Operating manual Digital Transducer-Electronics AED 9301A Part 1, Profibus basic device
1/24 Part 1 Description of the hardware of the AED9301A-basic device Contents Page Safety Notes... 3 1 Introduction and se... 4 2 Mechanical construction... 5 3 Electrical connection... 7 3.1 Transducer connect. AED9301A with AD103 or AD101B... 7 3.2 Connection of the operating supply voltage... 12 3.3 Profibus connection... 13 3.4 Connection digital inputs/outputs... 16 3.5 Cable connection AED 9301A via PG unions... 20 4 Technical data of the basic device AED9301A... 21 Part 2 Description of the hardware and the functions of the measurement amplifier board AD103 or AD101B Part 3 Description of the commands for the serial communication with the measurement amplifier board AD103 or AD101B Part 4 Description of the commands for dosing / filling control with the measurement amplifier board AD103 Part 5 Description of the Profibus communication
2/24 Important notes Without our express approval, the device must not be modified in terms of its design and/or technical safety aspects. Any modification excludes any and all liability on our part for any damage resulting therefrom. In particular, it is prohibited to carry out any repairs, soldering work etc whatsoever on the boards and to exchange components. Repairs may only be carried out by HBM. The complete factory settings are stored nonvolatile in the measurement board AD101B and cannot be deleted or overwritten; they can be reset at any time by means of the command TDD0. You will find further information in the chapter Individual descriptions of the commands AD101B, AD103; Part 3. The manufacturing number set in the factory should also not be changed. The transducer must always be connected up (connect transducer or bridge model).
3/24 Safety Notes Normally, the product does not represent any hazard if the notes and instructions for project planning, assembly, use within specifications and maintenance are complied with. The relevant accident prevention regulations, as applicable in each individual case, must be complied with. Assembly and commissioning may only be carried out exclusively by qualified personnel. Prevent dirt and humidity from ingressing into the inside of the equipment. When connecting lines implement measures against electrostatic discharges which may cause damage to the electronics. For power supply, a small voltage (18...30V) with safe disconnection from mains is required. When connecting additional units, the safety regulations according to EN61010 1) must be complied with. se shielded lines for Profibus and transducer connections. The screen is to be connected flush to ground on both sides. Lines for connecting the power supply as well as the digital I/Os are to be implemented as shielded lines only if a cable length of 30m is exceeded or if lines are laid outside enclosed buildings. 1) "Safety regulations for electrical measurement, control, regulatory, and laboratory units"
4/24 1 Introduction and se The digital transducer electronic units AED9301A belong to the family of AED components which digitally condition and network as bus-capable signals from mechanical measured value transducers. This includes digital measurement amplifier boards, base units with RS-485 or Profibus DP interface and intelligent sensors with integrated signal processing. The objective of these components is the digitization and conditioning of the measuring signals directly at the transducer location. Via the digital transducer electronics AED9301A, SG 1) transducers can be connected directly to a Profibus DP within a full bridge circuit. This enables you to build up complete measurement chains fast and at low cost. AED9301basic: = Basic device AED9301A + Amplifier AD101B AED9301plus: = Basic device AED9301A + Amplifier AD103 The digital inputs and outputs offer the controling of processes via two limit values (LIV1/2), the detrmination of triggered measing values (MAV), and the controling of a filling or dosing process (only AD103) The transducer electronic units AD101B and AD103 are also abbreviated with AED in the following text. 1) Strain Gages
5/24 2 Mechanical construction The basic device AED9301A offers the following functions: Degree of (mechanical) protection (IP65) Slot for measurement amplifier board AD101B or Ad103 Voltage supply for the measurement amplifier board and transducer supply (potential-isolated) Total bridge resistance transducer >80Ω...4000Ω Profibus DP interface (potential-isolated) from measurement amplifier and from the digital inputs / outputs) Digital inputs/outputs (potential-isolated from measurement amplifier and from Profibus) EMC protection The measuring amplifier board is designed as a plug-in type board, which can be plugged into the carrier board of the basic unit via a 25pin D connector. The basic device comprises the terminals for transducer, power supply unit, digital inputs outputs and profibus connection, the slide switches for bus connection and end-resistors, as well as the voltage stabilizer. The connection cables are fed out of the side of the housing, via PG boltings.
6/24 Connector meas. Amplifier Voltage supply and digital I/O LED 4: red LED 3: yellow LED 2: green LED 1 Profibus- LEDs Transducerconnection Adresssetting Profibusconnection Bus termination and diagnosis switch Fig. 2-1: Mechanical construction AED9301A (without measurement amplifier)
7/24 3 Electrical connection A connection diagram is enclosed with the basic unit AED 9301A. When making connections, please ensure that the cable wires do not protrude beyond the connection terminals (risk of short circuits). Please also ensure that the cable shield is correctly connected to the PG bolting (see Chapter 5.5). 3.1 Transducer connect. AED9301A with AD103 or AD101B Important note The transducer must always be connected up (connect transducer). AED9301A with AD101B It is possible to connect strain gage transducers in a full bridge circuit with a total bridge resistance of R B = 80...4000 Ω. The bridges are supplied by means of the basic device AED9301A (5V DC ). Bridge supply voltage (+) Sense line (+) Meas. signal (-) Meas. signal (+) Sense line (-) Bridge supply voltage (-) Cable shield on housing Wire colour blue green red white grey black Pin 3 3 4 1 2 2 Fig. 3.1-1: Transducer connection in 6-wire technology (colour coding HBM) The 6 wire connection avoids a long cable influencing the measured value. When using several transducers and a junction box, the 6-wire technology is routed through to the junction box.
8/24 Load cell KL4 3 3 4 1 2 2 B GN RD WH GY BK Fig. 3.1-2: Transducer connection KL 4 in the basic device AED9301A as 6-wire connection (Wire colours: B blue, GN - green, RD red, WH white, GY grey, BK black) For transducers that are calibrated in four-wire-technology, there are two types of connection: Connection via a six wire extension cable; sensor line bridged in transducer connector ) Connector Transducer bl rt ws sw bl gn rt ws gr sw Cable to transducer electronics Cable shield Fig. 3.1-3: Transducer connection in four-wire technology via six-wire cable extension (HBM colours)
9/24 Connection without an extension cable; sensor line bridged on the transducer electronics ( connect 3 to 3 and 2 to 2 ) When connecting several transducers, it is recommended to use a junction box VKK4 or VKK6 by HBM. In general the supply lines to the AED should be implemented as shielded lines. Notes on connection type, cable length and cable cross-section: Depending on the bridge resistance of the transducer used, cable length, and cable cross-section of the load cell connection cable, voltage drops arise that lead to a reduction in the bridge supply voltage. Additionally, the voltage drop on the connection cable is also temperature-dependent ( copper resistance ). The load cell output signal also changes in proportion to the bridge supply voltage. Effect on the measurement result with ATOCAL (command ACL1) activated: 6-wire circuit (standard operation mode): With the 6-wire-circuit the return lines 2 and 3 in the load cell ( for load cells with 6-wire-connection) or directly on the load cell connection ( for load cells with 4-wire circuit) with the supply lines 2 and 3 bridged (Fig.3.1-2 ). This corrects all influences. Even a change of cable length following a calibration does not lead to any deviations in the measurement results. 4-wire circuit: With the 6-wire-circuit the return lines 2 and 3 on the connection terminals 2 and 3 are connected directly to the AED (Fig.3.1.3 ). As the correction by ATOCAL can only be effected up to the return points 2, 3, all changes in cable resistance are reflected in the measurement result. That is, even if the 4- wire cable used for a calibration is no longer changed, there still result measurement errors in conditions with changing temperatures, caused by the temperature-dependent cable resistance and possibly also by transitory resistances in the connectors.
10/24 Replacement circuit for the bridge with bridge resistance RB and the supply lines with line resistances R L1 and R L2 : R L1 = R L2 : = (4 x ρ C /π) x (l[m] / A[mm 2 ] R L1 ρ C = 0,0178 [Ωmm 2 /m] for copper R B R L2 BR π = 3.14 l = line length, A = line cross section R L1 = R L2 = 1.6Ω at l = 10m and A = 0.14mm 2 From the bridge resistance R B and the line length I, line cross-section A and the bridge supply voltage, the voltage across the supply lines of the bridge can be determined: B + RL1 + RL2 = BR For R B = 80Ω, R L1 = R L2 = 1.6Ω (l = 10m) and BR = 5V there results a a supply current I BR = BR / (R L1 + R L2 + R B ) = 60mA and thus a voltage drop across the two line resistors of a total approx. 0.2V ( Bridge = 4.8V). For R B = 80Ω, R L1 = R L2 = 16Ω (l = 100m) and BR = 5V there results a a supply current I BR = BR / (R L1 + R L2 + R B ) = 45mA and thus a voltage drop across the two line resistors of a total approx. 1.4V ( Bridge = 3.6V). For the 6-wire circuit, this is without significance as the voltage drop is taken into account via the sensor lines in the measurement signal.
11/24 However, for the 4-wire circuit, the dependence of the copper resistance of the lines directly influences the measurement result via the temperature, as the bridge supply voltage Bridge changes: R L(t) := R L20 (1 + α (t 20 C)), with R L20 being the line resistance at 20 C and α being the temperature coefficient of copper R L20 Calculation see page 11, α C := 0.00392 [1/K] For a line length of l= 100m and a temperature difference of 10 C the following line resistance results R L1(t) = R L2(t) := 16 (1 + 0.00392 10) = 16.6 Ω This changes the bridge supply voltage from Bridge = 3.6V (at 20 C) to Bridge = 3.53V. This change in the bridge supply voltage directly at the transducer changes the measured signal of the bridge by 2% ( = 100% (1 3.53V / 3.6V)). This exemplary calculation shows that for long line lengths only 6-wire technology may be used.
12/24 3.2 Connection of the operating supply voltage The voltage supply must meet the following requirements: AED9301A supply voltage range B = +18V... +30V (DC) Current consumption = 200mA + current of control outputs OT1..4 (for 80Ω Bridge / 24V supply, see technical data Chapter 6) 0V 24VDC external PS N I B B B KL1 Digital I/ O KL2 B B V 0 3 8 1 + 24 V other 0 V units Fig. 3.2-1: Connection of voltage supply B The AED supply voltage can be connected at the terminals KL1 or KL2. The three ground terminals as well as the two voltage terminals, respectively, are internally connected. The supply voltage coming from the power supply unit is connected to terminal KL1; at terminal KL2 this supply voltage can be fed on to other units. The potential-isolated digital outputs OT1..OT4 are also supplied from this voltage. Potential-separation is effected in the direction of the AED. Thus, the units controlled by OT1..4 can also be supplied from B (see Section 5.4)
13/24 The control inputs IN1 and IN2 are initially potential-separated from the supply voltage B. The two grounds (ground B and ground IN) can be connected to terminal KL1, if required (see Section 5.4). 3.3 Profibus connection The Profibus DP is completely standardized in accordance with IEC 61 158 / EN 50 170 for universal automation; this provides for the troublefree connection of standard components. In the case of the AED9301A, the Profibus is a DP Slave according to DIN 19245-3. It offers a simple and fast to implement way in which to connect electro-mechanical measured value transducers with automation systems such as e.g. SIEMENS SIMATIC S7 or PCs. The Profibus is potentail-isolated separated from the measuring system and from the supply voltage, the transfer process is RS485. The maximum possible baud rate for RS485 is 12 Mbaud. The subscriber address can be set by means of two BCD coded rotary switches S5 and S4. The Profibus connection KL3 is equipped with four terminals so that it can be fed through to the next bus subscriber. The connection lines should be implemented as shielded and twisted 2-wire lines (see Profibus cable specification). At both ends of the Profibus line, the bus termination must be activated (with the AED switch S2 = on). For all other bus subscribers this switch is to be set to 'off'. For diagnosis purposes the module can be disconnected from the Profibus (S3 = off), the works setting is on.
14/24 S5 0 1 8 9 2 7 3 6 5 4 S4 00 ------ 99 0 1 8 9 2 7 3 6 5 4 Profibus KL3 IN OT A B A B Bus conn. on off S3 S2 Bus term. off on from Master next unit Fig. 3.3-1: Profibus - connection via terminal KL3 Maximum cable length in relation to the baud rate: Baud rate [kbit/s] Max. Cable length [m] 9.6 19.2 93.75 187.5 500 1500 12000 1200 1200 1200 1000 400 200 100 Setting the Profibus address: Address = S5 x 10 + S4 (permitted adress range: 3...99) The address is to be set with the unit in a deactivated condition and is read in from the AED when supply voltage is applied. The address is set to 03 at the factory.
15/24 Function of light emitting diodes (LEDs) Different Profibus states are indicated by 4 LEDs (Fig. 2-1) LED1: Voltage supply (green, r/h next to the diagnosis switch) supply voltage of the RS485 driver is applied, if LED 1 is constantly illuminated in green. LED2: Profibus Data Exchange (green) The 'Data Exchange' state is indicated by the green LED 2 in cyclic data exchange. LED3: Profibus Diagnosis (yellow) The yellow LED 3 illuminates if there is an internal fault. The measured values are possibly invalid. LED4: Profibus Error (red) In the event of a bus error, LED 4 will illuminate in red for as long as the error state exists. Possible causes of the fault: - Incorrect wiring (A and B poss. mixed up) - Profibus Master does not (yet) operate Installation of the Profibus: 1. Connection of the supply lines to the AED when deactivated (acc. to Chapters 5.1 to 5.5). Via KL3, the Profibus line is fed through from one unit to the next. 2. Setting the subscriber address via S5, S4. 3. Set switch for connecting in the bus termination (S2) to 'on' only for the first and last units; otherwise leave in position 'off'. If the first or last bus subscriber is not an AED, then it is usually possible to connect in the bus termination by means of a slide switch on the housing of the Profibus connector. 4. Check whether the switch for the bus connection (S3) is set to on. 5. Switch-on of the supply voltage B. 6. Configuration and parameterization of the Profibus subscriber with the respective tools.
16/24 The configuration and parameterization of the Profibus telegram by means of a configuration tool and GSD file is described in the operating instructions, Part 5 (communication via Profibus with AED9301A), as well as the bus coupling via PC and the HBM Profibus Panel Program. For diagnosis purposes the Profibus can be disconnected from the AED (bus connection (S3) to 'off') 3.4 Connection digital inputs/outputs At the terminals KL1 and KL2, the digital control inputs and control outputs and their associated reference grounds are connected up. The amplifier is allways disconnected potentially from supply voltage B and the igital inputs and outputs. Control inputs: The control inputs IN1 and IN2 are initially isolated from the supply voltage B and the measurement ground, the reference potential is ground IN on terminal KL1 on the right-hand side of the inputs. PS 2 0V 10..30V DC PS 1 IN1 IN2 0V 24 V DC KL1 Digital I/O 1 N 2 N I N I I B B B V 0 3 5 1 + KL2 T1 O T2 O T3 O T4 O B B external load Fig. 3.4-1: Connection digital inputs and outputs, inputs and external power supply unit 1 potential isolated
17/24 Logic level: IN1: Trigger: Break Dosing: Quiescent level = High, active Flanke = High Low- edge Quiescent level = Low, activat. = Low High Low-Impuls (duration 20ms) IN2: Quiescent level = Low, activat. = Low High Low- Impuls (duration 20ms) Function: Tare or Start dosing Note nused inputs remain open. If the input circuit is also supplied via B, then the ground of the inputs and the ground of B must be connected. PS IN1 IN2 0V 24V DC Digital I/O O O O O External load Fig. 3.5-2: Connection digital inputs and outputs with one external power supply unit (i.e. IN1=Trigger)
18/24 Control outputs: The digital outputs OT1..4 are potential-isolated towards the AED and are supplied via the external supply voltage B. They are designed as H-sideswitches. Thus the loads need to be connected against ground. The outputs are short-circuit proof and can drive ohmic and inductive loads with currents up to approx. 0.5 A per output. Logic level: OT inactive voltage is low (H-side-switch deactivated) OT active voltage is high (H-side-switch activated The functions of the digital inputs and outputs are different according to the measuring amplifier. 3.4.1 AED9301basic The measurement amplifier board AD101B features two inputs (IN1 and IN2) and two outputs (OT1 and OT2, do not connect OT3,4). The functions are determined via the commands IMD, LIV (see operating instructions, Part 3): Input functions: IMD0: Input functions deactivated, status can be read in via the command POR. IMD1: IN1 = Tare, IN2 = external trigger for the trigger function (TRC). IMD2: not selectable Output functions: LIV1 deactivated: LIV2 deactivated: LIV1 activated: LIV2 activated: Control OT1 via POR command Control OT1 via POR command Limit value LIV1 controls output OT1 Limit value LIV2 controls output OT2 The outputs OT3/4 cannot be driven by the AD101B.
19/24 3.4.2 AED9301plus The measurement amplifier board AD103 features two inputs (IN1 and IN2) and 4 outputs (OT1...4). The functions are determined via the commands IMD, LIV, OMD (see operating instructions, Part 3): Input functions: IMD0: Input functions deactivated, status can be read in via the command POR. IMD1: IN1 = external trigger for the trigger function (TRC), IN2 = Tare, IMD2: IN1 = stop filling, IN2 = start filling (Dosing function) Output functions: IMD < 2 (no dosing mode, as AD101B): LIV1 deactivated: Control OT1 via POR command LIV2 deactivated: Control OT2 via POR LIV1 activated: Limit value LIV1 controls output OT1 LIV2 activated: Limit value LIV2 controls output OT2 The outputs OT3/4 cannot be driven. IMD = 2 (dosing mode, only for AD103, see manual part 4) OT1: Coarse flow - control OT2: Fine flow - control OT3: Ready signal or emptying control (see operating instructions AD103, Part 4, dosing) OT4: Tolerance fault or alarm (see operating instructions AD103, Part 4, dosing)
20/24 3.5 Cable connection AED 9301A via PG unions As a connection line between the AED 9301A and transducer or Profibus DP, only a connection line with a shield grounded on both sides may be used. The shield is to be full-surface applied to the PG union. The cable shield is to be fullsurface connected to ground (housing). If large ground potential differences exist between AED9301A and the partner device, an equipotential bonding conductor is to be provided additionally. Dep. on req. wire length L remove ext. cable sheath Strip off wire ends and tin. Slide cable unions with sealing ring and press. rings over the cable ends Shorten cable shields and strip off strands. Ground sleeve Fan out cable shield radially. Slide ground sleeve between strands and cable shield to stop pos., press shield against sleeve flange, cut off protrusions. Slide cable through intermediate supports on the housing to stop pos., adv. cable union and bolt securely. Fig. 3.6-1: Cable connection via PG unions
21/24 4 Technical data of the basic device AED9301A Type Transducer Measured signal input Bridge excitation voltage DC SG transducer (1...4 full bridges, each 350Ω), R B mv/v V Ω AED9301A ±3, nominal ±2 5 >80 Transducer connection Transducer cable length Profibus DP Protocol Baud rate, max. Subscriber address, can be set by switch Interface cable length Profibus Control inputs (potential-isolated) Number Input voltage range, LOW Input voltage range, HIGH Input current, typ., High-level = 24 V Control outputs (potential-isolated) Number max. output current per output Short circuit current, typ., B = 24 V; R L < 0,1 Ω Short circuit duration Output current at Low-level Output current at High-level Insulation voltage, typ. (DC) Supply Operating voltage (DC) Current consumption (with load cell (R B = 80Ω) plus output currents of control outputs Iout1..4) m Mbit/s m V V ma A A ma V V V ma 6-wire circuit 100 Profibus-DP Slave, acc. DIN19245-3 12 3...99 1200 (for 9,6 / 19,2 / 93,75 kbit/s) 1000 (for 187,5 kbit/s) 400 (for 500 kbit/s) 200 (for 1,5 Mbit/s) 100 (for 12 Mbit/s) 2 0...5 10...30 12 4 0.5 0.8 unlimited <2 >15 at I max 500 18...30 250 (Calculation see below)
22/24 Technical Data, Continuation Type Temperature range Nominal temperature range Service temperature range Storage temperature range In addition Dimensions (L x W x H) Gewicht Degree of protection DIN40050 (IEC529) C C C mm g AED9301A -10...+40-20...+60-25...+85 195 x 100 x 70 approx. 925 IP65 Calculation of the total current consumption (for 80Ω bridge) Current consumption at 18V supply: 250mA + I OT 1...4 Current consumption at 24V supply: 200mA + I OT 1...4 Current consumption at 30V supply: 170mA + I OT 1...4 I OT 1...4 = Current of the control outputs The technical data of the measuring amplifier AD101B or AD103 are included in the operating manual AD101B, AD103;Part 2. Within the shielded structure (see Sect. 3), the entire measuring chain including the AED is insensitive against HF interference and conducted interference in accordance with OIMLR76, EN45501 or EN55011B (interference emissions) and EN50082-2.
Modifications reserved. All details describe our products in general form. They are not to be understood as express warranty and do not constitute any liability whatsoever. AED9301A_P1_e_020517 Hottinger Baldwin Messtechnik GmbH Postfach 100151 D-64201 Darmstadt Im Tiefen See 45 D-64293 Darmstadt Tel.: +49/6151/803-0 Fax: +49/6151/8039100 E-mail: support@hbm.com www.hbm.com