Sensormate GE1029-DU1D User manual

C.0118_v1.0 ENG
Operating manual
GE1029-DU1D
TIE-BAR STRAIN SENSOR WITH
1- CHANNEL MONITOR DU1D

IT
“Attuazione della direttiva 2012/19/UE
sui riuti di apparecchiature elettriche ed
elettroniche (RAEE)”
Il simbolo del cassonetto barrato ri-
portato sull’apparecchiatura o sulla
sua confezione indica che il pro-
dotto alla ne della propria vita utile
deve essere raccolto separatamente
dagli altri riuti.
La raccolta differenziata della presente apparec-
chiatura giunta a ne vita è organizzata e gestita
dal produttore.
L’utente che desideri disfarsi dell’apparecch-
iatura dovrà quindi contattare il produttore per
ricevere indicazioni sul sistema da quest’ultimo
adottato per consentire la raccolta separata de-
ll’apparecchiatura giunta a ne vita.
L’adeguata raccolta differenziata per l’avvio
successivo dell’apparecchiatura dismessa al ri-
ciclaggio, al trattamento e allo smaltimento am-
bientalmente compatibile contribuisce ad evitare
possibili effetti negativi sull’ambiente e sulla sa-
lute e favorisce il reimpiego e/o riciclo dei mate-
riali di cui è composta l’apparecchiatura.
EN
“Implementation of Directive 2012/19/EU on
waste electrical and electronic equipment
(WEEE)”
The symbol showing a crossed-out
wheeled bin on equipment or its
packaging indicates that the product
must be collected separately from
other waste at the end of its useful
life.
The manufacturer is responsible for organising
and managing the separate collection of this
piece of equipment at the end of its useful life.
Users wishing to dispose of the equipment must
therefore contact the manufacturer to obtain
instructions from the same on how to have the
equipment collected separately at the end of its
useful life.
By collecting the disused equipment separately,
it can be recycled, treated or disposed of in an
environmentally friendly manner, thus helping to
prevent the environment and public health from
being affected negatively and enabling reuse
and/or recycling of the materials forming the
same equipment.
DE
„Umsetzung der Richtlinie 2012/19/EU
über Elektro- und Elektronik-Altgeräte
(EEA)“
Das Symbol der durchgekreuzten
Mülltonne auf dem Gerät oder der
Geräteverpackung weist darauf hin,
dass Sie das Produkt am Ende sei-
nes Lebenszyklus separat entsorgen
müssen.
Die Getrenntsammlung dieses Geräts an sei-
nem Lebenszyklusende wird vom Hersteller or-
ganisiert und besorgt.
Der Nutzer, der das Gerät entsorgen möchte,
muss sich daher an den Hersteller wenden,
um Auskunft über seine Vorgehensweise zur
Getrenntsammlung des Geräts an dessen
Lebenszyklusende zu erhalten.
Die entsprechende Getrenntsammlung für die
anschließende Zuführung des Altgeräts zum
Recycling, zur Wiederaufbereitung und zur um-
weltverträglichen Entsorgung trägt dazu bei,
negative Auswirkungen auf die Umwelt und die
Gesundheit zu unterbinden und begünstigt die
Wiederverwendung und/oder das Recycling von
Werkstoffen, aus denen das Gerät besteht.
FR
“Transposition de la Directive 2012/19/
UE relative aux déchets d’équipements
électriques et électroniques (RAEE)”
Le pictogramme de la poubelle
barrée, gurant sur l’équipement ou
sur son emballage, indique que le
produit en n de vie doit être traité
séparément des autres déchets.
Le ramassage sélectif de cet équipe-
ment en n de vie est organisé et géré par le
constructeur.
Tout utilisateur qui souhaiterait se débarrasser
de l’équipement devra donc contacter le cons-
tructeur pour obtenir des informations concer-
nant la méthode adoptée pour permettre le ra-
massage sélectif de l’équipement en n de vie.
Un ramassage sélectif correct, en vue de
l’acheminement de l’équipement vers des
opérations de recyclage, de traitement et de
mise au rebut respectueuses de l’environ-
ne-ment, contribue à réduire les impacts
poten-tiellement néfastes sur l’environnement
et la santé, outre à favoriser la réutilisation des
matériaux/composants dont l’équipement est
constitué.
WEEE Information

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GE1029
Product description
The strain gauge sensor GE1029 measure the surface-strain directly at the mounting loca-
tion in the same quality as bonded strain gages. The press-on technology, developed by
Sensormate AG, presses the strain gauges under the stainless protective lm so strongly
against the surface to be measured that frictional contact occurs.
The sensor does not have to be recalibrated between remove and re-installation. The sensor
is mounted using stainless steel straps, is non-destructive, very fast and simple. For each
tie-bar diameter outside tolerance of ± 2.5mm a different pair of steel straps is required. The
sensor can not be overloaded. The GE1029 sensors require a cyclic reset.
• Direct measurement of surface strain
• Quick and easy non-destructive assembly
• High accuracy and linearity in tension and
pressure (like bonded strain gauges)
• Ideal for use on presses, injection-moulding
and die-casting machines
• One system for many different tie bar diame-
ters (25…400mm)
• Dynamic applications
• Without amplier (passive)
• Ideal for online monitoring of clamping force
• Ideal for self-made load cells
GE1029
TIE-BAR STRAIN SENSOR Main features:

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Strain gauge type Foil (GF = 2.0)
Bridge resistance 350Ω
Measuring range ± 1000 με
Sensitivity tolerance ± 0.2%
Transverse sensitivity 0.9 ± 0.2 %
Accuracy <± 0,5% FS
Linearity <± 0,5% FS
Hysteresis <± 0,2% FS
Repeatability < 0,1% FS
Supply voltage 5VDC (max. 8VDC)
Supply current < 15mA
Operating temperature range -20...+70°C
Storage temperature range -20...+70°C
Overload capabilitiy indenite (offset occurs)
Protection class IP64
Case material Anodised aluminium
Weight, including cable 200g
Technical Data

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GE1029
Dimensions
Dimensions in mm
Installation requirements
Press-on torque (M4 screws) 2.0 Nm
Surface installation spot N7
Application: Self-made load-cell
Stainless steel belt:
10 x 0.4mm

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Electrical Connection
Strain gauge 1
Strain gauge 2
Strain gauge 1
Strain gauge 2
Option C
Connector
Pin
Option O
open leads Function
1 red Strain gauge1
2red Strain gauge1
3 - n.a.
4 yellow Strain gauge 2
5yellow Strain gauge 2
6 - n.a.
6
4
3
5
2
1
Option C: cable with connector
Option O: cable with open leads
2/4 Bridge
2x PVC screened cable (standard); 2 x 0.14 mm�; Ø 3.5mm
Shield

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GE1029
Electrical Connection
Option C
Connector
Pin
Function
1Excitation +
2 Excitation +
3 Excitation -
4Signal +
5Signal -
6 Excitation -
6
4
3
5
2
1
Option C: cable with connector
4/4 Bridge
Excitation +
Signal +
Signal -
Excitation -

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Assembly
These sensors are precision instruments. The devices must be handled with the
appropriate care. These instructions must be read and understood by every user.
Preparation
• Oil and other surface impurities as well as paint must be removed from the place of
installation.
• The surface roughness of the place of installation has not to be rougher than N7.
• Check the foil of the sensor GE1029 for damage.
• The foil of the sensor GE1029 must be absolutely clean.
Assembly procedure
1.
There are markings on the stainless
steel bands.
(The distance between these mar-
kings depends on the diameter of the
object to be measured)
2.
The stainless steel strips are xed at
the marked position with the individu-
al measuring modules.

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GE1029
Contact points
3.
Place the sensor around the object to be
measured and screw it on carefully.
Do not tighten with nal torque yet!
Cables must not be jammed.
4.
Slightly loosen the xing so that the individual
measuring modules can rest perfectly on the
circumference of the measuring object.
5.
The contact points must lie
exactly in the axial direction on
the surface to be measured.

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Attention:
It is important that the screws are checked with the above torque after the
machine has warmed up or after two days of operation at the latest.
Torque = 2 Nm
6.
Screw the sensors hand-tight.
Torque = 2 Nm
The two measuring modules must be
exactly opposite each other.
The system is now ready to measure.
Maintenance
Inspection
To prevent damage to the lm, it should always be checked before using the sensor.
Remove any impurities immediately.
Maintenance
The sensor GE1029 should be checked every 12 months. For maintenance the sensor
must be sent to Sensormate AG.

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DU1D
Product description
The DU1D Monitor is an industrial signal amplier and monitor for strain gauges and
strain sensors. It has integrated functions for external and internal (automatic) reset.
Force measurement on tie bars displays in kN or tons and diameter input. Strain
measurement displays in με (micro strain). Direct switch units and change parameters.
The handling is very user-friendly.
Application:
The device DU1D is used in conjunction with tie bar strain-sensors of the Sensormate
AG for the control of the clamping force on presses, injection-moulding and die-casting
machines. The ALARM relay allows to stop the machine in case of overload. Ideal to retrot
on existing machines.
• Available for all Sensormate sensors (2/4
bridges)
• Direct display of the measured values
in με, kN or t
• High accuracy and stable reset
• Automatic reset, external reset and alarm
output
• Ideal for control cabinet installation
(96x96mm, DIN 43700)
• Battery operation possible (optional) / not
rechargeable
DU1D
1- CHANNEL MONITOR Main features:

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Input bridge resistance 350...1000Ω
Signal input range (FS) 0,1...1mV/V
Resolution ADC 16-Bit
Sampling rate 500Hz
Output rate 40Hz
Display refresh 100Hz
Output signal Display (± 9999 digit, 1 channel)
Noise ≤ 1 digit
Accuracy <± 0,05% FS
Accuracy of zero point ≤ 1 digit
Linearity <± 0,5% FS
Alarm reaction time > 25ms
Reset time > 200ms
Reset voltage 15...28VDC
Supply voltage 12VDC
Supply current < 100mA
Inverse polarity protection Yes
Accidental short-circuit protection No
Operating temperatur range 0...+65°C
Storage temperatur range -40...+80°C
Temperatur coefcient at 10°C < 0,1 (0,05 typical)
Protection class IP50
EMC 2014/30/EU
Case material Plastic
Weight 210g
Technical Data

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DU1D
Dimensions in mm
Dimensions
Dimensions in mm
Option: Box-Housing
Option: Installation-Housing

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Mounting and installation
Electrical connection
Option:
Installation Housing
Connection pin
Function
Option:
Box-Housing
Connection M16 x 6-pin
1Power supply 12VDC alternative connection
2GND alternative connection
3Reset + -
4 Reset - -
5Alarm switch -
6 Alarm switch open -
7Alarm switch closed -
8Strain gauge 1 1
9Strain gauge 1 2
10 Shield -
11 Strain gauge 2 4
12 Strain gauge 2 5
Option: Installation Housing
Option: Box-Housing
6
2
3
1
4
5

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DU1D
Operation and control
Faceplate description
Decrease chosen value
Increase chosen value
ALARM Set alarm threshold
DIAM Set tie-bar diameter
UNIT Select unit (με, kN or tons)
RESET Set measurement to zero
LED‘s Indicate actual unit and/or mode
ALARM LED LED on = alarm out active

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Calibration
The monitor is factory calibrated to a cable length of 3m, 5m or 10m.
Attention:
The cable length inuences the signal because the supplementary resistors and the cable
enter the bridge.
Calibration cycle:
The DU1D monitor should be calibrated every 12 months. For calibration, the DU1D monitor
must be sent to Sensormate AG. With the optionally available strain simulator, the calibration
can be carried out at the customer level.
Functions
Unit
με
(micro strain) Displays the strain measured in με (1000μm/m)
kN
(kilo Newton) Displays the load in kN (diameter must be set).
tons Displays the load in tons. (diameter must be set)
T.Force Displays the value in kN or tons, multiplied by 4
(diameter must be set)
Custom Displays the value calibrated by the user.
Adjust diameter
For the force calculation in kN or tons the diameter of the cylindrical structure (column)
must be set.
Press and hold the “DIAM” button, while adjusting the diameter with the “UP/DOWN”
buttons. Then release the “DIAM” button. The diameter value is set now. Check the diameter
setting any time by pressing the “DIAM” button.

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DU1D
Alarm setting
• Press and hold the „ALARM“ button and simultaneously set the alarm value with the
„UP/DOWN“ buttons. Then release the „Alarm“ button.
-> the alarm is activated.
An alarm value = „0“ causes the alarm to be deactivated.
• Alarm values must be set separately for each unit.
• Alarm values for kN and tons are interdependent. This means that if the setting value is
changed to kN, this automatically changes the setting value in tons, corresponding to
the conversion „kN? tons“ and vice versa.
-> the alarm values in T. Force are also dependent on it because they only have the
kN-value or tone value quadruple.
• The custom alarm setting values „Custom-kN“ and „Custom-tons“ are also
interdependent.
Upper and lower limit value of the alarm
The function for changing the operating mode of the alarm from UL to LL and vice versa is
available as of software version 3.4.
Setting the operating mode:
1. The DU1D must be switched off.
2. Press and hold the‘ ALARM‘ -button, then switch on the instrument during this time
(respectively plug in the power supply). -> Release the alarm button.
3. One of the two displays appears:
- UL active: 4 lines appear in the display at the top: ¯ ¯ ¯ ¯
- LL active: 4 lines appear in the display at the bottom: _ _ _ _
4. Use the UP or DOWN buttons to select the operating mode.
5. Press the “RESET” button -> The operating mode is stored.
UL = Upper limit value
LL = Lower limit value

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Automatic reset
The DU1D monitor is set to the maximum value of 1000µε at the factory. From a strain
signal of 30με (cycle start value), the monitor displays values.
As soon as the current value falls below 5% of the maximum value measured in the current
cycle, the DU1D monitor carries out a reset (minimum 500ms). For correct measurements,
the reset time (= time without load) must be at least 500ms.
Measured value > value of the cycle start -> Current value is displayed
Measured value < value of the cycle start -> Display: ‘0000’
Value of the cycle start in “microStrain, kiloNewton or Tons”: 30με
Value of the cycle start in „Custom mode”: 10% of the calibrated
value
Minimum display value: 30 Digit
Auto-Reset function ON/OFF:
1. Press and hold UP/DOWN buttons together, press DIAM button and hold.
2. Keep pressing all 3 keys until in the display appears:
-> “AutO” for Auto-Reset ON
-> or “OFF” for Auto-Reset OFF
max-value 1
max-value 2
Value of the
cycle start
5% of the
max-value 1
5% of the
max-value 2
Value of the
cycle start
Force
Time
minimum
500s

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DU1D
Custom calibration
Set customer-specic maximum value
1. 1. Select on the display “Custom-kN” or “Custom-t”.
2. 2. Press the UP and DOWN buttons simultaneously for 5 seconds.
-> Display: “SErO”:
3. The machine must be open, i. e. without load, -> then press the „RESET“ button.
-> Display:”LOAd”:
4. Now move the machine to full load, -> then press the „RESET“ button.
-> Display:”Set”:
5. Set the alarm value with the „UP“ and „DOWN“ buttons.
6. Press the „RESET“ button.
7. The custom calibration is set.
Check software version
1. The DU1D must be switched off.
2. Press the “UNIT” and “UP” button simultaneously.
3. Turn on the device while both buttons are still pressed.
4. The software version of the device is now displayed.