Reference Manual SERIES 8000 ENCLOSURES Copyright © 2000 PART NO: 860093-001 Last Revised: 3/16/01 Kaman Aerospace Corporation Measuring & Memory Systems 217 Smith Street Middletown, CT 06457 www.kamansensors.
Series 8000 Enclosures Reference Manual 1/2 Rack Instrumentation Case (3U/42HP) 3/4 Rack Instrumentation Case (3U/63HP) Full 19" Subrack (3U/84HP) Kaman Measuring Systems P/N 860093-001, Revised 3/16/01
Series 8000 Systems The Series 8000 is a modular packaging system for Kaman Instrumentations line of inductive displacement transducer electronics. The Series 8000 enclosures integrate various measuring channels, function cards, power supplies, and displays into a coherent application specific industrial package. Sensors for the measuring channels are available that measure displacements in the microinch/nanometer ranges as well as sensors that can make accurate displacement measurements at up to 1000oF.
Table of Contents Getting Started Quickly Series 8000 Enclosures Subracks Instrument Enclosure NEMA Integral Power Supply Input Voltage Selection (120VAC/240VAC) The Internal Back Plane Internal Back Plane Connectors Adding Additional Modules The Back Panel Back Panel Power Input Back Panel I/O and Labeling Back Panel Sensor Inputs The Front Panels Module Side Panel Labeling MCD-8000 and 1/8 DIN Panel Mounted Displays Using the Multi-Inputs Input wiring to the Display 0-10VDC Display Input Configuration
List of Illustrations fig. 1 -- Full 19" Subrack Rear/Front Outline drawing fig. 2 -- Full 19" Subrack Top View Outline Drawing fig. 3 -- Full 19" Subrack Rear/Front with Display fig. 4 -- Full 19" Subrack Rear/Front with Dual Display fig. 5 -- 1/2 Rack with Display Outline Drawing fig. 6 -- 1/2 Rack Outline Drawing fig. 7 -- 3/4 Rack with Display Outline Drawing Table 1 -- Power Supply Specifications fig. 8 -- Power Entry Module fig. 9 -- Accessing the Voltage Selector Card fig.
Getting Started Quickly The Series 8000 rack systems are typically prewired and set up at the factory with all measuring channels and function cards installed.
Series 8000 Enclosures Subracks The subrack is a 19" wide frame having solid side panels and horizontal rails across the top and bottom to hold the system modules in place. Use of a subrack enables you to install your Series 8000 system into a standard 19" test equipment rack, or bolt it into a NEMA enclosure. The subrack has a built in 120VAC/240VAC selectable power supply to provide +/-15VDC at 1 amp.
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Instrument Enclosure The instrument case is a fully enclosed stand-alone enclosure for your series 8000 system with a tilt bar to elevate the front of the case. The subrack has a built in 120VAC/240VAC selectable power supply to provide +/-15VDC at 500 milliamp. The subrack also can be configured with either one or two MCD 8000 display modules that have up to six selectable inputs. The display modules draw no current from the +/-15DC volt supply.
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NEMA The NEMA 12 configuration is an 8"x8"x4" continuous hinge enclosure. It can contain either 1 or 2 synchronized measuring channels and an optional function card. An optional integral power supply and/or display is available. In the NEMA the modules do not have separate enclosures. This configuration is not described further in this manual, please refer to the NEMA manual PN 860060 for further information on the NEMA enclosure.
Integral Power Supply Warning: The integral power supply in racks utilize high voltage (120 or 240VAC). Unplug the unit before servicing. The power supply for the series 8000 rack enclosures are integral to the chassis and mounted on the back panel for better heat dissipation. All of the Series 8000 power supplies provide a +/-15VDC+/-.5V linear regulated output for low noise operation.
Input Voltage Selection (120VAC/240VAC) Warning: When you change the input voltage on the rear panel you must also change the MCD 8000 input voltage or you may damage the unit. Warning: The integral power supply in racks utilize high voltage (120 or 240VAC). Unplug the unit before servicing. To change the input voltage you must first select the proper input voltage on the power entry module on the unit. To change the selected voltage: a Open the cover using a small blade screwdriver or similar tool.
b Using the indicator pin orient the selector card so that the desired voltage is readable at the bottom. Orient the indicator pin to point up when the desired voltage is readable at bottom ( note that when indicator pin is fixed, successive voltages are selected by rotating the card 90o clockwise). See fig. 10 for voltage selector orientation. c Insert voltage selector card into housing with printed side of card facing toward IEC connector and edge containing the desired voltage first.
If you have an MCD 8000 (for other 1/8 DIN panel meter configurations you will need to see the specific manual on the meter for changing the input voltage) 110VAC or 220VAC is selectable using a switch on the indicators main circuit board. Check the instruments tag for the voltage range set at the factory. If you are changing the input voltage to the unit you will need to set this switch appropriately.
fig. 11 -- Top View of Main board on display.; Warning: Dangerous voltages are exposed at the screw terminals. Always remove power before working in this area for rewiring, disassembly, and all other activities that involve proximity to electrical circuitry.
The Internal Back Plane The back plane of the series 8000 rack system is typically hand wired at the factory. Channels configured as blanks are normally left unconfigured because it is not always specified as to what will be in a slot in the future. In designing the series 8000 modules some standards have been adhered to accommodate expansion. The diagram in figure 12 details physical pin locations for the standard Eurocard connector.
Caution: Be careful when connecting power, incorrect connections may damage your system.
Internal Back Plane Connectors The bare chassis eurocard connector is available for expansion and is part number 826020002 for function cards. For most Kaman measuring systems use the SMA connector for coaxial connection, two part numbers are available: 853503-001 for single coil systems or 853503002 for dual coil or differential systems. These connectors are prewired to the eurocard connector with bulkhead SMA's. fig. 13 -- Single Coil Coaxial; fig.
Adding Additional Modules To add additional modules you will need to wire in additional Eurocard connectors to the back panel. You must have a soldering iron and 24AWG bus wire as well as insulated wire to connect any outputs that are required to the display or the back panel. Warning: The integral power supply in racks utilize high voltage (120 or 240VAC). Unplug the unit before servicing. 1) Using the back plane template provided in fig. 15 map out the wiring of the unit.
6) Install the guide rails. Be sure to space as other guide rails in the unit are spaced (there should be 5 empty holes between guide rails). The guide rails snap into place in the upper and lower horizontal parts of the rack. 7) Solder in the power and ground connections. You will need to use 24AWG bus wire to connect the power and ground of any Kaman supplied module. The back plane template (fig. 15) shows the power and ground connections.
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The Back Panel The exact back panel configuration will depend on the specific enclosure, measuring channels, and function cards to build a system. Figures 3, 5, and 7 show the back panel configurations for the 3 standard rack mounted enclosure types. Exact terminal block outputs depend on the measuring channel/function module configuration of the specific rack. See the section on Back Panel I/O and Labeling for specific information on terminal block outputs.
Back Panel I/O and Labeling Each back panel has terminal blocks used for I/O with special laser markings depending on the cards installed in the rack. The half rack has one 12 position terminal block, the 3/4 and full racks have two 12 position terminal blocks. The outputs are labeled to be consistent with the table below where `x' refers to the channel number. Unfortunately, because of the density of the outputs on the back plane vs.
Back Panel Sensor Inputs The back panels are configured with holes for panel mounted SMA connectors for coaxial sensor inputs. Depending on the number and type of measuring channels some of the holes may be plugged. The two rows of sensor inputs are marked A (or `Active') and B (or `Inactive')(for dual coil or differential sensor configurations) with a number between the A/B sensor inputs corresponding to the particular measuring channel input.
The Front Panels The series 8000 enclosure front panels are essentially self configuring depending on the mix of function card and measuring channels. You will need to refer to the manual on the specific module for information on the front panel controls. See appendix A and B for some brief information on measuring channels and function cards. Since the MCD-8000 is essentially an integral part of the chassis, information on its operation and calibration is included in this manual.
MCD-8000 and 1/8 DIN Panel Mounted Displays The MCD 8000 is a scalable 4 digit display module designed for accurate, reliable , measurement of voltage or milliamps from up to 6 inputs. The panel cutout for the MCD-8000 is a standard 1/8 DIN size. This allows flexibility in choosing an appropriate meter for a particular application. For most applications the MCD-8000 with its multi-channel scalable input is adequate. Information on the MCD-8000 is included in this manual.
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Using the Multi-Inputs Select the input you wish to display by turning the front panel selector switch. The knob's index mark indicates the selected input as labeled on the front panel lens. fig. 21 -- MCD 8000 Front Panel; The display is normally configured to display the measuring channel output in the numbered position starting to the right of the display.
Input wiring to the Display The display can come in several configurations depending on the rack requirements. The basic connectors to the back of the module are from the measuring channels to the terminal block as shown in fig. 22 with the measuring channel output wired to the (+) terminal and the GND wired to the (-) terminal for a particular channel. If you have a bipolar meter please request drawing 853727 for information on special wiring. fig.
0-10VDC Display Input Configuration The 0-10VDC input is by far the most common display configuration. It has differential inputs to the meter. It has a maximum resolution of 200 microvolts per count. +/-5VDC Display Input Configuration The +/-5VDC input option is used where a high resolution bipolar input is required. It has a maximum resolution of 200 microvolts per count with the inputs configured single ended.
4-20mA Display Input Configuration The MCD 8000 can take either voltage or current inputs. When configuring for current input you need to snap off the front panel lens to gain access to the display board. Behind the display is a DIP switch used to set the indicators input measuring mode. You will also need to change the wiring on the display terminal block (see section on Input Wiring to the Display) to go into the +I and -I terminals.
Calibration The MCD-8000 calibration consists of a 2 point calibration that adjusts the offset and slope of the resulting display. The scale factor of the MCD-8000 can be adjusted for a minimum of 200 microvolts per count (400 microvolts per count with +/-10VDC input option). In order to calibrate the unit the following steps should be followed: 1) Select the input channel with the maximum voltage range to calibrate from. The selector switch only changes the input.
3) Pull off the switch cap and pop off the front of the meter panel using a small flat head screwdriver and twisting slightly in the slot near the bottom center of the panel. Note: The DIP switch may either be a rocker type (press down on appropriate end) or a slider type (slide toward appropriate end). The drawing in fig. 26 details the adjustment activities. fig. 26 -- MCD 8000 Adjustment Switches; 4) Actual calibration occurs in the SCALING mode.
a Position the sensor or simulated input so that it is near the low scale point (e.g. 0 mils, 0 Volts, 4 mA) push the "ENTER" button. b Use the "SET" button to change the value of the flashing digit. When the flashing digit is correct, push the enter button. The flashing digit will now move to the next right hand digit. Continue until all digits are correct with the rightmost digit still flashing. (e.g.
Note: Pushing both the "SET" and "ENTER" button at the same time always causes the indicator to recalibrate itself to the given input and what is on the display at that moment. As a protective measure, if scaling changes are made and not terminated this way no recalibration will occur, previous values will remain. Note: As a further protective measure, the "SET" and "ENTER buttons are not functional unless the PROCESS/SCALING switch is in the SCALING position. fig.
Appendix A -- Measuring Channel Configuration The heart of the system is the measuring channel. Currently Kaman offers a wide variety of signal conditioning modules and inductive sensors. The table below is a brief description of ranges and display parameters for the standard line of sensors. Please refer to the KDM-8200 instruction manual for further information on calibration and usage of the inductive sensors.
Basic Measuring Channel Configuration Most of the displacement measuring channels offered by Kaman have the same pinout and front panel configuration. They utilize inductive bridge technology which has a high sensitivity and is generally insensitive to contaminants such as dust, dirt, and oil.
Appendix B -- Function Card Configuration Any series 8000 enclosure can be configured with optional function cards. Function cards available include Voltage to Current conversion (for 4-20mA outputs), dual set points, summation/comparator (for thickness applications), dynamic measurement (RMS->DC conversion or Peak measurements), and a prototyping card. Each function card will have its own manual describing pinouts and usage. Please refer to the appropriate function card manual for specific questions.
VC8000 Voltage to Current Converter Configuration The VC8000 was designed to convert a 0-5 volt DC input to either a 0-20mA or 4-20mA output. The isolated loop supply and current output make it ideal for noisy industrial environments. Please see the VC8000 user manual (PN 860061) for more specific information.
SC8000 Summation/Comparator Configuration The SC8000 Summation/Comparator module was designed for use when a direct reading of ID, OD, or thickness was desirable. The module performs an analog summation on the inputs and has an integral window comparator for monitoring out of tolerance conditions. Please see the SC8000 user manual (PN 860062) for more specific information.
DY8000 Dynamic Module Configuration The DY8000 Dynamic Module was designed to take dynamic inputs such as shaft runout, vibration or ultrasonic weldhorn amplitude and convert them to a DC voltage easily readable and quantifiable on the display module. The DY8000 can perform either single peak-to-peak, dual positive peak, dual negative peak, or dual RMS measurements. Integral progressive comparators allow for easy monitoring of out of tolerance conditions.
SP8000 Dual Set Point Configuration The Dual Set Point module was designed with two separate channels of either window or progressive comparator operation. The configuration allows for alarm and shutdown with Hi, Lo, or Go outputs. Please see the SP8000 user manual (PN 860090) for more specific information.
Appendix C -- MCD-8000 Display Specifications MCD 8000 Functional Specifications Input Range: 0-10VDC or 0-20mA Note: Sensitivity: Kaman Special input module (PN 853727) allows either a +/-5VDC or +/-10VDC input to the meter but changes it to be a single ended input. 200 microvolts/count or 0.4microamps per count Note: Input Impedance: Note: on units with the Kaman input module (PN 853727) with a +/-10VDC input, the display will only have 400 microvolt per count sensitivity.
MCD 8000 Performance Specifications Reference Operating Conditions (ROC): +/-10% line voltage 23+/-2oC ambient temperature <80% RH non-condensing Accuracy (at ROC): 0.02% of reading +/-1 count Noise Rejection: NMRR: >-60dB @ 50/60Hz, +/-.1Hz CMRR: >-120dB @ 50/60Hz, +/-.1Hz with 250 ohm unbalanced Overload Protection: Power lead to ground: 1500VDC or ACRMS Across inputs: Voltage up to 250VDC or VAC for 1 min., +V to -V Current up to 150mADC or mAAC for 1 min., +I to -I Zero 1uV/oC, Span 0.
Appendix D -- Replacement or Expansion Parts Rack Parts: PN Description 814873-001 Single meter 1/8 DIN 21T Wide Front Panel 814873-002 Dual meter 1/8 DIN 21T Wide Front Panel 853737-001 MCD-8000 1/8 DIN Replacement Meter (1-6 label) 853737-002 MCD-8000 1/8 DIN Replacement Meter (7-12 label) 822238-C001 Power Cord 110V 814639-001 Single Slot Blank Front Panel 814639-002 Dual Slot Blank Front Panel 826029-001 Thumbscrews (4 per panel required) 853503-001 Rack Side Euroconnector with single SMA connector
Series 8000 Sensor Family SENSOR SCALE MODELS 8000 .5SU/.5U2 1U1/1U2 2S1 2UB1 2U2 3U1 4S1 6U1/6U2 (_6.00) 15U1/15U2 (15.00) 30U1/30U2 (30.00) 60U1 (_60.0) 15N (diff) 9.00. (+/-.250) 20N (diff) 9.00. (+/-.250) 1925(HT) (_1.27) 1925M(HT) (_1.00) 1950(HT) (_3.81) 1950M(HT) (_2.54) 1975(HT) (_5.00) 1975M(HT) (_2.54) MEASURING TYPICAL ANALOG DISPLACEMENT FULL MCD- RANGE OFFSET VOLTAGE SENSITIVITY Inch (mm) English (Metric) .020 (0.5) .040 (1.0) .080 (2.0) .080 (2.0) .100 (2.5) .120 (3.0) .160 (4.
Appendix E -- Warranty and Repair Kaman Instrumentation Operations Products Standard Limited Warranty Products of Kaman Instrumentation are warranted to be free from defects in materials and workmanship when installed and operated in accord with instructions outlined in the instruction manual.
Customer Service Information Should you have any questions regarding this product, please contact an applications engineer at Kaman Measuring Systems 800-552-6267. You may also contact us through our web site at: www.kamansensors.com.
