HBM MGCplus Operating Manual

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Operating Manual

English

MGCplus

Page 2

Hottinger Baldwin Messtechnik GmbH Im Tiefen See 45 D-64239 Darmstadt Tel. +49 6151 803-0 Fax +49 6151 803-9100 info@hbm.com www.hbm.com

Mat.: 7-2002.0612 DVS:

A0534-30.0 HBM: public

03.2018

E Hottinger Baldwin Messtechnik GmbH.

Subject to modifications. All product descriptions are for general information only. They are not to be understood as a guarantee of quality or durability.

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Table of contents

1 Safety instructions 11.......................................................................

1.1 Electromagnetic compatibility 14........................................................

2 Markings used 15...........................................................................

2.1 Markings on the device 15.............................................................

2.2 The markings used in this document 15..................................................

3 Introduction 17.............................................................................

3.1 Degree of protection 17................................................................

3.2 Notes on documentation 18............................................................

3.3 System description 19.................................................................

3.4 Layout of the MGCplus device 21.......................................................

3.5 MGCplus housing designs 22...........................................................

3.6 Possible amplifier/connection board combination 23.......................................

3.7 Installation of the CP52 communication processor 26......................................

3.8 Conditions at the place of installation 29.................................................

3.9 Maintenance and cleaning 30...........................................................

4 Connection 31.............................................................................

4.1 Connecting the MGCplus in a tabletop housing/rack frame 31...............................

4.1.1 Mains connection 31..........................................................

4.1.2 Synchronization of multiple CP52 devices 32.....................................

4.1.2.1 Synchronization of multiple CP52 devices via a synchronization jack 32.....

4.1.3 Synchronization of CP52 with CP22/CP42 34.....................................

4.2 Shielding design 36...................................................................

4.3 Connecting the transducer 39..........................................................

4.3.1 Connecting separate TEDS modules 39..........................................

4.3.2 SG full bridges, inductive full bridges 42..........................................

4.3.3 Full bridge circuits on AP810i/AP815i 43.........................................

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4.3.4 Strain gage half bridges, inductive half bridge circuits 44...........................

4.3.5 LVDT transducers 45..........................................................

4.3.6 Strain gage half bridges on AP810i 46...........................................

4.3.7 Strain gage half bridges on AP815i 47...........................................

4.3.8 Single strain gage 48..........................................................

4.3.9 SG chains and strain gage rosettes on AP815i 51.................................

4.3.10 Torque flange T10 series, T40 series) 53.........................................

4.3.11 Torque shaft (T4A, T5, TB1A) 59................................................

4.3.12 Thermocouples 62............................................................

4.3.13 DC voltage sources 63.........................................................

4.3.14 DC power sources 70..........................................................

4.3.15 Resistors, Pt100 72...........................................................

4.3.16 Frequency measurement without directional signal 73..............................

4.3.17 Frequency measurement with directional signal 74................................

4.3.18 Pulse counting, single-pole 75..................................................

4.3.19 Pulse counting, differential 76...................................................

4.3.20 Active piezoelectric transducers 77..............................................

4.3.21 Piezoresistive transducers 78...................................................

4.3.22 Potentiometric transducers 79..................................................

4.3.23 Connection via the distributor board VT810/815i 80................................

4.3.8.1 Single strain gage on AP14 48.........................................

4.3.8.2 Single strain gage on AP814Bi 49......................................

4.3.8.3 Single strain gage on AP815i 50.......................................

4.3.10.1 Torque measurement 53..............................................

4.3.10.2 Rotational speed measurement (symmetrical signals) 55..................

4.3.10.3 Rotational speed measurement (symmetrical signals) with reference pulse 57

4.3.11.1 Torque measurement (slip rings or direct cable connection) 59.............

4.3.11.2 Rotational speed measurement with inductive transducers 61..............

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4.4 Connecting CANHEAD modules 82.....................................................

4.4.1 Communication card ML74B 83.................................................

4.4.2 AP74 connection board 84.....................................................

4.5 Inputs and outputs, remote controls 85...................................................

4.5.1 Inputs/outputs of the CP52 85..................................................

4.5.2 Analog output on the front panel 87..............................................

4.5.3 Connection boards AP01i/AP03i/AP14/AP17 87...................................

4.5.3.1 Socket assignment AP01i/AP03i/AP14/AP17 88..........................

4.5.3.2 AP460i connector pin assignment 92...................................

4.5.3.3 AP77 93............................................................

4.5.4 Inputs and outputs of AP75 94..................................................

4.5.5 Analog outputs on the AP78 97.................................................

5 Starting up 99..............................................................................

5.1 Devices in the desktop housing and rack frame 99........................................

6 Functions and symbols of the AB22A 103.....................................................

6.1 Control elements of the AB22A 103......................................................

6.2 Display 104...........................................................................

6.2.1 The first display 104............................................................

6.2.2 Display in measuring mode 105..................................................

6.2.3 Messages of AB22A/AB32 109..................................................

6.3 AB22A in Setup mode 110..............................................................

6.3.1 Call menus 112................................................................

6.3.2 Exit menus 113................................................................

6.3.3 Channel selection in measuring mode 114.........................................

6.3.4 Channel selection in Setup mode 115.............................................

6.3.5 Saving settings 115............................................................

6.3.6 Drop-down menus 116..........................................................

6.3.7 Setting elements in the setup windows 116........................................

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7 Measuring 121...............................................................................

7.1 General information 121................................................................

7.2 General principles for adjusting a measurement channel 122.................................

7.2.1 Adapting to the transducer 124...................................................

7.2.1.1 Extended functions of the ML38B 125....................................

7.2.2 TEDS transducers 126..........................................................

7.2.3 Signal conditioning 128.........................................................

7.2.4 Display 131...................................................................

7.2.5 Analog outputs (single-channel modules only) 132..................................

7.3 Adapting to the transducer 135..........................................................

7.3.1 SG transducers 135............................................................

7.3.1.1 Direct entry of transducer characteristics 136.............................

7.3.1.2 Calibrating the characteristic curve of the transducer 139...................

7.3.2 Strain gages 140...............................................................

7.3.2.1 Direct entry of transducer characteristics 143.............................

7.3.3 Inductive transducers 145.......................................................

7.3.3.1 Direct entry of transducer characteristics 146.............................

7.3.3.2 Calibrating the characteristic curve of the transducer 148...................

7.3.4 Torque transducer 151..........................................................

7.3.4.1 Direct entry of torque characteristics 153.................................

7.3.4.2 Calibration with shunt installed 155......................................

7.3.5 Adjusting the rotational speed channel, frequency measurement 159..................

7.3.6 Adjusting the rotational speed channel, power measurement 162.....................

7.3.7 Thermocouples 164............................................................

7.3.7.1 Direct entry of transducer characteristics 165.............................

7.3.8 Current and voltage measurement 166............................................

7.3.8.1 Direct entry of transducer characteristics 167.............................

7.3.9 Resistance temperature sensors 169.............................................

7.3.9.1 Direct entry of transducer characteristics 170.............................

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7.3.10 Resistors 172..................................................................

7.3.10.1 Direct entry of transducer characteristics 172.............................

7.3.11 Pulse counting 174.............................................................

7.3.11.1 Direct entry of transducer characteristics 175.............................

7.4 Current-fed piezoelectric transducer 179..................................................

7.4.1 Direct entry of transducer characteristics 180......................................

7.5 Piezoresistive transducers 182...........................................................

7.5.1 Direct entry of transducer characteristics 182......................................

7.5.1.1 Calibrating the characteristic curve of the transducer 184...................

7.6 Potentiometric transducers 186..........................................................

7.6.1 Direct entry of transducer characteristics 187......................................

7.6.1.1 Calibrating the characteristic curve of the transducer 189...................

8 Additional functions 191.....................................................................

8.1 Remote control (single-channel modules only) 191.........................................

8.1.1 Turning on remote control 191...................................................

8.1.2 Assigning remote control contacts 192............................................

8.2 Limit values (single-channel modules only) 194............................................

8.2.1 Turning on limit switches 195....................................................

8.2.2 Adjusting limit values 196.......................................................

8.2.3 Selection keys in the Limit switches menu 198.....................................

8.3 Limit value combination (single-channel modules only) 199..................................

8.4 Set peak values 202....................................................................

8.4.1 Peak-value memory 202........................................................

8.4.2 Combining peak-value memories 203.............................................

8.4.3 Control of peak-value memory 205...............................................

8.4.4 "Peak value" operating mode 205................................................

8.4.5 "Instantaneous value" operating mode 206........................................

8.4.6 Envelope curve operating mode 207..............................................

8.4.7 Clear peak-value memory 208...................................................

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8.5 Version 209...........................................................................

8.6 Switching 210.........................................................................

9 Display 213.................................................................................

9.1 Display format 213.....................................................................

9.1.1 Select setup window 214........................................................

9.1.2 Setup window Display format 215................................................

9.1.3 Setup window components 216..................................................

9.1.3.1 Numeric value display 217.............................................

9.1.3.2 Graphic display 227...................................................

9.1.4 Limit value status 230..........................................................

9.1.5 Recording status 231...........................................................

9.2 F keys 232............................................................................

9.2.1 F keys in measuring mode 232...................................................

9.2.2 F keys in Setup mode 234.......................................................

9.3 Channel names 235....................................................................

10 System 237.................................................................................

10.1 Password 237.........................................................................

10.1.1 Define new user 238............................................................

10.1.2 Password protection activation 239...............................................

10.1.3 Set access for operator 240.....................................................

10.1.4 Delete user 241................................................................

10.1.5 Change password 242..........................................................

10.2 Save/load 243.........................................................................

10.3 Recording series of tests 248............................................................

10.3.1 Setting parameters of test series 249.............................................

10.3.2 Format of the MGCplus measurement files 267....................................

10.3.2.1 Measured values 267..................................................

10.3.2.2 Time channels 269....................................................

10.3.3 MEA format in detail (MGC binary format 2) 270...................................

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10.4 Interface 275..........................................................................

10.4.1 Port usage 279................................................................

10.4.2 Communication processor and multi-client mode 279...............................

10.5 Language 281.........................................................................

10.6 Time 282.............................................................................

11 Menu structure 283..........................................................................

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1 Safety instructions

Safety instructions

Intended use

The amplifier system is to be used exclusively for measurement tasks and directly related control tasks. Use for any purpose other than the above is deemed to be non-designated use.

In the interests of safety, the device should only be operated as described in the operating manuals. It is also essential to comply with the legal and safety requirements for the relevant application during use. The same ap plies to the use of accessories.

Each time, before starting up the equipment, you must first run a project planning and risk analysis that takes into account all the safety aspects of automation technology. This particularly concerns personal and machine protection.

Additional safety precautions must be taken in plants where malfunctions could cause major damage, loss of data or even personal injury. In the event of a fault, these precautions establish safe operating conditions.

This can be done, for example, by mechanical interlocking, error signaling, limit switches, etc.

General dangers of failing to follow the safety instructions

The amplifier system is a state of the art unit and as such is reliable. The device may give rise to residual dangers if it is inappropriately installed and operated by untrained personnel.

Any person instructed to carry out installation, commissioning, maintenance or repair of the device must have read and understood the operating manuals and in particular the technical safety instructions.

Residual dangers

The scope of supply and performance of the amplifier system covers only a small area of measurement technology. In addition, equipment planners, installers and operators should plan, implement and respond to the safety engineering considerations of measurement technology in such a way as to minimize residual dangers. On-site regulations must be complied with at all times. There must be reference to the residual dangers connected with measurement technology.

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Safety instructions

After making settings and carrying out activities that are passwordprotected, you must make sure that any controls that may be connected re main in a safe condition until the switching performance of the amplifier system has been tested.

Working safely

The supply voltage connection, as well as the signal and sense leads, must be installed in such a way that electromagnetic interference does not ad versely affect device functionality (HBM recommendation: "Greenline shielding design", can be downloaded from http://www.hbm.com/Greenline).

Automation equipment and devices must be designed in such a way that adequate protection or locking against unintentional actuation is provided (access checks, password protection, etc.).

When devices are working in a network, these networks must be designed in such a way that malfunctions in individual nodes can be detected and shut down.

Safety precautions must be taken both in terms of hardware and software, so that a line break or other interruptions to signal transmission, such as via the bus interfaces, do not cause undefined states or loss of data in the auto mation device.

Error messages should only be acknowledged once the cause of the error is removed and there is no further danger.

Conversions and modifications

The amplifier system must not be modified from the design or safety engi neering point of view except with our express agreement. Any modification shall exclude all liability on our part for any resultant damage.

In particular, any repair or soldering work on motherboards (replacement of components, apart from EPROMs) is prohibited. When exchanging com plete modules, use only original parts from HBM.

The amplifier system and/or individual components are delivered from the factory with a fixed hardware and software configuration. Changes can only be made within the possibilities documented in the operating manuals.

Qualified personnel

are persons entrusted with siting, mounting, starting up and operating the product and who possess the appropriate qualifications for their function.

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Safety instructions

This device is only to be installed and used by qualified personnel strictly in accordance with the specifications and with the safety rules and regulations which follow. It is also essential to comply with the legal and safety require ments for the relevant application during use. The same applies to the use of accessories.

Qualified personnel includes people who meet at least one of the following requirements:

- Knowledge of the safety concepts of automation technology is a re quirement and as project personnel, you must be familiar with these concepts.

- As automation plant operating personnel, you have been instructed how to handle the machinery and are familiar with the operation of the systems, components and technologies described in this documenta tion.

- As commissioning engineers or service engineers, you have success fully completed the training to qualify you to repair the automation sys tems. You are also authorized to activate, ground and label circuits and equipment in accordance with safety engineering standards.

Safety rules

Before starting up, make sure that the mains voltage and type of current stated on the type plate match the mains voltage and type of current at the place of operation and that the circuit used is sufficiently protected.

The mains plug must only be inserted into a grounded socket with a protec tion switch (protection class I).

Use only the mains cable included with delivery, which is fitted with a ferrite core.

The device must be switched off and the mains plug disconnected from the socket before opening the device.

Never pull the mains plug out of its socket by the supply lead. Do not operate the device if the mains lead is damaged. If an amplifier channel is removed, the module must be sealed with a blind

panel. Only operate built-in devices once they are installed in the housing pro

vided.

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Electromagnetic compatibility

The device complies with the safety requirements of DIN EN 61010 Part 1 (VDE 0411 Part 1); protection class I.

The insulation resistance of the connecting cables (v50V) must be at least 350V(AC).

1.1 Electromagnetic compatibility

The MGCplus device has been tested based on EMC product standard EN 61326-1:2013. This standard includes definitions of limit values and test levels for various electromagnetic environments.

Regarding emission (EME), requirements are included for class A (industrial environments) and class B (residential, business and commercial environ ments as well as small businesses). Laboratory applications also usually require class B.

The product standard here references to EN 55011:2009+A1:2010. Regarding immunity to interference, the product standard includes require

ments for controlled electro-magnetic environments (lowest requirements), general environments and industrial environments (highest requirement).

MGCplus meet the following requirements:

Emission (EME): Class B

- Immunity to interference: Industrial environment

The MGCplus series and the individual modules thus essentially meet the highest requirements and are therefore suitable for use in all environments described in the product standard.

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2 Markings used

Markings used

Markings on the device

2.1 Markings on the device

CE mark

By way of the CE mark the manufacturer guarantees that the product com plies with the requirements of the relevant EC directives (the Declaration of Conformity can be found at http://www.hbm.com/HBMdoc

Statutory waste disposal mark

In accordance with national and local environmental protection and material recovery and recycling regulations, old devices that can no longer be used must be disposed of separately and not with normal household garbage.

Electrostatic sensitive devices

Components marked with this symbol can be damaged beyond repair by electrostatic discharge. Please observe the handling instructions for electro static sensitive devices.

Any risk of residual dangers when working with the amplifier system are pointed out in these instructions by means of the following symbols:

2.2 The markings used in this document

Symbol Meaning

DANGER

WARNING

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This marking warns of an imminently threatening dangerous situation in which failure to comply with safety requirements will result in death or extremely serious physical injury.

This marking warns of a potentially dangerous situation in which failure to comply with safety requirements could result in death or serious physical injury.

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Markings used

The markings used in this document

MeaningSymbol

CAUTION

Notice

Important

Tip

Information

Emphasis See …

Device -> New Bold text indicates menu items, as well as dialog and window headings in

Sampling rate Bold text in italics indicates inputs and input fields in the user interfaces.

This marking warns of a potentially dangerous situation in which failure to comply with safety requirements could result in slight or moderate physi cal injury.

This marking draws your attention to a situation in which failure to comply with safety requirements could lead to property damage.

This marking draws your attention to important information about the product or about handling the product.

This marking indicates tips for use or other information that is useful to you.

This marking draws your attention to information about the product or about handling the product.

Italics are used to emphasize and highlight text and identify references to sections, diagrams, or external documents and files.

the program environment. Arrows between menu items indicate the se quence in which the menus and sub-menus are called up

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3 Introduction

Introduction

Degree of protection

3.1 Degree of protection

The degree of protection given in the technical data indicates the suitability of the housings for various ambient conditions and also the protection of persons against potential risks when used. The letters IP (International Pro tection) which are always present in the designation, are followed by two digits. These indicate which degree of protection a housing offers against contact or foreign objects (first digit) and moisture (second digit).

MGCplus devices are available with degree of protection IP20.

IP 2 0

Code index

2 Protection against contact

Degree of protection against contact and foreign objects

with fingers, protection against foreign objects with > 12 mm

Code index

0 No water protection

Degree of protection against water

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Introduction

Notes on documentation

3.2 Notes on documentation

The complete documentation for the MGCplus amplifier system includes the following documents:

S The operating manual,

which explains manual operation of the device and how to perform mea surements with it.

CD-ROMs containing the following documentation are included with every system device:

S Operation with computer or terminal,

which contains commands for programming and measuring with com puter or terminal.

S MGCplus Assistant,

Documentation of the program for parameterization and control of the MGCplus measuring amplifier system.

This manual contains all the information required to operate the MGCplus.

Guides

Several guides are available to help you: S The header shows you which section or sub-section you are currently

reading. For example:

Introduction

Notes on documentation

S See

è section 6 „Functions and symbols of the AB22A“ for explanations

of the AB22A display and control unit.

è Section 11 „Menu structure“ provides an overview of the drop-down

and setting menus of the display and control unit.

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Introduction

System description

3.3 System description

The MGCplus system is structured modularly. Depending on the housing variant, up to 16 slots are available for single and multi-channel amplifier modules. Thus up to 128 measuring points can be measured in an MGCplus.

Each amplifier module works independently through its own CPU. Data preparation, for example taring, filtering and measuring range adjustment, is carried out digitally. This eliminates the disadvantages of analog data prepa ration, such as time and temperature-dependent drift, errors due to compo nent tolerances, greatly limited flexibility and extensive circuitry. An essen tial precondition for this is analog/digital conversion with no loss of information. The digitally conditioned signal is directed to the internal bus.

For single-channel modules, two analog outputs (voltage) are available in addition to the digital measured values.

An internal standard PC computer in credit-card format collects data with a total sampling rate of up to 307,200 measured values per second (4-byte integer format: 3-byte measured value + 1-byte status). All measurement signals can be acquired in parallel, since each channel has its own ADU. No Sample & Hold or Multiplexer is used in the MGCplus. This ensures continu ous digital filtering and maximum signal stability.

Data is sent to an external computer or PLC via interfaces such as Ethernet. A large part of the system functionality is implemented by device-internal

software (also called firmware). We therefore recommend you use our free firmware updates and always keep your devices updated to the latest firmware version. For further information go to www.hbm.com/downloads.

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Introduction

System description

...

12 8

...

2400Hz

signal conditioning

Filtering, scaling,

zero balance, ...

2400Hz

Digital

CPU

8-channel

module

...

Digital signal

conditioning

Filtering

Scaling, zero

balance, ...

Single

channel

module

Fig. 3.1 Block diagram of MGCplus

"10V

Digital control inputs, limit

switches

...

CPU

CPU CPU

CPU

CAN

...

Profi-bus

CPU

Display

and

control

panel

Serial bus

Storage medium (optional)

Communication

processor CPxx

PC interface

Additional MGCplus

Synchronization

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3.4 Layout of the MGCplus device

Introduction

Layout of the MGCplus device

Connection boards

(AP01i, AP815i, ...)

Power supply

Communication processor

AB22A display and control unit

CPxx

Amplifier plug−in board

(ML30B, ML55B, ML801B...)

Fig. 3.2 Device layout with display and control unit AB22A

Double-width connection boards (AP03i, AP455i) must be plugged into the odd-numbered slots. This also applies to the corresponding amplifiers, re gardless of the width.

Double-width amplifiers (ML38B) must be plugged into the odd-numbered slots. This also applies to the corresponding connection board, regardless of the width.

When asynchronous modules are used (ML7XB with more than eight sub channels), the sequence ‘asynchronous-synchronous-asynchronous’ is not permissible.

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Introduction

MGCplus housing designs

3.5 MGCplus housing designs

The MGCplus system is available with different housing versions (dimensions in mm; 1 mm = 0.03937 inches):

Desktop housing TG009E (173x171x367) Desktop housing TG001E (255x171x367)

Desktop housing TG003E (458x171x367)

Desktop housing Rack frame Slots Supply voltage (V) Weight, approx. (kg)

TG001E − 6 230 (115) 5.9

TG003E ER003E 16 230 (115) 8.3 / 5.5

TG009E − 2 230 (115) 5.0

With the NT030 power pack, the enclosures weigh about 150g less each

19” rack frame ER003E (482x133x375)

TG/ER

All basic devices consist of the following components:

S AB22A display and control unit S Amplifier modules (ML10B, ML30B, ML55B, ML801B ...) S Housing S Connection boards (AP01i, AP815i, ...) S Power supply

Options:

S CP52 (Communication processor for communication with computer that

allows for data storage)

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Introduction

MGCplus housing designs

3.6 Possible amplifier/connection board combination

Single-channel amplifier

ML01B ML10B ML30B ML38B ML55B ML60B

TEDS

AP01i

TEDS

AP03i

AP14

AP17

SG full bridge circuit

SG half bridge circuit

1,4,5,B1

Piezoresistive transducer

Voltage

1,4,5,B1 1,4,5,B1

T3...T10

Torque / rotational speed T3...T10

1,4,5,B1

Torque T1, T4, T5, TB1

SG quarter bridge circuit

Inductive half bridge

Inductive full bridge

For the combination of ML55B with AP14, a one-time zero calibration must always be performed after setting up the measurement chain.

Current

Pulse counter, frequency

Potentiometric transducers

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Introduction

MGCplus housing designs

ML801B ML455 ML460

AP402i

TEDS

AP418i

TEDSTEDSTEDSTEDSTEDSTEDSTEDS

AP455i

AP455iS6

AP460i

Multi-channel amplifiers

AP801

AP801S6

AP809

AP810i

AP814Bi

AP815i

AP835

AP836i

SG full bridge circuit

SG half bridge circuit

SG quarter bridge circuit

Inductive half bridge

Inductive full bridge

Piezoresistive transducer

Voltage

Current

Current−fed piezo− electric transducer

Thermo−resistors

Thermo−resistors PT100

Ohmic resistor

Thermocouples

Pulse counter, frequency

Potentiometer 200 −5000

LVDT

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Special function modules

Introduction

MGCplus housing designs

AP71

AP72

AP74

AP75

AP77

AP78

ML70B ML71B ML77B ML78B

CAN CAN

Serial I/O

ML74B

CANHEAD

Digital output

Digital input

Analog output

ProfiBus

CAN

CANBus

Serial I/O

CANHEAD HBM hardware

RS232, RS422, RS485 I/O

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Introduction

Installation of the CP52 communication processor

3.7 Installation of the CP52 communication processor

For type "D" housings (ER003D or TG001D, etc.) the existing communica tion processor (CP22/CP42) can be replaced by the CP52 communication processor.

► Loosen the screws on the old communication processor, the blind panel

(only with CP22) and the cover of the NT030 power supply unit. ► Remove the parts. ► Insert the new CP52 communication processor and screw it in place. ► Fit the power supply cover of the NT030 and screw the cover in place. The process is similar when subsequently installing a CP52 communication

processor in an MGCplus housing (type "D" or type "E") that was initially configured without a communication processor.

► Loosen the screws on the blind panels, if there are any, of the SY03 syn

chronization interface and the power supply cover. ► Remove the parts. ► Insert the new CP52 communication processor and screw it in place. ► Fit the power supply cover of the NT030 or NT040 and screw the cover

in place.

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Introduction

Installation of the CP52 communication processor

CARDBUS

YE SLAVE

RD ERROR

GN MASTER

CP42

SYN

RS 232

USB DEVICE

USB HOST

ETHERNET

CTRL I/O

24V 21 GND

OUT

Communication processor CP42, power supply unit NT030

Communication processor CP52, power supply unit NT040

Fig. 3.3 Rear views

If the communication processor is installed subsequently in a system where none was present before, the housing cover must also be removed to check the setting of the CP switch (S3). It must be set to "yes" so the system can be started with the communication processor. Then the housing cover can be closed again.

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Introduction

Installation of the CP52 communication processor

Without CP … View from above With CP … View from above

yes (1)

no (2)

yes (1)

no (2)

General plan of the interface switches(housing cover open, view from above):

Housing

Flat ribbon cable

Power supply

CP switch

p 2

Interface switch

Fig. 3.4 General plan of the interface switches

Due to the new functions of the CP52 communication processor, a firmware update of the AB22A display and control unit is necessary. The firmware update program MGCpLoad and the latest firmware are available from www.hbm.com/downloads.

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Page 29

Introduction

Conditions at the place of installation

3.8 Conditions at the place of installation

CAUTION

S Protect the devices in a desktop housing from moisture and dampness

or weather conditions such as rain, snow, etc.

S Make sure that you do not cover the ventilation openings at the side, the

openings for the power pack fan on the back side of the device and the openings underneath the device.

S Do not expose the device to direct sunlight. S Comply with the maximum permissible ambient temperatures for the sys

tem devices, as stated in the technical data sheet.

S For installation in 19" electrical enclosures, due to poorer heat dissipa

tion, measures must be taken to ensure that the maximum permitted am bient temperature (refer to the technical data sheet) is not exceeded! We recommend forced venting in any case and in especially critical cases intermediate spaces between the upper and lower rack frames.

S The devices are classified in overvoltage category II, degree of pollution 2. S Install the device so that it can be disconnected from the mains at any

time without difficulty.

S It is safe to operate the MGCplus up to an altitude of 2000 m.

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Introduction

Maintenance and cleaning

3.9 Maintenance and cleaning

The MGCplus system devices are maintenance-free. Please note the follow ing points when cleaning the housing:

CAUTION

Disconnect the mains plug from the socket before cleaning.

S Clean the housing with a soft, slightly damp (not wet!) cloth. You should

never use solvents, since this may damage the labeling on the front

panel and the display field. S When cleaning, ensure that no liquid gets into the device or connections.

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4 Connection

Mains connection

Connection

Connecting the MGCplus in a tabletop housing/rack frame

4.1 Connecting the MGCplus in a tabletop housing/rack frame

4.1.1 Mains connection

The NT030 and NT040 power supply units are designed for a 115 - 230 V connector and for a maximum configuration of 16 modules and connection boards. Voltage adaptation to a 115V/230V network occurs automatically. The power pack fan is temperature-controlled and is automatically switched on only when necessary.

Housing ground

Grounding switch

If the MGCplus is connected with the mains cable included with delivery, a safe and reliable connection via the protective conductor is ensured.

The power pack is protected internally with a fine-wire fuse.

CAUTION

The power supply fuse may only be replaced by the manufacturer's service personnel!

Grounding switch

In the factory setting ( zero with the protective conductor. If external devices (transducer, com puter) have already set up this connection resulting in ground loops (hum-

pickups), the grounding switch must be opened (

), the grounding switch connects supply voltage

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Connection

Connecting the MGCplus in a tabletop housing/rack frame

4.1.2 Synchronization of multiple CP52 devices

4.1.2.1 Synchronization of multiple CP52 devices via a synchronization jack

Connected devices are automatically detected and synchronized when syn chronization jacks are occupied. Connect the master device with the first slave device (Sync In, X1) via the output jack (Sync Out, X2). If there are additional slave devices, connect the input jack (Sync In, X1) in turn with the output jack (Sync Out, X2) of the previous slave device (Sync Out, X2).

LED Sync Out Status

Green Device is ready for operation and the time signal is

Yellow There is no valid time signal present on the Sync out

LED Sync In Status

Green The device is in slave mode, correctly synchronized

Yellow The device is in slave mode but is not synchronized.

present on the Sync output.

put.

and ready for operation.

Synchronization sockets

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Connection

Connecting the MGCplus in a tabletop housing/rack frame

If several MGCplus systems are to be synchronized with each other, each system must be equipped with a CP52 communications processor. To syn chronize MGCplus systems with CP52, you need a synchronization cable with the HBM part number 1-KAB2125-2 (2 m in length).

Fig. 4.1 Example of synchronizing two MGCplus systems equipped with CP52.

The overall length of the synchronization chain (total length of cable be tween the sync master and the last sync slave) must be less than 150 m. A termination resistor should be used if the line length is >15 m. We recom mend that you attach a termination resistor connector to the Sync Out socket (X2) of the last sync slave. This connector is available from HBM on request. The maximum number of MGCplus units that can be synchronized is 32.

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Connection

Connecting the MGCplus in a tabletop housing/rack frame

Powering up the system

When connecting the system, the sync slaves must be connected first. Connect the system that will work as the sync master last of all.

4.1.3 Synchronization of CP52 with CP22/CP42

The synchronization jack enables MGCplus systems with CP52 to be synchronized with MGCplus systems with CP22/CP42.

To do this note the following points: Both CP42 and CP52 can be the synchronization master. CP22 can only be

a synchronization slave. Use the following cables for this:

1-KAB2126-2: CP52 (master) to CP22/CP42 (slave) 1-KAB2127-2: CP42 (master) to CP52 (slave)

The synchronization status for CP22/CP42 is indicated by a multicolor LED.

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Connection

Connecting the MGCplus in a tabletop housing/rack frame

CP42

RS 232

CARDBUS

USB DEVICE

USB HOST

YE SLAVE

CTRL I/O

RD ERROR

GN MASTER

SYNC

OUT

ETHERNET

24V 21GND12

OUT

Fig. 4.2 Example of synchronizing two MGCplus systems equipped with CP52

and CP42.

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Connection

Shielding design

4.2 Shielding design

Sources of interference can cause electromagnetic fields which can induce interference voltages inductively or capacitively via the connection cable and device housing in the measuring circuit and therefore interfere with the device function. It must be ensured that the devices used in the system also do not transmit any electromagnetic interference. Electromagnetic compati bility (EMC), which encompasses both the required electromagnetic interfer ence immunity (EMI) and the permissible electromagnetic interference emis sions (EME), has become increasingly important over the years.

The HBM Greenline shielding design

The measurement chain is completely enclosed by a Faraday cage by appropriate routing of the cable shield. The cable shield is extensively con nected with the transducer housing and is routed via the conductive plug to the amplifier housing. The influence of electromagnetic interference is signif icantly reduced by these measures.

The conductive housing ensures the connection to the plug or device housing

Signal-carrying contacts

Fig. 4.3 Routing of the cable shield on the plug

The cable shield is connected with the conductive housing via strain relief

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Connection

Shielding design

Notice

All parts of the measurement chain (including all cable connection points such as plugs and couplings) must be surrounded by a closed EMC-tested shield. Shield junctions must represent a full contact, closed and low-imped ance connection. This is the case for original HBM plug connections.

Ground connection and grounding

As the signal ground and shielding are separated in EMC-compliant cabling, the shielding can be connected at more than one point to the ground, i.e. via the transducer (metal housing) and the amplifier (housing is connected to the ground conductor).

If there are differences in potential in the measuring system, a potential compensating line must be laid (recommended value: highly flexible stranded wire, wire cross section 10mm set up so they are physically separated from current-carrying power lines. Ideally, cable ducts made of sheet metal with an internal partition should be used. Signal ground, ground and shielding must be laid out separated as much possible.

). Signal and data leads must be

In order to minimize the effect of electromagnetic interference and differ ences in potential, the signal ground and ground (or shielding) are designed to be physically separate in the HBM devices. The ground connection or a separate mains protective conductor should serve as the ground connec tion, as is the case for potential compensation in buildings, for example. The ground cable should not be connected to a radiator body, water pipe or simi lar objects.

Connecting transducers with double shield technique

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Connection

Shielding design

AP01i

AP14

AP03i

AP455i

Measurement signal (-)

Measurement signal (+)

Bridge excitation voltage (-) Bridge excitation voltage (+)

Cable shield Sense lead (+) Sense lead (-)

Hsg.

13 12

8 5 6

B C D

Hsg.

RB / 2 (on the transducer)

Hsg. = Housing

HBM recommends this connection technique for measuring amplifiers ML10B, ML30B, ML38B, ML55B and ML455 with connection boards AP01i, AP03i, AP14 and AP455i with very small measuring ranges, in environments especially subject to interference and when long cables are used.

This applies to all bridge connections. With cable lengths >50 m, a resistor with half the value of the bridge

resistance (R_B/2) must be connected in each sense lead of the trans ducer.

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Connection

Connecting the transducer

Measurement signal (+)

Bridge excitation

Feedback

voltage (-) Bridge excitation

voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

bridges

4.3 Connecting the transducer

Transducers with four-wire configuration If you connect a transducer with a 4-wire cable, you must connect the sense lead with the corresponding bridge excitation circuit in the transducer plug (sense line (-) with bridge excitation voltage (-) and sense lead (+) with bridge excitation voltage (+)

Important

. A cable extension may only be implemented

with 6-wire configuration.

TEDS

TEDS data

AP01i

AP455i

4.3.1 Connecting separate TEDS modules

Single-channel amplifier MLxx (together with connection board AP01i) must

Important

have at least hardware revision 1.32 or higher.

For cable lengths >50m, a resistor of half the value of the bridge resistance (RB/2) must be activated on the transducer instead of each feedback bridge. If the transducers are calibrated in a 6-wire configuration, resistors must be activated directly into the sense lead.

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Connection

Connecting separate TEDS modules

AP402i

View of the mating connector

(solder side)

TEDS

TEDS data

Hsg.

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TEDS

TEDS data

AP460i

Hsg.

Cable color code:

wh= white;

bk= black;

bu= blue;

rd= red;

ye= yellow;

gn= green;

gy= gray

910

Connection

Connecting separate TEDS modules

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Page 42

Connection

SG full bridges, inductive full bridges

4.3.2 SG full bridges, inductive full bridges

AP01i

AP03i

AP455iS6

AP14

AP455i

Hsg.

Measurement signal (+)

Bridge excitation

b u r d

g y

voltage (-) Bridge excitation

voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

Hsg.

A B

Hsg.

F G

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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AP810i/AP815i

Subchannel 1...4

Subchannel 5...8

Full bridge circuits on AP810i/AP815i

4.3.3 Full bridge circuits on AP810i/AP815i

Subchannel

1/5

Measurement signal (+)

Bridge excitation

voltage (-) Bridge excitation

voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

)

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

Subchannel

2/6

Hsg. Hsg.

Subchannel

3/7

Connection

Subchannel

4/8

Hsg.

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Connection

Strain gage half bridges, inductive half bridge circuits

4.3.4 Strain gage half bridges, inductive half bridge circuits

AP01i

AP03i

AP455iS6 AP14 AP455i

Hsg.

Measurement signal (+)

Bridge excitation

b u

g y

voltage (-) Bridge excitation

voltage (+)

Cable shield

Sense lead (+)

Sense lead (-)

Hsg. Hsg.

A B C

F G

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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4.3.5 LVDT transducers

Connection

LVDT transducers

Measurement signal (+)

Bridge excitation voltage (-)

Bridge excitation voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

)

AP455i

Hsg.

AP455iS6

Hsg.

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Connection

Strain gage half bridges on AP810i

AP810i

4.3.6 Strain gage half bridges on AP810i

1/5

Subchannel

2/6

Subchannel

3/7

Subchannel

4/8

Subchannel

1...4

rd wh/rd

wh/gn

Sense lead (-)

Bridge excitation voltage (-)

Measurement signal (+)

Cable shield

Subchannel

5...8

wh/br br

Bridge excitation voltage (+)

Sense lead (+)

Hsg.

Hsg. Hsg.

Hsg.

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AP815i

Connection

Strain gage half bridges on AP815i

4.3.7 Strain gage half bridges on AP815i

1/5

Subchannel

2/6

Subchannel

3/7

Subchannel

4/8

Subchannel

1...4

Subchannel

5...8

rd wh/rd

wh/gn

wh/br br

Sense lead (-)

Bridge excitation voltage (-)

Measurement signal (+)

Cable shield

Measurement signal (-)

Bridge excitation voltage (+)

Sense lead (+)

Hsg.

Hsg. Hsg.

Hsg.

AP815i can measure decentralized half bridge circuits for which the active SGs are separated by a line.

With decentralized half bridge circuits the measured value must be acquired at both ends of the connecting line between the active SGs. With standard half bridge circuits a connector can also be bridged.

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Connection

Single strain gage

4.3.8 Single strain gage

4.3.8.1 Single strain gage on AP14

AP14

Three-wire connection Four-wire connection

Sense lead (-)

Excitation voltage (-)

Excitation voltage (+)

Measurement signal (+), sense lead (+)

Hsg.

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AP814Bi

Connection

Single strain gage

4.3.8.2 Single strain gage on AP814Bi

Subchannels

Subchannel 1...8

Measurement signal (+), excitation voltage (+)

Cable shield

Excitation voltage (-)

Sense lead (-)

Hsg.

Hsg.15Hsg.

Hsg.5Hsg.

Hsg.

Hsg.18Hsg.

Hsg.

Hsg.21Hsg.

Hsg.11Hsg.

Hsg.24Hsg.Hsg.

Three-wire connection

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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Connection

Single strain gage

AP815i

4.3.8.3 Single strain gage on AP815i

1/5

Subchannel

2/6

Subchannel

3/7

Subchannel

4/8

Subchannel

1...4

wh/rd

Subchannel

5...8

wh/gn

Excitation voltage (-)

Sense lead (-)

Cable shield

Measurement signal (+), sense lead (+)

Excitation voltage (+)

Hsg.

Hsg. Hsg.

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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AP815i

Subchannel

1...4

Subchannel

5...8

Connection

SG chains and strain gage rosettes on AP815i

4.3.9 SG chains and strain gage rosettes on AP815i

Subchannel

4/8

3/7

SG 2/6

Excitation voltage (-)

Sense lead (-)

Cable shield

Measurement signal (+), sense lead (+)

Excitation voltage (+)

Hsg.

Subchannel

2/6

Subchannel

3/7

Subchannel

4/8

Subchannel

You can operate a maximum of eight SGs at 120 ohms with a 5-V current feed. Make certain that sensor point 2' of the SG chain is as close as possi ble for the individual strain gages and the distances between the individual strain gages are short.

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Connection

SG chains and strain gage rosettes on AP815i

If the distances between the individual strain gages cannot be kept small (for example two 90 strain gage rosettes in different places), they must be connected as follows:

AP815i

Subchannel

1...4

5...8

SG2 SG1

SG4 SG3

Subchannel

Excitation voltage (-)

Sense lead (-)

Cable shield

Measurement signal (+), sense lead (+)

Excitation voltage (+)

Hsg.

Subchannel

Excitation voltage (-)

Sense lead (-)

Cable shield

Measurement signal (+), sense lead (+)

Excitation voltage (+)

Hsg.

Subchannel

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Connection

Torque flange T10 series, T40 series

4.3.10 Torque flange T10 series, T40 series

4.3.10.1 Torque measurement

Plug 1

7/5 6

r d

w h ye

g y

Power supply (0V)

Supply voltage (18V ... 30 V)

Torque measurement signal, frequency output (+)

Torque measurement signal, frequency output (-)

Cable shield

Calibration signal trigger (approx. 5V)

Ground

AP17

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

Does not apply to version KF1.

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Connection

Torque flange T10 series, T40 series

AP460i

Plug 1

7/5

d w

h ye

g y

Torque measurement signal, frequency output (+)

Torque measurement signal, frequency output (-)

Cable shield

Ground

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

910

Information

The torque flanges must be powered externally.

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Connection

Torque flange T10 series, T40 series

4.3.10.2 Rotational speed measurement (symmetrical signals)

AP17

Plug 2

bk and bu

g y

Ground

Rotational speed measurement signal, 0 (+)

Rotational speed measurement signal, 0 (-)

Rotational speed measurement signal, 90 (-)

Cable shield

Rotational speed measurement signal, 90 (+)

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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Page 56

Connection

Torque flange T10 series, T40 series

AP460i

Plug 2

g y

Ground

Rotational speed measurement signal, 0 (+)

Rotational speed measurement signal, 0 (-)

Rotational speed measurement signal, 90 (-)

Cable shield

Rotational speed measurement signal, 90 (+)

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

910

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Connection

Torque flange T10 series, T40 series

4.3.10.3 Rotational speed measurement (symmetrical signals) with reference pulse

AP17

Plug 2

b u

g y

Ground

Rotational speed measurement signal, 0 (+)

Rotational speed measurement signal, 0 (-)

Rotational speed measurement signal, 90 (-)

Cable shield

Reference signal (+)

Reference signal (-)

Rotational speed measurement signal, 90 (+)

5V (out)

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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Page 58

Connection

Torque flange T10 series, T40 series

AP460i

Plug 2

b u

g y

Ground

Rotational speed measurement signal, 0 (+)

Rotational speed measurement signal, 0 (-)

Rotational speed measurement signal, 90 (-)

Cable shield

Reference signal (+)

Reference signal (-)

Rotational speed measurement signal, 90 (+)

Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

910

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Connection

Torque shaft (T4A, T5, TB1A)

4.3.11 Torque shaft (T4A, T5, TB1A)

4.3.11.1 Torque measurement (slip rings or direct cable connection)

AP01i

AP14

AP03i

AP455i

A B

Feedback bridges for

transducer in a four wire

configuration *

SG full bridge only

Transducer in a 6-wire configuration: see connection diagram page 42

b u r d

Measurement signal (+)

Bridge excitation voltage (-)

Bridge excitation voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

Hsg. Hsg.

Cable color code: wh= white; bk= black; bu= blue; rd= red; ye= yellow; gn= green; gy= gray

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Connection

Torque shaft (T4A, T5, TB1A)

Jumper (factory settings 0V)

Supply voltage +16V

No function (for special versions only)

Supply voltage +8V

Supply voltage +5V

Connection board AP 460 (side view)

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Connection

Torque shaft (T4A, T5, TB1A)

4.3.11.2 Rotational speed measurement with inductive transducers

AP460i

Rotational speed

Inductive

measurement signal

Rotational speed

measurement signal

(+)

= 30V

max

(-)

tachometer (T-R coil)

Please note the setting information for T-R coils on page 152.

910

1 k 5 k

5 V

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Connection

Thermocouples

4.3.12 Thermocouples

Thermocouple

Compensating

line

(-)

(+)

line

Miniature thermo connector (see table for matching type)

AP809

−

Miniature thermo connector, uncompensated

Type Thermal material 1 (+) Thermal material 2 (-)

J Iron Copper-nickel K Nickel‐chrome (color code

green)

Nickel‐aluminum (color code white)

T Copper Copper-nickel

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4.3.13 DC voltage sources

Maximum input voltage against ground = 12V

DC voltage sources

AP01i AP03i

Connection

(+)

Supply voltage zero

(-)

Cable shield

With a potential-free DC voltage source you must connect pin 15 with pin 6.

Hsg. Hsg.

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Connection

DC voltage sources

AP402i

Maximum input voltage against ground = " 100V

(+)

(-)

Cable shield

Hsg.

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Connection

DC voltage sources

Maximum input voltage against ground = +50V

(+)

(-)

AP801

Hsg.

Supply voltage 8V/16V

Power supply 0V

*) For information on switching the supply voltage see next page

AP801S6

(+)

(-)

Hsg.

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Connection

DC voltage sources

Supply voltage +16V

No function (for special versions only)

Jumper

Connection board AP 801S6 (side view)

No function (for special versions only)

Supply voltage +8V

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AP402i

Connection

DC voltage sources

Supply voltage 5V/8V/16V

Power supply 0V

For information on switching the supply voltage see next illustration

Jumper

(+)

(−)

Hsg.

Supply voltage +5V Supply voltage +8V

Supply voltage +16V No function (factory setting)

Connection board AP402i (side view)

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Connection

DC voltage sources

AP836i

Subchannels

2/61/5 3/7 4/8

Subchannel 1...4

Subchannel 5...8

0 V

(+)

OUT

Bridge excitation voltage (+)

Sense lead (+)

Measurement signal (+)

Measurement signal (-)

Cable shield

Sense lead (-)

Bridge excitation voltage (-)

Hsg.

Common signal and supply voltage zero, power line not corrected on one side.

Since the bridge excitation voltage used to supply the active transducer is symmetrical to GND/ground, the design of the active transducer must without exception be potential-free!

Subchannels

2/61/5 3/7 4/8

Hsg.

Subchannel 1...4

Ub(-)

(+)

OUT

0 V

Subchannel 5...8

Bridge excitation voltage (+)

Sense lead (+)

Measurement signal (+)

Measurement signal (-)

Cable shield

Sense lead (-)

Bridge excitation voltage (-)

Hsg.

Separate signal and supply voltage zero, power lines not corrected

Since the bridge excitation voltage used to supply the active transducer is symmetrical to GND/ground, the design of the active transducer must without exception be potential-free!

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Connection

DC voltage sources

AP836i

Subchannels

2/61/5 3/7 4/8

Subchannel 1...4

Subchannel 5...8

(+)

OUT

0 V

Bridge excitation voltage (+)

Sense lead (+)

Measurement signal (+)

Measurement signal (-)

Cable shield

Sense lead (-)

Bridge excitation voltage (-)

Hsg.

Common signal and supply voltage zero, power lines fully corrected.

Since the bridge excitation voltage used to supply the active transducer is symmetrical to GND/ground, the design of the active transducer must without exception be potential-free!

Subchannels

2/61/5 3/7 4/8

Hsg.

Subchannel 1...4

(+)

OUT

0 V

(-)

Subchannel 5...8

Bridge excitation voltage (+)

Sense lead (+)

Measurement signal (+)

Measurement signal (-)

Cable shield

Sense lead (-)

Bridge excitation voltage (-)

Hsg.

Separate signal and supply voltage zero, power lines fully corrected.

Since the bridge excitation voltage used to supply the active transducer is symmetrical to GND/ground, the design of the active transducer must without exception be potential-free!

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Connection

DC power sources

4.3.14 DC power sources

Maximum input voltage against ground = 12V

AP01i AP03i

Supply voltage zero

(-)

(+)

Cable shield

Hsg.

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Maximum input voltage against ground = ±100V

AP402i

Connection

DC power sources

(-)

(+)

Cable shield

Hsg.

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Connection

Resistors, Pt100

4.3.15 Resistors, Pt100

AP835

Excitation voltage (-)

Measurement signal (-)



Cable shield

Measurement signal (+)

Excitation voltage (+)

Hsg.

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Frequency measurement without directional signal

4.3.16 Frequency measurement without directional signal

AP01i AP03i

Connection

Frequency generator/ pulse generator

Supply voltage zero

Cable shield

Rotational speed/pulse signal 1 (frequency f1)

Deactivate the analysis of the f2 signal in this mode (factory setting: Off), see page 159.

Hsg.Hsg.

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Connection

Frequency measurement with directional signal

4.3.17 Frequency measurement with directional signal

AP01i AP03i

Frequency generator / pulse generator

Supply voltage zero

Cable shield

Rotational speed/pulse signal 1 (frequency f1)

Pulse signal 2 (frequency f2)

Activate the analysis of the f_2 signal in this mode (factory setting: Off), see page 159

Hsg.Hsg.

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4.3.18 Pulse counting, single-pole

Connection

Pulse counting, single-pole

Industrial pulse generators

Zero index

Transducer error

AP01i AP03i

AP460i

AP17

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Connection

Pulse counting, differential

4.3.19 Pulse counting, differential

Industrial pulse generators

Zero index signal +

Zero index signal -

Transducer error

f1+

f2-

AP17

AP460i

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4.3.20 Active piezoelectric transducers

* Use special coaxial cable

Shield

Piezoelectric transducer with preamplifier (with T‐ID/TEDS for AP418i)

Connection

Active piezoelectric transducers

AP418i

Input *

Information

Information about AP418i connection boards: When laying transducer cables outside of enclosed areas or with cable lengths greater than 30 m between the connection board and transducer, the sensor cables must be designed with an additional, separately grounded shield to ensure overvoltage protection. This can be done for example by laying the cable in a metallic pipe or using double-shielded cable, in which case the outer shield must be connected to ground potential or protective conductor potential where it is close to the connection board (for example where it enters the switch cabinet). HBM recommends Triaxial cable for this purpose.

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Connection

Piezoresistive transducers

4.3.21 Piezoresistive transducers

AP01i AP03i

Hsg.

B C D

Hsg.

Measurement signal (+)

Bridge excitation

voltage (-) Bridge excitation

voltage (+)

Measurement signal (-)

Cable shield

Sense lead (+)

Sense lead (-)

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4.3.22 Potentiometric transducers

Potentiometric transducers

AP01i AP03i

Connection

AP836

Subchannel 1...4

Subchannel 5...8

Measurement signal (+)

Bridge excitation voltage (-)

Bridge excitation voltage (+)

Cable shield

Sense lead (+)

Sense lead (-)

Hsg. Hsg.

A B C

F G

Subchannels

2/61/5 3/7 4/8

Measurement signal (+)

Bridge excitation voltage (-)

Bridge excitation voltage (+)

Cable shield

Sense lead (+)

Sense lead (-)

Hsg. Hsg. Hsg. Hsg.

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Connection

Connection via the distributor board VT810/815i

4.3.23 Connection via the distributor board VT810/815i

Single SG; four-wire connection, AP815i only

wh/rd

Excitation voltage (-)

Sense lead (-)

Cable shield

wh/gn

Measurement signal (+)

Excitation voltage (+)

SG full bridge

circuit

wh/gn rd

wh/rd

wh/br

Measurement signal (+)

Sense lead (-)

Bridge excitation voltage (-)

Measurement signal (-)

Bridge excitation voltage (+)

Sense lead (+)

Cable shield

Strain gage half bridge on (AP810i) on VT810/815i

RJ45 socket RJ45 socket

Hsg.

rd wh/rd

wh/gn

wh/br br

Sense lead (-)

Bridge excitation voltage (-)

Measurement signal (+)

Cable shield

Bridge excitation voltage (+)

Sense lead (+)

Hsg.

7 8

Strain gage half bridge on (AP815i) on VT810/815i

RJ45 socket

Hsg.

wh/rd

wh/gn

wh/br br

Sense lead (-)

Bridge excitation voltage (-)

Measurement signal (+)

Cable shield

Measurement signal (-)

Bridge excitation voltage (+)

Sense lead (+)

RJ45 socket

Hsg.

7 8

The color code refers to 1-KAB156-3.

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Connection via the distributor board VT810/815i

Connecting diagram

Measuring point Distributor board VT810/815i Connection board AP810i/815i

SG 1

1-Kab156-3

RJ45

D‐Sub25

Connection

SG 2

SG 8

D‐Sub25

1-Kab156-3

1-Kab263-3

D‐Sub25

1-AP810i

1-AP815i

Extensive connection instructions are enclosed with the distributor board.

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Connection

Connecting CANHEAD modules

4.4 Connecting CANHEAD modules

To connect CANHEAD modules to the MGCplus system you need the ML74B communication card and the AP74 connection board.

tion with the NT030 power pack, you can connect a maximum of 12 modu les per board and a maximum of 25 modules per MGCplus device (a maxi mum of 256 channels per CP42 and 512 channels per CP52 in total). The combination of NT040 with CP52 enables up to 50 modules per MGCplus device to be connected.

operation see the "CANHEAD measurement electronics" assembly instruc tions.

For further information regarding connection and

10 measurement

channels

In combina

ML74B / AP74

MGCplus

measurement

channels

Maximum 24 CANHEAD modules

Fig. 4.4 Connection to MGCplus

The T-piece 1-CANHEAD-M12-T is used when a branch circuit will be cre ated.

The AP74 connection board in the MGCplus contains a built-in termination resistor.

T-piece

measurement

channels

No termination resistor required

measurement

channels

Termination resistor

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ML74B

Communication card ML74B

4.4.1 Communication card ML74B

LED Labeling Color Meaning

1 CHAN. Yellow Channel is selected. 2 ERROR/WARN. Red Error/Warning 3 Rx Yellow CAN protocol being received 4 Tx

Yellow

CAN protocol being sent

Connection

OVRN

Red

Overrun occurred 5 BUS-/ERR Red Bus error 6 CONFIG Yellow The assigned CANHEADS are being

set up 7 AP74

STATUS

Yellow Off Red

Power supply via AP74

No power supply via AP74

Error in power supply via AP74 8 SCAN Yellow Bus scan is being performed 9 - - -

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Connection

AP74 connection board

AP74

4.4.2 AP74 connection board

LED color Meaning

Green Normal status in operation Red Short circuit or force overshoot None Power supply turned off

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Connection

Inputs and outputs, remote controls

4.5 Inputs and outputs, remote controls

4.5.1 Inputs/outputs of the CP52

The CP52 communication processor has two digital inputs and outputs each. The digital inputs and outputs must be operated with an external cur rent feed (12 V ... 24 V).

Inputs (0 V ... 24 V)

You can assign the following functions to the digital inputs: S Start to record measured data with an external trigger The status of the inputs and outputs can also be queried with the MGCplus

terminal commands.

Outputs (0 V ... 24 V)

The following functions are assigned to the digital outputs: S Disk is full If the remaining storage space of the USB mass storage medium in the

CP52 is 1 Mbyte, the output is set to logical High. The status can be changed using the MGCplus terminal commands.

S System is up and running

Inputs and outputs

When the initialization is completed and measured values are acquired, the output is set to logical High.

Notice

Functions can only be assigned to the digital inputs and outputs of the CP52 communication processor by using the MGCplus Assistant software from HBM.

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Connection

Inputs and outputs, remote controls

COM

24V DC

Fig. 4.5 Wiring example for the "Start Trigger" function at the CP52 control inputs

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Connection

Inputs and outputs, remote controls

4.5.2 Analog output on the front panel

On the front panel of a single-channel module there is a BNC socket for the analog output signal VO1. (This socket is used for test purposes. Stationary wiring should always be done with the connection boards, since there is no noise voltage with this method).

Notice

Please note: The input resistance of the connected device must be greater than 1MΩ.

When connecting a coaxial cable to the analog output of the ML60B ampli fier module, a ferrite (available from Würth, art. no. 742 711 72, or similar) must be placed on the cable for operation in environments of limit value class B in accordance with EN55011 and EN55022 (residential applications, business and commercial applications as well as small businesses).

4.5.3 Connection boards AP01i/AP03i/AP14/AP17

In addition to the transducer connection, the connection boards also provide several output and control signals, depending on the option selected.

They are explained in greater detail in the following sections.

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Connection

Inputs and outputs, remote controls

Outputs OUTPUT

Sct 2

4.5.3.1 Socket assignment AP01i/AP03i/AP14/AP17

Pin Function

Digital 2 Remote control 1 Input 3 Remote control 2 Input 4 Remote control 3 Input 5 Remote control 4 Input 6 Remote control 5 Input 7 Remote control 6 Input 8 Remote control 7 Input 9 Remote control 8 Input 10 no function 11 no function 12 VO2 (Ra>5k) Output 13 VO1 (Ra>5k) Output 16

Digital

Input 17 Limit value output 1 Output 18 Limit value output 2 Output 19 Limit value output 3 Output 20 Limit value output 4 Output 21 Warning Output 22 no function 23 no function 24

Analog

to Pin 12 to Pin 13

Tab. 4.1 Sct2

Assignment of outputs

Analog outputs

S On pin 12 the analog output signal V

is present.

The connected load resistor must be greater than 5 kohms.

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Connection

Inputs and outputs, remote controls

S On pin 13 the analog output signal of VO1 is present (and also on the

BNC socket on the front panel). The connected load resistance must be greater than 5 kohms.

The following signals can be assigned to outputs VO1 and VO2:

S S1: Gross S S2: Net S S3: Peak value 1 S S4: Peak value 2 S S5: various differential, integration and mean value S On pins 17 to 20 the switching states of limit switches 1...4 are present.

The switching states are indicated by two different HCMOS voltage lev els:

Positive logic:

Level 0 V: limit switch OFF Level 5 V: limit switch ON

S On pin 21 a level of 5 V (High level) is present, which can be used as a

warning signal. In case of a fault or broken transducer cable the output signal is set to 0 V (Low). However, this signal is also set to zero during the autocalibration cycle (every 5 minutes for about 1 s).

Remote controls

On pins 2 to 9 of socket 2, remote controls CTRL 1...8 are present for con trol of some amplifier functions. These contacts are active if they have been enabled with the AB22A display and control unit, i.e. in REMOTE operating mode. The assignment of these remote controls is freely selectable. The possible functions are described in section 8 Additional functions.

Information

In the factory settings the contacts are not assigned.

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Connection

Inputs and outputs, remote controls

External triggering

Remote control 7 is used as an external trigger input. With AP01i and AP03i, jumpers can be used to adapt the filter settings of

the two analog outputs follows:

Analog output filtering

With AP01i and AP03i, jumpers can be used to adapt the filter settings of the two analog outputs follows:

Filter

approx. 3 kHz

Analog output V

approx. 2. order

OFF

for ML10B

for all others MLxx

ST1

Additional instructions for AP17: Pin assignment of the input socket

Pin Function I/O

1 Shield 2 Zero index (+) Input 3 Zero index (-) Input 4 Ground 5 Transducer supply voltage -16V (max. 500mA) 6 Transducer supply voltage +16V (max. 500mA)

Output Output

ST6

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Inputs and outputs, remote controls

I/OFunctionPin

7 Not assigned 8 Ground 9 SDA for XM001 external memory module Input 10 SLC for XM001 external memory module Output 11 Transducer supply voltage 5V (max. 300mA)

Output 12 F1+ rotational speed 0, angle of rotation, torque, frequency Input 13 F1- rotational speed 0, angle of rotation, torque, frequency Input 14 F2- rotational speed 90, calibration signal trigger Input/output 15 F2+ rotational speed 90, calibration signal trigger ground Input/output

The current information is for the maximum permitted continuous currents of the AP17. The number of connection boards per housing is not limited, but a maximum of three connection boards can be used for transducer supply (5V/16V, for example for torque flange T10F-SF1).

Termination resistors must be connected for long lines (>100m) and high frequencies (>200kHz). To do this the 3x DIP switch S2 on the motherboard of the AP17 must be switched to "ON".

Connection

AP17

2 1

Switch S2

Fig. 4.6 AP17 component layout

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Connection

Inputs and outputs, remote controls

)

Lemo

(Top view)

910

socket

4.5.3.2 AP460i connector pin assignment

Pin Function

1 Frequency signal 1, input a 2 Frequency signal 1, input b 3 Frequency signal 2, input a 4 Frequency signal 2, input b 5 Zero index, input a 6 Zero index, input b 7 Transducer supply (0V, 5V, 8V or 16V, depending on the jumper

position 8 Transducer detection (TEDS) 9 Supply ground 10 Signal ground

Connection

Symmetrical input signals (RS 422): Input a/input b Asymmetrical input signal, bipolar: Input a (signal ground on input b) Asymmetrical input signal, unipolar: Input a (signal ground on pin 10, input b

must remain open)

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Connection

Inputs and outputs, remote controls

Profibus

4.5.3.3 AP77

The pin assignment of the 9‐pin Sub‐D socket complies with Profibus stan dards IEC 61158/61784.

Pin Function

1 2 3 RS485-B 4 RS485-RTS 5 GND 6 VCC 7 8 RS485-A 9 GND

Information

Further information can be found in the ML77B operating manual.

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Connection

Inputs and outputs, remote controls

D01

Wiring example for using an analog output.

4.5.4 Inputs and outputs of AP75

The AP75 connection board has 8 digital inputs, 8 digital outputs and 2 ana log outputs. The digital outputs must be operated with an external current feed (12 V...24 V). The AP75 connection board can be operated together with the special function modules ML78B or ML70B.

24V

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Wiring example for use of a digital input. (digital inputs 4 and 7 in this case)

24V

Connection

Inputs and outputs, remote controls

Please note that the measuring systems of the digital inputs and outputs are separated from each other.

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Connection

Inputs and outputs, remote controls

Wiring example for using analog output V01.

Analog outputs V

and V

have a common ground system that is sepa

rated from the ground systems of the digital inputs and outputs.

OUT

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A03 A04

Connection

Inputs and outputs, remote controls

4.5.5 Analog outputs on the AP78

The AP78 connection board has 10 analog outputs. The analog outputs out puts designated A03...A10 are electrically isolated, while outputs VO1 and

GND A03 GND A04 GND A05

VO2 can be digitally filtered (together with ML78B). The AP78 connection board can be used together with the ML78B and the freely programmable ML70B module (CoDeSys).

A010

V01 V02

GND A010

GND V01 GND V02

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Connection

Inputs and outputs, remote controls

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5 Starting up

Starting up

Devices in the desktop housing and rack frame

This section shows you the necessary operating steps to place your mea surement chain (measuring amplifier system and transducer) in operation.

This will enable you to perform a functional test of all the components. The steps are deliberately described in very general terms so that there is no need to go into the details of specific transducers or amplifier modules. However the description can easily be applied to your measurement chain. In some cases – especially when connecting transducers – reference is made to the following sections. We also point out some typical errors that may occur during start-up.

After the initial start-up is performed and the amplifier module is adapted to your transducer, you will be ready to become familiar with the remaining functions and possibilities of the MGCplus measuring amplifier system.

S Unpack the MGCplus. S Check the MGCplus for damage. S Is the delivery complete? S Compare the contents of the package with the enclosed documentation

list. Is the documentation complete?

5.1 Devices in the desktop housing and rack frame

If you have not already received your measuring amplifier system complete, note the following information as you put together your system:

S Plug in the measurement cards from the front and the corresponding

connection boards from the back. The assignment is important in this process.

S If you are using the wide connection board or amplifiers (8 sub-units),

plug them into slots 1, 3, 5, etc. Slots 2, 4, 6, etc. on the front and back must be left free or fitted with blind panels.

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Starting up

Devices in the desktop housing and rack frame

S For safety reasons all free slots (amplifiers or connection boards) must

S Check to make certain the amplifiers and connection boards are securely

S Connect the device to the mains with the mains cable provided. S Connect your transducer to the applicable socket on the back of the

be covered by blind panels.

plugged in.

connection board (designation BU01). If you are using a cable preassembled in-house, please note the pin assignments for your transducer in section B.

Switching on

Comply with the safety instructions on

è page 11.

S Turn the device on using the POWER button on the front of the device. The AB22A is initialized (all the LEDs light up briefly) and detects the

components present.

MGCplus initialization

Baud rate detection ...

If a transducer is not connected, an overload is displayed! After the opening display, the measured value of image type "1 measured

value" appears in the standard configuration (factory settings). Pressing the Switch key

takes you to Setup mode, where you can configure the

system, display, amplifier and additional functions.

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HBM MGCplus Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 Safety instructions

1.1 Electromagnetic compatibility

2 Markings used

2.1 Markings on the device

2.2 The markings used in this document

3 Introduction

3.1 Degree of protection

3.2 Notes on documentation

3.3 System description

3.4 Layout of the MGCplus device

3.5 MGCplus housing designs

3.6 Possible amplifier/connection board combination

3.7 Installation of the CP52 communication processor

3.8 Conditions at the place of installation

3.9 Maintenance and cleaning

4 Connection

4.1 Connecting the MGCplus in a tabletop housing/rack frame

4.1.1 Mains connection

4.1.2 Synchronization of multiple CP52 devices

4.1.2.1 Synchronization of multiple CP52 devices via a synchronization jack

4.1.3 Synchronization of CP52 with CP22/CP42

4.2 Shielding design

4.3 Connecting the transducer

4.3.1 Connecting separate TEDS modules

4.3.2 SG full bridges, inductive full bridges

4.3.3 Full bridge circuits on AP810i/AP815i

4.3.4 Strain gage half bridges, inductive half bridge circuits

4.3.5 LVDT transducers

4.3.6 Strain gage half bridges on AP810i

4.3.7 Strain gage half bridges on AP815i

4.3.8 Single strain gage

4.3.8.1 Single strain gage on AP14

4.3.8.2 Single strain gage on AP814Bi

4.3.8.3 Single strain gage on AP815i

4.3.9 SG chains and strain gage rosettes on AP815i

4.3.10.1 Torque measurement

4.3.10.2 Rotational speed measurement (symmetrical signals)

4.3.10.3 Rotational speed measurement (symmetrical signals) with reference pulse

4.3.11 Torque shaft (T4A, T5, TB1A)

4.3.11.1 Torque measurement (slip rings or direct cable connection)

4.3.11.2 Rotational speed measurement with inductive transducers

4.3.12 Thermocouples

4.3.13 DC voltage sources

4.3.14 DC power sources

4.3.15 Resistors, Pt100

4.3.16 Frequency measurement without directional signal

4.3.17 Frequency measurement with directional signal

4.3.18 Pulse counting, single-pole

4.3.19 Pulse counting, differential

4.3.20 Active piezoelectric transducers

4.3.21 Piezoresistive transducers

4.3.22 Potentiometric transducers

4.3.23 Connection via the distributor board VT810/815i

4.4 Connecting CANHEAD modules

4.4.1 Communication card ML74B

4.4.2 AP74 connection board

4.5 Inputs and outputs, remote controls

4.5.1 Inputs/outputs of the CP52

4.5.2 Analog output on the front panel

4.5.3 Connection boards AP01i/AP03i/AP14/AP17

4.5.3.1 Socket assignment AP01i/AP03i/AP14/AP17

4.5.3.2 AP460i connector pin assignment

4.5.3.3 AP77

4.5.4 Inputs and outputs of AP75

4.5.5 Analog outputs on the AP78

5 Starting up

5.1 Devices in the desktop housing and rack frame