gauge operation and software by scott a. ager. computer recommendations 750 mhz pentium iii 64 meg...

Gauge Operation and Software

by Scott A. Ager

Computer Recommendations

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

IES Software

Main Software Window

Recorder Operation Modes

Recorder Operating Modes

• “Sleeping”• “Standby”• “Recording Data”


• “Sleeping”

– Gauge 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 gauge.

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

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


Sleeping…


• “Standby”– Gauge and sensors are fully powered up, but the gauge is NOT

recording data.

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

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


Standby…


• “Recording Data”– Gauge and sensors are fully powered up, and the gauge is

recording data in the “SLOW SPEED” sampling mode.

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

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

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


Recording Data…

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


• “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).


• “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 gauge 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

Allows you to set certain defaults when the software starts.

Test Sensors


This tests the sensors and internal voltages of the gauge. You can perform this test on your own.

Voltage Monitoring

Monitors Internal and Sensor Input Voltages.


Gauge Test Log

Selected in the Main Software Window and the “View Recorder Data” Window

Contains the log showing how many jobs the gauge has done.

Job Report


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

Edit Recorder Channel Data

Contains the sensor calibration information for each channel, and general user information.


Gauge Settings Menu


Displaying OWR Data


View Test Data

Selected in the “View Recorder Data” Window

Shows data about the job and the data you downloaded.

Convert Data to ASCII File

Allows you to exporting the gauge data to an ASCII file for use in Windows Excel or other programs.


View the Gauge Battery Voltage and OWR 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


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)

5 10 15 20 25 30 35 40 45 50 55 60 65Time - m inutes

0

1

2

3

4

5

6

7

8

9

10P

ress

ure

- M

Pa

0

5

10

15

20

25

30

35

40

45

Tem

pera

ture

Penn W estSlow speed data

file: 684a.grf

C C Lcorre la tion

ign ition --

pressure

tem perature

“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 gauge

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


Fast Speed Time Window

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

-0 .001 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.010Time seconds

0

5

10

15

20

25

30

35

40

45

50

Pre

ssur

e -

MP

aKey West

High speed pressure data

file 686b1perf -gun

- propellant burn

m ax. vertica lstress ~36 M Pa -

m ax. horizonta l stress ~27 M Pa?

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 gauge 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

0 1 2 3 4 5 6 7 8 9 10 11Time seconds

- 6

- 3

0

3

6

9

1 2

1 5

1 8

2 1

2 4

2 7

Pre

ssur

e -

MP

a

Penn W est tool movement/pressure

file 684b1

tool m ovem ent - m eters

*

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

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…

“Start” Options

• Starting…– The Recorder and Sensors (if enabled) is tested before

the Recorder is Started.

“Start” Options

• Starting…– 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 Gauge is

powered up. This occurs when the

“Kill Switch” is removed from the battery

pack.

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– Gauge is enabled to “Start Recording Data” after the programmed

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

NOTE: If the “Kill Switch” is installed, the delay start count down does not begin until the “Kill Switch” is removed.

– Gauge will NOT start recording data until the count reaches zero

– Draws 8 – 10 mA when the gauge 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 mA

This feature must be first, enabled in the “Recorder Settings” menu, and second, “Started” in the “START/STOP” pull down menu.

Step #1

Step #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 gauge goes back to sleep for another 5 minutes. If the sensor value IS above the threshold, and remains above it for 5 – 10 minutes longer, the gauge will start recording data .

– Draws ~0.7 mA when the gauge 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 gauge will start recording data .

– Draws 40 - 100 mA when the gauge 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)

5 10 15 20 25 30 35 40 45 50 55 60 65Time - m inutes

0

1

2

3

4

5

6

7

8

9

10

Pre

ssur

e -

MP

a

0

5

10

15

20

25

30

35

40

45

Tem

pera

ture


file: 684a.grf

C C Lcorre la tion

ign ition --

pressure

tem perature

Gauge 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.



“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.



“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.



“Start” Options• “Auto” Start

– 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 gauge 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.

Internal G Switch bounces

This Start feature is useful for Drop Bar applications.

“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 gauge 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)

5 10 15 20 25 30 35 40 45 50 55 60 65Time - m inutes

0

1

2

3

4

5

6

7

8

9

10

Pre

ssur

e -

MP

a

0

5

10

15

20

25

30

35

40

45

Tem

pera

ture


file: 684a.grf

C C Lcorre la tion

ign ition --

pressure

tem perature

Gauge 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 gauge 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


• 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.


• If the Recorder is still “Recording Data”, you must first “STOP” the Recorder, before you can download the data.


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


• 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

Gauge Operation and Software

by Scott A. Ager

gauge operation and software by scott a. ager. computer recommendations 750 mhz pentium iii 64 meg...

Documents

slow speed sampling

fast speed sampling

fast speed mode

fast speed sampling

slow speed sampling

slow speed mode

intermediate speed mode

fast sampling speedwhen