Model 64 Operation and Software - IES Global,...

Model 64 Operation and Software

by Scott A. Ager

1-15-03

Computer Recommendations

• 750 MHz Pentium III or Better• 64 Meg SRAM• 40 Gig Hard Drive• 1024 x 768 graphics• CD Writer• USB Port• Standard RS-232 (COM port)• Windows 2000, XP or NT

IES Software

Main Software Window

Model 64 Pin Layout

Model 64 Interface Boxes

Feedback Test Plug for Small Interface Box

Small Interface BoxRegular Interface Box

Small Interface Box Connector

Dale MMP22G-11027L (Male)

Pin A – External Power (Orange)

Pin B – n.c.

Pin C – Ground (Brown)

Pin D – n.c.

Pin E – RX (Gray)

Pin F – Ground (Brown)

Pin H – External Power (Orange)

Pin J – RX (Gray)

Pin K – TX (Purple)

Pin L – n.c.

Pin M – TX (Purple)

Direct Computer to Recorder Interface

The recorder can be directly connected to the RS-232 port of a computer. Only a DB-9 Female Connector and three wires, are required.

DB-9 Recorder

Pin 2 - TXPin 3 - RXPin 5 - Ground

Sensor – Recorder Interface• To increase the odds of collecting data in harsh environments,

care must be taken to prevent sensor wire breakage

• Small sensor wires are connected to an interface board and epoxy is used to prevent wire movement.

• Interface boards allow easy sensor replacement and protects the recorder solder pads

Sensor – Recorder Interface• The sensor cable goes through the strain relief hole on the

interface board, and the shield is soldered to the board.

Sensor – Recorder Interface• The small sensor wires can be carefully stripped with a

soldering iron and a flat surface.

Sensor – Recorder Interface• The wires are carefully soldered to the interface board.

Usually, IN+ is Green, IN- is White, Vref is Red, and Ground is Black.

Sensor – Recorder Interface• After the wires are soldered, use epoxy to stabilize the wires to

prevent breakage.

Sensor – Recorder Interface• Use resistor leads to connect the interface board to the

recorder.

Sensor – Recorder Interface• Important: Use Kapton Tape between the interface board and

the recorder to prevent the solder pads from sticking to each other. This will allow easy removal of the interface board.

Sensor – Recorder Interface• Align the interface board with the recorder and solder the feed

through wires to the board. Be sure the round and square holes match up.

Sensor – Recorder Interface• Sensor Balancing (if required).

– Do not cut the feed through wires until you have balanced the sensor.– To balance the sensor, first program the recorder channel for maximum

Gain and set the Bias to 128. Put the recorder in STANDBY or “Battery Test” Mode, and go to the “View: Recorder Voltages” and monitor the analog voltage output for that channel.

– Connect a resistor decade box to either IN+ and ground OR IN- and ground, using the leads extending out of the interface board on the recorder. One or the other combination will allow you to balance the sensor. Adjust the resistance until the analog output of the recorder channel is approximately bit 128 (~1.7 volts). This value is the resistor you will solder on the termination board. Be sure to use 1% ceramic SM resistors.

– After you install the balance resistor, epoxy it in place, and your sensor is now balanced.

Sensor – Recorder Interface• Sensor Balancing.

– Leave the feed through wires in place and connect the resistor decade box. With the channel Gain set to maximum and the Bias set to bit 128, put the recorder in the “STANDBY” mode.


– Adjust the decade box until the analog Vout is in the middle (~Bit 128). (View: Recorder Voltages) Try IN+/ground or IN-/ground.


– Install the closest 1%, ceramic SM resistor that matches the decade box. (If a resistor is needed)


– Epoxy the balance resistor.

Recorder Operation Modes

Recorder Operating Modes

• “Sleeping”• “Standby” (Battery Test)• “Recording Data”

Recorder Operating Modes• “Sleeping”

– Recorder is in a low power mode and is NOT recording data. The sensors are OFF. Any data in memory is maintained as long as there is power connected to the Recorder.

– Draws 10 – 15 mA when connected to the computer.

– Draws ~0.6 mA when NOT connected to the computer.


Sleeping…

Recorder Operating Modes• “Standby”

– Recorder and sensors are fully powered up, but the Recorder is NOT recording data.

– Draws 40 – 100 mA, depending on the number of channels and sensors connected to the Recorder.

– The mode is typically used to test the battery and sensors for proper voltages.


Standby…

Recorder Operating Modes• “Recording Data”

– Recorder and sensors are fully powered up, and the Recorder is recording data in the “SLOW SPEED” sampling mode.

– Draws 35 – 100 mA, depending on the number of channels and sensors connected to the Recorder.

– When the Recorder is disconnected from the computer, it will continue recording data.

NOTE: The Recorder cannot be triggered into “FAST Speed” while it is connected to the computer.

Recorder Operating ModesRecording Data…

Recorder Sampling Speeds

Recorder Sampling Speeds

• Multi-Speed Data Recording Modes.– Fast Speed

• 115,000 data points/second– Intermediate Speed

• 115 data points/second toto 14,700 data points/second– Slow Speed

• One data point every 10 seconds toto 14 data points/second

“Recorder Settings” Menu

Multiple recording modes can be selected

Recorder Sampling Speeds• “SLOW Sampling Speed”

– When the Recorder starts recording data, it begins storing data at the “Slow Speed” sampling rate.

– The ONLY time the Recorder does NOT start in the “Slow Speed” is if the “Fast Speed on Startup” has been enabled.

• “FAST Sampling Speed”– When an “Internal Auto Trigger” occurs (i.e. the pressure exceeds

the programmed threshold), the Recorder begins storing data at the “FAST Speed” sampling rate (115,000 data points per second).

Recorder Sampling Speeds• “INTERMEDIATE Sampling Speed”

– After the “FAST Speed” sampling window has completed, the Recorder will begin storing data at the “INTERMEDIATE Speed” sampling rate (if this mode is enabled).

– After the “INTERMEDIATE Speed” sampling window has completed, the Recorder go back to storing data at the “SLOW Speed” sampling rate.

– NOTE: The Recorder might go back into the “FAST Speed” mode before it return to the “SLOW Speed” mode, if another “Auto Trigger” occurs while in the “INTERMEDIATE Speed” mode.

Auto “LOW BATTERY” Shutdown

Auto “LOW BATTERY” Shutdown

• When the Recorder is “Recording Data” and the battery voltage goes below a safe operating voltage (typ. 4.5 volts), the Recorder will automatically stop recording data and go to SLEEP (0.5 milliamps).

• This feature ensures that data is not lost if the Recorder cannot be recovered in a timely manner. In the SLEEP mode, the data can be maintained in memory for up to 30 days (or longer depending on the batteries).

NOTE: ALWAYS use an External 9 volt battery for backup power when you connect the computer to the recorder.

Recorder Software Features

Software Preferences

Selected in the Main Software Window under “LINK”

Allows you to set certain defaults when the software starts.

Test Sensors

Selected in the Main Software Window under “Control”

Tests the sensors and internal voltages of the recorder. You can perform this test on your own.

Voltage Monitoring

Monitors Internal and Sensor Input Voltages.

Selected in the Main Software Window, under “View”

Job Report

Selected in the Main Software Window, under “Edit”

Allows you to to store information about a job or test directly into the Recorder or data file.

Edit Recorder Channel DataContains the sensor calibration information for each channel, and general user

information.


Recorder Settings Menu


Displaying Recorder Data

Selected in the Main Software Window, under “View”

View Test Data

Selected in the “View Recorder Data” Window, under “View”

Shows data about the job and the data you downloaded.

Convert Data to ASCII FileAllows you to exporting the Recorder data to an ASCII file for use in Windows Excel

or other programs.

Selected in the “View Recorder Data” Window, under “File”

View the Recorder Battery Voltage and Recorder Temperature EEPROM Data.

Battery Data

Select the “Display : Slow Speed Data”, and then display “Battery” and “Temperature” to view this data (dotted lines).

Temperature Data

Selected in the “View Recorder Data” Window

Programming the Recorder Settings

Changing the Recorder Settings

• To program the Recorder Options, go to the “Recorder Settings” menu

Recorder Settings Menu

To EDIT the recorder “Settings”, FIRST go to the “Edit” pull down menu and select “Recorder Settings”

Second, you must enter the password “IES”. Now you can EDIT the Recorder Settings.

Recording Speed Options

• Data Recording Modes.– “Slow Speed ONLY”– “Slow -> Fast -> Slow Speed”– “Slow -> Fast Speed”– “Multi-Speed”


• Data Recording Modes.– Fast Speed

• 115,000 data points/second– Intermediate Speed

• 115 data points/second toto 14,700 data points/second– Slow Speed

• One data point every 10 seconds toto 14 data points/second


Multiple recording modes can be selected


• Slow Speed Data Recording.– Records data from one data point every 10 seconds up toup to

14 data points/second– When not in “Fast” or “Intermediate” recording speeds, the

data is sampled at “Slow” Speed


“Slow” speed sampling rate can be selected

(8 values)

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“Slow Speed” Data

Slow Speed Data(2 data points/second)

Fast and Intermediate Speed

Data

Recording Options

• Fast Speed Data Recording.– Changes sampling rate to Fast speed (115,000 data

points/second) when pressure* exceeds programmed Trigger Level


Trigger Level

Trigger Threshold“Actual Value” or “Above Static”Trigger Channel

* Or other analog channels

Recording Options

• Fast Speed Data Recording.– After the trigger level has been reached, and the Recorder

records at Fast Speed for a “preset” time window (10 millisecand greater, depending on memory available)


Fast Speed Time Window

“Fast Speed” Data(115,000 data points/second)

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High speed pressure data

file 686b1perf -gun

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max. verticalstress ~36 MPa -

max. horizontal stress ~27 MPa?

Static Pressure of 1500 psi

Trigger Point

Trigger Level of 2500 psi above Static Pressure

4000 psi

Fast Speed Time Window

40 millisec of Pre-Trigger Fast Speed Data is saved

Recording Options• Intermediate Speed Data Recording.

– After the Recorder is done recording at “Fast” speed, it starts collecting data at a “Intermediate” speed, at a “preset”sampling rate and time window (depending on memory available), ONLY IF this MODE (Multi-Speed Speed) has been enabled.


Intermediate Speed Time Window (in seconds)

Intermediate Sampling Speed (8 values)

“Intermediate Speed” Data

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Intermediate Speed Data

(1000 data points/second)

Tool Movement Tool Pressure

Fast Speed Data

Intermediate Speed Time Window (in seconds)

Other Features

• Programmable Features.– Over 130,000 pressure* Range Combinations.– Automatic Sensor Balancing at “Start” – Automatic Sensor Balancing “During the Test”

• Used for sensors that are sensitive to drifting during to temperature. Mainly High G Accelerometers

– Automatic Sensor Testing


Sensor Balance

Sensor Test / Display Data

Sensor Range

Programming New Settings into the Recorder

• Saving any changes to the Recorder

“Starting” the Recorder to Collect Data

Connecting Battery Power to the Recorder

• When power is first connected to the Recorder, a “Power Interruption”error will always occur. This is normal and indicates power has just been applied. NOTE: If this error occurs after data has been collected, it could indicate a battery problem occurred.

Connecting Battery Power to the Recorder

• Clear the “Power Interruption” error with the “Clear Error Flags”

“Start” Options

• Multiple “Start” Recording Data Options– Manual Start– Start on “Power Up”– Start after Delay– Auto Start – External Start (T1)

“Start” Options• “Manual” Start

– Manually Starts recording data in the “Slow Speed Mode”.

“Start” Options• Starting…

– When the recorder is Started, all data that is in memory will be erased…


– The Recorder and Sensors (if enabled) is tested before the Recorder is Started.


– If the Sensor Test fails for some reason, you still have the option to “Start” the recorder anyway…

“Start” Options• Recording Data…

– If the Recorder is actually RECORDING DATA into memory (in the Slow Speed Mode), the main menu display will indicate this.

“Start” Options• Other Ways to Start the Recorder…

– To enable other “START” options, go to the “Recorder Settings” menu

Start / Stop Recording Options

“Start” Options• “Power Up” Start

– Starts recording data when Recorder is powered up.

This will activate ONLY if “Checked”in the “Recorder Settings” Menu.


“Start” OptionsIf the “Power Up Start” is enabled and these new settings are saved to the

Recorder, the Recorder will automatically perform a Sensor Test.

“Start” Options• “Power Up” Start

– When activated, the Main menu shows this feature is will occur when the battery/power is connected to the recorder.

NOTE: if the computer is connected to the recorder when battery / power is applied, the “Power Up” Start will not be activated.

“Start” Options

• “Delay” Start– Recorder is enabled to “Start Recording Data” after the

programmed delay reaches zero. This count down only occurs while the Recorder is NOT connected to the computer.

Recorder will NOT start recording data until the count reaches zero

– Draws 8 – 10 mA when the Recorder is not connected to the computer, and while it is counting down.

“Start” Options• “Delay” Start

– Start recording data after 1 to 255 hours (±30 minutes)– Draws 6 – 8 mAThis feature must be first, enabled in the “Recorder Settings” menu,

and second, “Started” in the “START/STOP” pull down menu.

Step #1Step #2


“Start” Options• “Delay” Start

– When the “Delay” Start feature is activated, the Main Menu will indicated this feature is enabled.

NOTE: The delay counter will not start until the computer is disconnected from the recorder.

“Start” Options• “Auto” Start

– The Recorder is enabled to “Start Recording Data” after the actual sensor value (i.e.500 psi) exceeds the programmed threshold. This only can occur if the Recorder is NOT connected to the computer.

– In the “Low Power Mode”, the Recorder will “wake up” for one second, once every 5 minutes, to check the sensor (i.e. pressure) to see if it has exceed the programmed threshold. If not, the Recorder goes back to sleep for another 5 minutes. If the sensorvalue IS above the threshold, and remains above it for 5 – 10 minutes longer, the Recorder will start recording data .

– Draws ~0.7 mA when the Recorder is not connected to the computer, and it is checking the sensor.

“Start” Options

• “Auto” Start– In the “Constant Monitor Mode”, the Recorder continuously monitors the

sensor (i.e. pressure) to see if it has exceed the programmed threshold. If the sensor value IS above the threshold, and remains above it for the programmed Threshold Time, the Recorder will start recording data .

– Draws 40 - 100 mA when the Recorder is not connected to the computer, and it is checking the sensor.

“Start” Options

• “Auto” Start– Starts recording data when pressure* reaches a preset

value** (Entered in “Recorder Settings” menu)

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Recorder Starts when pressure reaches 2300** psi


“Start” Options• “Auto” Start Options

– “Low Power Mode” (Advantage: Long Battery Life)• Checks Pressure* once every 5 minutes. (Draws only 0.5 milliamps of battery

power until the recorder starts.) • If Pressure* exceed the “Threshold”, the Pressure* must then remain above the

“Threshold” for the “Threshold Time”. If this happens, the recorder is then “Started”.

• If the Pressure* falls below the “Threshold” at any time, this Mode is reset and goes back to sleep for 5 more minutes.

“Recorder Settings” Menu * Or other analog channels

“Threshold”“MODE”

“Threshold Time”


– “Constant Monitor Mode” (Advantage: Quick Recorder “Start”)• Checks Pressure* continuously. (Draws up to 100 milliamps of battery power.)• If Pressure* exceed the “Threshold”, the Pressure* must then remain above the

“Threshold” for the “Threshold Time”. If this happens, the recorder is then “Started”.

• If the Pressure* falls below the “Threshold” at any time, the “Threshold Timer” is reset back to zero.

“Recorder Settings” Menu * Or other analog channels

“Threshold”“MODE”

“Threshold Time”


– “Delay before Auto Start”• If the “Delay before Auto Start” box is checked, AND the “Threshold” has been

exceeded for the “Threshold Time”, the recorder will not “Start” until after the “Delay Time” has timed out.

During the delay, the recorder draws 6 – 8 milliamps.




– This feature must FIRST be enabled in the “Recorder Settings” menu.



Step #1


After this feature is enabled in the “Recorder Settings” menu, it must be selected in the “START/STOP” pull down menu.

Step #2



– When the “Delay” Start feature is activated, the Main Menu will indicated this feature is enabled.

NOTE: The delay counter will not start until the computer is disconnected from the recorder.


“Start” Options

• “External” Start (T1)Starts recording data when the External (T1) signal occurs (either External T1 or an internal G Switch in the recorder).

– “Bounces” (Internal G Switch or External T1 Signal)• If the selected “Number of Bounces” occurs within a certain

“Bounce Time Window”, the recorder will “Start” recording. – “Level Signal” (This feature might not be available)

• If the External (T1) remains HIGH for the “Min. Pulse Length” the recorder will “Start” recording.

– Draws ~0.7 mA when the Recorder is not connected to the computer, and it is checking the sensor.

“Start” Options

• “External” Start (T1)– Starts recording data when the External (T1) signal occurs (either External T1 or an

internal G Switch in the recorder). This feature draws 0.5 milliamps.

“Start” Options• “External” Start (T1)

– “Bounces” (Internal G Switch or External T1 Signal)• If the selected “Number of Bounces” occurs within a certain “Bounce Time

Window”, the recorder will “Start” recording. – “Level Signal” (This feature might not be available)

• If the External (T1) remains HIGH for the “Min. Pulse Length” the recorder will “Start” recording.


“# of Bounces”“MODE”

“Bounce Time Window”

“Min. Pulse Length”

“Start” Options• “External” Start (T1)

– “Quick START” (This feature might not be available)• If an “External Start (T1)” occurs, and this feature is enabled, the recorder will

instantly start recording data without warming up the analog channels or testing the sensors. Normal startup requires several seconds, whereas, this will start recording data instantly.

NOTE: The recorder will normally Start recording data in the FAST SPEED mode.


“Start” Options“External” Start (T1)

This feature must FIRST be enabled in the “Recorder Settings” menu.


Step #1


After this feature is enabled in the “Recorder Settings” menu, it must be selected in the “START/STOP” pull down menu.

Step #2


– When the “External (T1)” Start feature is activated, the Main Menu will indicated this feature is enabled.

NOTE: The “External (T1)” will not be activated until the computer is disconnected from the recorder.

“Stop” Options

• Manual Stop– The Recorder can be manually stopped when

connected to the computer.• Auto Stop

– When enabled in the Recorder Settings Menu, the recorder will stop recording data and go to “Sleep” after the Pressure* falls below a set Threshold.


“Stop” Options• “Manual” Stop

– Stops recording data.

“Stop” Options• Stop…

– When the Recorder has Stopped recording data, the Main Menu Display will indicate this.

“Stop” Options• “Auto” Stop

– Stops recording data when the pressure* falls below a preset value** (Entered in “Recorder Settings” menu)

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Recorder Stops when pressure reaches 500** psi


“Stop” Options• “Auto” Stop

– The channel, pressure* threshold, and time must be selected, and enabled– Checks pressure* while in the “Slow Speed Mode” – If the pressure* falls below the threshold, for a “preset” time (in seconds), the Recorder

stops recording data, and goes to “Sleep”

NOTE: This feature is activated when it is selected in the “Recorder Settings” menu, and then programmed into the recorder.

This feature is enabled in the “Recorder Settings” menu



Downloading the Data

Downloading the Data• Always be sure an external 9 volt battery is connected to the interface

box before you connect the computer to the Recorder. This is to ensure you do not loose data if the internal Recorder battery is LOW.

Downloading the Data• If the Recorder is still “Recording Data”, you must first “STOP” the

Recorder, before you can download the data.

Downloading the Data• After the Recorder is in the “SLEEP” mode, you can download the data.

Downloading the Data

• Download ALL Data– Downloads all the data in memory.

• Quick Download– Downloads only the “Valid Memory” data.

When collecting data, sometimes not all the memory is used to store the data, so the Recorder keeps track of how much data has actually been stored in memory. The Recorder will indicate how much data was stored into memory, and this download option downloads ONLY that data.

NOTE: If in doubt, use the “Download ALL Data” option.

Downloading the Data• If a “Parity Error” occurs while downloading the data, just try

downloading the data again.

• The data can be downloaded as many times as you want to. The data remains in memory until EITHER you remove battery power OR you “START” the Recorder again.

Displaying the Data

Data Display Software

Recorder Operation and Software

by Scott A. Ager

Model 64 Operation and Software - IES Global,...

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