SIGMA TEK AI 022-1 User manual

AI 022-1
S-DIAS Strain Gauge Input Module
Operating Manual
Date of creation: 24.09.2018
Version date: 04.11.2020
Article number: 20-009-022-1E

Publisher: SIGMATEK GmbH & Co KG
A-5112 Lamprechtshausen
Tel.: [phone]
Fax: [phone]
Email: [email protected]
WWW.SIGMATEK-AUTOMATION.COM
Copyright © 2018
SIGMATEK GmbH & Co KG
Translation from German
All rights reserved. No part of this work may be reproduced, edited using an electronic system, duplicated or dis-
tributed in any form (print, photocopy, microfilm or in any other process) without express permission.
We reserve the right to make changes in the content without notice. SIGMATEK GmbH & Co KG is not responsible for
technical or printing errors in this handbook and assumes no responsibility for damages that occur through its use.

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
04.11.2020 Page 1
S-DIAS Strain Gauge Input Module AI 022-1
with 2 analog inputs
The S-DIAS AI 022-1 strain gauge input module is used to analyze meas-
uring bridges (i.e. strain gauge load cells). With a 24-bit resolution, meas-
urement values are provided with an overall accuracy of 0.035 %.
The AI 022-1 differs from the AI 022 in the following technical data:
- the resolution of the measurement range is increased to a max-
imum of 100 %, the reduction in the expanded measurement
range of 100-150 % for evaluating overstretching of the load cell
by 50 % was eliminated.
- For increased noise suppression, the hardware input filter has a
lower limiting frequency of 8 Hz instead of 180 Hz.
- the support of lower impedance load cells (e.g. via the parallel
connection of several load cells) –loads of at least 60 Ω / chan-
nel from the AI 022-1 are now supported; lower load cell loads
lead to a higher current consumption of the module on the
S-DIAS bus

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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Contents
1Technical Data ........................................................................ 4
1.1 Analog Channel Specifications...................................................4
1.2 Electrical Requirements...............................................................5
1.3 Miscellaneous ...............................................................................7
1.4 Environmental Conditions...........................................................7
2Mechanical Dimensions......................................................... 8
3Connector Layout................................................................... 9
3.1 Status LEDs.................................................................................10
3.2 Applicable Connectors...............................................................10
3.3 Labeling Field..............................................................................11
4Wiring......................................................................................12
4.1 Wiring Example...........................................................................12
4.2 Note..............................................................................................13
4.3 Connection Variants...................................................................14
5Mounting.................................................................................15
6Supported Cycle Times.........................................................17
6.1 Cycle Times below 1 ms (in µs).................................................17
6.2 Cycle Times equal to or higher than 1 ms (in ms) ..................17
7Hardware Class AI022_1 .......................................................18
7.1 General.........................................................................................19
7.2 Analog Inputs..............................................................................20
7.3 Communication Interfaces.........................................................21

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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7.4 Setting the FilterDepth ...............................................................22
7.5 Setting the Force Sensor ...........................................................22

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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1 Technical Data
1.1 Analog Channel Specifications
Number of channels
2
Bridge supply voltage
+5 V
Load cell rated values
0.25 mV/V
0.5 mV/V
1 mV/V
2 mV/V
16 mV/V
Measurement range (1)
±1.25 mV
±2.5 mV
±5 mV
±10 mV
±80 mV
Measurement value
±8388608 d
The hardware class returns -2147483632 with an open input.
Resolution
24 bits
Hardware filter
8 Hz, 1st order
Filter setting, conversion time and
noise-free resolution.
filter word
2
...
5
...
1023
filter type
Sinc4
...
Sinc4
...
Sinc4
cutoff frequency
(-3 dB)
144 Hz
...
57.7 Hz
...
0.282 Hz
conversion time
4 ms
...
9 ms
...
1702 ms
noise-free reso-
lution (2)
15.5 bits
...
16 bits
...
20-bit
Sensor break detection
yes
Load per channel
60-5000 Ω
Noise (3)
±0.0031 % referred to the full scale value for filter Word 2
Temperature drift (3)
±0.001 % / °C referred to the full scale value of the measuring range
Overall accuracy (3)
±0.035 % referred to the full scale value of the measuring range
Calibration data
Null-voltage protected
yes
Calibratable
no
(1) the measurement ranges are not designed for overstretching of the load cell
(2) These are typical values with an active Sinc4 filter and measurement range of 2 mV/V
(3) To maintain the accuracy of the analog channel measurement, a system calibration with the sensor is required.
Whereby the null point and full-scale deflection are calibrated. The system must be re-calibrated when a sensor is
replaced or the measurement range changed. Generally, the zero point is first calibrated and then the full deflection.
The calibration of the full deflection is only possible between 50 and 100 % of the positive measurement range.

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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1.2 Electrical Requirements
Voltage supply from S-DIAS bus
+5 V
Current consumption on the
S-DIAS bus
(+5 V power supply)
typically 50 mA
maximum 55 mA
Voltage supply from S-DIAS bus
+24 V
Current consumption on the
S-DIAS bus
(+24 V supply) without a load on
the measurement bridge supply
typically 17 mA at +18 V
typically 15 mA at +24 V
typically 14 mA at +30 V
maximum 20 mA at +18 V
maximum 18 mA at +24 V
maximum 17 mA at +30 V
Current consumption on the
S-DIAS bus
(+24 V supply) with maximum
load on both measurement
bridge supplies
typically 92 mA at +18 V
typically 71 mA at +24 V
typically 59 mA at +30 V
maximum 110 mA at +18 V
maximum 85 mA at +24 V
maximum 71 mA at +30 V
If this S-DIAS module is connected to an S-DIAS supply module with several other
S-DIAS modules, the total current of the modules used must be determined and
checked.
The total current of the +24 V supply cannot exceed 1.6 A!
The total current of the +5 V supply cannot exceed 1.6 A!
The specification for the current can be found in the module-specific documentation
under "Electrical Requirements".
Si ce module S-DIAS est connecté à un module d’alimentation S-DIAS suivi de
plusieurs modules S-DIAS, le courant total des modules utilisés doit être déterminé
et vérifié.
Le courant total de l'alimentation +24 V ne peut pas dépasser 1,6 A!
Le courant total de l'alimentation +5 V ne peut pas dépasser 1,6 A!
Le cahier des charges pour le courant peut être trouvé dans la documentation
spécifique au module sous "Spécifications électriques".

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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1.3 Miscellaneous
Article number
20-009-022-1
Hardware version
1.x
Standard
UL 508 (E247993)
Approvals
UL, cUL, CE
1.4 Environmental Conditions
Storage temperature
-20 ... +85 °C
Environmental temperature
0 ... +55 °C
Humidity
0-95 %, non-condensing
Installation altitude above sea
level
0-2000 m without derating
> 2000 m with derating of the maximum environmental temperature by 0.5
°C per 100 m
EMC resistance
in accordance with EN 61000-6-2:2007 (industrial area)
EMC noise generation
in accordance with EN 61000-6-4 (industrial area)
Vibration resistance
EN 60068-2-6
3.5 mm from 5-8.4 Hz
1 g from 8.4-150 Hz
Shock resistance
EN 60068-2-27
15 g
Protection type
EN 60529
IP20

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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2 Mechanical Dimensions

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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3 Connector Layout

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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3.1 Status LEDs
Module status
green
ON
module active
OFF
no supply available
BLINKING (5 Hz)
no communication
User
yellow
ON
can be set from the application
(e.g. the module LED can be set to blinking through the visuali-
zation, so that it is easily found in the control cabinet)
OFF
BLINKING (2 Hz)
BLINKING (4 Hz)
Status AI1/AI2
green
BLINKING (3 Hz)
A/D converter active
OFF
A/D converter inactive
Error AI1/AI2
red
ON
sensor break or overload/short circuit of the bridge supply.
OFF
no errors
BLINKING (1 Hz)
input initialization error
3.2 Applicable Connectors
Connectors:
X1-X5: Connectors with spring terminals (included in delivery)
The spring terminals are suited for the connection of ultrasonically compacted (ultrasonically
welded) stranded wire.
Connections
Stripping length/sleeve length:
10 mm
Mating direction:
parallel to the conductor axis or circuit board
Conductor cross section rigid:
0.2-1.5 mm2
Conductor cross section flexible:
0.2-1.5 mm2
Conductor cross-section strands ultrasonically compacted:
0.2-1.5 mm2
Conductor cross section AWG/kcmil:
24-16
Conductor cross section flexible with ferrule:
0.25-1.5 mm2
Conductor cross section flexible with ferrule and plastic sleeve:
0.25-0.75 mm2(reason for reduction d2 of the
ferrule)

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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3.3 Labeling Field
Manufacturer
Weidmüller
Type
MF 10/5 CABUR MC NE WS
Article number Weidmüller
1854510000
Compatible printer
Weidmüller
Type
Printjet Advanced 230V
Article number Weidmüller
1324380000

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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4 Wiring
4.1 Wiring Example

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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4.2 Note
The signals recorded by the analog modules are very small, as compared to the digital sig-
nals. To ensure error-free operation, a careful wiring method must be followed:
•The DIN rail must have an adequate connection to mass.
•The lines connected to the source of the analog signals must be as short as possible and
parallel wiring to digital signal lines must be avoided.
•The signal lines must be shielded.
•The shielding must be connected to a shielding bus.
•Avoid parallel connections between input lines and load-bearing circuits.
•Protective circuits for all relays (RC networks or free-wheeling diodes).
The ground bus should be connected to the control cabinet when possible!
Si possible la terre doit être connectée à l'armoire de commande!
IMPORTANT:
The S-DIAS module CANNOT be connected or disconnected while voltage is applied!
IMPORTANT:
Le module S-Dias NE PEUT PAS être inséré ou retiré sous tension.

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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4.3 Connection Variants
Two connection Types can be used when measuring with strain gauges:
4-wire measurement:
The advantage of this variant is that a 4-pin connector cable can be used for the strain
gauge. The voltage drop over the circuit for the bridge voltage supply however, cannot be
compensated.
6-wire measurement:
This configuration provides the advantage of voltage compensation using the bridge voltage
supply measurement on the strain gauge directly.

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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5 Mounting
The S-DIAS modules are designed for installation into the control cabinet. To mount the mod-
ules, a DIN-rail is required. The DIN rail must establish a conductive connection with the back
wall of the control cabinet. The individual S-DIAS modules are mounted on the DIN rail as a
block and secured with latches. The functional ground connection from the module to the DIN
rail is made via the grounding clamp on the back of the S-DIAS modules.The modules must
be mounted horizontally (module label facing up) with sufficient clearance between the ven-
tilation slots of the S-DIAS module blocks and nearby components and/or the control cabinet
wall. This is necessary for optimal cooling and air circulation, so that proper function up to the
maximum ambient temperature is ensured.

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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Recommended minimum distances of the S-DIAS modules to the surrounding components
or control cabinet wall:
a, b, c … distances in mm (inches)

S-DIAS STRAIN GAUGE INPUT MODULE AI 022-1
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6 Supported Cycle Times
6.1 Cycle Times below 1 ms (in µs)
FW
50
100
125
200
250
500
V3.00
x
x
x
x
x
6.2 Cycle Times equal to or higher than 1 ms (in ms)
FW
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
V3.00
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
FW
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
V3.00
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

AI 022-1 S-DIAS STRAIN GAUGE INPUT MODULE
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7 Hardware Class AI022_1
Hardware Class AI022_1 for the S-DIAS AI022-1 analog module
This hardware class is used to control the AI022-1 hardware module. The module has two
analog inputs for resistance bridges (e.g. DMS weighing cells). More information on the hard-
ware can be found in the module documentation.