Burster DIGIFORCE 9307 User manual

OPERATION MANUAL
DIGIFORCE®
Model 9307
© 2016
burster präzisionsmesstechnik gmbh & co kg
Manufacturer
burster präzisionsmesstechnik gmbh & co kg
All rights reserved Talstraße 1 – 5
76593 Gernsbach
Postfach 1432
76587 Gernsbach
Valid from:
31.08.2016
Tel.:
(+49) 07224 / 6450
Fax.: [phone] / 64588
E-Mail:
[e-mail]
www.burster.de
2447-BA9307EN-5170-081524

Exclusion of warranty liability for operating manuals
All information in the present documentation was prepared and compiled with great care and
reproduced subject to effective control measures. No warranty is provided for freedom from errors. We
reserve the right to make technical changes. The present information as well as the corresponding
technical data can change without notice. Reproduction of any part of this documentation or its
processing or revision using electronic systems is prohibited without the manufacturer's prior written
approval.
Components, devices and measured value sensors made by burster praezisionsmesstechnik
(hereinafter referred to as "product") are the results of targeted development and meticulous research.
As of the date of delivery, burster provides a warranty for the proper condition and functioning of these
products covering material and production defects for the period specified in the warranty document
accompanying the product. However, burster excludes guarantee or warranty obligations as well as
any liability beyond that for consequential damages caused by improper use of the product, in
particular the implied warranty of success in the market as well as the suitability of the product for a
particular purpose. Furthermore, burster assumes no liability for direct, indirect or incidental damages
as well as consequential or other damages arising from the provision and use of the present
documentation.

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Table of contents
1Safety instructions .....................................................................................................12
1.1 Symbols ..............................................................................................................12
2Introduction ................................................................................................................13
2.1 Intended use........................................................................................................13
2.2 Environmental conditions.....................................................................................13
2.2.1 Storage conditions..................................................................................13
2.2.2 Conditions of use....................................................................................13
2.3 Personnel ............................................................................................................13
2.4 Deliverables.........................................................................................................14
2.5 Setting the user-interface language .....................................................................14
2.6 Conversions and modifications ............................................................................14
2.7 Installation in an instrument panel .......................................................................15
2.7.1 Instrument panel cut-out.........................................................................15
2.7.2 Instrument installation ............................................................................16
3Equipment design and functions ..............................................................................17
3.1 Range of functions...............................................................................................17
3.1.1 Expansion levels ....................................................................................18
3.1.2 32 measurement programs ....................................................................18
3.1.3 128 measurement programs...................................................................18
3.2 Suitable sensors..................................................................................................19
3.3 Recording measurement curves ..........................................................................20
3.3.1 Starting/stopping a measurement...........................................................20
3.3.2 Sampling methods for the measurement signals ....................................21
3.3.3 Specifying the X-axis reference ..............................................................21
3.3.3.1 ABSOLUTE reference.............................................................22
3.3.3.2 FINAL FORCE reference ........................................................23
3.3.3.3 REFERENCE LINE reference (overshoot/undershoot) ...........24
3.3.3.4 TRIGGER reference (overshoot/undershoot) ..........................25
3.4 Evaluation methods .............................................................................................26
3.4.1 Evaluation windows................................................................................27

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3.4.2 Trapezium window .................................................................................28
3.4.3 Thresholds .............................................................................................29
3.4.4 Envelopes ..............................................................................................29
3.4.5 Mathematical functions...........................................................................30
3.4.6 Rotary switch evaluation.........................................................................31
3.5 Tare function .......................................................................................................31
3.6 Sensor Test .........................................................................................................32
3.7 Online switching points........................................................................................32
3.8 Visualization, signaling and transfer.....................................................................33
3.9 Setup tools ..........................................................................................................33
4Controls and connections..........................................................................................34
4.1 DIGIFORCE®9307, front.....................................................................................34
4.2DIGIFORCE®9307, rear......................................................................................35
4.3 Grounding and shielding......................................................................................36
4.4 Interfaces ............................................................................................................36
4.4.1 PLC-Interface .........................................................................................36
4.4.1.1 PLC input................................................................................36
4.4.1.2 PLC output..............................................................................38
4.4.1.3 PLC outputs with fixed assignment .........................................39
4.4.1.4 PLC outputs with configurable assignment..............................40
4.4.2 Connectors A, B (strain gauge, potentiometer and normalized signal)....41
4.4.2.1 Connector A and B: Connection guidance for strain gauge
sensors without sensor lead....................................................42
4.4.2.2 Connector A and B: Connection guidance for strain gauge
sensors with sensor leads.......................................................42
4.4.2.3 Connector A and B: Connection guidance for potentiometric
sensors ...................................................................................43
4.4.2.4 Connector A and B: Connection guidance for normalized-signal
sensors ...................................................................................43
4.4.3 Connector C: incremental sensors and EnDat/SSI .................................44
4.4.3.1 Connector C: Connection guidance for incremental sensor.....45
4.4.3.2 Connector C: Connection guidance for EnDat / SSI ................45
4.4.4 Connector D: incremental sensors, strain gauge, potentiometer and
normalized-signal sensors......................................................................46
4.4.4.1 Connector D: Connection guidance for torque sensors that have
analog process signal and integral angle measurement (e.g.
8661) ......................................................................................47

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4.4.4.2 Connector D: Connection guidance for strain-gauge torque
sensors that have integral angle measurement (e.g. 86043 or
86413) ....................................................................................47
4.4.5 Connector E: Resistance measurement .................................................48
4.4.6 Connector F: Connection guidance for piezoelectric sensors .................49
4.4.7 RS-232 interface ....................................................................................50
4.4.8 USB-interface.........................................................................................51
4.4.9 Ethernet interface ...................................................................................51
4.4.10 Profibus interface ...................................................................................52
4.4.11 Ethernet-based fieldbus interface (dual RJ45)........................................52
5Instrument configuration ...........................................................................................53
5.1 Minimal Setup menu............................................................................................54
5.2 Main setup menu.................................................................................................55
5.3 Basic setup menu ................................................................................................56
5.3.1 Function keys assignments ....................................................................56
5.3.2 Password protection and access authorization.......................................57
5.3.3 Controlling the measurement display menus ..........................................58
5.3.4 Info-menu...............................................................................................58
5.3.5 Screen brightness and background color ...............................................58
5.3.6 Date and time.........................................................................................58
5.3.7 Operating language................................................................................59
5.3.8 Interfaces ...............................................................................................59
5.3.8.1 RS232 interface settings .........................................................59
5.3.8.2 Standard data format for the RS-232 interface:.......................59
5.3.8.3 USB interface settings ............................................................60
5.3.8.4 Ethernet interface settings ......................................................60
5.3.9 Assigning PLC outputs ...........................................................................61
5.3.10 Acknowledgement function.....................................................................63
5.3.11 Order sheet ............................................................................................65
5.3.12 Profibus settings (option)........................................................................66
5.4 Selecting a program number ...............................................................................66
5.5 Specifying the program name..............................................................................66
5.6 Channel settings..................................................................................................67
5.6.1 Scaling of analog sensors (strain gauge, potentiometer and standard
signal) ....................................................................................................68
5.6.2 Inverting measurement signals...............................................................69

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5.6.3 Strain gauge sensors .............................................................................69
5.6.4 Potentiometric sensors...........................................................................72
5.6.5 Sensors with standard signal..................................................................75
5.6.6 Piezoelectric sensors .............................................................................77
5.6.7 Sensors with incremental interface.........................................................79
5.6.8 Connecting sensors that have an SSI interface ......................................82
5.6.8.1 SSI linear encoder ..................................................................83
5.6.8.2 SSI singleturn encoder............................................................84
5.6.8.3 SSI multiturn encoder .............................................................85
5.6.9 Connecting sensors that have an EnDat 2.2 interface ............................89
5.6.9.1 EnDat linear encoder ..............................................................89
5.6.9.2 EnDat singleturn encoder........................................................91
5.6.9.3 EnDat multiturn angle sensor..................................................92
5.6.10 Resistance measurement.......................................................................96
5.6.11 Torque sensors with integral angle measurement ..................................97
5.7Measurement mode.............................................................................................98
5.7.1 Measurement-channel sampling.............................................................98
5.7.2 Measurement curve reference................................................................99
5.7.2.1 „Absolut“ reference .................................................................99
5.7.2.2 "Final force" reference...........................................................100
5.7.2.3 "Y1/2 reference line overrun / underrun" reference .................100
5.7.2.4 Y1/2 trigger overrun / underrun" reference..............................100
5.7.3 Curve recording, return point ................................................................101
5.7.4 Start/Stop mode ...................................................................................102
5.7.5 Bend-up factor......................................................................................103
5.7.5.1 Finding the bend-up factor ....................................................104
5.8 Configuring evaluation .......................................................................................106
5.8.1 Window ................................................................................................106
5.8.1.1 Configuring an evaluation window.........................................107
5.8.1.2 Advanced window results......................................................111
5.8.2 Trapezoid window ................................................................................114
5.8.2.1 Configuring a trapezoid window ............................................116
5.8.3 Thresholds ...........................................................................................120
5.8.3.1 Configuring a threshold.........................................................121
5.8.3.2 Advanced results for threshold of type Y...............................123

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5.8.4 Envelopes ............................................................................................127
5.8.5 Mathematical functions.........................................................................128
5.8.6 Evaluations specific to rotary-switch testing..........................................131
5.8.6.1 Configuring rotary-switch evaluation .....................................132
5.8.6.2 Evaluation results for rotary switch evaluation:......................135
5.8.7 Tolerance band for evaluation elements...............................................136
5.9 Online switching points......................................................................................138
5.10 Simple test operation.........................................................................................140
5.10.1 Numerical Test operation - Overview....................................................141
5.10.2 Numerical Test Operation - Live sensor values ....................................142
5.10.3 Numerical Test Operation - PLC signals...............................................143
5.10.4 Numerical Test Operation - Shunt Calibration ......................................144
5.10.5 Numerical Test Operation - Tare ..........................................................144
5.10.6 Numerical Test Operation - Run sensor test.........................................144
5.10.7 Graphical Test Operation - Overview....................................................145
5.10.8 Graphical Test Operation - Zoom .........................................................146
5.10.9 Graphical Test Operation - Configuring windows..................................147
5.10.10 Graphical Test Operation - Configuring trapezoid windows ..................149
5.10.11 Graphical Test Operation - Configuring thresholds ...............................151
5.10.12 Graphical Test Operation - Configuring envelopes ...............................153
5.10.13 Graphical test operation - Cursor..........................................................156
5.10.14 Graphical test operation - Reference curve ..........................................157
5.10.15 Graphical Test Operation - Displaying a curve array ............................157
5.10.16 Graphical test operation - Marks...........................................................159
5.11 Complex test operation......................................................................................160
5.12 Sensor Test .......................................................................................................161
5.12.1 Menu parameters in Menu 36 "Sensor test" for channel X, Y1and Y2...161
5.13 User defined values...........................................................................................163
5.14 Copying / Deleting a measurement program......................................................166
5.14.1 Copying a measurement program or sensor settings ...........................166
5.14.2 Deleting a measurement program ........................................................167
6Measurement results display...................................................................................169
6.1 Top-level view measurement results..................................................................169
6.1.1 Global header.......................................................................................170
6.1.2 Status display in measurement mode...................................................170

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6.1.3 Overall result of last measurement .......................................................171
6.1.4 Individual evaluation status in measurement mode ..............................172
6.2 Measurement curve graphs (M1-1 to M1-3).......................................................174
6.2.1 Displaying numerical results in the M1-1 and M1-2 curve view.............175
6.2.2 Measurement curve graphs Y1and Y2(M1-3) ......................................176
6.3 General curve data (M2-1 and M2-2).................................................................177
6.4 Info page overall result (M3) .............................................................................178
6.5 Info page, Entry/Exit for windows (M4-1) ...........................................................179
6.6 Info page, Entry/Exit (M4-2)...............................................................................180
6.7 Info page, User selected values (M5-1 and M5-2) ............................................181
6.8 Info page, Statistics (M6) ...................................................................................182
6.8.1 Statistics, Histogram info page (M6-H) .................................................184
6.8.2 Statistics, Trend info page (M6-T) ........................................................185
6.9 Info page, Order sheet (M7) ..............................................................................186
7Signal timing diagrams ............................................................................................187
7.1 Selecting a measurement program....................................................................187
7.1.1 Changing the measurement program without program acknowledgement187
7.1.2 Changing the measurement program with program acknowledgement 188
7.2 Starting / stopping a measurement externally ....................................................189
7.2.1 Without measurement data logging ......................................................189
7.2.2 With measurement data logging ...........................................................190
7.3 External tare ......................................................................................................191
7.3.1 Without tare warning ............................................................................191
7.3.2 With tare warning .................................................................................191
7.4 Online signals....................................................................................................193
7.4.1 Window evaluation with online signal ...................................................193
7.4.2 Online switching signals S1 to S4.........................................................194
7.4.2.1 Switching signals for channel "X" with ABSOLUTE reference195
7.4.2.2 Switching signals for channel "X" with TRIGGER reference..196
7.4.2.3 Switching signals for channel "Y" ..........................................197
7.5 Acknowledgement function................................................................................198
7.5.1 Example of a NOK evaluation using following parameter settings ........198
7.5.2 Example of a NOK evaluation (without acknowledgement)...................199
7.5.3 Example of an OK evaluation (without acknowledgement) ...................200
7.6 External actuation of a statistics reset................................................................201

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7.7 External actuation of sensor test........................................................................202
7.8 Reference travel - incremental sensors .............................................................202
8Index..........................................................................................................................204

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Safety instructions
1 Safety instructions
1.1 Symbols
On the device and in this manual the following symbols warn about risks:
Symbols in this manual
Notice
A property damage can result if proper precautions are not taken
Warning
A property damage and a severe personal injury or death can result if proper
precautions are not taken..
Symbols on the device
Notice text on the device
Read and observe the text beside / below the alert-symbol:
"To prevent electrical shock do not open device. To prevent fire replace only with
same type and rating of fuse."
Electrostatic discharge. Don't touch!
Electrostatic discharge can damage the connector (F).
Avoid electrostatic discharge at connector F .

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Intended use
2 Introduction
2.1 Intended use
The DIGIFORCE®9307 is an instrument for monitoring repetitive production processes. Its core
function is to record and analyze signals from processes in which physical variables, such as force,
pressure or torque, vary as a function of displacement, angle or time according to a defined curve. The
resultant measurement curve is analyzed using graphical evaluation elements such as windows,
envelopes and thresholds. The result of the analysis is classified as "OK" or "NOT OK" (NOK) and can
be retrieved from various interfaces.
The instrument is not a substitute for a safety device; for instance it cannot be used as an emergency
stop device in a press for when the pressure exceeds a set limit.
2.2 Environmental conditions
2.2.1 Storage conditions
•Pack the DIGIFORCE®9307 in clean packaging.
•The DIGIFORCE®9307 must be stored under the following conditions only:
•dry
•no condensation
•temperature between 0 °C and 60 °C
2.2.2 Conditions of use
•Indoors
•maximum altitude: 2000 m above sea level
•Operating temperature: +5 °C ... +23 °C ... +40 °C
•Humidity: up to 31 °C 80 %, decreasing linearly above that temp. to 50 % at T max,
no condensation
•Class I equipment
•Transient voltages: overvoltage category II
•Potential to ground: ≤ 12 V DC between analog ground and ground
•Supply voltage: 90 to 264 Veff, 47 to 63 Hz
2.3 Personnel
Personnel must be familiar with the relevant regulations. They must follow these regulations.

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Introduction
2.4 Deliverables
•DIGIFORCE®9307
•Operating manual
•1 x mains cable
•2 x D-Sub male connector, 9-pin for sensor port (A, B)
•1 x D-Sub male connector, 37-pin for PLC port *
•1 x D-Sub female connector, 37-pin for PLC port *
*) not included on instruments with Fieldbus option
2.5 Setting the user-interface language
When switching on the DIGIFORCE®9307, you can press the function key [F2] during boot-up in order
to select the user-interface language (default: German). During normal operation, the language can
also be selected in the "Language" menu of the General settings (see section 5.3.7).
2.6 Conversions and modifications
If you open or dismantle the DIGIFORCE®9307 during the warranty period, this will void the warranty
immediately.
The DIGIFORCE®9307 must only be opened by our technical personnel.
We will not accept liability for any modifications made to the DIGIFORCE®9307 without our written
approval.

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Installation in an instrument panel
2.7 Installation in an instrument panel
Notice!
Damage from excessive tightening torque
Over tightening the screws can damage the fixing rails.
•Use screws supplied to precut the thread. Minimum depth: must be able to insert
screw as far as end face of fixing rail
•Max. tightening torque of screws "F" is 1 Nm for precut thread.
2.7.1 Instrument panel cut-out

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Introduction
2.7.2 Instrument installation
Name
Explanation
A DIGIFORCE®9307
B
Cut-out in the instrument panel
C
Case feet
D
Instrument panel
E
Fixing rail (4x)
F
Self-tapping Torx screw (4x)
Set of accessories
9300-Z003

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Range of functions
3 Equipment design and functions
3.1 Range of functions
The DIGIFORCE®9307 monitors processes in which precisely defined functional relationships
between two or more measured quantities need to be demonstrated. These measured quantities are
recorded synchronously during the manufacturing process or subsequent functional testing to produce
a measurement curve, which is then assessed using graphical and mathematical evaluation
techniques. After internal evaluation, the measurement curve and computed evaluation results are
visualized on the color display and are also output at the external control interfaces. A powerful real-
time operating system optimizes processes to run at a very fast cycle speed in the controller. It
typically takes just 20ms to provide the global OK or NOK evaluation result, which can then be
analyzed by the higher-level control system.
The DIGIFORCE®9307 offers a variety of graphical evaluation elements: in addition to traditional
evaluation windows with defined entry and exit sides, you can also use thresholds, trapeziums of type
X or Y and envelopes. You can then input the individual evaluation results from the graphical tools into
mathematical functions, providing even more analysis flexibility for a huge range of signal curves.
The DIGIFORCE® 9307 has a wide range of process control applications, including monitoring
processes such as joining, riveting or calking, or checking torque curves, for instance for hinges or
high-quality rotary controls. You can even monitor complex signal/time curves (e.g. pressure curves,
leaks etc.) using the large choice of evaluation techniques. Simultaneous recording of up to two Y
variables (Y1and Y2) with respect to a common X variable means that you can use one
DIGIFORCE®9307 controller to monitor two synchronous processes. Alternatively, you can also
evaluate an application with three process variables, for instance the force/displacement curve and an
associated electrical value of a lifting electromagnet. While the DIGIFORCE®9307 is used in many
automated production areas, it is equally at home in the manual workstation, for instance to monitor
force/displacement when using hand presses for assembly or for random spot-checking in goods
inwards.

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Equipment design and functions
3.1.1 Expansion levels
The DIGIFORCE®9307 lets you store 32 or optionally 128 measurement programs, and to switch
rapidly between them during the process. This means that you can simply change the measurement
program when you change parts or when performing sequential sub-processes on one work piece. A
measurement program contains the full set of parameters for the sensors, the measurement
procedure and the evaluation of the measurement curve(s). Select the program you require via the
PLC interface (digital I/O or Fieldbus), a communications port or manually via the keypad.
3.1.2 32 measurement programs
The standard DIGIFORCE®9307 model lets you manage up to 32 measurement programs. In
addition, the DIGIFORCE®9307 provides a very large memory for recording measurement curves with
a depth of up to 5000 value pairs or value triplets.
3.1.3 128 measurement programs
Your DIGIFORCE®9307 can handle up to 128 measurement programs if you use the DigiControl PC
software to download a different instrument firmware package. The memory depth, however, is then
reduced to 400 value pairs or value triplets.

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Suitable sensors
3.2 Suitable sensors
The DIGIFORCE®9307 is able to process signals from a vast range of sensor technologies.
Note
The physical connectors, and hence the sensors connected to these connectors, are assigned to the
recorded curve variables (X/Y1/2 curve) in the "Channel settings" configuration menu.
The DIGIFORCE
®
9307 works with these sensor technologies
Symbol
Model
Connector
Strain gauge sensor A, B, D*
Potentiometer A, B, D*
Process signal A, B, D*
Incremental encoder
with/without reference signal,
distance coding
C
SSI sensor C
Heidenhain EnDat 2.2 C
Torque / angular displacement D*
Piezoelectric (option) F*
Resistance measurement E*
*) connectors D, E and F are optional

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Equipment design and functions
Connection example:
3.3 Recording measurement curves
An external control signal or an internal condition triggers the measurement. Immediately after
receiving this active start condition, the DIGIFORCE®9307 starts to write to the data memory the
values measured by the sensors as X/Y value pairs. The DIGIFORCE®9307 stops making these
measurements when a stop condition is met.
Evaluation of the recorded measurement curve begins straight afterwards, with the DIGIFORCE®9307
checking whether the curve satisfies all the defined evaluation elements. If this is the case, the
measurement is assessed as "OK“. If at least one evaluation condition has been infringed, however,
the DIGIFORCE®9307 assesses the measurement as "NOK".
The DIGIFORCE®9307 refreshes the display in the measurement menu and also the control signals at
the PLC interface as soon as the evaluation has finished.
3.3.1 Starting/stopping a measurement
You can use different events as a start and/or stop signal. These events do not need to relate to each
other.
Starting a measurement:
•External control signal
•Sensor reading above or below a defined X-value (e.g. a linear position).
•Sensor reading above or below a defined Y-value (e.g. a force).
Stopping a measurement:
•External control signal
•Sensor reading above or below a defined X-value (e.g. a linear position).
•Sensor reading above or below a defined Y-value (e.g. a force).
•Time (timeout)
•Specified number of recorded measurements reached (user can specify number)