HBM MGCplus ML85C User manual

B0541-5.3 en
Amplifiersystem
MGCplus
Press-fit monitoring
module ML85C
Operating Manual

m

Contents
3
Contents
ML85C
A Introduction
1 Safety instructions A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Notes on the documentation A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 What does a press-fit monitoring module do? A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Connecting
1 Inputs and outputs, remotes B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Outputs and AP75 remotes B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 AP75 connection board B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Commissioning
1 Instructions in brief C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Basic set up of the amplifier C-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 ML85C press-fit module C-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Setting up the “force” and “displacement“ measuring amplifiers C-17. . . . . . . . . . . . . . . . . . . . . .
3 Evaluation methods C-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Tolerance window procedure C-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4Contents
ML85C
4 Setting up measurement parameters C-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 System of coordinates C-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Setting up the coordinate system C-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Alarm window C-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Range window C-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Thread-in window C-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Fitting window C-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 End window and method C-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Transducer test C-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Data acquisition (CP42 only) C-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Printing the press-fit results C-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PLC link C-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Basic wiring C-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Expansion options for basic wiring C-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Online supervision of thread-in process C-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Transducer test C-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Autocalibration C-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Identification of wiring problems C-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Zero balance before the press-fit process C-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 Trigger print task C-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.7 Coding windows with errors C-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.8 Selecting data sets C-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Troubleshooting C-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
Contents
ML85C
D Measure
1 LED display on front panel D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Amplifier plug-in units D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Evaluation channel ML85C D-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 AB22A/AB32 in measuring mode D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Display D-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 The first display D-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Display in measuring mode D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Possible displays D-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Current values D-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 I/O status D-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Diagnosis D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4 Transducer test D-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.5 Force-displacement diagram D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.6 Force-time diagram D-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.7 Displacement-time diagram D-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Statistics D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Statistics: Total D-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Statistics: windows D-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Statistics: end position D-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Calculation formulae D-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6Contents
ML85C
E Menu structure
1 Measuring mode E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Setup mode E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F Specifications
1.1 Amplifier modules ML85C F-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 AP75 connection board F-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G Keywords
H Certificate of conformity

A Introduction
A-1
Introduction ÝSafety instructions
ML85C

A-2 Introduction ÝSafety instructions
ML85C

1 Safety instructions
A-3
Introduction ÝSafety instructions
ML85C
Insert the mains plug only into a socket with a protection switch (Protection Class I).
Before you open the device, make sure it is switched off; remove the mains plug from the
socket. Never pull the mains plug from the socket by the mains cable. Do not operate the
device, if the mains cable is damaged.
If an amplifier module is to be removed, close off the plug-in unit with a blank plate.
The device complies with the safety requirements of DIN EN 61010-Part 1 (VDE 0411-Part
1); Protection Class I.
To ensure adequate immunity from interference, use only Greenline shielded ducting (see
HBM offprint ”Greenline shielding design, EMC-compliant measuring cable; G36.35.0)
The insulation resistance of the connecting cables (v50 V) must be a minimum of 350 V
(AC).
Battery operation:
When connected to a 12 V battery, there is no potential separation.

A-4 Introduction ÝSafety instructions
ML85C
To ensure adequate immunity from interference, use only Greenline shielded ducting (see
HBM offprint ”Greenline shielding design, EMC-compliant measuring cable; G36.35.0)
Use in accordance with the regulations
The press-fit controller and its connected transducers are to be used exclusively for
measurement tasks and directly related control tasks. Use for any additional purpose shall
be deemed to be not in accordance with the regulations.
To ensure safety, only operate the device in accordance with the information given in the
Operating Manual. It is also essential to comply with the legal and safety requirements for
the application concerned during use. The same applies to the use of accessories.
General dangers of failing to follow the safety instructions
The press-fit controller is a state-of-the-art device and is fail-safe. The device may give rise
to residual dangers if it is inappropriately installed and operated by untrained personnel.
Any person instructed to carry out installation, commissioning, maintenance or repair of the
device must have read and understood the Operating Manual and in particular the technical
safety instructions.

A-5
Introduction ÝSafety instructions
ML85C
Conditions on site
Protect the desktop and plug-in devices from moisture or atmospheric influences such as
rain, snow, etc.
Make sure that the ventilation slots on the side and the power pack ventilation slots on the
back of the device are not covered up.
Maintenance and cleaning
The press-fit controller is maintenance-free. Please note the following points when cleaning
the housing:
Withdraw the mains plug from the socket before carrying out any cleaning.
Clean the housing with a soft, slightly damp (not wet!) cloth. On no account use
solvents, since these may damage the labelling on the front panel.
When cleaning, ensure that no liquid gets into the device or connections.
Residual dangers
The scope of supply and list of components provided with the press-fit controller only cover
part of the scope of measurement technology. In addition, equipment planners, installers and
operators should plan, implement and respond to the safety engineering considerations of
measurement technology in such a way as to minimize residual dangers. Existing regulations
on the subject must be observed. Reference must be made to residual dangers connected
with measurement technology.

A-6 Introduction ÝSafety instructions
ML85C
Any risk of residual dangers when working with the press-fit controller is pointed out in this
introduction by means of the following symbols:
Symbol: DANGER
Meaning: Maximum danger level
Warns of a decidedly dangerous situation in which failure to comply with safety
requirements will lead to death or serious physical injury.
Symbol: WARNING
Meaning: Possibly dangerous situation
Warns of a potentially dangerous situation in which failure to comply with safety
requirements can lead to death or serious physical injury.
Symbol: CAUTION
Meaning: Dangerous situation
Warns of a possibly dangerous situation in which failure to comply with safety requirements
could cause damage to property or lead to some form of physical injury.

A-7
Introduction ÝSafety instructions
ML85C
Symbols indicating application notes and useful information:
Symbol: NOTE
Means that important information about the product or its handling is being given.
Symbol:
Meaning: CE mark
The CE mark enables the manufacturer to guarantee that the product complies with the
requirements of the relevant EC guidelines (see Declaration of conformity at the end of this
Operating Manual).

A-8 Introduction ÝSafety instructions
ML85C
Working safely
Error messages must only be acknowledged when the cause of the error has been removed
and no further danger exists.
Conversions and modifications
The press-fit controller must not be modified from the design or safety engineering point of
view except with our express agreement. Any modification shall exclude all liability on our
part for any damage resulting therefrom.
In particular, any repair or soldering work on motherboards is prohibited. When exchanging
complete modules, use only original parts from HBM.
Qualified personnel
This instrument is only to be installed and used by qualified personnel strictly in accordance
with the Specifications and with the safety rules and regulations which follow. It is also
essential to observe the appropriate legal and safety regulations for the application
concerned during use. The same applies to the use of accessories.
Qualified personnel means persons entrusted with the installation, mounting, commissioning
and operation of the product who possess the appropriate qualifications for their function.
Maintenance and repair work on an open device with the power on must only be carried out
by trained personnel who are aware of the dangers involved.

2 Notes on the documentation
A-9
Introduction ÝNotes to the documentation
ML85C
The full documentation for the press-fit controller consists of the following publications:
The Operating Manual
explains how to operate the device manually and use it for taking measurements.
If the system device is equipped with the CP22 or CP42 communications processor, there is
also a CD-ROM containing the following documentation:
Operation with computer or terminal,
contains the commands for programming and measuring with a computer or terminal.
MGCplus Assistant,
documentation of the program for assigning parameters and controlling the MGCplus
measuring amplifier system.

A-10 Introduction ÝNotes to the documentation
ML85C
This manual holds all the information you need to operate the ML85C.
There are still more guidelines available:
•The header tells you which chapter or sub-section you are currently reading.
Example: Mains connectionConnections ÝC-12
•The page numbering is combined with capital letters corresponding to the chapter
headings.
•Page C-3 (Control Elements) explains about the display and the control keys.
•Chapter E (Menu Structure) gives you an overview of the selection window and the setup
window.

3 What does a press-fit monitoring module do?
A-11
Introduction ➝Mechanical construction
ML85C
The ML85C press-fit monitoring module was specifically developed to monitor press-fit processes, with the aim
being to safeguard quality even during the production process.
The module monitors two physical quantities (e.g. force and displacement) and their relation to one another. The
two measured quantities can also be displayed as the functions of time (force-time or displacement-time diagram).
The two physical quantities are measured by two single-channel amplifiers (ML01B, ML10B, ..., ML60B), inserted in
two adjacent slots of the MGCplus housing. The press-fit monitoring module is installed directly to the right of these
two measuring amplifiers.
The two measured quantities are evaluated in so-called ”windows” (see also C-18). The size and position of the
windows can be changed and the direction in which they operate can be defined.
Power pack,
communications
processor,
display and control
panel
Connection board
(AP...)
Amplifier
plug−in unit
MLxy MLxy ML85C
APxy APxy AP75 (optional)
Fig.3.1: ML85C press−fit monitoring module in the MGCplus housing (TG010B)

A-12 Introduction ➝Mechanical construction
ML85C
8 digital outputs
ML85C AP75 8 digital inputs A.1 ... A.8 ML xx ML xx ML85C AP75
AP75 B.1 ... B.8
A.1 ... A.8
Blank plate
APxx APxx
2 analog outputs VO1, VO2 2 analog outputs VO1, VO2
Power pack,
communications
processor,
display and
control panel
Fig.3.2: Use of one or two AP75 connection boards
If the AP75 connection board is located directly behind the ML85C module, the inputs and the outputs are identified
in the set-up menus and in the display by A. If they are directly to the right, the numbers of the inputs and outputs
are preceded by B.

B Connecting
B-1
Connections
ML85C

B-2 Connections
ML85C