HBM MGCplus User manual

Operating Manual
English
MGCplus

Hottinger Baldwin Messtechnik GmbH
Im Tiefen See 45
D-64239 Darmstadt
Tel. [phone]
Fax [phone]
[email protected]
www.hbm.com
Mat.: 7-2002.0612
DVS: A0534-30.0 HBM: public
03.2018
EHottinger Baldwin Messtechnik GmbH.
Subject to modifications.
All product descriptions are for general information only.
They are not to be understood as a guarantee of quality or
durability.

Table of contents
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Table of contents
1 Safety instructions 11.......................................................................
1.1 Electromagnetic compatibility 14........................................................
2 Markings used 15...........................................................................
2.1 Markings on the device 15.............................................................
2.2 The markings used in this document 15..................................................
3 Introduction 17.............................................................................
3.1 Degree of protection 17................................................................
3.2 Notes on documentation 18............................................................
3.3 System description 19.................................................................
3.4 Layout of the MGCplus device 21.......................................................
3.5 MGCplus housing designs 22...........................................................
3.6 Possible amplifier/connection board combination 23.......................................
3.7 Installation of the CP52 communication processor 26......................................
3.8 Conditions at the place of installation 29.................................................
3.9 Maintenance and cleaning 30...........................................................
4 Connection 31.............................................................................
4.1 Connecting the MGCplus in a tabletop housing/rack frame 31...............................
4.1.1 Mains connection 31..........................................................
4.1.2 Synchronization of multiple CP52 devices 32.....................................
4.1.2.1 Synchronization of multiple CP52 devices via a synchronization jack 32.....
4.1.3 Synchronization of CP52 with CP22/CP42 34.....................................
4.2 Shielding design 36...................................................................
4.3 Connecting the transducer 39..........................................................
4.3.1 Connecting separate TEDS modules 39..........................................
4.3.2 SG full bridges, inductive full bridges 42..........................................
4.3.3 Full bridge circuits on AP810i/AP815i 43.........................................

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4.3.4 Strain gage half bridges, inductive half bridge circuits 44...........................
4.3.5 LVDT transducers 45..........................................................
4.3.6 Strain gage half bridges on AP810i 46...........................................
4.3.7 Strain gage half bridges on AP815i 47...........................................
4.3.8 Single strain gage 48..........................................................
4.3.8.1 Single strain gage on AP14 48.........................................
4.3.8.2 Single strain gage on AP814Bi 49......................................
4.3.8.3 Single strain gage on AP815i 50.......................................
4.3.9 SG chains and strain gage rosettes on AP815i 51.................................
4.3.10 Torque flange T10 series, T40 series) 53.........................................
4.3.10.1 Torque measurement 53..............................................
4.3.10.2 Rotational speed measurement (symmetrical signals) 55..................
4.3.10.3 Rotational speed measurement (symmetrical signals) with reference pulse 57
4.3.11 Torque shaft (T4A, T5, TB1A) 59................................................
4.3.11.1 Torque measurement (slip rings or direct cable connection) 59.............
4.3.11.2 Rotational speed measurement with inductive transducers 61..............
4.3.12 Thermocouples 62............................................................
4.3.13 DC voltage sources 63.........................................................
4.3.14 DC power sources 70..........................................................
4.3.15 Resistors, Pt100 72...........................................................
4.3.16 Frequency measurement without directional signal 73..............................
4.3.17 Frequency measurement with directional signal 74................................
4.3.18 Pulse counting, single-pole 75..................................................
4.3.19 Pulse counting, differential 76...................................................
4.3.20 Active piezoelectric transducers 77..............................................
4.3.21 Piezoresistive transducers 78...................................................
4.3.22 Potentiometric transducers 79..................................................
4.3.23 Connection via the distributor board VT810/815i 80................................

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4.4 Connecting CANHEAD modules 82.....................................................
4.4.1 Communication card ML74B 83.................................................
4.4.2 AP74 connection board 84.....................................................
4.5 Inputs and outputs, remote controls 85...................................................
4.5.1 Inputs/outputs of the CP52 85..................................................
4.5.2 Analog output on the front panel 87..............................................
4.5.3 Connection boards AP01i/AP03i/AP14/AP17 87...................................
4.5.3.1 Socket assignment AP01i/AP03i/AP14/AP17 88..........................
4.5.3.2 AP460i connector pin assignment 92...................................
4.5.3.3 AP77 93............................................................
4.5.4 Inputs and outputs of AP75 94..................................................
4.5.5 Analog outputs on the AP78 97.................................................
5 Starting up 99..............................................................................
5.1 Devices in the desktop housing and rack frame 99........................................
6 Functions and symbols of the AB22A 103.....................................................
6.1 Control elements of the AB22A 103......................................................
6.2 Display 104...........................................................................
6.2.1 The first display 104............................................................
6.2.2 Display in measuring mode 105..................................................
6.2.3 Messages of AB22A/AB32 109..................................................
6.3 AB22A in Setup mode 110..............................................................
6.3.1 Call menus 112................................................................
6.3.2 Exit menus 113................................................................
6.3.3 Channel selection in measuring mode 114.........................................
6.3.4 Channel selection in Setup mode 115.............................................
6.3.5 Saving settings 115............................................................
6.3.6 Drop-down menus 116..........................................................
6.3.7 Setting elements in the setup windows 116........................................

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7 Measuring 121...............................................................................
7.1 General information 121................................................................
7.2 General principles for adjusting a measurement channel 122.................................
7.2.1 Adapting to the transducer 124...................................................
7.2.1.1 Extended functions of the ML38B 125....................................
7.2.2 TEDS transducers 126..........................................................
7.2.3 Signal conditioning 128.........................................................
7.2.4 Display 131...................................................................
7.2.5 Analog outputs (single-channel modules only) 132..................................
7.3 Adapting to the transducer 135..........................................................
7.3.1 SG transducers 135............................................................
7.3.1.1 Direct entry of transducer characteristics 136.............................
7.3.1.2 Calibrating the characteristic curve of the transducer 139...................
7.3.2 Strain gages 140...............................................................
7.3.2.1 Direct entry of transducer characteristics 143.............................
7.3.3 Inductive transducers 145.......................................................
7.3.3.1 Direct entry of transducer characteristics 146.............................
7.3.3.2 Calibrating the characteristic curve of the transducer 148...................
7.3.4 Torque transducer 151..........................................................
7.3.4.1 Direct entry of torque characteristics 153.................................
7.3.4.2 Calibration with shunt installed 155......................................
7.3.5 Adjusting the rotational speed channel, frequency measurement 159..................
7.3.6 Adjusting the rotational speed channel, power measurement 162.....................
7.3.7 Thermocouples 164............................................................
7.3.7.1 Direct entry of transducer characteristics 165.............................
7.3.8 Current and voltage measurement 166............................................
7.3.8.1 Direct entry of transducer characteristics 167.............................
7.3.9 Resistance temperature sensors 169.............................................
7.3.9.1 Direct entry of transducer characteristics 170.............................

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7.3.10 Resistors 172..................................................................
7.3.10.1 Direct entry of transducer characteristics 172.............................
7.3.11 Pulse counting 174.............................................................
7.3.11.1 Direct entry of transducer characteristics 175.............................
7.4 Current-fed piezoelectric transducer 179..................................................
7.4.1 Direct entry of transducer characteristics 180......................................
7.5 Piezoresistive transducers 182...........................................................
7.5.1 Direct entry of transducer characteristics 182......................................
7.5.1.1 Calibrating the characteristic curve of the transducer 184...................
7.6 Potentiometric transducers 186..........................................................
7.6.1 Direct entry of transducer characteristics 187......................................
7.6.1.1 Calibrating the characteristic curve of the transducer 189...................
8 Additional functions 191.....................................................................
8.1 Remote control (single-channel modules only) 191.........................................
8.1.1 Turning on remote control 191...................................................
8.1.2 Assigning remote control contacts 192............................................
8.2 Limit values (single-channel modules only) 194............................................
8.2.1 Turning on limit switches 195....................................................
8.2.2 Adjusting limit values 196.......................................................
8.2.3 Selection keys in the Limit switches menu 198.....................................
8.3 Limit value combination (single-channel modules only) 199..................................
8.4 Set peak values 202....................................................................
8.4.1 Peak-value memory 202........................................................
8.4.2 Combining peak-value memories 203.............................................
8.4.3 Control of peak-value memory 205...............................................
8.4.4 "Peak value" operating mode 205................................................
8.4.5 "Instantaneous value" operating mode 206........................................
8.4.6 Envelope curve operating mode 207..............................................
8.4.7 Clear peak-value memory 208...................................................

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8.5 Version 209...........................................................................
8.6 Switching 210.........................................................................
9 Display 213.................................................................................
9.1 Display format 213.....................................................................
9.1.1 Select setup window 214........................................................
9.1.2 Setup window Display format 215................................................
9.1.3 Setup window components 216..................................................
9.1.3.1 Numeric value display 217.............................................
9.1.3.2 Graphic display 227...................................................
9.1.4 Limit value status 230..........................................................
9.1.5 Recording status 231...........................................................
9.2 F keys 232............................................................................
9.2.1 F keys in measuring mode 232...................................................
9.2.2 F keys in Setup mode 234.......................................................
9.3 Channel names 235....................................................................
10 System 237.................................................................................
10.1 Password 237.........................................................................
10.1.1 Define new user 238............................................................
10.1.2 Password protection activation 239...............................................
10.1.3 Set access for operator 240.....................................................
10.1.4 Delete user 241................................................................
10.1.5 Change password 242..........................................................
10.2 Save/load 243.........................................................................
10.3 Recording series of tests 248............................................................
10.3.1 Setting parameters of test series 249.............................................
10.3.2 Format of the MGCplus measurement files 267....................................
10.3.2.1 Measured values 267..................................................
10.3.2.2 Time channels 269....................................................
10.3.3 MEA format in detail (MGC binary format 2) 270...................................

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10.4 Interface 275..........................................................................
10.4.1 Port usage 279................................................................
10.4.2 Communication processor and multi-client mode 279...............................
10.5 Language 281.........................................................................
10.6 Time 282.............................................................................
11 Menu structure 283..........................................................................

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Safety instructions
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1 Safety instructions
Intended use
The amplifier system is to be used exclusively for measurement tasks and
directly related control tasks. Use for any purpose other than the above is
deemed to be non-designated use.
In the interests of safety, the device should only be operated as described in
the operating manuals. It is also essential to comply with the legal and
safety requirements for the relevant application during use. The same ap
plies to the use of accessories.
Each time, before starting up the equipment, you must first run a project
planning and risk analysis that takes into account all the safety aspects of
automation technology. This particularly concerns personal and machine
protection.
Additional safety precautions must be taken in plants where malfunctions
could cause major damage, loss of data or even personal injury. In the
event of a fault, these precautions establish safe operating conditions.
This can be done, for example, by mechanical interlocking, error signaling,
limit switches, etc.
General dangers of failing to follow the safety instructions
The amplifier system is a state of the art unit and as such is reliable. 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
manuals and in particular the technical safety instructions.
Residual dangers
The scope of supply and performance of the amplifier system covers only a
small area 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. On-site regulations must be complied with at all
times. There must be reference to the residual dangers connected with
measurement technology.

Safety instructions
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After making settings and carrying out activities that are password-
protected, you must make sure that any controls that may be connected re
main in a safe condition until the switching performance of the amplifier
system has been tested.
Working safely
The supply voltage connection, as well as the signal and sense leads, must
be installed in such a way that electromagnetic interference does not ad
versely affect device functionality (HBM recommendation: "Greenline
shielding design", can be downloaded from http://www.hbm.com/Greenline).
Automation equipment and devices must be designed in such a way that
adequate protection or locking against unintentional actuation is provided
(access checks, password protection, etc.).
When devices are working in a network, these networks must be designed
in such a way that malfunctions in individual nodes can be detected and
shut down.
Safety precautions must be taken both in terms of hardware and software,
so that a line break or other interruptions to signal transmission, such as via
the bus interfaces, do not cause undefined states or loss of data in the auto
mation device.
Error messages should only be acknowledged once the cause of the error is
removed and there is no further danger.
Conversions and modifications
The amplifier system must not be modified from the design or safety engi
neering point of view except with our express agreement. Any modification
shall exclude all liability on our part for any resultant damage.
In particular, any repair or soldering work on motherboards (replacement of
components, apart from EPROMs) is prohibited. When exchanging com
plete modules, use only original parts from HBM.
The amplifier system and/or individual components are delivered from the
factory with a fixed hardware and software configuration. Changes can only
be made within the possibilities documented in the operating manuals.
Qualified personnel
are persons entrusted with siting, mounting, starting up and operating the
product and who possess the appropriate qualifications for their function.

Safety instructions
MGCplus A0534-30.0 HBM: public 13
This device 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 comply with the legal and safety require
ments for the relevant application during use. The same applies to the use
of accessories.
Qualified personnel includes people who meet at least one of the following
requirements:
- Knowledge of the safety concepts of automation technology is a re
quirement and as project personnel, you must be familiar with these
concepts.
- As automation plant operating personnel, you have been instructed
how to handle the machinery and are familiar with the operation of the
systems, components and technologies described in this documenta
tion.
- As commissioning engineers or service engineers, you have success
fully completed the training to qualify you to repair the automation sys
tems. You are also authorized to activate, ground and label circuits
and equipment in accordance with safety engineering standards.
Safety rules
Before starting up, make sure that the mains voltage and type of current
stated on the type plate match the mains voltage and type of current at the
place of operation and that the circuit used is sufficiently protected.
The mains plug must only be inserted into a grounded socket with a protec
tion switch (protection class I).
Use only the mains cable included with delivery, which is fitted with a ferrite
core.
The device must be switched off and the mains plug disconnected from the
socket before opening the device.
Never pull the mains plug out of its socket by the supply lead.
Do not operate the device if the mains lead is damaged.
If an amplifier channel is removed, the module must be sealed with a blind
panel.
Only operate built-in devices once they are installed in the housing pro
vided.

Electromagnetic compatibility
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The device complies with the safety requirements of DIN EN 61010 Part 1
(VDE 0411 Part 1); protection class I.
The insulation resistance of the connecting cables (v50V) must be at least
350V(AC).
1.1 Electromagnetic compatibility
The MGCplus device has been tested based on EMC product standard
EN 61326-1:2013. This standard includes definitions of limit values and test
levels for various electromagnetic environments.
Regarding emission (EME), requirements are included for class A (industrial
environments) and class B (residential, business and commercial environ
ments as well as small businesses). Laboratory applications also usually
require class B.
The product standard here references to EN 55011:2009+A1:2010.
Regarding immunity to interference, the product standard includes require
ments for controlled electro-magnetic environments (lowest requirements),
general environments and industrial environments (highest requirement).
MGCplus meet the following requirements:
-Emission (EME): Class B
-Immunity to interference: Industrial environment
The MGCplus series and the individual modules thus essentially meet the
highest requirements and are therefore suitable for use in all environments
described in the product standard.

Markings used
Markings on the device
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2 Markings used
2.1 Markings on the device
CE mark
By way of the CE mark the manufacturer guarantees that the product com
plies with the requirements of the relevant EC directives (the Declaration of
Conformity can be found at http://www.hbm.com/HBMdoc).
Statutory waste disposal mark
In accordance with national and local environmental protection and material
recovery and recycling regulations, old devices that can no longer be used
must be disposed of separately and not with normal household garbage.
Electrostatic sensitive devices
Components marked with this symbol can be damaged beyond repair by
electrostatic discharge. Please observe the handling instructions for electro
static sensitive devices.
Any risk of residual dangers when working with the amplifier system are
pointed out in these instructions by means of the following symbols:
2.2 The markings used in this document
Symbol Meaning
DANGER This marking warns of an imminently threatening dangerous situation in
which failure to comply with safety requirements will result in death or
extremely serious physical injury.
WARNING This marking warns of a potentially dangerous situation in which failure to
comply with safety requirements could result in death or serious physical
injury.

Markings used
The markings used in this document
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MeaningSymbol
CAUTION This marking warns of a potentially dangerous situation in which failure to
comply with safety requirements could result in slight or moderate physi
cal injury.
Notice This marking draws your attention to a situation in which failure to comply
with safety requirements could lead to property damage.
Important
This marking draws your attention to important information about the
product or about handling the product.
Tip
This marking indicates tips for use or other information that is useful to
you.
Information
This marking draws your attention to information about the product or
about handling the product.
Emphasis
See …
Italics are used to emphasize and highlight text and identify references to
sections, diagrams, or external documents and files.
Device -> New Bold text indicates menu items, as well as dialog and window headings in
the program environment. Arrows between menu items indicate the se
quence in which the menus and sub-menus are called up
Sampling rate Bold text in italics indicates inputs and input fields in the user interfaces.

Introduction
Degree of protection
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3 Introduction
3.1 Degree of protection
The degree of protection given in the technical data indicates the suitability
of the housings for various ambient conditions and also the protection of
persons against potential risks when used. The letters IP (International Pro
tection) which are always present in the designation, are followed by two
digits. These indicate which degree of protection a housing offers against
contact or foreign objects (first digit) and moisture (second digit).
MGCplus devices are available with degree of protection IP20.
IP 2 0
Code
index
Degree of protection
against contact and
foreign objects
Code
index
Degree of protection
against water
2Protection against contact
with fingers, protection
against foreign objects
with > 12 mm
0No water protection

Introduction
Notes on documentation
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3.2 Notes on documentation
The complete documentation for the MGCplus amplifier system includes the
following documents:
SThe operating manual,
which explains manual operation of the device and how to perform mea
surements with it.
CD-ROMs containing the following documentation are included with every
system device:
SOperation with computer or terminal,
which contains commands for programming and measuring with com
puter or terminal.
SMGCplus Assistant,
Documentation of the program for parameterization and control of the
MGCplus measuring amplifier system.
This manual contains all the information required to operate the MGCplus.
Guides
Several guides are available to help you:
SThe header shows you which section or sub-section you are currently
reading. For example:
Introduction
Notes on documentation
SSee èsection 6 „Functions and symbols of the AB22A“ for explanations
of the AB22A display and control unit.
SèSection 11 „Menu structure“ provides an overview of the drop-down
and setting menus of the display and control unit.

Introduction
System description
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3.3 System description
The MGCplus system is structured modularly. Depending on the housing
variant, up to 16 slots are available for single and multi-channel amplifier
modules. Thus up to 128 measuring points can be measured in an
MGCplus.
Each amplifier module works independently through its own CPU. Data
preparation, for example taring, filtering and measuring range adjustment, is
carried out digitally. This eliminates the disadvantages of analog data prepa
ration, such as time and temperature-dependent drift, errors due to compo
nent tolerances, greatly limited flexibility and extensive circuitry. An essen
tial precondition for this is analog/digital conversion with no loss of
information. The digitally conditioned signal is directed to the internal bus.
For single-channel modules, two analog outputs (voltage) are available in
addition to the digital measured values.
An internal standard PC computer in credit-card format collects data with a
total sampling rate of up to 307,200 measured values per second (4-byte
integer format: 3-byte measured value + 1-byte status). All measurement
signals can be acquired in parallel, since each channel has its own ADU. No
Sample & Hold or Multiplexer is used in the MGCplus. This ensures continu
ous digital filtering and maximum signal stability.
Data is sent to an external computer or PLC via interfaces such as Ethernet.
A large part of the system functionality is implemented by device-internal
software (also called firmware). We therefore recommend you use our free
firmware updates and always keep your devices updated to the latest
firmware version. For further information go to www.hbm.com/downloads.

Introduction
System description
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Synchronization
Serial bus
Storage medium (optional)
Additional MGCplus
... Display
and
control
panel
CPU
Profi-bus
...
CPU
...
12 8
2400Hz 2400Hz 2400Hz
...
CPU
CAN
...
"10V
Digital control inputs, limit switches
Digital
signal conditioning
Filtering, scaling,
zero balance, ...
Digital signal
conditioning
Filtering
Scaling, zero
balance, ...
CPU CPU
8-channel
module
Single
channel
module
Communication
processor CPxx
CPU
PC interface
Fig. 3.1 Block diagram of MGCplus