Sensor Calibration

If you need help with calibration of Resin, Gelcoat, and/or Glass, hopefully the instructions below will help you. If not, please feel free to call us anytime @ 888-222-9828.

You can also download our TFM Manual or just the pages dealing with Calibration.

Easiest first:

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99.9% of the time, for Boom Mounted Glass sensors, to calibrate the glass sensor, you just divide the “yield” of the glass by how many strands you are running through the gun. In a typical case, your yield is 207, and you are running 2 strands of glass. so, 207 / 2 = 103.5 which is the number you enter in the calibration menu on the keypad.

For the Motor Mount Glass sensor, it is a little different. However, using the steps below for fine tuning the calibration, it will calibrate correctly and just as easily.

To fine tune the calibration for glass after entering the initial numbers, the formula is: Display Weight / Actual Weight X current calibration number. For example, you spray only glass into a bag or bucket until the monitor reads 1.0 on the glass line. At this point, you have 1 pound (454 grams) displayed. Then, weigh the glass, and for the purpose of this example, the scale shows that you actually have 416 grams. Using 103.5 as the current calibration number entered in the monitor, below is the equation to find the new calibration number:

454/416 = 1.091

1.091 X 103.5 = 112.9

112.9 = New calibration number for glass.

To get to the calibration menu on the keypad, you would press CTRL + A (both at the same time). You will then see the option for Calibration, which is F3. If you press F3 once then wait about 4 seconds, the screen will revert to the Menu. So, Press F3, then press F3 again. You will see where it tells you to enter the New Glass number, which in this case is 103.5. (as a side note, to enter the decimal (.) you would hold SHFT then press X). After you enter the Glass number, you would then press ENTER.

Then, it will tell you to enter the new Resin (or Gelcoat) number, which is explained below how to get this number.

 

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The steps for calibrating your Resin and/or Gelcoat are the same, using either the Exhaust type or Mechanical type sensors.

Things you need are either some plastic bags and/or disposable buckets capable of holding around 5 pounds of material. Pumps will vary in their volume output per stroke. Also, you will need a scale, portable is preferred and easier.

First thing you want to do is turn off the catalyst! This is for safety reasons and the fact that we want to calibrate only for resin/gelcoat.

Next you want to find stroke. Spray the material until the monitor “clicks” up one count on the resin line, at this point, it does not matter what the number is. Then stop pumping. This is the starting stroke for the pump. Push the Reset Button so the monitor reads “0” and you are ready to go.

Now, spraying into the bucket or bag you are going to weigh, you want to watch the monitor’s resin line for ten “clicks” or “counts”. Right when you hit the tenth count, stop.

Now you will weigh the material filled bucket or bag. Before doing so, you will want to “tare” the scale so the weight of the bag or bucket is not included in the actual weight of the material. Okay, your bag or bucket is on the scale, and the weight is displayed. We prefer weighing in grams for more accuracy. So, for example, the scale is displaying 2079 grams. Let’s take that number and figure out the calibration number the monitor needs.

2079 grams / 454 grams (454 grams = 1 pound)

= 4.579 (we only need to go 3 numbers past the decimal point.

Now for the monitor to display the actual weight of the material, we need to move the decimal point one time to the left. which would make it:

.4579 = the number you need to input using the keypad.

Like above in the Glass calibration/keypad instructions here is again how to enter the Glass – Resin/Gelcoat calibration number:

To get to the calibration menu on the keypad, you would press CTRL + A (both atthe same time). You will then see the option for Calibration, which is F3. If you press F3 once then wait about 4 seconds, the screen will revert to the Menu. So, Press F3, then press F3 again. You will see where it tells you to enter the New Glass number, which in this case is 103.5. (as a side note, to enter the decimal (.) you would hold SHFT then press X). After you enter the Glass number, you would then press ENTER.

Then it asks for the Resin/Gelcoat number. Hold SHFT and then press X for the decimal point, then press 4 5 7 9, then press ENTER. Then it will display the “new” calibration numbers then revert to the Menu screen. Press F5 to go to the Main Menu. At this point, we repeat the steps to verify the calibration and barring any unforeseen pump maintenance issues, what you see on the monitor is going to match what is on the scale.

(Another note here: When calibrating resin, you do have to enter the glass number. Basically just enter the number that is already displayed. Also, on glass numbers, only go one digit past the decimal point. For example, your glass weighs or displays 180.456, only enter 180.4. On resin or gelcoat numbers, only go 4 digits past the decimal point. For example, your resin or gelcoat weighs or reads 3.56794, only enter .3567.)

That’s it for calibration. Easy as pie and only takes a few minutes.

That is the great thing about TFM equipment, what you see on the monitor is what has been sprayed from the gun, no question about it!

Unless you suspect a bad batch of glass material or switch to a different yield, you should not have to ever adjust the calibration number for Glass. However, we recommend that Resin and Gelcoat be calibrated at least once a month. Also, they must be re-calibrated after any maintenance to the pump.

The sensors can also act as an indicator to pump problems. For example, sometimes when you calibrate, then verify that calibration, but it seems that in both instances, the numbers are not coinciding, this could be an indication that some maintenance is required to the pump itself.


 

For companies that use the Metric System, calibrating the sensors is as easy as above. In fact, most of the steps above still apply.

For resin and/or gelcoat sensors, after you have filled the bag or bucket with the ten clicks or up counts, you still would weigh it by grams. Let’s say the scale reads “9.53” KG. Divide that by 10 and you will have the calibration number = .9530. That is the number you enter into the keypad.

Again, to calibrate the Boom Mounted Glass sensor, you just divide the “yield” of the glass by how many strands you are running through the gun. In a typical case, your yield is 207, and you are running 2 strands of glass. 207 yield converted to metric = 455.4 KG. So,  455.4 / 2 = 227.7 which is the number you enter in the calibration menu on the keypad.

For the Motor Mount Glass sensor, it is a little different. However, using the steps below for fine tuning the calibration, it will calibrate correctly and just as easily.

To fine tune the calibration for glass after entering the initial numbers, the formula is: Display Weight / Actual Weight X current calibration number. For example, you spray only glass into a bag or bucket until the monitor reads 1.0 on the glass line. At this point, you have 1 KG (1000 grams) displayed. Then, weigh the glass, and for the purpose of this example, the scale shows that you actually have 976 grams. Using 227.7 as the current calibration number entered in the monitor, below is the equation to find the new calibration number:

1000/976 = 1.024

1.024 X 227.7 = 233.1

233.1 = New calibration number for glass.


 

 

Hope this helps, and again, you can call us @ 888-222-9828 or

You can download our TFM Manual or just the pages dealing with Calibration.