Burster 9221 Series User manual

Page 1 of 82
Date: 27.01.06
Sensor Profibus
Module 9221
©2005 burster Manufacturer:
präzisionsmeßtechnik gmbh & co kg burster präzisionsmeßtechnik gmbh & co kg
All rights reserved Talstraße 1-5 PO Box 1432
Stand 23.8.2005 76593 Gernsbach 76587 Gernsbach
Note:
The following information may be amended without notice. No part document may
be reproduced or processed using electronic systems without prior consent in
writing.
burster provides no warranty of any kind with respect to this material, including the
implied warranty of merchantable quality and fitness for purpose.
burster is not liable under any cicumstances for errors, incidental damage or
consequential loss sustained in connection with the function or use of this material.

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Date: 27.01.06
List of chapters
1. General preliminary remarks
2. Description of operation
3. Technical data
4. Operating instructions for the IP20 version
5. Operating instructions for the IP65 version
6. Configuring for use and testing
7. Profibus configuration
8. Profibus communication
9. Dimensioned drawings
10. Appendix

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Date: 27.01.06
CONTENTS
1 GENERAL PRELIMINARY REMARKS .......................................6
1.1 About this manual........................................................................6
1.2 Important note .............................................................................6
1.3 Unpacking ...................................................................................6
1.4 Deliverables ................................................................................6
2 DESCRIPTION OF OPERATION................................................7
2.1 Equipment function......................................................................7
2.2 Applications.................................................................................8
3 TECHNICAL DATA .....................................................................9
4 OPERATING INSTRUCTIONS FOR THE IP20 VERSION .......11
4.1 Installation / Fixing.....................................................................11
4.2 Degree of protection..................................................................11
4.3 Ambient temperature.................................................................11
4.4 Front panel / terminal assignments ...........................................11
5 OPERATING INSTRUCTIONS FOR THE IP65 VERSION .......13
5.1 Installation / Fixing.....................................................................13
5.2 Degree of protection..................................................................13
5.3 Ambient temperature.................................................................13
5.4 Front panel / terminal assignments ...........................................13
6 CONFIGURING FOR USE AND TESTING...............................16
6.1 Block diagram and internal signal processing ...........................16
6.2 Unpacking the unit.....................................................................16
6.3 Before switching on...................................................................17
6.4 Terminal assignments ...............................................................17
6.5 Supply voltage...........................................................................17
6.6 Grounding and surge protection................................................18
6.7 After switching on......................................................................18
6.8 Configuring addresses and calibration ......................................18
6.8.1 Address configuration................................................................18
6.8.2 Calibration using PC software 9221-P001.................................19
6.9 Calibration and setup ................................................................19
6.9.1 Measurements using a strain gage ...........................................20
6.9.1.1 Connection ................................................................................20
6.9.1.3 Calibration of strain gage sensors.............................................23
6.9.1.3.1 Calibration using a physical variable by the teach-in method....24
6.9.1.3.2 Calibration using the sensor test and calibration certificate.......25
6.9.1.3.3 Calibration using a precision voltage source .............................27
6.9.2 Measurements using a potentiometer .......................................29
6.9.2.1 Connection ................................................................................30
6.9.2.2 Sensor excitation, input range and input reference ...................31
6.9.2.3 Calibration of a potentiometer by the teach-in method..............32
6.9.3 Measurements using a reference signal / transmitter................34
6.9.3.1 Connection ................................................................................34

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Date: 27.01.06
6.9.3.2 Sensor excitation, input range and input reference ...................35
6.9.3.3 Calibration of a transmitter with voltage output .........................36
6.9.3.3.1 Calibration using a physical variable by the teach-in method....36
6.9.3.3.2 Calibration using the sensor test certificate...............................37
6.10 Signal processing......................................................................38
6.10.1 Measurement rate / Cut-off frequency / Filter............................38
6.10.2 Averaging ..................................................................................38
6.10.3 Reference measurement...........................................................39
6.10.4 Evaluation / Digital outputs (limits) ............................................40
6.10.5 Minimum and Maximum value buffer ....................................41
6.10.6 Digital inputs..............................................................................42
6.11 Monitor output ...........................................................................43
6.12 Instrument LED display .............................................................43
6.13 Test measurement ....................................................................43
6.13.1 Display ......................................................................................44
6.13.2 Options......................................................................................45
6.13.3 Saving measurement data in an Excel spreadsheet .................46
6.14 Electromagnetic compatibility....................................................46
6.15 Behavior in the event of a fault..................................................46
7 PROFIBUS CONFIGURATION.................................................47
7.1 RS485 interface........................................................................47
7.2 Bus structure .............................................................................47
7.3 Number of bus stations .............................................................47
7.4 Transmission speed ..................................................................47
7.5 Bus cable, bus connector and bus terminating resistor.............47
7.6 Shielding ...................................................................................49
7.7 Equipotential bonding................................................................49
7.8 Setting the baud rate.................................................................49
8 PROFIBUS COMMUNICATION................................................50
8.1 Bus interface and GSD file ........................................................50
8.2 Bus protocol and data format ....................................................50
8.2.1 Cyclic communication (DP-V0)..................................................50
8.2.1.1 Mode summary..........................................................................50
8.2.1.2 Bit coding details .......................................................................52
8.2.1.3 Byte reference list......................................................................57
8.2.2 Acyclic communication (DP-V1) ................................................65
8.2.2.1 General information...................................................................65
8.2.2.2 Slot-index directory....................................................................66
8.2.2.3 Representation of floating-point values .....................................71
8.2.2.4 Calculation tip............................................................................74
9 DIMENSIONED DRAWINGS ....................................................75
9.1 IP-20 version .............................................................................75
9.2 IP-65 version .............................................................................75
10 APPENDIX ................................................................................77
10.1 Recommendations for use ........................................................77

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10.2. Display of measurement results ................................................78
10.2.1 Introduction ...............................................................................78
10.2.2 Dependence of the quantization error on input drive level ........78
10.2.3 Increasing the resolution by averaging and filtering ..................79
10.2.4 Optimum device configuration...................................................79
10.3 Factory settings.........................................................................80
10.4 Maintenance, Customer service and Warranty .........................80
10.4.1 Maintenance..............................................................................80
10.4.2 Customer service ......................................................................80
10.4.3 Factory warranty........................................................................81
10.5 Accessories and options ...........................................................82
10.6 Contact details for queries.........................................................82

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Date: 27.01.06
1 General preliminary remarks
1.1 About this manual
This equipment manual contains important information on the operation,
installation and configuration of the Sensor Profibus Module type 9221, IP20 and
IP65 versions.
1.2 Important note
Note that the Sensor Profibus module type 9221 must be used in accordance with
the instructions, technical data and conditions of use listed in this manual. If
handled improperly or used incorrectly, one cannot rule out the possibility of
faults, incorrect measurements, effects on or from other equipment and
installations or potential risks to life and property. Please note the specific
requirements that must be observed for applications in a hazardous area
(EExi, ...).
1.3 Unpacking
The unit is packaged for protection against shock during shipment. Carefully
unpack the unit and verify that all items are present. Inspect the instrument
carefully for damage. If you suspect that the unit has been damaged during
shipping, notify the delivery company immediately. The packaging should be
retained for examination by a representative of the manufacturer and/or the
delivery company. The Sensor Profibus Module 9221 must be shipped only in its
original packaging or in a container capable of providing an equivalent degree of
protection.
1.4 Deliverables
A standard package includes:
1 Sensor Profibus Module
1 CD-ROM with configuration software
1 manual

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Date: 27.01.06
2 Description of operation
2.1 Equipment function
The Sensor Profibus Module type 9221 is intended for the acquisition and
processing of sensor signals and digital status information and for producing
digital signals for the fieldbus level (Profibus).
The Sensor Profibus Module is a user-configurable, single-channel module
operated via an RS232 interface (configuration only) or RS485 interface
(Profibus-DPV1). The universal Sensor Profibus Module is ideally suited to
measuring mechanical variables such as force, torque, pressure, acceleration,
displacement and angle. Acquisition and processing of strain-gage,
potentiometric and reference signals is straightforward.
Signal conditioning parameters such as gain, offset correction etc., which depend
on the sensors used, can be set as required by the user in software. No external
amplifier needs to be used. A high-performance A/D converter combined with
special ratiometric measurement techniques ensure accurate and high-speed
processing of the analog sensor signals.
Functions such as arithmetic averaging, input-signal filtering, zero calibration,
MIN/MAX memory and thresholds can be used via the Profibus with a speed of
up to 12 Mbaud. Two floating, user-configurable inputs are provided for external
control (resetting MIN/MAX buffer, tare and limit status).
The module generates its own stable and precise sensor supply voltage. The
calibration and configuration data is saved in an EEPROM to prevent loss in the
event of power failure.
The digital signal outputs can be used to transmit two alarm signals if the preset
measuring-range limits are exceeded.
The instrument also includes d.c. isolation.
Three LEDs on the instrument provide an immediate indication of the operating
status such as bus connection, sensor error or module active. All data can be
transferred to the higher-level controller (e.g. PLC) via the integral RS485
communications interface (Profibus DPV1). Up to 127 modules can be connected
to the Profibus line (32 in the same segment without repeater, 127 addressable).
The communications interfaces are also used for application-specific
programming and configuration of the Sensor Profibus Modules, carried out
centrally from a PC or PLC via the bus (simultaneous configuration is not
possible).
The delivered equipment includes suitable configuration software, which can run
on standard commercial PCs under Windows 98 / NT / Me / 2000 and XP.
The Profibus DPV1 interface can be used for parameterization and backup, and
for remote diagnostics and measured-data acquisition via Profibus. The DIN-rail
design in the IP20 version allows quick and easy installation in the control
cabinet. An IP65 version is available for particularly harsh environments.

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Date: 27.01.06
2.2 Applications
The Sensor Profibus Module type 9221 has been specifically developed for high-
speed control functions and real-time operations, and therefore covers a huge
range of applications. The instrument has been designed to integrate the
maximum possible range of analog sensor output signals into complex,
networked and distributed automation structures.
Thanks to its secure and reliable transmission protocol, its high transmission rate
and its simple design, the module is perfectly qualified for use in both industrial
automation engineering and test-bench technology. Exploiting the instrument's
quick response time, the extra inputs and outputs (provided in addition to those
used for external addressing) can be used for zero-point triggering via proximity
switch, for instance, or for rapid alerting when a setpoint value is exceeded.
Industry-compatible connection and installation technologies makes it easier for
the user to adapt and integrate the unit in existing mechanical and electrical
environmental conditions. The outstanding measuring quality combined with a
large number of values used for averaging means it is suitable for use in both
development and testing.
The Sensor Profibus Module is only suitable for measurement functions in
industry and is not intended for use in medical applications or where humans are
at risk.
Specific examples of Sensor Profibus Module applications include:
Complex gear and engine test benches
- Weight measurement in high-rack facilities
- Automotive industry
- Manufacture of custom machinery
- Packaging industry
- Manufacturing technology
- Recording of various mechanical and physical variables in test facilities

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Date: 27.01.06
3 Technical data
9221 version IP 20 IP 65
Input signal
Strain gage Bridge resistor: 120 Ω- 5 kΩ
Connection type:4 or 6 wire
Configurable sensitivities, infinite adjustment
strain-gage full bridge: < 1 mV/V ... 40 mV/V
Excitation: 2.5 V / 5 V / 10 V
Supply current: max. 60 mA
Input impedance: > approx. 1 GΩ
Potentiometer Terminal resistance: 100 Ω... 100 kΩ
Excitation: 2.5 V / 5 V / 10 V
Supply current: max. 60 mA
Voltage Reference signal: 0 V ... + 10 V
Input impedance: > approx. 1 GΩ
General data
Supply voltage
Measuring error
Temperature drift
Power consumption
Cut-off frequency
Internal fuse
d.c. isolation
from Profibus
Ambient temperature
Storage temperature
Electromagnetic
compatibility
20...36 VDC /14...26 VAC
< 0.03 % of input (5 mV input range and above)
< 50 ppm/K
approx. 6 VA
approx. 2 kHz (-3 dB)
integral reversible overcurrent and
overvoltage protection, reverse voltage protection
500 V
0 ... + 60°C
-30 ... + 85°C
complies with EMC Directive 89/336/EEC
Case
Material
Dimensions (WxHxD)
Weight
Degree of protection
Installation version
Connection cross-section
Extruded aluminum sect.
60x105x120 mm
approx. 1 kg
IP20
Snap-fit mounting on
35 mm rail
to DIN EN 50022
max. 1.5 mm2(AWG 16)
Die-cast aluminum
160x120x80 mm
approx. 1.0 kg
IP65
Screw fitting
max. 1.5 mm2(AWG 16)
Electrical connections
Supply voltage
Sensor connection
Inputs/outputs
Serial interface
Profibus
plug-in screw terminals
plug-in screw terminals
plug-in screw terminals
9-pin sub-min D-connector
9-pin sub-min D-connector
PG 7 cable gland
PG 7 cable gland
PG 7/PG 9 cable gland
9-pin sub-min D-connector
5-pin M12 plug/socket
Signal processing
A/D conversion
Measurement rate
Resolution
16 bit
> 1 kHz
8000 ... 50000 digits, depending on meter configuration

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Date: 27.01.06
Profibus
Baud rate
Number of devices
on bus
Potential
Addressing
automatic detection 9.6 kBaud ... 12 Mbaud
up to 32 stations without repeater
up to 127 stations with repeater
floating potential
Hardware or software addressing
Functions
Configurable via PC
or Profibus
Mean value, filter, tare, Min/Max buffer,
limits, evaluation status, sensor test
Filter settings
Cut-off frequency
No filter
none; 5; 10; 25; 50; 100; 200; 400 Hz
1 kHz
Analog output
Function
Monitor output
Process status, configuration mode
approx. + 8 V max.
Digital outputs
Limits
Logic
2 limit outputs
1 classification output (too high, too low, OK)
PLC level, open input, p-switching, 24 VDC,
floating, maximum output load Imax = 400 mA
Digital inputs
Inputs
Logic
2 user-configurable inputs, floating
PLC level, DIN EN 61131-2, p-switching
Electrical testing of the
measuring chain
By shunt calibration 59, 80, 100 kΩ
Status display
LED green “on”
LED yellow “flashing”
LED red / “flashing” red
Bus connection working OK
Module active, normal program execution
Error / Evaluation result frozen