Misswind checking module VPM Operating manual

Copyright(c)2009-2010 Ingenieurburo Sesselmann, Steinach Revision B: 24.08.2010

Inhaltsverzeichnis - 2

Inhaltsverzeichnis
1 Functional description
1.1 1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanic specication for implementation in switchboards . . . . . . . . . . . . .

3
3 3

2 Connection and wiring

2.1 2.2 2.3 2.4 2.5 2.6 2.7 PLC connector pinout Pin description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-current probe connector pinout Absolute maximum ratings Typical characteristics Error codes LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3 3 4 4 5 5 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PC analysis and parametrization

3.1 3.2 3.3 3.4 3.5 3.6 Connecting the box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameterize the VPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Managing parameter arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling measured data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automated measurement logging Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6
6 6 6 7 7 7

4 Parameter description
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATTENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: Mean current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: s-Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: Stoppage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: Stoppage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: Local rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Criterion: Local s-Value

8
8 9 9 9 10 10 10 10 11 11 11

4.10 Criterion: Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Version history
5.1 5.2 5.3 Compatible software versions Revision A (version 9.9.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision B (version 10.10.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12
12 12 12

6 Update instructions 7 Emergency update instructions

7.1 Possible problems leading to errors . . . . . . . . . . . . . . . . . . . . . . . . . .

13 14
14

8 Konformittserklrung

15

Connection and wiring - 3

1 Functional description
1.1 Introduction
The VPM module is designed to test several kinds of mechanic assemblies with continuous current motor. It detects possible failures during the mechanic assembly based on the analysis of the motor current. As a stand-alone module VPM processes up to 15 dierent test sequences, each of them dened by a specic set of parameters. The test sequence is started by a superior control (PLC) providing a part ok/nok-decision.

1.2 Mechanic specication for implementation in switchboards

The VPM module needs 90mm in width and 110mm in height and is designed to t in all switchboards providing 35mm-mounting rails. Including cable mounts the module needs about 250mm in depth. All connectors and displays are located at the front side of the module. The connection to the superior control is done using a 25 pin SubD cable (max 2m in length) either directly to the VPM or wired using a handover component (SubD-25 similar to

Brklin 09H8264 ).

This component needs additional space of W 75mm x H 90mm on the mounting rail.

2 Connection and wiring

2.1 PLC connector pinout
1 2 3 4 5 6 7 8 9 10 11 12 13 VCC VPM Reserved Reserved ERRORCODE3 ERRORCODE2 ERRORCODE1 ERRORCODE0 NOK OK READY /BUSY GND PLC VCC PLC 14 15 16 17 18 19 20 21 22 23 24 25 GND VPM Reserved Reserved /RESET START PARAM3 PARAM2 PARAM0 PARAM1 TEST CALIB Reserved

2.2 High-current probe connector pinout

The right layout has to be respected! Wrong connection will not damage the VPM module but it will not be able to measure correctly. The current path has a galvanic isolation from the evaluation circuit and a typical resistance of less than

25m.

Connection and wiring - 4

Connector type: CONEC type 17W2, with 2 power current and 15 signal connections: A1 A2 1-15 motor current + motor current reserved (do not connect)

2.3 Pin description

The VPM power supply features a galvanic isolation from the PLC Power and signal lines. Therefore both power supplies need to be connected! All output pins feature full short-circuitprotection. Reserved pins shall not be connected. Pin 1,14 4-7 8 9 10 11 17 18 Name VPM power ERRORCODE OK NOK READY /BUSY RESET START Type power output active H active H active H active L active H active H Description 8..28VDC, 300mA max. see table below Positive test result when active Negative test result when active LOW when a fault condition occurred (see section 2.7 ) Active while RESET, data transfer, measurement and oset calibration Resets the module to a dened initial state Starts a measurement using the parameter record set by PARAM0-3 when READY is active and /BUSY is inactive 19-22 23 PARAM TEST input active H Select parameter record by applying a binary number of 0 to 14. 15 is reserved. If BUSY=HIGH a active level on this line will toggle all 8 PLC outputs alternating. /BUSY, OK, ERRORCODE0, ERRORCODE 2 and READY, NOK, ERRORCODE1 and ERRORCODE 3 will each have the same state at a time. Test mode overrides normal pin function. 24 CALIB active H Triggers an oset calibration. BEWARE: Box is delivered in an factory-calibrated state so there is no need for further calibration. When done wrong you risk the box becoming non-functional! 12,13 PLC power Power 8..28VDC, 200mA max.

2.4 Absolute maximum ratings

Description Vcc VPM Vcc PLC Min 8 8 0 Typ Max 28 28 40 40 60 Unit Vdc Vdc

Isensor Isensor

Tambient (t < 5s) (t < 2s)

C
A A

Connection and wiring - 5

2.5 Typical characteristics

Description RESET-Pulse width Power-On until ready Test-mode toggling frequency Oset-calibration Pulse width 0.5 0 8 Min 0.1 2 Typ 8 1.5 4 28 Max 4 Unit s s Hz s Vdc Vdc

IL PLC input LOW IH PLC input HIGH

level level

2.6 Error codes

Error states (concerning ERRORCODE0-3 [referred to as EC0-3], READY): READY L L L H H H H H EC0 H L L L H X X X EC1 L H L L X H X X EC2 L L X L X X H X EC3 L L X L X X X H Description Faulty calibration - please contact service short circuit / overload on PLC-Output Reserved Normal operation, no problems occurred s-Value alert occurred Average mean current out of range Stoppages (type 1 or 2) occurred Running time out of range during last measurement

2.7 LED Display

power on (yellow) on on on on on on blinking blinking test (yellow) on on on ok (green) on on on nok (red) on on on on VPM is operating normal VPM evaluates current measurement data Last measurement / calibration was successful Last measurement was bad Measurement in progress VPM RESET in progress PLC Output overload or short-circuit Oset calibration failed. Please contact service Description

In case the Ready pin is inactive the VPM will not start any measurement. Furthermore the power LED will blink in fast sequence. Possible fault reasons are:

Bus failure: short circuit or overload on one of the outputs - Make sure no output pin has overload condition. Oset calibration fault - Please contact service.

An animation (sequenced cation.

power,test,ok,nok,ok,test,power on ) expresses a watchdog reset leading

to the same initial state as a RESET does. This may occur at communication outside of speci-

PC analysis and parametrization - 6

3 PC analysis and parametrization

3.1 Connecting the box
The VPM comes with a powerful PC-tool for parametrization and analysis. To take advantage of its rich functionality connect the module either by USB or a serial cable to your PC and start the software. Make sure no other software uses the COM-Port the VPM is connected with and establish a connection. It is recommended to plug via USB for usual use because of its faster data transfer rate. Although for updating the rmware it is mandatory to connect the VPM using the serial RS-232 port.

3.2 Parameterize the VPM

The software is capable of editing and organizing parameter arrays consisting of all 15 parameter records the VPM can hold. The page control located at the top can be used to switch between the 15 available parameter records plus the parameter record the currently loaded measurement data was taken with. Beside each record number the

Description

pa-

rameter is shown to help nding the right record. Each record except the measurement result can be edited using the controls in the right area of the window. Just enter the input eld corresponding to a parameter name and enter a new value. The data is validated either by pressing return or selecting another parameter. A complete record may be copied using

+ C.

Copy parameter record

in the menu or by pressing

CTRL

The currently edited record is copied to the internal clipboard and can be pasted to any

record slot using

CTRL + V.

ATTENTION: All data in the selected parameter record will be

overwritten by pasting. Do not forget to save your changes to disk or write them to the VPM!

3.3 Managing parameter arrays

Each parameter array is saved to one le to simplify exchanging. Saving and loading can be done using the options in the parameter array menu. A le system based navigator gives the possibility to investigate each les contents before loading. Using the

ter record to clipboard

Copy parame-

button any previewed

record can easily be copied to a slot of the currently edited parameter array. Because of the diering archive format of older software than version nine a complete parameter array

PC analysis and parametrization - 7

can not be read from the old parameter archive. To open these records anyway please use the copy and paste method.

3.4 Handling measured data

After each measurement the VPM box sends a detailed measurement result is over both the USB and the serial interface to an attached PC. After reception the software loads the corresponding data to illustrate it in the center area of the main window. This result record is loaded to the 16th page

measurement result

and cannot be edited but archived using the export and import

options in the box menu. To interrupt this process just uncheck the option in the box menu. The last result may also be read using the

read last results.

Auto get results

For easy evaluation

of a parameters' inuence to the result a post-analysis and visualization can be enabled using

Simulate analysis

option. Both the rmware and software use the same algorithms for their

analyses so any change in parameter directly takes an eect in the post-analysis result to speed up parametrization. The result box in the bottom of the window shows the OK / NOK decision of each criteria. Boxes with red background express a NOK decision of the corresponding criterion during measurement analysis in the VPM. Any numbers in these boxes express the number of areas the corresponding parameter has exceeded its limits in and are currently shown in the main area. Please keep in mind that software analysis and box result may dier when editing the parameter record which also changes the basis for post-analysis. Zooming in the current diagram is possible at any time by click and drag an area using your right mouse button. Double-click causes reset to full view.

3.5 Automated measurement logging

The software is capable of recording multiple measurements in .csv-les as well as .vbm-les. This mode, enabled with

Automated data logging

in the box menu, saves every received measurement result in a .csvle whereas every le can contain multiple measurements. The data can be stored using either Europe (.) or USA (,) decimal separator. During logging any already existing les will get overwritten one after another. Thus recorded data can be further analyzed with third-party software like excel or MatLab. For further parametrization the .vbm export max be used. In this mode every le created contains exactly one measurement which can be processed as usual after logging. A unique timestamp representing the moment the measurement was received by the PC software will be appended to the lename you specied.

3.6 Software Version

The current software version can be obtained using the

Program - Info

command. The following

dialog will show the version number of the PC software, box rmware and box hardware. Please verify that any newer versions support your hardware version before updating. For further information see section 5.1.

Parameter description - 8

4 Parameter description
4.1 Measurement
By applying a HIGH-level to the START pin a measurement is triggered. The binary value applied to the PARAM[0-3] pins select the parameter record used for measuring. Please note that parameter record 15 is reserved and will return a

nok

decision immediately! The box supports

two current ranges: up to 30A, supplied directly by the sensor and up to 10A, boosted by an x3 pre-amplier. For oering maximum exibility four modes of behaviour are supported and can be selected using the Start when starting up

Start when

and

Stop when

switches:

Description The box waits for a start condition (falling edge below current treshold) before beginning the measurement. If the current edge does not appear within ve seconds the measurement is cancelled ( the PLC.

nok ) and an TIME-error

is returned to

pin active Stop when blocking

The box begins measuring immediately. Description The box measures until the current raises above the specied treshold. If the current remains below this treshold the box measures until the sample buer is full (16.000 samples).

pin inactive

The box stops measuring when either the START pin goes inactive or the sample buer is full.

Please take care of correct settings for block detection during parametrization. The only way to interrupt a measurement is to drive the so no result will be returned after all.

RESET

into an active state but keep in mind that doing

Parameter description - 9

Name Samplerate

Range 32-1024 Hz

Description Note that all time-dependent parameters base on the samplerate. Therefore a automatic adaption of these parameters is oered and recommended. Nevertheless doublecheck all settings after changing!

Current level start Current level end Fade at start Fade at end

0-65.535 A 0-65.535 A 0-255 0-255

Current treshold for start detection. Current treshold for block detection. Number of samples to skip from beginning. Number of samples to skip from end.

4.2 Analysis
After data measuring completed the analysis starts (

ok

and

nok

LED are both on). Now the

box checks all selected criteria for alerts. When one criterion detects an alert this analysis is interrupted and nok is returned. Any criterion can be disabled by unchecking the corresponding box during parametrization (Parameter group

NOK alarm when ).

Any alert from a deselected

criterion will not lead to a nok decision. If all criteria are disabled, no nok decision can be made except the measurement boundaries are violated. The beginning and the end of the data is discarded before analysis according to the setting of the parameters

Fade at start

and

Fade at end.

All further processing steps rely on the trimmed

data so the rst sample of any following equation is the (Fade at start + 1)th sample of the measured data. In case less than 2 samples remain after trimming the box returns to the PLC and aborts immediately. As basis for some criteria(stoppage 1 and 2, s-Value) a linear regression line is used. This is needed for motors drawing increasingly more current for example due to warming up during test.

TIME-error

4.3 ATTENTION
Do not forget to save the parameter record to disk or write to the box after changing it!

4.4 Criterion: Mean current

For detecting too high current consumption pointing to energy loss in a bad part this criterion gives alert when the mean current rises above or falls below a specied limit. Following parameters inuence decision: Name Expected mean current max. mean current Range 0-65.535 A 0-100 % Description Sets the expected reference current. Sets the upper limit for mean current.

Imax = Iexp
min. mean current 0-100 %

100+parameter 100 100parameter 100

Sets the lower limit for mean current.

Imin = Iexp

Parameter description - 10

4.5 Criterion: s-Value

The s-Value expresses the standard deviation of the data excluding the faded areas in relation to the mean current. For compensation of drifting currents the regression line is used as basis. Name Limit s-value Range 0.0-100.0 % Description Sets the maximum s-Value with 0.1% resolution.

4.6 Criterion: Stoppage 1

A stoppage is a current pulse caused by a mechanic blockade or otherwise generated mechanical or electrical stress. This criterion gives alert when the current stays for a dened number of samples above or below a specied limit around the regression line. Name Width stoppage 1 di. stoppage 1 (+%) Range 0-255 % 0-100 % Description Number of successive faulty samples. Percent of mean current the stoppage has to exceed above regression line:

I(x) > r(x) + Imean

di. stoppage 1 (-%) 0-100 % below regression line:

parameter 100

Percent of mean current the stoppage has to fall

I(x) < r(x) Imean

parameter 100

4.7 Criterion: Stoppage 2

This stoppage calculates the standard deviation over a small window of the data with the regression line as basis. When this extract of the global s-value exceeds a given limit an alarm occurs. Every window of successive samples from the beginning to the end will be examined. Name Width stoppage 2 di. stoppage 2 Range 2-250 0.0-100.0 % Description

Window-width of stoppage 2 ( tion (limit in formula)

in formula)

Limit for local deviation in percent with 0.1% resolu-

4.8 Criterion: Local rise

Using this criterion an alert can be given when the current change rises above a specied limit. The current rise is determined by the rise of a local-window regression line of xed length. Every window of successive samples from the beginning to the end will be examined. Name Width local rise di. local rise (%) Range 2-250 0-100 % Description

Window-width of stoppage 2 ( mula)

in formula)

Maximum tolerated rise within this window (

limit

in for-

Parameter description - 11

4.9 Criterion: Local s-Value

Using this criterion an alert can be given when the standard deviation of a sample window with its mean as basis exceeds a specied limit. Every possible window of successive samples from the beginning to the end will be examined. Name Width local s-value max. local s-value Range 2-250 0.0-100.0 % Description

Window-width of stoppage 2 ( resolution (

in formula)

Maximum tolerated s-Value of the window with 0.1%

limit

in formula)

4.10 Criterion: Time

This criterion may be used to force a

nok

decision if the measuring time exceeded limits for

example due to an too slowly moving test device. Name Expected running time Range 0-16.000 Description Although specied as a time in software this parameter depends on the selected sample rate and is always saved as a number of samples (value in the brackets). max. running time (+%) 0-100 % Sets the upper limit for running time.

tmax = texp
min. running time (-%) 0-100 %

100+parameter 100 100parameter 100

Sets the upper limit for running time.

tmin = texp

4.11 Organization
Some parameters are provided for descriptive use. These shall be mentioned shortly: Name Project Description Range 32 characters 32 characters Description A text eld to specify project name. A text eld to describe part and additional info. This eld will be displayed in the tab control to represent roughly the parameter records' contents. Owner Date 16 characters Date-Time A text eld to specify responsible person for maintainance. Contains a timestamp which is updated every time the parameter record is either saved to disk or written to the VPM.

Version history - 12

5 Version history
5.1 Compatible software versions
Any version number below 6 should not be used. Anyway it is recommended to update both rmware and software to the newest available versions. The following software/rmware version combinations are designed to work together. Anyhow updating to the newest available combinations supported by your hardware is recommended. Software 6 7 9 10 Firmware 6 6 9 10 Hardware 6 7 7 7 Notes First release Minor xes and usability improvements New revision including new features and functionality. Fixed some bugs, changed and improved functionality. For detailed information see section 5.3 !

5.2 Revision A (version 9.9.7)

Corresponding to manual revision A from January 2009.

5.3 Revision B (version 10.10.7)

Changed behaviour of start condition detection: A start condition now has to be a falling edge with

current level start

as trigger treshold. The condition must occur within 5 seconds

after applying HIGH-level to the START-Pin or an and the measurement is cancelled immediately

TIME -error

is returned to the PLC

Measurements with less than 2 samples after cutting the regions now lead to an The

TIME -error

Fade at start

and

fade at end

Automated data logging

now features an .vbm export option. See section 3.5 for further

information. The complete parameter record returned with the sampled data is now stored in the csv log. The time-parameters have no more inuence on the sampling phase. Only the selected STOP-Criterion is able to interrupt the sampling. FIXED BUG: The

TIME -error

(EC1-line) is cleared when the box is in idle state and no

output is short-circuited. FIXED BUG: For measurements with less than 2 samples after cutting the fade regions no status LED was set when returning to the idle state though a to the PLC and a result information was sent to the PC.

NOK -decision was reported

A new bootloader PC program oers the exibility to directly update the rmware without having to interrupt the modules power supply.

Update instructions - 13

6 Update instructions
1. If not done yet, update the VPM Software by replacing the old les

verspulbox.exe, verspulbox.DEU and verspulbox.ENG in your local installation path with the new ones located on the CD.

2. Connect the VPM to the serial port of your PC using the serial cable delivered with the VPM. If your PC does not have any serial port you can also use any RS232-USB bridge. 3. Run the software and answer the

Port -Dialog with cancel. Update rmware

Open COMBox
menu

4. Select

from the

5. Select the serial port you have connected the VPM with and press

Gert erkennen.

6. When using bootload PC-software version 1.00.2 this step is no longer necessary: Now interrupt the power supply of the VPM. One second after turning the power back on the VPM shall be in bootload mode and the bootload dialog shall show you more update instructions. If this does not work please refer to step 10. 7. Select the new rmware le found in the folder by clicking

Durchsuchen.

VPM Software

8. Update the rmware by clicking on update. 9. The rmware succeeded when the bootloader shows your VPM restarts with the new rmware. 10. If the rmware update did not succeed please refer to the emergency update instructions.

Update erfolgreich. Finish the update by clicking Verbindung beenden. Now

Emergency update instructions - 14

7 Emergency update instructions

1. Unscrew the 4 top screws of the VPM as indicated in the picture and lift up the now loosened top cover. 2. Connect the VPM to the serial port of your PC using the serial cable delivered with the VPM. If your PC does not have any serial port you can also use any RS232-USB bridge. 3. Power up the VPM. 4. At the top edge of the PCB are two buttons, of which the right one is marked with a label on PCB. 5. Press and hold the left button. Now press the right

RES RES
button and release it before you

release the still held left button. Now the processor is in download-mode. 6. Start the program with. 7. Press

BootWizard.exe

located in

VPM Update

on

the CD and select the serial port you have connected the VPM

Write Bootloader

- now the bootloader program of the

processor gets re-written. 8. Retry programming the VPM using the standard update instructions - in case you already updated the PC software beginning at step four . 9. When successful reinsert the top cover and screw down the 4 screws. In case the update did not succeed please retry steps ve to seven or feel free to contact us for further assistance.

7.1 Possible problems leading to errors

The COM port selected is still held open by another application: Ensure that no application holds the selected port open while trying to program the bootloader code. Especially the VPM or rmware update program - if open - should be checked for open COM ports.

A wrong COM port is selected the VPM box is not attached to. The processor is not in download mode: make sure to perform step ve properly. The device driver for USB bridges tend to get stuck in some cases. Try reconnecting the bridge to ensure proper function.

Konformittserklrung - 15

8 Konformittserklrung
Wir, die Firma

Ingenieurbro Sesselmann Me-, Steuer- und Regelungstechnik Dr.-Max-Volk-Strae 28 96523 Steinach

erklren in alleiniger Verantwortung, dass das Produkt

Verspulprfmodul VPM

auf das sich die Erklrung bezieht, mit den folgenden Normen oder normativen Dokumenten bereinstimmt:

EMV

EN 60730-1 :2000 EN 60730:2-11 :1993 +A1 :1997 EN55022 :1998 +A1 :2000, Klasse B (Straussendung) EN 61000:6-2 :2001 (Strfestigkeit)

Gertesicherheit

EN 60730-1 :2000 EN 60730:2-11 :1993 +A1 :1997 EN 61010-1 :1993

Gem den Bestimmungen der Richtlinien

89/336/EWG EMV-Richtlinie 73/23/EWG Niederspannungsrichtlinie

Steinach, den 01.September 2008

Sesselmann