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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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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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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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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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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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

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Date: 27.01.06
4 Operating instructions for the IP20 version
4.1 Installation / Fixing
The Sensor Profibus Module type 9221 has a snap-fit design for mounting on a
standard 35 mm DIN (top-hat) rail to DIN EN 50022. The unit is fixed to the DIN
rail via a clip on its rear side. First place the clip on the DIN rail from above and
then press the module down onto the DIN rail until the lower edge of the clip
snaps onto the DIN rail. For optimum measurement quality the DIN rail must be
grounded.
To remove the module, once again push down on the module from above while
tilting the lower edge of the clip forwards to release the module from the rail. The
module must only be installed by a qualified person.
4.2 Degree of protection
The Sensor Profibus Module type 9221 has IP20 degree of protection. This
means that the module is not protected against water ingress, but is protected
against ingress of solid particles of diameter > 12.5 mm.
4.3 Ambient temperature
The permitted ambient temperature range for the Sensor Profibus Module type
9221 during operation is 0 °C to +60 °C. The unit can be stored at temperatures
between -30 °C and +85 °C.
4.4 Front panel / terminal assignments
The following diagram shows the front and rear view of the Sensor Profibus
Module with connectors, indicators and configuration and fixing elements. The
terminal assignments for the Sensor Profibus Module are given in subsection 6.4.

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Terminal assignments
Wires are connected via screw terminals on the module. All terminal blocks have
a plug-in design, so they can be removed from the module for convenient cable
connection. No more than two wires should be connected to one terminal.
Ferrules are recommended for connecting stranded wires.
Shielded cables must be used for the voltage-supply lines and signal conductors
to avoid interference on sensor signals or in the module.
Front view
Profibus port
(RS485)
Configuration interface
(RS232)
Sensor
connection
Input / Output
Supply voltage
Status LEDs
Address setting
Fixing clip for DIN-
rail
mounting
Rear view

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Date: 27.01.06
5 Operating instructions for the IP65 version
5.1 Installation / Fixing
The Sensor Profibus Module type 9221 has four mounting holes for fixing the
module in place. The module must only be installed by a qualified person.
5.2 Degree of protection
The Sensor Profibus Module type 9221 has IP65 degree of protection. The
module is therefore protected against ingress of dust and water jets.
5.3 Ambient temperature
The permitted ambient temperature range for the Sensor Profibus Module type
9221 during operation is 0 °C to +60 °C. The unit can be stored at temperatures
between -30 °C and +85 °C.
5.4 Front panel / terminal assignments
Front panel
The following diagram shows the plan view of the Sensor Profibus Module with
connectors, indicators and configuration and fixing elements.

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Status LEDs
Plan view
Profibus port
(RS485) – B-coded
Plan view
Ad
dress
setting
Mounting
holes
Configuration
interface (RS232)
Sensor
connectio
n
Input Output
Supply
voltage
Profibus
terminating
resistance

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Terminal assignments
Cables are connected via PG cable glands and screw terminals on the module.
All terminal blocks have a plug-in design, so they can be removed from the
module for convenient cable connection.
No more than 2 wires should be connected to one terminal. Ferrules are
recommended for connecting stranded wires.
Shielded cables must be used for the voltage-supply lines and signal conductors
to avoid interference on sensor signals or in the module.
1: +5V
2: A
1 (4): 24 V - PLC supply
2 (5): PLC - Output 1
3: PLC ground
2: PLC - Input 2
1: PLC - Input 1
7. Shield
3: Signal input +
2: Sensor +
1: Excitation +
3: Ground 24 V
2: Protective ground
1: 24 V
5: Shield
4: B
3: GND
7 (10): Monitor output ground
6 (9): Monitor output 8V
3 (6): PLC – Output 2
4 (7): PLC – Output 3
5 (8): Protective ground
5: Sensor -
6: Excitation, ground -
4: Signal input -

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6 Configuring for use and testing
6.1 Block diagram and internal signal processing
The A/D converter amplifies and converts the signals according to the design and
type of the connected sensor. The A/D converter digitizes all incoming signals
with a resolution of 16 bits. The analog multiplexer and A/D converter are
controlled by the microprocessor. The A/D converter contains an amplifier with
various amplifier stages. The gain and the corresponding accuracy and resolution
of the measured value depends on the measuring range selected. In addition,
there is an option for arithmetic averaging of the measurement signal by the
processor.
This can be preset by the user by configuring the Sensor Module accordingly.
The processor then linearizes, scales and stores the signal in programmable units
ready for bus transmission. In addition, the processor monitors the measured
value with respect to user-selectable limits. The configuration settings,
linearization and scaling data etc. required by the microprocessor are saved in an
EEPROM to prevent loss in the event of power failure.
6.2 Unpacking the unit
Inspect the instrument for damage. If you suspect that the unit has been
damaged during shipping, notify the delivery company within 72 hours. The
packaging should be retained for examination by a representative of the
manufacturer and/or the delivery company.
The Sensor Profibus Module 9221 should be shipped only in its original
packaging or in packaging capable of providing an equivalent degree of
protection.
LED´s
µController
RS 485
Interface
optical
RS 232
Interface
Digital
I/O
optical
Profibus Asic
Sensor
Monitor
Output
Voltage supply
A/D
converter

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6.3 Before switching on
Before applying the supply voltage to the sensor module, make a final check that
the unit is installed correctly and set to the correct voltage. It is essential to check
that the unit has been grounded in accordance with regulations and that the
supply voltage for all the Sensor modules does not exceed the specified
+ 36 VDC.
6.4 Terminal assignments
Terminal
block 1 Function Meaning
1 Input PLC level 1
2 Input PLC level 2
3 Input PLC ground
4 Input 24 V – PLC supply
5 Output PLC level A1 >
6 Output PLC level A2 <
7 Output PLC level A3 =
8 Output Protective ground
9 Output Monitor output ± 8 VDC
10 Output Monitor ground
Terminal
block 2
1 Input + / ~ supply voltage
2 Input Protective ground
3 Input + / ~ supply voltage / ground
Terminal
block 3
1 Sensor + strain-gage excitation / + potentiometer excitation
2 Sensor + strain-gage sensor lead
3 Sensor + strain-gage signal input / + potentiometer signal input
4 Sensor - strain-gage signal input
5 Sensor - strain-gage sensor lead
6 Sensor - strain-gage excitation / - potentiometer excitation
7 Sensor Sensor shield
6.5 Supply voltage
The Sensor Profibus Module can be supplied with 20 - 36 VDC (d.c. supply) or
with 14 - 26VAC (a.c. supply). The instrument has its own internal protection to
safeguard the supply input against overvoltage, overcurrent and polarity reversal.
To avoid unnecessary noise on the supply-voltage line for the modules, a
separate voltage supply is recommended for sensors with high current
consumption.
The maximum power consumption of the Sensor Profibus Module is 6 VA. The
supply voltage must be protected by a fuse ( max. 1 A, slow-blowing).

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6.6 Grounding and surge protection
The case of the Sensor Profibus Module must be connected to ground.
The grounding cable can be connected to pin 2 of the supply voltage screw-
terminal, or directly via the DIN rail on the rear of the case.
Suitable protective devices must be provided against lightning damage (surge
voltages).
6.7 After switching on
After switching on the supply voltage, the LEDs on the front of the Sensor
Profibus Module indicate the current operating status of the instrument. The
subsection LED – Instrument LED display explains the meaning of the LEDs.
6.8 Configuring addresses and calibration
6.8.1 Address configuration
The address must be specified before a controller or a computer can exchange
data with a Sensor Profibus Module via a bus. The following point must be
observed when assigning addresses:
• An address must not occur more than once in the bus system.
An address can be assigned via the PC configuration software, Profibus or
hardware (rotary switch).
Hardware addressing
Addresses from 01 to 99 can be assigned to the stations on the bus. The address
00 cannot be assigned in hardware to the Sensor Profibus Module. For a module
to be addressed via PC software or the Profibus, its hardware-set address must
be 00.
Software addressing
Addresses from 00 to 99 can be assigned to the stations.
Note
The hardware-set address can be overwritten by a software address. The
hardware-set address is valid again after restarting the device.

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6.8.2 Calibration using PC software 9221-P001
The PC configuration program “9221-P001” and a notebook PC can be used for
convenient configuration of the instrument via the RS232 socket. The
configuration program is held on the CD-ROM supplied with the instrument.
You can use this software to:
• Create instrument configurations offline and online
• Create and reload backups of instrument configurations
• Print instrument configurations
• Perform teach-ins of sensor signals
• Perform graphical test measurements including data storage in Excel files
The configuration software can run on the following operating systems:
• Windows 98/98SE
• Windows ME
• Windows NT 4.0 SP6a
• Windows 2000
• Windows XP
The technical requirements can be found in the file "Readme.txt".
6.9 Calibration and setup
The Sensor Profibus Module can be calibrated using a variety of methods. The
instrument settings should be checked after calibration.
 Calibration using a physical variable
 Calibration by entering data from the sensor test certificate
 Calibration using a precision voltage source
 Calibration using a shunt resistance

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6.9.1 Measurements using a strain gage
6.9.1.1 Connection
Note:
A measuring chain contains a number of components, each contributing to the
overall measurement accuracy of the test setup. One can avoid these accuracy
problems by using the standard solution of the 6-wire circuit, or by calibrating as a
unit the 4-wire circuit as complete measuring chain.
4-wire connection
In most applications, however, the 4-wire connection is quite adequate. In this
case, the sensor lines (Pin 2 and Pin 5) are not connected.
6-wire connection
This connection should be used to achieve the best possible measurement
accuracy with strain gages, because the complex effect of resistances, such as
the internal excitation lines and connecting elements in the Sensor Profibus
Module, do not affect the behavior of the measuring chain. In this arrangement,
the measuring lead contains additional “sensor lines” that detect the excitation
voltage at the sensor input and feed this information back to the instrument.
Strain-gage connection
Shield (7)
- Sensor line (5)
-
Excitation (6)
+ Signal (3)
-
Signal
(4)
+ Excitation (1)
+ Sensor line (2)