PMA UNIFLEX SG45 User manual

PMA Prozeß- und Maschinen-Automation GmbH
Transmitter UNIFLEX SG45
+SENSE-
+ INP -
EX+ EX-
2
kg
SG
UNIFLEX
UNIFLEX SG 45
SG 45
Operating manual
English
9499-040-82311
valid from: 10/2009

ûBlueControlÒ
More efficiency in engineering, more overview in operating:
The projecting environment for the BluePortâcontrollers,
indicators and rail line - measuring converters / universal controllers, temperature limiters
Explanation of symbols:
gGeneral information
aGeneral warning
lCaution: ESD-sensitive components
Caution: Read the operating instructions
Read the operating instructions
+Note
© 2008 ·PMA Prozeß- und Maschinen-Automation GmbH ·Printed in Germany
All rights reserved ·No part of this document may be reproduced or published in any form
or by any means without prior written permission from the copyright owner.
A publication of
PMA Prozeß- und Maschinen Automation
P.O.Box 310229
Germany
ATTENTION!
Mini Version and Updates on
or on PMA-CD
www.pma-online.de

SG 45 3
Content
1. General ............................................5
2. Safety hints ..........................................7
2.1 MAINTENANCE, REPAIR AND MODIFICATION ....................8
2.2 Cleaning .........................................8
2.3 Spare parts .......................................8
3. Mounting ...........................................9
3.1 Connectors .......................................10
4. Electrical connections ..................................11
4.1 Connecting diagram ..................................11
4.2 Terminal connections .................................11
4.3 Connecting diagram ..................................13
4.4 Connection examples .................................14
4.5 Hints for installation ..................................15
4.6 UL approval (optional) .................................15
5. Operation ..........................................16
5.1 Front view .......................................16
5.2 Operating structure ..................................17
5.3 Behaviour after supply voltage switch-on.......................17
5.4 Displays in the operating level ............................18
5.4.1 Display line 1..................................18
5.4.2 Display line 2..................................18
5.4.3 Switch-over with the enter-key ........................18
5.4.4 Slave pointer function .............................19
5.4.5 Selecting the units ...............................19
5.4.6 Extended operating level............................20
6. Functions ..........................................21
6.1 Measuring input INP ..................................21
6.2 Input scaling ......................................22
6.3 Linearization ......................................23
6.4 Filter ..........................................24
6.5 Substitue value for inputs ...............................24
6.6 Input forcing ......................................24
6.7 Set zero ........................................25
6.8 Tare function ......................................25
6.9 Sample&hold amplifier ................................25
6.10 Integrator function ...................................26
6.11 Limit value processing .................................27
6.11.1 Input value monitoring .............................27
6.11.2 Monitoring the number of operating hours and switching cycles ......29
6.12 Analog output configuration ..............................30
6.12.1 Analog output .................................30
6.12.2 Analog output forcing .............................31
6.13 Maintenance manager / error list ...........................31
6.14 Detection and display of sensor and wiring errors ..................32
6.15 Resetting to factory setting ..............................33

4 SG 45
7. Configuration level.....................................34
7.1 Configuration survey ................................34
7.2 Adjustment: ......................................34
7.3 Configurations .....................................35
8. Parameter-level ......................................41
8.1 Parameter-survey ...................................41
8.2 Adjustment: ......................................41
8.3 Parameters .......................................42
9. Installation and calibration................................43
9.1 Initial setting ( SEt) ................................43
9.2 Calibration ( CAL)..................................44
9.3 Scaling (SCAL)....................................45
10.Engineering Tool BlueControlÒ.............................46
11.Versions ...........................................47
12.Technical data .......................................48
13.Index ..........................................51

.1General
Thank you very much for buying a transmitter for load cells, strain gauges, and melt pressure sensors UNIFLEX SG 45.
The UNIFLEX SG 45 transmitters are suitable for precise, cost-efficient contol tasks in all industrial applications.
Every SG 45 is equipped with a strain gauge signal input, an universal output and two relays. Optionally the tranmitter
can be fitted with various interfaces.
Galvanic isolation is provided between inputs and outputs as well as from the supply voltage and the communica-
tion interfaces.
Applications
CI 45 is used for measurement, scaling of electrical signals, e.g. for
·Strain gauges
·Load cells
·Melt pressure sensors
·Pressure sensors
...
At-a-glance survey of advantages
Compact construction, only 22,5 mm wide
Clips onto top-hat DIN rail
Plug-in screw terminals or spring clamp connectors
Dual-line LC display with additional display elements
Process values always in view
Convenient 3-key operation
Ability for wireless cross-communication with other units mounted on top-hat rail
Strain gauge input with high signal resolution (>15 bits)
Universal output with high resolution (14 bits) as combined current / voltage output
Quick response, only 50 ms cycle time, i.e. also suitable for fast signals
Two relay outputs
Customer-specific linearization
Tare function
Min/max indicator (‘slave pointer’)
Logical linking of digital outputs, e.g. for common alarms
Preset for output value
Further documentation for DMS Messumformer SG 45:
–This operating manual 9499 040 82318
–Data sheet SG 45 9498 737 57333
–Operating note SG 45 9499 040 82441
–Interface description 9499 040 72018
General
SG 45 5

General
6 SG 45

.2Safety hints
This unit was built and tested in compliance with VDE 0411-1 / EN 61010-1 and was delivered in safe condition.
The unit complies with European guideline 89/336/EWG (EMC) and is provided with CE marking.
The unit was tested before delivery and has passed the tests required by the test schedule. To maintain this condition
and to ensure safe operation, the user must follow the hints and warnings given in this operating manual and operate
this instrument in compliance with the instructions given in this manual.
aThe unit is intended exclusively for use as a measurement and control instrument in technical
installations.
aWarning
If the unit is damaged to an extent that safe operation seems impossible, the unit must not be taken into
operation.
ELECTRICAL CONNECTIONS
The electrical wiring must conform to local standards (e.g. VDE 0100). The input measurement and control leads must
be kept separate from signal and power supply leads.
Using screened cables is mandatory! The screening must be connected to ground potential.
In the installation of the controller a switch or a circuit-breaker must be used and signified. The switch or cir -
cuit-breaker must be installed near by the controller and the user must have easy access to the controller.
COMMISSIONING
Before instrument switch-on, check that the following information is taken into account:
•Ensure that the supply voltage corresponds to the specifications on the type label.
•All covers required for contact protection must be fitted.
•If the controller is connected with other units in the same signal loop, check that the equipment in
the output circuit is not affected before switch-on. If necessary, suitable protective measures must
be taken.
•The unit may be operated only in installed condition.
•Before and during operation, the temperature restrictions specified for controller operation must
be met.
aWarning
During operation, the ventilation slots of the housing must not be covered.
aThe measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
aWarning
The ventilation slots must not be covered during operation.
aThe measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
SHUT-DOWN
For taking the unit out of operation, disconnect it from all voltage sources and protect it against accidental operation.
If the controller is connected with other equipment in the same signal loop, check that other equipment in the output
circuit is not affected before switch-off. If necessary, suitable protective measures must be taken.
Safety hints
SG 45 7

2.1 MAINTENANCE, REPAIR AND MODIFICATION
The units do not need particular maintenance.
There are no operable elements inside the device, so the user must not open the unit
Modification, maintenance and repair work may be done only by trained and authorized personnel. For this purpose,
the PMA service should be contacted.
aWarning
When opening the units, or when removing covers or components, live parts and terminals may be
exposed. Connecting points can also carry voltage.
lCaution
When opening the units, components which are sensitive to electrostatic discharge (ESD) can be
exposed.
gYou can contact the PMA-Service under:
PMA Prozeß- und Maschinen-Automation GmbH
Miramstraße 87
D-34123 Kassel
Tel. +49 (0)561 / 505-1257
Fax +49 (0)561 / 505-1357
e-mail: [email protected]
2.2 Cleaning
gThe cleaning of the front of the controller should be done with a dry or a wetted (spirit, water)
handkerchief.
2.3 Spare parts
As spare parts für the devices the following accessory parts are allowed:
Description Order-No.
Connector set with screw terminals 9407-998-07101
Connector set with spring-clamp terminals 9407-998-07111
Bus connector for fitting in top-hat rail 9407-998-07121
Connector for bus connector inverted, left side, horizontal cable outlet *1 9407-998-07131
Connector for bus connector inverted, right side, vertical cable outlet *11 9407-998-07141
*1 screw connection
Safety hints
8 MAINTENANCE, REPAIR AND MODIFICATION SG 45

.3Mounting
The unit is provided for vertical mounting on 35 mm top-hat rails to EN 50022.
If possible, the place of installation should be exempt of vibration, aggressive media (e.g. acid, lye), liquid, dust or
aerosol.
The instruments of the rail line series can be mounted directly side by side. For mounting and dismounting, min. 8 cm
free space above and below the units should be provided.
For mounting, simply clip the unit onto the top-hat rail from top and click it in position.
To dismount the unit, pull the bottom catch down using a screwdriver and remove the unit upwards.
gThe transmitter SG 45 does not contain any maintenance parts, i.e. the unit need not be opened by the
customer.
aThe unit may be operated only in environments for which it is suitable due to its protection type.
aThe housing ventilation slots must not be covered.
aIn plants where transient voltage peaks are susceptible to occur, the instruments must be equipped with
additional protective filters or voltage limiters!
lCaution! The instrument contains electrostatically sensitive components.
aPlease, follow the instructions given in the safety hints.
aTo maintain contamination degree 2 acc. to EN 61010-1, the instrument must not be installed below
contactors or similar units from which conducting dust or particles might trickle down.
Mounting
SG 45 9
%
max.
95% rel.
max. 55°C
-10°Cmin.
22.5
(0,87”) 117.5 (4,63”)
99 (3,90”)
2.3
111 (4,37”)
5.5
(0,08”)
(0,20”)
click
Montage / mounting
A
bmessungen / dimensions
Demontage / dismantling
1
Klemme /
terminal
5678
1234
1516 17 18 11 12 13 14
Klemme /
terminal

3.1 Connectors
The four instrument connectors are of the plug-in type. They plug into the housing from top or bottom and click in posi -
tion (audible latching). Releasing the connectors should be done by means of a screwdriver.
Two connector types are available:
•Screw terminals for max. 2,5 mm2conductors
•Spring-clamp terminals for max. 2,5 mm2conductors
gBefore handling the connectors, the unit must be disconnected from the supply
voltage.
Tighten the screw terminals with a torque of 0,5 - 0,6 Nm.
With spring-clamp terminals, stiff and flexible wires with end crimp can be introduced into
the clamping hole directly. For releasing, actuate the (orange) opening lever.
aContact protection: Terminal blocks which are not connected should remain in the socket.
Mounting
10 Connectors SG 45

.4Electrical connections
4.1 Connecting diagram
4.2 Terminal connections
aFaulty connection might cause destruction of the instrument !
1Connecting the supply voltage
Dependent on order
•90 … 260 V AC terminals: 15,16
•24 V AC / DC terminals: 15,16
For further information, see section "Technical data"
gInstruments with optional system interface:
Energization is via the bus connector of field bus coupler or power supply module. Terminals 15, 16 must
not be used.
2Connecting input INP1
Input for strain gauge (in 4 and 6-wire connection) or for melt pressure sensors (with/without calibration shunt).
aExcitation voltage for bridge (EXITATION ) terminals: 1, 4
bExcitation voltage measuring signal (Sense) terminals: 2, 3
cBridge signal (input) terminals: 5, 6
Electrical connections
SG 45 Connecting diagram 11
Data A
Data A
Data B
Data B
OUT3
PWR
OUT1
OUT2
di1
RGND
RGND
RS 485
1
INP1
2
3
4
5
6
a
c
b
d
e
11 12 13 14
11 12 13 14
15 16 17 18
15 16 17 18
1234
1234
top
14
13
12
16
15
11
17 18
LN
~90-260V
~24V
V
16
15 17 18
System
8
76
3
2
1
5
34
INP
+-
EX + EX -
+ Sense -
R-CAL

3Connecting input di1
Digital input
control input (as a potentialfree contact) terminals: 7, 8
4Connecting outputs OUT1 / OUT2 (optional)
Relay outputs max. 250V/2A NO contacts with a common terminal.
•OUT1 terminals: 17, 18
•OUT2 terminals: 17, 14
5Connecting output OUT3
Universal output
dcurrent (0...20mA) terminals: 11, 12
evoltage (0...10V) terminals: 12, 13
6Connecting the bus interface (optional exept d)
RS 485 interface with MODBUS RTU protocol
*see interface description MODBUS RTU: (9499-040-72011)
Electrical connections
12 Terminal connections SG 45

4.3 Connecting diagram
The instrument terminals used for the engineering can be displayed and printed out via BlueControl Ò( menu File \ Print
preview - Connection diagram).
Example:
Electrical connections
SG 45 Connecting diagram 13
Device1.bct
Connecting plan
Terminal connector 1
Terminal connector 2
Terminal connector 3
Name Description
Name Description
Name Description
Probe cable
Process value X1
0...20 mA continuous, signal source: Process value
Alarm INP1-Error
Alarm Limit 1, Alarm INP1-Error
Sensor supply

4.4 Connection examples
only with 6-wire bridge
After initialization, a test for connection of the sense signal is made automatically (6-wire connections )
Electrical connections
14 Connection examples SG 45
1
4EX-
Excitation-
Excitation+
Ausgang
EX+
5INP+
6INP-
3 SENSE -
2 SENSE +
Sense+
Sense-
+SENSE-
+ INP -
EX+ EX-
Example: Connection load cell with 4 or 6-wire bridge
1
4EX-
5INP+
6INP-
3 SENSE -
Excitation
Excitation
Ausgang
EX+
R-CAL
+SENSE-
+ INP -
EX+ EX-
Example: Connection of a (melt) pressure sensor in 4-wire technology with a calibrating resistor
Master z.B. / e.g.
Converter RS 232-RS 485
(ADAM-4520-D)
DATA+ 1
DATA-
TX+
TX-
RX+
RX-
(R)+Vs
(B)GND 10
Data A
Data A
Data B
Data B
RGND
(RS-485) (RS-422)
LT
LT
Example: RS 485 interface with RS 485-RS 232 converter
See documentation 9499-040-72011

4.5 Hints for installation
wMeasurement and data lines should be kept separate from control and power supply cables.
wSensor measuring cables should be twisted and screened, with the screening connected to
earth.
wExternal contactors, relays, motors, etc. must be fitted with RC snubber circuits to manufacturer
specifications.
wThe unit must not be installed near strong electric and magnetic fields.
wThe temperature resistance of connecting cables should be selected in accordance with the
local conditions.
aThe unit is not suitable for installation in explosion-hazarded areas.
aFaulty connection can lead to the destruction of the instrument.
aThe measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
Please, follow the instructions given in the safety hints.
4.6 UL approval (optional)
For compliance with UL regulations, the following points must be taken into account:
qUse only copper (Cu) wires for 60 / 75 °C ambient temperature.
qThe connecting terminals are designed for 0,5 – 2,5 mm2Cu (12-30 AWG) conductors.
qThe screw terminals must be tightened using a torque of 0,5 – 0,6 Nm.
qThe instrument must be used exclusively for indoor applications.
qMax. ambient temperature: 55°C.
qMaximum operating voltage: see technical data.
qMax. ratings of relay contacts: 250VAC, 2A (resistive)
Electrical connections
SG 45 Hints for installation 15

Electrical connections
16 UL approval (optional) SG 45

.5Operation
5.1 Front view
1Line 1: process value display
2Line 2: display of unit / extended operating level / error list /
Conf and PArA level values
3Tare / sample & hold activated
4Error list (2 x ô), e.g.
·Fbf.xsensor fault INP. X
·Pol.xwrong polarity INP. X
·Lim.xlimit value alarm
·...
5Increment key / "slave pointer", maximum value
6Enter key to select extended operating level or error list
Parameter-, Konfigurations-, Installations-Ebene
7Status indicator LEDs
·green: limit value 1 OK
·green blinking: no data exchange with bus coupler
(only on instruments with optional
system interface)
·red: limit value 1 active
·red blinking: instrument fault, configuration mistake
8Display elements, active as bars
9Status of switching output OUT1 active
0Status of switching output OUT2 active
!Decrement key/ "slave pointer", minimum value
§PC connection for the BlueControlÒengineering tool
gIn the first LCD-display line the measured value is shown. The second LCD-line normally shows the
setpoint. When changing over to the parameter setting, configuration or calibration level and at the
extended operating level, the parameter name and value are displayed alternately.
+§: To facilitate withdrawal of the PC connector from the instrument, please, press the cable left.
Operation
17 Front view SG 45
+SENSE-
+ INP -
EX+ EX-
2
kg
SG

5.2 Operating structure
The instrument operation is divided into four levels:
The access to the parameter, configuration and calibrating level can be disabled using the following two methods:
wLevel disabling by adjustment in the engineering tool (IPar, ICnf, ICal). Display of disabled levels
is suppressed.
wThe access to a level can be disabled by entry of a pass number (0 … 9999). After entry of the
adjusted pass number, all values of the level are available.
With faulty input, the unit returns to the operating level.
Adjusting the pass number is done via BlueControlÒ.
Individual parameters which must be accessible without pass number, or from a disabled
parameter level, must be copied into the extended operating level.
Factory-setting: all levels are accessible without restrictions, pass number PASS =OFF
5.3 Behaviour after supply voltage switch-on
After switching on the supply voltage, the instrument starts with the operating level.
The operating status is as before power-off.
Operation
SG 45 Operating structure 18
3s
PASS
ô
12FE
450.3
KG
äüüü
12FE
450.3
12FE
450.3
12FE
450.3
END
äüüü
ô
PASS
ô
PASS
ô
ô
CONF
äüüü
12FE
450.3
PARA
äüüü
InSt
äüüü
Operating level
Installation and
Calibrating level
See page
Parameter level
See page 45
Calibrating level
See page 38
PASS

5.4 Displays in the operating level
5.4.1 Display line 1
The display value is the value resulting from function.1, function.2, function.3 handling.
It is also called process value (see also section/page 23.)
5.4.2 Display line 2
The value to be displayed continuously in the second LCD line can be selected from different values via the
BlueControlÒengineering tool.
As default, the adjusted engineering unit is displayed.
1Default settings as setpoint
2Display of output OUT3 in % (with corre-
sponding scaling)
gThe values in display line 2 can only be displayed, but not changed.
gReset to display of the engineering unit is possible by deleting the entry for line 2..
gWith faulty input values, signals dependent on the inputs (e.g. Inp1, Inp2, display value, Out3) also indicate FAIL.
5.4.3 Switch-over with the enter-key
By using the enter-key, different values can be called in display 2.
·1Displaying the defined display 2 value (via BlueControlÒ).
Standard setting is unit
·2Calling up the error list, if messages are supplied.
If there is more than one message with every push of
the enter key the next message is displayed.!!!
·3Calling up the extended operating level, if messages
are supplied. If there is more than one message with
every push of the enter key the next message is displayed.!!!!
·4Returning to the original displayed value.
If for 30 s no key is pushed, the display automatically
returns to the origin.
Operation
19 Displays in the operating level SG 45
12FE
450.3
äüü
Kg
12FE
450.3
55.0
äüüü
12
12FE
278.3
°C
äüüä
1
2
12FE
278.3
FbF.1
äüüä
3
ô
ô
ô
12FE
278.3
L.1
äüüäü
4
ô
12FE
278.3
°C
äüüä
ô

5.4.4 Slave pointer function
The minimum and maximum input values are stored in the unit.
The minimum input value is displayed as long as key Ìis
pressed.
The maximum input value is displayed as long as key È
is pressed.
Deleting the minimum value
The minimum value is deleted by pressing key Èwhilst key Ìis kept pressed.
Whether the minimum value should be deleted also by the digital input (rES.L) can be determined during configura-
tion.
Deleting the maximum value
To delete the maximum value, press key Ìwhilst keeping key Èpressed.
Whether the maximum value should be deleted also by the digital input (rES.H) can be determined during configura-
tion.
Deleting the minimum and maximum values is possible also via interface.
gWhen de-energizing UNIFLEX SG 45 the minimum and maximum values are deleted.
gIn case of error of the display value (e.g. input fail behaviour), the minimum and maximum values are also
set to FAIL. When a valid value is displayed again, the minimum and maximum value are deleted.
5.4.5 Selecting the units
The unit to be displayed is determined via configuration D.Unt.
By selecting D.Unt =22, display of any max. 5-digit unit or text can be determined.
1Unit (example): kilogram
2Text (example): TAG no.
Operation
UNIFLEX SG 45 Displays in the operating level 20
1
2
FE
450.3
502.4
äüüü
12FE
450.3
ûC
äüüü
max
12FE
450.3
26.7
äüüü
12FE
450.3
ûC
äüüü
min
12FE
4.5
Kg
äüüü
1
2
FE
450.3
TI451
äüüü
1
2