Instruction Manual

Model 8020-59

Vibrating Wire to Analog Converter

No part of this instruction manual may be reproduced, by any means, without the written consent of Geokon, Inc. The information contained herein is believed to be accurate and reliable. However, Geokon, Inc. assumes no responsibility for errors, omissions or misinterpretation. The information herein is subject to change without notification.

Copyright © 2006 – 2016 by Geokon, Inc. (Doc Rev H, 05/2016

Warranty Statement Geokon, Inc. warrants its products to be free of defects in materials and workmanship, under normal use and service for a period of 13 months from date of purchase. If the unit should malfunction, it must be returned to the factory for evaluation, freight prepaid. Upon examination by Geokon, if the unit is found to be defective, it will be repaired or replaced at no charge. However, the WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of being damaged as a result of excessive corrosion or current, heat, moisture or vibration, improper specification, misapplication, misuse or other operating conditions outside of Geokon's control. Components which wear or which are damaged by misuse are not warranted. This includes fuses and batteries. Geokon manufactures scientific instruments whose misuse is potentially dangerous. The instruments are intended to be installed and used only by qualified personnel. There are no warranties except as stated herein. There are no other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and of fitness for a particular purpose. Geokon, Inc. is not responsible for any damages or losses caused to other equipment, whether direct, indirect, incidental, special or consequential which the purchaser may experience as a result of the installation or use of the product. The buyer's sole remedy for any breach of this agreement by Geokon, Inc. or any breach of any warranty by Geokon, Inc. shall not exceed the purchase price paid by the purchaser to Geokon, Inc. for the unit or units, or equipment directly affected by such breach. Under no circumstances will Geokon reimburse the claimant for loss incurred in removing and/or reinstalling equipment. Every precaution for accuracy has been taken in the preparation of manuals and/or software, however, Geokon, Inc. neither assumes responsibility for any omissions or errors that may appear nor assumes liability for any damages or losses that result from the use of the products in accordance with the information contained in the manual or software.

TABLE of CONTENTS Page 1. INTRODUCTION:........................................................................................................................................... 1  2. INSTALLING AND CONFIGURING THE 8020-59 SOFTWARE APPLICATION ............................... 3  2.1 CONFIGURING THE COM PORT..................................................................................................................... 9  3. QUICK START (SINGLE CHANNEL): ..................................................................................................... 11  4. SINGLE AND MULTI-CHANNEL OPERATION: ................................................................................... 14  4.1. THEORY OF OPERATION............................................................................................................................. 15  4.2. OPERATING MODES ................................................................................................................................... 15  4.2.1. Single Channel Mode: .................................................................................................................. 15  4.2.2. Sixteen Channel Multiplexed Mode: ........................................................................................... 16  4.2.3. Thirty-two Channel Multiplexed Mode:....................................................................................... 17  4.3. CONVERSION TO “DIGITS” ......................................................................................................................... 18  4.4. CONNECTION TO A VOLTAGE INPUT DAS ................................................................................................. 19  4.5. CONNECTION TO A CURRENT INPUT DAS.................................................................................................. 19  4.6. TEMPERATURE MEASUREMENT ................................................................................................................. 20  5. COMMUNICATIONS .................................................................................................................................. 21  5.1. COMMAND LINE INTERFACE ...................................................................................................................... 21  6. 8020-59 WINDOWS APPLICATION ......................................................................................................... 24  6.1. SOFTWARE INSTALLATION ........................................................................................................................ 24  6.2. STARTING THE 8020-59 APPLICATION ....................................................................................................... 24  6.3.COMMUNICATIONS TIMEOUT ERROR.......................................................................................................... 24  6.4. SINGLE CHANNEL CONFIGURATION .......................................................................................................... 25  6.5 SIXTEEN CHANNEL CONFIGURATION.......................................................................................................... 26  6.6 THIRTY-TWO CHANNEL CONFIGURATION................................................................................................... 30  APPENDIX A. - SPECIFICATIONS: .............................................................................................................. 31  APPENDIX B. – THERMISTOR RESISTANCE/TEMPERATURE TABLE: ........................................... 34  APPENDIX C. – WIRING CONFIGURATIONS: ......................................................................................... 35  C.1. VOLTAGE OUTPUT – SINGLE CHANNEL MODE (DIGITAL I/O DAS) .......................................................... 35  C.2. VOLTAGE OUTPUT – 16 CHANNEL MODE (DIGITAL I/O DAS) ................................................................. 36  C.3. VOLTAGE OUTPUT – 32 CHANNEL MODE (DIGITAL I/O DAS) ................................................................. 37  C.4. CURRENT OUTPUT – SINGLE CHANNEL MODE (DIGITAL I/O DAS) .......................................................... 38  C.5. CURRENT OUTPUT – 16 CHANNEL MODE (DIGITAL I/O DAS): ................................................................ 39  C.6. CURRENT OUTPUT – 32 CHANNEL MODE (DIGITAL DAS): ...................................................................... 40  C.7. VOLTAGE OUTPUT – SINGLE CHANNEL MODE (PLC DAS) ...................................................................... 41  C.8. VOLTAGE OUTPUT – 16 CHANNEL MODE (PLC DAS) .............................................................................. 42  C.9. VOLTAGE OUTPUT – 32 CHANNEL MODE (PLC DAS) .............................................................................. 43  C.10. CURRENT OUTPUT – SINGLE CHANNEL MODE (PLC DAS) .................................................................... 44  C.11. CURRENT OUTPUT – 16 CHANNEL MODE (PLC DAS) ............................................................................ 45  C.12. CURRENT OUTPUT – 32 CHANNEL MODE (PLC DAS) ............................................................................ 46  APPENDIX D. – DATA REDUCTION:........................................................................................................... 47  D.1. PRESSURE CALCULATION ......................................................................................................................... 47  D.2. TEMPERATURE CORRECTION .................................................................................................................... 48 

APPENDIX E. – SAMPLE CALIBRATION SHEET: .................................................................................. 50  APPENDIX F. - NONLINEARITY AND THE USE OF A SECOND ORDER POLYNOMIAL .............. 51  APPENDIX G. - BAROMETRIC CORRECTION (NON-VENTED TRANSDUCERS ONLY)............... 52 

LIST of FIGURES, TABLES and EQUATIONS Page FIGURE 1 - MODEL 8020-59, VIBRATING WIRE TO ANALOG CONVERTER .............................................................. 1  FIGURE 2 - EXTRACTING THE 8020-59 INSTALLER .................................................................................................. 3  FIGURE 3 - SELECT DESTINATION FOLDER .............................................................................................................. 4  FIGURE 4 - EXTRACTED 8020-59 INSTALLER .......................................................................................................... 4  FIGURE 5 - INSTALL WIZARD, START SCREEN ......................................................................................................... 5  FIGURE 6 - INSTALL WIZARD, CHOOSE USERS ........................................................................................................ 5  FIGURE 7 - INSTALL WIZARD, CHOOSE START MENU FOLDER................................................................................ 6  FIGURE 8 - INSTALL WIZARD, INSTALLATION COMPLETE ....................................................................................... 7  FIGURE 9 - INSTALL WIZARD, LAUNCH 8020-59 APP.............................................................................................. 8  FIGURE 10 - 8020-59 SOFTWARE APPLICATION, STARTUP DIALOG ........................................................................ 9  FIGURE 11 - COMMUNICATIONS PARAMETERS DIALOG ........................................................................................ 10  FIGURE 12 - SINGLE CHANNEL CONFIGURATION SCREEN ..................................................................................... 12  FIGURE 13 - SINGLE CHANNEL MONITOR.............................................................................................................. 13  FIGURE 14 - CONTROL SIGNAL SEQUENCE: SINGLE CHANNEL MODE ................................................................... 15  FIGURE 15 - CONTROL SIGNAL SEQUENCE: 16 CHANNEL MODE (CHANS. 1 & 2 ONLY) ........................................ 16  FIGURE 16 - CONTROL SIGNAL SEQUENCE: 32 CHANNEL MODE (CHANS. 1 - 4 ONLY) .......................................... 17  FIGURE 17 - COMMUNICATION TIMEOUT WARNING MESSAGE ............................................................................... 24  FIGURE 18 - 16 CHANNEL CONFIGURATION SCREEN ............................................................................................. 26  FIGURE 19 - 16 CHANNEL MONITOR SCREEN ........................................................................................................ 28  FIGURE 20 - CHANNEL 1 MONITOR ....................................................................................................................... 28  FIGURE 21 - 32 CHANNEL MONITOR SCREEN ........................................................................................................ 30  FIGURE 22 - CHANNEL 3 MONITOR ....................................................................................................................... 30  FIGURE 23 - 16 CHANNEL MULTIPLEXER TIMING REQUIREMENTS........................................................................ 33  FIGURE 24 - 32 CHANNEL MULTIPLEXER TIMING REQUIREMENTS........................................................................ 33  FIGURE 25 - CONNECTION EX. FOR 1 CHAN. 8020-59 WITH VOLTAGE OUTPUT TO DIGITAL I/O DAS .................. 35  FIGURE 26 – CONNECTION EX. FOR 16 CHAN. MUX., 8020-59 WITH VOLTAGE OUTPUT AND DIGITAL I/O DAS . 36  FIGURE 27 - CONNECTION EX. FOR 32 CHAN. MUX., 8020-59 WITH VOLTAGE OUTPUT AND DIGITAL I/O DAS .. 37  FIGURE 28 - CONNECTION EX FOR 1 CHAN. 8020-59 WITH CURRENT OUTPUT TO DIGITAL I/O DAS ................... 38  FIGURE 29 - CONNECTION EX. FOR 16 CHAN. MUX., 8020-59 WITH CURRENT OUTPUT AND DIGITAL I/O DAS ... 39  FIGURE 30 - CONNECTION EX. FOR 32 CHAN. MUX., 8020-59 WITH CURRENT OUTPUT AND DIGITAL I/O DAS ... 40  FIGURE 31 - CONNECTION EX. FOR 1 CHAN. 8020-59 WITH VOLTAGE OUTPUT, 8020-59 PLC AND PLC DAS..... 41  FIGURE 32 - CONNECTION EX. FOR 16 CHAN. MUX., 8020-59 W/ VOLTAGE OUTPUT, 8020-59 PLC & PLC DAS 42  FIGURE 33 - CONNECTION EX. FOR 32 CHAN. MUX., 8020-59 W/ VOLTAGE OUTPUT, 8020-59 PLC & PLC DAS 43  FIGURE 34 - CONNECTION EX. FOR 1 CHAN. 8020-59 WITH CURRENT OUTPUT, 8020-59 PLC AND PLC DAS ..... 44  FIGURE 35 - CONNECTION EX. FOR 16 CHAN. MUX., 8020-59 W/CURRENT OUTPUT, 8020-59 PLC & PLC DAS. 45  FIGURE 36 - CONNECTION EX. FOR 32 CHAN. MUX., 8020-59 W/CURRENT OUTPUT, 8020-59 PLC & PLC DAS. 46  FIGURE 37 - VIBRATING WIRE PRESSURE TRANSDUCER CALIBRATION SHEET ..................................................... 50  TABLE 1 - CONNECTOR PINOUT AND SIGNAL DESCRIPTION .................................................................................... 2  TABLE 2 - THERMISTOR RESISTANCE VERSUS TEMPERATURE............................................................................... 34  TABLE 3 - ENGINEERING UNITS MULTIPLICATION FACTORS ................................................................................. 47

  EQUATION 1 - VIBRATING WIRE FREQUENCY TO DIGITS CONVERSION................................................................. 18  EQUATION 2 - ANALOG OUTPUT TO DIGITS CONVERSION ..................................................................................... 18  EQUATION 3 - ANALOG OUTPUT TO TEMPERATURE CONVERSION ........................................................................ 20  EQUATION 4 - DIGITS CALCULATION .................................................................................................................... 47  EQUATION 5 - CONVERT DIGITS TO PRESSURE ...................................................................................................... 47  EQUATION 6 - TEMPERATURE CORRECTION .......................................................................................................... 48  EQUATION 7 - BAROMETRIC CORRECTION ............................................................................................................ 48  EQUATION 8 - CORRECTED PRESSURE CALCULATION ........................................................................................... 49 

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1. Introduction: The Model 8020-59 Vibrating Wire (VW) to Analog Converter is a low cost module (see Figure 1) that provides a simple way to connect Geokon’s vibrating wire transducers to data acquisition systems that are not capable of reading frequency signals nor able to generate the proper signals required to excite VW transducers. The converter can operate with single transducers, as a stand-alone device, or with multiple transducers in conjunction with the Geokon Model 8032 Multiplexer. The converter is powered using either a 12V or 24V supply. The 8020-59 VW to Analog Interface is capable of outputting a 0-5V or 4-20mA signal that is directly proportional to “digits”, a vibrating wire sensor’s native units. These outputs are easily converted to digits via several simple formulas (see section 4.3). The analog outputs are automatically scaled to minimum and maximum parameters (defaults are: 0 and 25,000) and sloped to provide their complete 05V or 4-20mA range for each individual transducer. These analog outputs offer 20-bit resolution (1 part in 1,048,576) with an accuracy of better than 0.1% of full scale span (0-5V output) throughout the operating temperature range (-20ºC min, +80ºC max). In a similar fashion, the temperature reading from the transducer’s thermistor is available with 10-bit resolution (1 part in 1024). When configured for single-channel operation, the 8020-59 updates the reading approximately once every second.

Figure 1 - Model 8020-59, Vibrating Wire to Analog Converter

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Pin Number 1 2 3 4 5 6 7 8 9 10 11 12

Signal Name GND V OUT +24V +24V GND I-RET +12V GND TH+ THC+ CVALID

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ENABLE

Signal Description Analog Signal Ground Conversion Voltage Output, 0 to 5 Volts 24 Volt Power In Ground for 24V Power Return for Conversion Current Output 12 Volt Power Supply In OR +12V Output, if powered by 24V Ground for 12 Volt Power Thermistor Positive Lead Thermistor Negative Lead Vibrating Wire Positive Lead Vibrating Wire Negative Lead Valid Output: 5V indicates conversion complete 0V indicates conversion not done Enable Input: Single Channel Mode: 0V = VW output (digits) 5V = Temperature output (˚C) 16/32 Channel Mode:

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15

CLOCK

I-OUT

Clock Input: Single Channel Mode:

0V = Conversion Disabled 5V = Conversion Enabled 0V = 8020-59 ON 5V = 8020-59 OFF

16 Channel Mode:

0 → 5V transition = increment channel and select VW Analog or Temperature Analog

32 Channel Mode:

0 → 5V transition = increment chnl.

VW and Thermistor Conversion Current Output Table 1 - Connector Pinout and Signal Description

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2. Installing and Configuring the 8020-59 Software Application A free setup and configuration application is available for download on Geokon’s website, providing a user-friendly way to set up the 8020-59 VW to Analog Converter. Follow the steps below to install the software: 1. After downloading the installer from the Geokon website, right-click on the zip file, “802059_setup.zip”, and select “Extract All…” from the resulting popup menu (see Figure 2). Another dialog will be displayed showing the editable default destination folder for the extracted contents (see Figure 3). When satisfied with the destination folder, click on the Extract button to extract the contents of the zipped installer (see Figure 3). Figure 4 shows the extracted installer in the destination folder. Double click on the file, “setup.exe”, to start the install process.

Figure 2 - Extracting the 8020-59 Installer

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Figure 3 - Select Destination Folder

Figure 4 - Extracted 8020-59 Installer

2. After a few moments the dialog shown in Figure 5 will be displayed:

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Figure 5 - Install Wizard, Start Screen

3. After clicking on the “Next >” button, the dialog shown in Figure 6 displayed:

Figure 6 - Install Wizard, Choose Users

6 4. Choose whether to install the 8020-59 Software Application for all users or just for the current user (see Figure 6). NOTE: without administrative privileges on the PC, the only option allowed will be “Install just for me”. After making the selection, clicking “Next >” causes the dialog shown in Figure 7 to be displayed.

Figure 7 - Install Wizard, Choose Start Menu Folder

5. The dialog shown in Figure 7 allows the installer to choose where the “shortcut” to launch the application will be located – the default is the “Geokon” folder. A “shortcut” will also be located on the desktop. Clicking on “Install” begins the process of copying files and causes the dialog box shown in Figure 8 to be displayed:

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Figure 8 - Install Wizard, Installation Complete

6. The installation process is now complete. Clicking “Next >” allows the opportunity to launch the 8020-59 application when finished by checking the box next “Launch 8020-59 Application” (see Figure 9). Click on “Finish” (see below) to close the install wizard.

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Figure 9 - Install Wizard, Launch 8020-59 App

9 2.1 Configuring the COM Port After launching the 8020-59 Software Application, the first thing that must be done is to configure the COM Port. Click on the “Com Setup” (or press the “Alt” and the “c” key at the same time ) to select a COM port for communication with the 8020-59 VW to Analog Converter (See Figure 10).

Figure 10 - 8020-59 Software Application, Startup Dialog

10 Select a COM port that corresponds to an available RS-232 communication port, whether it is builtin (such as COM1) or an external one via a USB to Serial Converter (see Figure 11). Some newer PCs are so fast that a small delay between characters is needed to give the 8020-59 time to process the characters. The “Inter-character Delay” is specified in milliseconds.

Figure 11 - Communications Parameters Dialog

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3. Quick Start (Single Channel): In order to properly set up and use the 8020-59 VW to Analog Converter, a field “Zero Reading” will need to be taken. This is required so that the 0-5V and 4-20mA outputs are scaled correctly for the transducer being monitored. This section will allow the user to quickly set up and obtain valid readings from the 8020-59 Converter: Equipment Required: Personal Computer (PC) with RS-232 COM port 8020-59 Software Application RS-232 Cable (supplied) VW Transducer VW Transducer Calibration sheet 1. If it isn’t already, install the 8020-59 software on the PC that will be used to interface to the 8020-59 unit (see section 2). 2. Connect the 8020-59 to the computer’s serial port (typically COM1). If using an external USB to Serial converter, drivers for this device will need to be installed before this step (see section 2.1). 3. Connect +12VDC to connector pin 6 OR +24VDC to connector pin 3 (see Table 1). 4. Connect the power supply return (or Ground) to connector pin 7 OR, if using a 24V supply, connector pin 4, 24V GND (see Table 1). 5. Connect the un-pressurized VW transducer to the 8020-59 (see Table 1): RED wire to connector pin 10 (C+). BLACK wire to connector pin 11 (C-). WHITE wire to connector pin 8 (TH+). GREEN wire to connector pin 7 (TH-). SHIELD wire to connector pin 1 (GND). 6. Start the 8020-59 program. 7. Click the “Single Channel” button (or press the “Alt” and “s” keys) from the program’s Startup Dialog (see section 2.1). 8. The Single Channel Configuration screen should now be displayed (see Figure 12). This screen is used to define the parameters that the 8020-59 uses to read the attached transducer. 9. Ensure that the Transducer Model drop-down control is correctly set to the proper VW model and that the “Use Defaults” checkbox is checked. 10. Click “Activate/Monitor” (or press the “Alt” and “m” keys). The “Upload Confirmation” dialog will be displayed with the prompt: “Do you want to upload the current settings to the 8020-59?”. Click the “Yes” button. The Single Channel Monitor screen should now appear (see Figure 13), and after several seconds should update with a reading. 11. Note the digits that are displayed. This will be the “Zero” or “Initial” reading, (R0), value used in future pressure calculations, P = (R1 – R0) x GF, where R1 equals the “Current Reading” and GF is the Gage Factor obtained from the calibration sheet for the sensor being measured. 12. Click “Exit” (or press the “Alt” and “e” keys) to return to the Setup Screen.

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Figure 12 - Single Channel Configuration Screen

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Figure 13 - Single Channel Monitor

After setup is complete, the PC is disconnected from the 8020-59 and the sensor is in a pressurized state, the “Current Reading” (R1) “Digits” will need to be calculated from the value read from the analog voltage (V OUT, in volts) or current (I-OUT, in milliamperes) output. See section 4.3 (“Conversion to “Digits”) for more information on how to convert from an analog voltage or current value into digits. Once a “Digits” value has been obtained, translation into other engineering units is accomplished by multiplying the “Digits” value by the Gage Factor for the particular sensor read.

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4. Single and Multi-Channel Operation: In addition to working as a stand-alone device to interface a single transducer to a Data Acquisition System (DAS), multiple channels may be configured in similar fashion to the Single Channel. The 802059 works in conjunction with the 8032 Multiplexer and the user’s Data Acquisition System to select either 1 of 16 or 1 of 32 transducers. The 8020-59 was developed with multiplexing in mind and uses the same control signals as the Geokon model 8032 Vibrating Wire Multiplexer (for control signal timing requirements, refer to the model 8032 Multiplexer Instruction Manual). With a simple control program executing on the host DAS, it is capable of working with 16 vibrating wire transducers (with thermistors), or 32 transducers (without thermistors). All setup parameters for each channel are stored in internal EEPROM memory, requiring no backup battery and can be retained for years. The 8020-59 is powered from either 12V or 24V(nominal) and draws approximately 70mA when taking readings. When it is “shut-off”, or between scans when multiplexing, the total current consumption is less than 10μA(12V) or 16.5mA(24V). The 8020-59 setup and configuration utility runs on a PC operating under the Windows operating system and communicates to the 8020-59 via the 8020-59’s RS-232 port. A “Command Line” interface is provided in the 8020-59 internal firmware, with a command set that allows all functions to be easily set up and calibrated.

15 4.1. Theory of Operation The 8020-59 provides excitation for a VW transducer using a swept frequency pluck that is optimized for the selected gage type. The period of the resulting VW signal is measured using a 25 MHz clock. This measurement is performed 512 times, resulting in an average period being stored in internal memory. The microprocessor then converts the average period into digits and scales the output accordingly, for the specific transducer being read. This information is then sent to a 20-bit D/A converter, which outputs a voltage (0-5V) that is directly proportional to the average digits. Post-processing circuitry converts this voltage to a non-isolated 4-20mA current signal. In addition, the 20-bit D/A is put through a self-calibration routine at the start of each measurement cycle to minimize errors due to temperature and power supply variations. The resulting 0-5V and 4-20mA signals are brought to the output connector for connection to the input(s) of the host DAS. 4.2. Operating Modes There are three modes of operation in which the 8020-59 may be used: 4.2.1. Single Channel Mode:

In this mode (Figure 14), the 8020-59 will maintain continuous excitation of the VW transducer and provide a continuous 0-5V and 4-20mA output to the host DAS, updated approximately every second. By controlling the ENABLE input to the 8020-59, the 8020-59 voltage and current outputs (VOUT and IOUT) will either be proportional to the transducer’s digits (ENABLE=0V – or disconnected) or the transducer’s temperature in degrees Centigrade (ENABLE=5V). By controlling the CLOCK input to the 8020-59, the 8020-59 will either be ON (CLOCK=0V − or disconnected) or OFF (CLOCK=5V).

Figure 14 - Control Signal Sequence: Single Channel Mode

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4.2.2. Sixteen Channel Multiplexed Mode:

In this mode (Figure 15), the 8020-59 will excite and provide output only when told to do so from the host DAS. As soon as the 8020-59 is powered, if ENABLE and CLOCK are low (0V), the 8020-59 will go to “sleep” and will wait for commands from the host DAS, drawing less than 10μA from the +12V system power supply (16.5mA if using a +24V system power supply). When a reading is to be taken, the host system first brings ENABLE high (5V) to enable the 8020-59 and then CLOCK high (5V) to activate channel 1 of 16 (for control signal timing requirements, refer to the model 8032 Multiplexer Instruction Manual). The 8020-59 will “wake up” and read the transducer connected to channel 1 of the multiplexer. When the reading is ready (approximately 1-2 seconds later), the 8020-59 will bring the VALID output high (5V), indicating to the host DAS that the voltage and current outputs (proportional to the digits) are at VOUT and IOUT and are ready to be acquired. Once the reading is acquired, the host system brings CLOCK low (0V), and then high (5V) again to read the temperature of the transducer. When this reading is ready (