KD-2440 electronics uses a standard DB-9 connector to bring +12 Vdc to +24 Vdc into the electronics and provide outputs for the analog voltage and switch functions. 1 2 6 3 7 4 8 5 9 Electronics DB-9 Connector Face 5 4 9 3 8 2 7 1 6 ORN CLR Mounting the KD-2440 electronics module can be done using either of the two holes in the enclosure, and an M3 or 4 screw. It is preferable not to remove both screws from the case for mounting purposes. An easier mounting method may be to use a cable tie wrap or zip tie. Positioning the electronics module so that it is not the low point in the cable will keep liquids from running down the cable and into the electronics. Take care to route the sensor cable to avoid crushing or crimping it during use. Damage to the sensor cable may affect the desired set points and overall operation of the electronics. I/O Cable DB-9 Connector Face Theory of Operation The KD-2440 system operates on a traditional Colpitts oscillator circuit where the sensor acts as the resonating coil for the oscillator. The proximity of the target to the sensor face pulls the oscillator, changing its frequency and amplitude of modulation, controlling a variable gain oscillator section within the electronic circuit. 10 12Vdc High Gain 9 12Vdc Low Gain 7 24Vdc Low Gain 5 3 50 100 6 Aluminum 4 303 Stainless 2 150 4130 Steel 0 Displacement, Mils 14 10 12 Vdc High Gain 8 6 24 Vdc Low Gain 4 12 Vdc Low Gain 2 12 10 8 6 Aluminum 4 303 Stainless 2 4130 Steel 0 0 0 50 100 Displacement, Mils 150 14 24 Vdc High Gain 12 50 100 Displacement, Mils Outputs at Medium Gain & 24 Volt Input 303 SS Output for 12 & 24V Inputs 0 150 50 100 Displacement, Mils 150 Example Output Noise @ 12Vdc Input, Mid Gain, Medium Displacement 0.80 4130 Steel 0.70 Aluminum 0.60 304 Stainless 0.50 0.40 0.30 0.20 0.10 0.00 100 1000 10000 Bandwidth, Hz 4130 Steel Output for 12 & 24 Volt Inputs 18 24 Vdc High Gain 16 14 12 Vdc High Gain 12 10 8 6 24 Vdc Low Gain 4 12 Vdc Low Gain 2 0 0 50 100 150 Displacement, Mils 5CM Sensor Response Data: 5CM Sensor Response Data: 2 8 0 0 The KD-2440 electronics has two potentiometers accessible through openings in the enclosure for adjusting the GAIN and SWITCH SET POINT level. Mounting Instructions 24Vdc High Gain 11 1 Electronics An LED indicates when the optically-isolated switch is in the closed position. The KD-2440 electronics and sensors utilize SMA type coaxial connectors: female on the electronics, and male on the sensor cable. Two production-sensor configurations are available, the 9C and the 5CM. Data for these two sensors is shown on the following pages. The sensor must be attached snugly (finger tight) to the electronics assembly for the unit to function properly. Outputs at Medium Gain & 12 Volt Input 12 DC Output Voltage Outstanding Precision: Static Resolution to 12 Microinches Easy to Adjust Excellent Performance with Ferrous Targets Variable Voltage Input from 12 to 24 Volts DC Adjustable Gain for up to 22 Volts Output with 24 Volts Input Compact Rugged Electronics and Sensors Temperature Tolerant Sensors (to 400°F) Level Adjustable Switched Output to 10Khz for Process Control Drop in Replacement to Kaman’s KD-2400 with Accessories Kit Aluminum Output for 12 & 24 Volt Inputs 13 DC Output Voltage • • • • RED Signal N/C SWITCH RX SWITCH TX VIN (ALTERNATE) COMM N/C VIN N/C VOUT CABLE SHIELD Differential Noise, mV p-p • BLU WHT GRN BLK Pin 1 2 3 4 5 6 7 8 9 - DC Output Voltage Features Summary / Advantages Wire Color DC Output Voltage Kaman Precision Products’ Displacement Measuring System Model KD-2440 is a noncontact linear proximity measuring system. This low-cost, easy-to-use system makes precision static and dynamic measurements of metal targets, and thickness measurements of nonconductive material backed by metal. The system includes a switching output that will track RPM measurement to 10Khz. DB-9 Connections and Power I/O Cable Color Chart: DC Output Voltage KD-2440 7 Home 9C Sensor Response Data: 12 Vdc High Gain 8 6 24 Vdc Low Gain 12 Vdc Low Gain 4 2 0 0 50 100 150 200 Displacement, Mils 6 12 Vdc Low Gain 4 2 0 0 50 100 150 200 Displacement, Mils 250 DC Output Voltage 4130 Steel Output for 12 & 24 Volt Inputs 14 24 Vdc High Gain 12 10 12 Vdc High Gain 8 6 4 24 Vdc Low Gain 12 Vdc Low Gain 2 0 0 50 100 150 200 Displacement, Mils 250 6 12V in Aluminum 12V in 303 Stainless 2 12V in 4130 Steel 0 50 100 150 200 Displacement, Mils 250 10 DC Output Voltage 12 Vdc High Gain 24 Vdc Low Gain 8 4 Outputs at Medium Gain & 24 Volt Input 12 8 6 4 1. Adjust the sensor / target to its maximum displacement, plus the offset, plus approximately 20% of the range (.058”). 2. Adjust the gain potentiometer to its minimum point (adjust clockwise until the analog output saturates) 3. Slowly increase the gain potentiometer (counter clockwise) until it saturates at its maximum point. this will be approximately two volts below the input voltage. 4. At this point, the module is calibrated to a maximum output per displacement condition. As the sensor is moved toward the target from approximately .058”, the output will decrease. If the sensor / target displacement is increased beyond .058”, the output will saturate at approximately two volts below the input. The gain (ratio of output voltage to target displacement) is used to adjust the output slope (output per displacement). When changing types of target materials or power supply voltages, it will be necessary to readjust the gain for the desired output voltage. The KD-2440 can easily be adjusted or “calibrated” to obtain maximum output per displacement, maximum range, or any variation in between. Note that when the KD-2440 is adjusted for maximum output per displacement, it is at a minimum usable range, whereas a minimum gain gives a voltage change throughout the largest displacement for the same sensor, target, and range as depicted in the following graph: 24V in Aluminum 24V in 303 Stainless 2 24V in 4130 Steel 0 0 50 100 150 200 Displacement, Mils 250 Example Output Noise @ 12Vdc Input, Mid Gain, Medium Displacement 4.00 4130 Steel 3.50 304 Stainless 3.00 2.50 Aluminum 2.00 1.50 1.00 0.50 0.00 100 1000 10000 Bandwidth, Hz Differential Noise, mV p-p DC Output Voltage 10 6 0 24 Vdc High Gain Adjustment and Calibration The KD-2440 is instrumented with a ten volt regulator to provide a clean repeatable output signal. The input voltage must be maintained at a minimum of twelve volts for the regulator to function. 8 250 303 SS Output for 12 & 24 Volt Input 14 12 10 saturation (the output begins to change with a gain increase). DC Output Voltage 10 Outputs at Medium Gain & 12 Volt Input 12 DC Output Voltage DC Output Voltage Aluminum Output for 12 & 24 Volt Input 14 24 Vdc High Gain 12 The signal is half-wave rectified and filtered to obtain an analog voltage proportional to the target position or displacement. The analog voltage output can be varied by adjustment of the gain. The input power is diode protected and regulated to provide a clean low-noise signal. The output is short-circuit current protected. 4130 Steel Output for 12 & 24 Volt Inputs 18 24 volt input w ith high gain 16 14 To maximize the output slope for an application using a 5CM sensor with a .010” offset and a range of .040”, follow these steps: Switched Output Operation The KD-2440’s switched output is a simple on / off switch with a corresponding LED indicator lamp. The switch is in a closed condition when the LED is illuminated. The switch can be adjusted to trip anywhere along the sensor range using the “Switch Setpoint” potentiometer. CLEANING 12 volt input w ith high gain 12 Example Calibration 10 8 The KD-2440 is not designed to be immersed or operated while immersed in liquids. Solvents may damage electronics module, sensor, or power I/O cable. Clean the unit with a damp cloth. EMI PERFORMANCE 6 12 or 24 volt input w ith low gain 4 2 0 0 50 100 Displacement, Mils 150 The minimum gain is defined as being the lowest gain obtainable without pulling the circuit into saturation. Minimum gain can be obtained by setting the sensor displacement to a point within the usable range (preferably mid range), then slowly decreasing the gain potentiometer (clockwise) until the output saturates. At this point, increase the gain slightly to a point just above The KD-2440 conforms with the applicable standards of Council Directive for Generic for Light Industrial and Commercial Use. Under some EMI environments, at specific frequencies, the KD-2440 unit may experience a change in output voltage. In general, when exposed to those environments covered by the EMC directive, the user can expect less than 5% deviation of output. Contact Kaman Instrumentation for specific data or for recommended solutions if you experience problems with the KD-2440. 3 Home KD-2440 9C Sensor Specifications: Specifications RG179 coax cable .320 Dia (8.13) 3/8-24 THD ELECTRICAL 1.030 (26.16) SMA Male Connector INPUT 1.250 (31.75) Voltage: Regulated 12 VDC to 24 VDC Current: Fuse limit input current from power source to 11 mA, .28W maximum at full load ANALOG OUTPUT Current (Full load): 4.2 mA maximum Impedance: 50 ohms Voltage: 0-22 VDC minimum with 24 VDC input 0-10 VDC minimum with 12 VDC input SWITCHED OUTPUT Opto-Isolated Load Current: 100 mA maximum AC or DC Load Voltage: 30V rms, 42.4V peak, or 60Vdc On Resistance: 30 ohms minimum / 50 ohms maximum Switch Point Hysterisis: 0.56% of full scale for 9C sensor, and 0.97% of full scale for 5CM sensor, using 24Vdc input on 4130 steel. FREQUENCY RESPONSE 0-10 KHz (± 3db) 96 (2438) Target Material Non-Ferrous (Aluminum) Non-Magnetic Steels (304 Stainless) Magnetic Steels (4130) 9C Sensor Measuring Range 0 - 0.175 in. (0 - 4.45 mm) 0.025 - 0.200 in. (0.64 - 5.08 mm) 0.040 - 0.275 in. (1.02 - 6.99 mm) 5CM Sensor Specifications: RESOLUTION Better than 0.008% of measuring range using a 5CM sensor on a 4130 steel target at mid scale, and 12Vdc input M5 x 0.8 THD RG179 coax cable .160 Dia. (4.1) ENVIRONMENTAL SMA Male Connector ENCLOSURE RATINGS Sensor: IP 67 Electronics: IP 61 1.60 (40.6) 1.85 (47.0) 120 (3048) OPERATING TEMPERATURE RANGE Sensor and cable: 0°F to 400°F (-18°C to 205°C) Electronics: 32°F to 150°F (0°C to 66°C) STORAGE TEMPERATURE RANGE Sensor and cable: -60°F to 400°F (-52°C to 205°C) Electronics: -58°F to 212°F (-50°C to 100°C) Target Material Non-Ferrous (Aluminum) Non-Magnetic Steels (304 Stainless) Magnetic Steels (4130) 5CM Sensor Measuring Range 0 - 0.100 in. (0 - 2.54 mm) 0.010 - 0.125 in. (0.254 - 3.18 mm) 0.015 - 0.150 in. THERMAL DRIFT Less than 0.22% per °C of full scale for sensor, electronics or system. Dimensions are in inches (millimeters) 4 5 (0.38 - 3.8 mm) Home KD-2440 9C Sensor Specifications: Specifications RG179 coax cable .320 Dia (8.13) 3/8-24 THD ELECTRICAL 1.030 (26.16) SMA Male Connector INPUT 1.250 (31.75) Voltage: Regulated 12 VDC to 24 VDC Current: Fuse limit input current from power source to 11 mA, .28W maximum at full load ANALOG OUTPUT Current (Full load): 4.2 mA maximum Impedance: 50 ohms Voltage: 0-22 VDC minimum with 24 VDC input 0-10 VDC minimum with 12 VDC input SWITCHED OUTPUT Opto-Isolated Load Current: 100 mA maximum AC or DC Load Voltage: 30V rms, 42.4V peak, or 60Vdc On Resistance: 30 ohms minimum / 50 ohms maximum Switch Point Hysterisis: 0.56% of full scale for 9C sensor, and 0.97% of full scale for 5CM sensor, using 24Vdc input on 4130 steel. FREQUENCY RESPONSE 0-10 KHz (± 3db) 96 (2438) Target Material Non-Ferrous (Aluminum) Non-Magnetic Steels (304 Stainless) Magnetic Steels (4130) 9C Sensor Measuring Range 0 - 0.175 in. (0 - 4.45 mm) 0.025 - 0.200 in. (0.64 - 5.08 mm) 0.040 - 0.275 in. (1.02 - 6.99 mm) 5CM Sensor Specifications: RESOLUTION Better than 0.008% of measuring range using a 5CM sensor on a 4130 steel target at mid scale, and 12Vdc input M5 x 0.8 THD RG179 coax cable .160 Dia. (4.1) ENVIRONMENTAL SMA Male Connector ENCLOSURE RATINGS Sensor: IP 67 Electronics: IP 61 1.60 (40.6) 1.85 (47.0) 120 (3048) OPERATING TEMPERATURE RANGE Sensor and cable: 0°F to 400°F (-18°C to 205°C) Electronics: 32°F to 150°F (0°C to 66°C) STORAGE TEMPERATURE RANGE Sensor and cable: -60°F to 400°F (-52°C to 205°C) Electronics: -58°F to 212°F (-50°C to 100°C) Target Material Non-Ferrous (Aluminum) Non-Magnetic Steels (304 Stainless) Magnetic Steels (4130) 5CM Sensor Measuring Range 0 - 0.100 in. (0 - 2.54 mm) 0.010 - 0.125 in. (0.254 - 3.18 mm) 0.015 - 0.150 in. THERMAL DRIFT Less than 0.22% per °C of full scale for sensor, electronics or system. Dimensions are in inches (millimeters) 4 5 (0.38 - 3.8 mm) Home 9C Sensor Response Data: 12 Vdc High Gain 8 6 24 Vdc Low Gain 12 Vdc Low Gain 4 2 0 0 50 100 150 200 Displacement, Mils 6 12 Vdc Low Gain 4 2 0 0 50 100 150 200 Displacement, Mils 250 DC Output Voltage 4130 Steel Output for 12 & 24 Volt Inputs 14 24 Vdc High Gain 12 10 12 Vdc High Gain 8 6 4 24 Vdc Low Gain 12 Vdc Low Gain 2 0 0 50 100 150 200 Displacement, Mils 250 6 12V in Aluminum 12V in 303 Stainless 2 12V in 4130 Steel 0 50 100 150 200 Displacement, Mils 250 10 DC Output Voltage 12 Vdc High Gain 24 Vdc Low Gain 8 4 Outputs at Medium Gain & 24 Volt Input 12 8 6 4 1. Adjust the sensor / target to its maximum displacement, plus the offset, plus approximately 20% of the range (.058”). 2. Adjust the gain potentiometer to its minimum point (adjust clockwise until the analog output saturates) 3. Slowly increase the gain potentiometer (counter clockwise) until it saturates at its maximum point. this will be approximately two volts below the input voltage. 4. At this point, the module is calibrated to a maximum output per displacement condition. As the sensor is moved toward the target from approximately .058”, the output will decrease. If the sensor / target displacement is increased beyond .058”, the output will saturate at approximately two volts below the input. The gain (ratio of output voltage to target displacement) is used to adjust the output slope (output per displacement). When changing types of target materials or power supply voltages, it will be necessary to readjust the gain for the desired output voltage. The KD-2440 can easily be adjusted or “calibrated” to obtain maximum output per displacement, maximum range, or any variation in between. Note that when the KD-2440 is adjusted for maximum output per displacement, it is at a minimum usable range, whereas a minimum gain gives a voltage change throughout the largest displacement for the same sensor, target, and range as depicted in the following graph: 24V in Aluminum 24V in 303 Stainless 2 24V in 4130 Steel 0 0 50 100 150 200 Displacement, Mils 250 Example Output Noise @ 12Vdc Input, Mid Gain, Medium Displacement 4.00 4130 Steel 3.50 304 Stainless 3.00 2.50 Aluminum 2.00 1.50 1.00 0.50 0.00 100 1000 10000 Bandwidth, Hz Differential Noise, mV p-p DC Output Voltage 10 6 0 24 Vdc High Gain Adjustment and Calibration The KD-2440 is instrumented with a ten volt regulator to provide a clean repeatable output signal. The input voltage must be maintained at a minimum of twelve volts for the regulator to function. 8 250 303 SS Output for 12 & 24 Volt Input 14 12 10 saturation (the output begins to change with a gain increase). DC Output Voltage 10 Outputs at Medium Gain & 12 Volt Input 12 DC Output Voltage DC Output Voltage Aluminum Output for 12 & 24 Volt Input 14 24 Vdc High Gain 12 The signal is half-wave rectified and filtered to obtain an analog voltage proportional to the target position or displacement. The analog voltage output can be varied by adjustment of the gain. The input power is diode protected and regulated to provide a clean low-noise signal. The output is short-circuit current protected. 4130 Steel Output for 12 & 24 Volt Inputs 18 24 volt input w ith high gain 16 14 To maximize the output slope for an application using a 5CM sensor with a .010” offset and a range of .040”, follow these steps: Switched Output Operation The KD-2440’s switched output is a simple on / off switch with a corresponding LED indicator lamp. The switch is in a closed condition when the LED is illuminated. The switch can be adjusted to trip anywhere along the sensor range using the “Switch Setpoint” potentiometer. CLEANING 12 volt input w ith high gain 12 Example Calibration 10 8 The KD-2440 is not designed to be immersed or operated while immersed in liquids. Solvents may damage electronics module, sensor, or power I/O cable. Clean the unit with a damp cloth. EMI PERFORMANCE 6 12 or 24 volt input w ith low gain 4 2 0 0 50 100 Displacement, Mils 150 The minimum gain is defined as being the lowest gain obtainable without pulling the circuit into saturation. Minimum gain can be obtained by setting the sensor displacement to a point within the usable range (preferably mid range), then slowly decreasing the gain potentiometer (clockwise) until the output saturates. At this point, increase the gain slightly to a point just above The KD-2440 conforms with the applicable standards of Council Directive for Generic for Light Industrial and Commercial Use. Under some EMI environments, at specific frequencies, the KD-2440 unit may experience a change in output voltage. In general, when exposed to those environments covered by the EMC directive, the user can expect less than 5% deviation of output. Contact Kaman Instrumentation for specific data or for recommended solutions if you experience problems with the KD-2440. 3 Home • • • • KD-2440 Unit The KD-2440 system consists of three subassemblies: the sensor with integrated cable, the signal conditioning electronics module, and the power and output cable. The KD-2440 electronics uses a standard DB-9 connector to bring +12 Vdc to +24 Vdc into the electronics and provide outputs for the analog voltage and switch functions. 1 2 6 3 7 4 8 5 9 Electronics DB-9 Connector Face 5 4 9 3 8 2 7 1 6 ORN CLR Mounting the KD-2440 electronics module can be done using either of the two holes in the enclosure, and an M3 or 4 screw. It is preferable not to remove both screws from the case for mounting purposes. An easier mounting method may be to use a cable tie wrap or zip tie. Positioning the electronics module so that it is not the low point in the cable will keep liquids from running down the cable and into the electronics. Take care to route the sensor cable to avoid crushing or crimping it during use. Damage to the sensor cable may affect the desired set points and overall operation of the electronics. I/O Cable DB-9 Connector Face Theory of Operation The KD-2440 system operates on a traditional Colpitts oscillator circuit where the sensor acts as the resonating coil for the oscillator. The proximity of the target to the sensor face pulls the oscillator, changing its frequency and amplitude of modulation, controlling a variable gain oscillator section within the electronic circuit. 10 12Vdc High Gain 9 12Vdc Low Gain 7 24Vdc Low Gain 5 3 50 100 6 Aluminum 4 303 Stainless 2 150 4130 Steel 0 Displacement, Mils 14 10 12 Vdc High Gain 8 6 24 Vdc Low Gain 4 12 Vdc Low Gain 2 12 10 8 6 Aluminum 4 303 Stainless 2 4130 Steel 0 0 0 50 100 Displacement, Mils 150 14 24 Vdc High Gain 12 50 100 Displacement, Mils Outputs at Medium Gain & 24 Volt Input 303 SS Output for 12 & 24V Inputs 0 150 50 100 Displacement, Mils 150 Example Output Noise @ 12Vdc Input, Mid Gain, Medium Displacement 0.80 4130 Steel 0.70 Aluminum 0.60 304 Stainless 0.50 0.40 0.30 0.20 0.10 0.00 100 1000 10000 Bandwidth, Hz 4130 Steel Output for 12 & 24 Volt Inputs 18 24 Vdc High Gain 16 14 12 Vdc High Gain 12 10 8 6 24 Vdc Low Gain 4 12 Vdc Low Gain 2 0 0 50 100 150 Displacement, Mils 5CM Sensor Response Data: 5CM Sensor Response Data: 2 8 0 0 The KD-2440 electronics has two potentiometers accessible through openings in the enclosure for adjusting the GAIN and SWITCH SET POINT level. Mounting Instructions 24Vdc High Gain 11 1 Electronics An LED indicates when the optically-isolated switch is in the closed position. The KD-2440 electronics and sensors utilize SMA type coaxial connectors: female on the electronics, and male on the sensor cable. Two production-sensor configurations are available, the 9C and the 5CM. Data for these two sensors is shown on the following pages. The sensor must be attached snugly (finger tight) to the electronics assembly for the unit to function properly. Outputs at Medium Gain & 12 Volt Input 12 DC Output Voltage Outstanding Precision: Static Resolution to 12 Microinches Easy to Adjust Excellent Performance with Ferrous Targets Variable Voltage Input from 12 to 24 Volts DC Adjustable Gain for up to 22 Volts Output with 24 Volts Input Compact Rugged Electronics and Sensors Temperature Tolerant Sensors (to 400°F) Level Adjustable Switched Output to 10Khz for Process Control Drop in Replacement to Kaman’s KD-2400 with Accessories Kit Aluminum Output for 12 & 24 Volt Inputs 13 DC Output Voltage • • • • RED Signal N/C SWITCH RX SWITCH TX VIN (ALTERNATE) COMM N/C VIN N/C VOUT CABLE SHIELD Differential Noise, mV p-p • BLU WHT GRN BLK Pin 1 2 3 4 5 6 7 8 9 - DC Output Voltage Features Summary / Advantages Wire Color DC Output Voltage Kaman Instrumentation’s Displacement Measuring System Model KD-2440 is a noncontact linear proximity measuring system. This low-cost, easy-to-use system makes precision static and dynamic measurements of metal targets, and thickness measurements of nonconductive material backed by metal. The system includes a switching output that will track RPM measurement to 10Khz. DB-9 Connections and Power I/O Cable Color Chart: DC Output Voltage KD-2440 7