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List of chapters General preliminary remarks Description of operation Technical data Operating instructions for the IP20 version Operating instructions for the IP65 version Configuring for use and testing Profibus configuration Profibus communication Dimensioned drawings 10. Appendix Page 2 of 82 Date: 27.01.06...
CONTENTS GENERAL PRELIMINARY REMARKS ........6 About this manual................6 Important note ................6 Unpacking ...................6 Deliverables ................6 DESCRIPTION OF OPERATION..........7 Equipment function..............7 Applications.................8 TECHNICAL DATA ..............9 OPERATING INSTRUCTIONS FOR THE IP20 VERSION ..11 Installation / Fixing..............11 Degree of protection..............11 Ambient temperature..............11 Front panel / terminal assignments ...........11 OPERATING INSTRUCTIONS FOR THE IP65 VERSION ..13 Installation / Fixing..............13 Degree of protection..............13...
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6.9.3.2 Sensor excitation, input range and input reference ....35 6.9.3.3 Calibration of a transmitter with voltage output ......36 6.9.3.3.1 Calibration using a physical variable by the teach-in method..36 6.9.3.3.2 Calibration using the sensor test certificate.......37 6.10 Signal processing ..............38 6.10.1 Measurement rate / Cut-off frequency / Filter......38 6.10.2 Averaging ..................38...
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10.2. Display of measurement results ..........78 10.2.1 Introduction ................78 10.2.2 Dependence of the quantization error on input drive level ..78 10.2.3 Increasing the resolution by averaging and filtering ....79 10.2.4 Optimum device configuration...........79 10.3 Factory settings .................80 10.4 Maintenance, Customer service and Warranty ......80 10.4.1 Maintenance................80 10.4.2...
General preliminary remarks About this manual This equipment manual contains important information on the operation, installation and configuration of the Sensor Profibus Module type 9221, IP20 and IP65 versions. Important note Note that the Sensor Profibus module type 9221 must be used in accordance with the instructions, technical data and conditions of use listed in this manual.
Description of operation Equipment function The Sensor Profibus Module type 9221 is intended for the acquisition and processing of sensor signals and digital status information and for producing digital signals for the fieldbus level (Profibus). The Sensor Profibus Module is a user-configurable, single-channel module operated via an RS232 interface (configuration only) or RS485 interface (Profibus-DPV1).
Applications The Sensor Profibus Module type 9221 has been specifically developed for high- speed control functions and real-time operations, and therefore covers a huge range of applications. The instrument has been designed to integrate the maximum possible range of analog sensor output signals into complex, networked and distributed automation structures.
Technical data 9221 version IP 20 IP 65 Input signal 120 Ω - 5 kΩ Strain gage Bridge resistor: Connection type:4 or 6 wire Configurable sensitivities, infinite adjustment strain-gage full bridge: < 1 mV/V ... 40 mV/V Excitation: 2.5 V / 5 V / 10 V Supply current: max.
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Profibus Baud rate automatic detection 9.6 kBaud ... 12 Mbaud Number of devices up to 32 stations without repeater on bus up to 127 stations with repeater Potential floating potential Addressing Hardware or software addressing Functions Configurable via PC Mean value, filter, tare, Min/Max buffer, or Profibus limits, evaluation status, sensor test Filter settings...
Operating instructions for the IP20 version Installation / Fixing The Sensor Profibus Module type 9221 has a snap-fit design for mounting on a standard 35 mm DIN (top-hat) rail to DIN EN 50022. The unit is fixed to the DIN rail via a clip on its rear side.
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Front view Configuration interface Input / Output (RS232) Status LEDs Supply voltage Profibus port (RS485) Sensor connection Rear view Address setting Fixing clip for DIN- rail mounting Terminal assignments Wires are connected via screw terminals on the module. All terminal blocks have a plug-in design, so they can be removed from the module for convenient cable connection.
Operating instructions for the IP65 version Installation / Fixing The Sensor Profibus Module type 9221 has four mounting holes for fixing the module in place. The module must only be installed by a qualified person. Degree of protection The Sensor Profibus Module type 9221 has IP65 degree of protection. The module is therefore protected against ingress of dust and water jets.
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Plan view Status LEDs Plan view Mounting holes Configuration interface (RS232) Ad dress setting Profibus terminating resistance Supply Sensor Input Output Profibus port voltage connectio (RS485) – B-coded Page 14 of 82 Date: 27.01.06...
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Terminal assignments Cables are connected via PG cable glands and screw terminals on the module. All terminal blocks have a plug-in design, so they can be removed from the module for convenient cable connection. No more than 2 wires should be connected to one terminal. Ferrules are recommended for connecting stranded wires.
Configuring for use and testing Block diagram and internal signal processing optical LED´s RS 485 Interface Voltage supply RS 232 Interface converter optical Digital Monitor Output The A/D converter amplifies and converts the signals according to the design and type of the connected sensor. The A/D converter digitizes all incoming signals with a resolution of 16 bits.
Before switching on Before applying the supply voltage to the sensor module, make a final check that the unit is installed correctly and set to the correct voltage. It is essential to check that the unit has been grounded in accordance with regulations and that the supply voltage for all the Sensor modules does not exceed the specified + 36 VDC.
Grounding and surge protection The case of the Sensor Profibus Module must be connected to ground. The grounding cable can be connected to pin 2 of the supply voltage screw- terminal, or directly via the DIN rail on the rear of the case. Suitable protective devices must be provided against lightning damage (surge voltages).
6.8.2 Calibration using PC software 9221-P001 The PC configuration program “9221-P001” and a notebook PC can be used for convenient configuration of the instrument via the RS232 socket. The configuration program is held on the CD-ROM supplied with the instrument. You can use this software to: •...
6.9.1 Measurements using a strain gage 6.9.1.1 Connection Strain-gage connection + Excitation (1) + Sensor line (2) + Signal (3) - Signal (4) - Sensor line (5) - Excitation (6) Shield (7) Note: A measuring chain contains a number of components, each contributing to the overall measurement accuracy of the test setup.
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6.9.1.2 Sensor excitation, input range and input reference Sensor excitation voltage The sensor excitation voltage must be set here, which you can find from the test and calibration certificate for the sensor. Input range The input range is calculated and selected as follows: Example calculation for a load cell, type 8431-100: Input measurement range = Sensor excitation voltage x Sensitivity in ref.
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Input reference “No ground reference” is selected as the measurement signal input reference for measurement using strain gage sensors with Wheatstone Bridge circuit. Page 22 of 82 Date: 27.01.06...
6.9.1.3 Calibration of strain gage sensors Calibration is necessary in order to specify the relationship between the electrical signals measured by the connected sensors and the measured values to be displayed. A two-point calibration procedure is used here. Normally the sensors have a test and calibration certificate containing details of the electrical signals.
6.9.1.3.1 Calibration using a physical variable by the teach-in method This method involves a two-stage online teach-in of sensor data to the Sensor Profibus Module, where two teach-in states are applied sequentially. The first state is the lower scale value, and the second state is the upper scale value. Example: Remove any load from the load cell and calibrate the zero point F = 0 N.
6.9.1.3.2 Calibration using the sensor test and calibration certificate This method involves using the test and calibration certificate to enter the sensor data directly in the Sensor Profibus Module. All necessary calibration data can be found from the certificate. About the values: These values are adopted directly from the test and calibration certificate.
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Note: Please note that when using this type of calibration for strain gage full-bridge sensors and potentiometric sensors, the measurement result also depends on the excitation voltage. Thus if you wish to verify that the instrument is working properly with sensors that produce a voltage signal, you must measure the sensor excitation voltage using a precision digital voltmeter and then use it to calculate the calibration voltage, or else you should select the “DC-R”...
6.9.1.3.3 Calibration using a precision voltage source This method can be used for all voltage-generating sensors e.g. for strain gages and potentiometric, transmitter and reference-signal sensors. The sensor is simulated by a precision voltage source. By TEACH-IN procedure + Signal - Signal Precision voltage source z.B.
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6.9.1.3.4 Calibration using a shunt resistance Note: Shunt calibration is the least accurate technique of the four calibration methods offered. Only select this option if there are no other means available. This method can be used quite satisfactorily, however, for occasional electrical checks of the measuring chain.
The “Upper scale value” is assigned to the "Upper calibration value” (calibration offset in this case). This calibration data must now be transferred to the instrument; if required it can also be saved. 6.9.2 Measurements using a potentiometer Calibration is necessary in order to specify the relationship between the electrical signals measured by the connected sensors and the measured values to be displayed.
6.9.2.1 Connection The connector-pin numbering for the potentiometric position sensor is given in the test and calibration certificate. Drawing showing physical arrangement Circuit diagram + Excitation (1) Upper scale value e.g. 100mm + Signal (3) Lo wer scale value 0 mm - Signal (4) Excitation (6) Page 30 of 82...
6.9.2.2 Sensor excitation, input range and input reference Sensor excitation voltage The maximum admissible sensor excitation voltage for the position sensor is given in the test and calibration certificate. A low excitation voltage, typically 2.5, 5 or 10 volts, is recommended to avoid high lead resistances. Input range The maximum measurement signal output from potentiometers to the Sensor Profibus Module is always the supply voltage.
6.9.2.3 Calibration of a potentiometer by the teach-in method This method involves a two-stage online teach-in of sensor data to the Sensor Profibus Module, where two teach-in states are applied sequentially. The first state is the lower scale value, and the second state is the upper scale value.
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Example calibration: Displacement measurement using potentiometric position sensor type 8712-100. Adjust the position sensor to give the zero setting 0.00 mm. Now press button “Teach-in lower calibration value”. Now move the sliding shaft using a calibrated gage block e.g. S = 100 mm and set the upper scale value. Now press button “Teach-in upper calibration value”.
6.9.3 Measurements using a reference signal / transmitter Calibration is necessary in order to specify the relationship between the electrical signals measured by the connected sensors and the measured values to be displayed. A two-point calibration procedure is used here. Normally the sensors have a test and calibration certificate containing details of the electrical signals.
6.9.3.2 Sensor excitation, input range and input reference Sensor excitation voltage The sensor excitation voltage for the position sensor is given in the test and calibration certificate. A typical value is 10 volts. If this value is greater than 10 VDC in the test certificate, the transmitter excitation must be provided by an external supply because the Sensor Profibus Module can provide a maximum supply voltage of 10 VDC.
6.9.3.3 Calibration of a transmitter with voltage output 6.9.3.3.1 Calibration using a physical variable by the teach-in method This method involves a two-stage online teach-in of sensor data to the Sensor Profibus Module, where two teach-in states are applied sequentially. The first state is the lower scale value, and the second state is the upper scale value.
6.9.3.3.2 Calibration using the sensor test certificate About the values: These values are adopted directly from the test and calibration certificate. The calibration was performed as follows: Electrical range of 0 to 5 V corresponds to a mechanical range 0 to 1 mm. This calibration data must now be transferred to the instrument;...
6.10 Signal processing 6.10.1 Measurement rate / Cut-off frequency / Filter The A/D converter digitizes every single signal at a user-definable rate. The filter cut-off frequencies can be set to 5, 10, 25, 50, 100, 200 and 400 Hz. 6.10.2 Averaging The large signal amplification required for small signals inevitably means a higher noise component.
6.10.3 Reference measurement Using the predefined calibration shunt under “Channel settings” and “Shunt resistance”, you can perform a reference measurement here in order to run a sensor test, e.g. for sensors with strain-gage bridges. For this purpose, the strain- gage sensor must be connected. The calibration resistance between the excitation and output, for an unloaded sensor and a calibrated zero point, gives the corresponding output value (unbalance).
6.10.4 Evaluation / Digital outputs (limits) Status information on the analog input appears at the digital outputs of the Sensor Profibus Module. The status output for each module can be customized by defining threshold values (limits). For instance, user-definable thresholds GW1 and GW2 can be used for alarm or threshold monitoring at the outputs A1 / A2, and the additional output A3 used for a classification.
Evaluation type One can choose between dynamic and static evaluation. For ‘dynamic’ evaluation, the present evaluation result is continually displayed. For ‘static’ evaluation, the evaluation result obtained once a threshold value is crossed is retained until the next evaluation reset. 6.10.5 Minimum and Maximum value buffer To clear or reset the minimum and/or maximum value buffer, check the...
6.10.6 Digital inputs The following control functions can be performed via the two digital inputs of the Sensor Profibus Module. When a signal is applied to the respective input A / B, the selected function is executed. Perform tare Clear tare Reset evaluation Reset minimum value buffer Reset maximum value buffer...
6.11 Monitor output The monitor output is primarily used for input configuration using a potentiometer. This output must not be loaded nor used for control purposes. If used incorrectly, the Sensor Profibus Module can suffer irreparable damage because this signal is taken from a point directly before the A/D converter.
6.13.1 Display Start measurement Click on this button to start a test measurement. First check the "Store measurement" box if you want to save this measurement data in an Excel file; before the measurement starts, another dialog box will open giving you the option of saving the measurement data.
6.13.2 Options Advanced options are displayed for the test measurement if you click on the "Options" button. Display The graphical display of the upper and lower limit values and the minimum and maximum values during the test measurement can be enabled/disabled here. This information is displayed by dashed lines in the graph.
Stop trigger settings – Measurement duration The end of the test measurement can also be set using a measurement period. Enter the measurement period here in seconds. The settings are activated with the Accept button or discarded with the Cancel button.
Profibus configuration RS485 interface The bus interface of the Sensor Profibus Module is a PROFIBUS interface. Compared with conventional RS232 interfaces, PROFIBUS allows a larger number of stations and higher transmission speeds and provides greater interference immunity. Bus structure The bus has a linear structure in which each bus segment has a terminating resistor at each end.
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Bus connector The signal wires A, B and Shield must be present for connections to the bus. IP20 version Pin-out for PROFIBUS connection RS485 designation Signal Meaning - Shield Shield, Protective Ground B / B´ RxD/TxD-P Receive/Transmit-Data-P C / C´ DGND Data Ground - VP...
Bus terminating resistor In order to avoid signal reflections on the bus, each bus segment must be terminated at its physical start and end point with a terminating resistor. A terminating resistor is connected between bus wires A and B. This provides a defined open-circuit potential when no data transmission is taking place on the bus.
The bus interface of the Sensor Profibus Module is a PROFIBUS interface. GSD file The GSD file for communicating with the PLC can be downloaded from our homepage http://www.burster.de/software.html or found in the 9221-P001 software package under “Device configuration” “Profibus”.
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PLCin PLCout Mirror Σ: 2 Current measured value bytes Contents of min value buffer Contents of max value buffer Σ: 16 bytes PLCin PLCout Mirror Upper limit Current measured value Lower limit Contents of min value buffer Σ: 10 Contents of max value buffer bytes Σ: 16 bytes...
8.2.1.2 Bit coding details PLCin: Data bytes from 9221 to master Byte 1: TARE Sensor test Sensor test Evaluation Evaluation Evaluation Evaluation active result result valid NOK too NOK too valid high Byte 2: Meas. Meas. Meas. Meas. toggle toggle toggle toggle count...
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• Meas. toggle count • These bits indicate when a new measured value has been recorded. • It is a 4-bit counter, which is incremented every time a new measurement reading is made. • Depending on the PROFIBUS cycle time and the averaging period, it may not be possible for every single measurement to be retrieved by the PROFIBUS.
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PLCout: Data bytes from master to 9221 Byte 1: Reset Reset Reset Reset Reset Perform Freeze evaluation Max value Min value evaluation mean TARE TARE buffer buffer value Byte 2: Shunt Shunt Shunt Adopt Save Test Test Perform etup in method method sensor test...
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Reset minimum value buffer / maximum value buffer • A 0-1 edge on these bits clears the corresponding extreme-value buffer, and then, logically, sets it to the current measured value automatically. • Perform sensor test • A 0-1 edge on this bit starts a sensor test. •...
8.2.1.3 Byte reference list Mode 1 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Data from slave to master Byte Meaning Section Comments Input byte 1 Input byte 2 Mirror byte 1 Mirror byte 2 4 Current measured value, byte 1/4 5 Current measured value, byte 2/3 The byte sequence can be...
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Mode 2 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Upper limit, byte 1/4 Upper limit, byte 2/3 The byte sequence can be changed in the gsd file Upper limit, byte 3/2 Upper limit, byte 4/1 Lower limit, byte 1/4 Lower limit, byte 2/3 The byte sequence can be...
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Mode 3 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Data from slave to master Byte Meaning Section Comments Input byte 1 Input byte 2 Mirror byte 1 Mirror byte 2 4 Current measured value, byte 1/4 5 Current measured value, byte 2/3 The byte sequence can be changed in the gsd file...
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Mode 4 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Upper limit, byte 1/4 Upper limit, byte 2/3 The byte sequence can be changed in the gsd file Upper limit, byte 3/2 Upper limit, byte 4/1 Lower limit, byte 1/4 Lower limit, byte 2/3 The byte sequence can be...
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Mode 5 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Data from slave to master Byte Meaning Section Comments Input byte 1 Input byte 2 Mirror byte 1 Mirror byte 2 4 Current measured value, byte 1/4 5 Current measured value, byte 2/3 The byte sequence can be changed in the gsd file...
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Mode 6 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Upper limit, byte 1/4 Upper limit, byte 2/3 The byte sequence can be changed in the gsd file Upper limit, byte 3/2 Upper limit, byte 4/1 Lower limit, byte 1/4 Lower limit, byte 2/3 The byte sequence can be...
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Mode 7 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Data from slave to master Byte Meaning Section Comments Input byte 1 Input byte 2 Mirror byte 1 Mirror byte 2 4 Current measured value, byte 1/4 5 Current measured value, byte 2/3 The byte sequence can be changed in the gsd file...
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Mode 8 Data from master to slave Byte Meaning Section Comments Output byte 1 Output byte 2 Upper limit, byte 1/4 Upper limit, byte 2/3 The byte sequence can be changed in the gsd file Upper limit, byte 3/2 Upper limit, byte 4/1 Lower limit, byte 1/4 Lower limit, byte 2/3 The byte sequence can be...
8.2.2 Acyclic communication (DP-V1) 8.2.2.1 General information With PROFIBUS DPV1, a master can use acyclical bus access to access individual device parameters for reading or writing new values for the parameter. To do this, it must be possible to address these parameters precisely so that the master knows how it can access a particular parameter.
8.2.2.2 Slot-index directory Slot Index Contents Type Access Len In bytes General information Software version STRING15 Valid values: String containing software version, e.g. “V200400BETA28” Serial number Valid values: Serial number e.g. “123456“ Calibration date STRING12 Valid values: Date of factory calibration, e.g.
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0: Off Valid values: 2: 400 Hz 3: 200 Hz 4: 100 Hz 5: 50 Hz 6: 25 Hz 7: 10 Hz 8: 5 Hz Calibration Units STRING11 Valid values: Units string Upper scale value REAL32 Valid values: Upper scale value Lower scale value REAL32 Valid values:...
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Valid values: Function not supported Function supported Input A function: Reset evaluation Valid values: Function not supported Function supported Input A function: Reset minimum value buffer Valid values: Function not supported Function supported Input A function: Reset maximum value buffer Valid values: Function not supported...
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Input B function: Inhibit evaluation, freeze current evaluation result Valid values: Function not supported Function supported Input B function: Reset mean value Valid values: Function not supported Function supported Evaluation results evaluation result Valid values: NOK: too high NOK: too low Contents of minimum REAL32 value buffer...
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Valid values: Delete contents of write any byte max value buffer Tare Measure new tare EVENT! value Valid values: Use current measured write any byte value as tare value Tare value REAL32 Valid values: Write/read tare value Measured values ADC value Valid values: Current uncalibrated measured value in...
8.2.2.3 Representation of floating-point values Floating-point numbers from measurement results are transferred as 4-byte float values as specified in IEEE-754- 1985. The following examples explain how the 4 bytes are interpreted in order to obtain the floating-point values. What components make up a float number? A floating-point number represented as a 4-byte float value consists of three elements: the sign bit (sign), the exponent (ex) and the mantissa (mant).
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x = -0.25 is represented as -1.0 * 2 , i.e. sign bit (sign): 1 (negative) exponent (ex): – 127 = -2 mantissa (mant): + 1.0 = 1.0 giving: − − − − − − − Encoding of the three formula components in the four bytes 1st byte (first byte) Bit 7 Bit 6...
8.2.2.4 Calculation tip This calculation can be performed relatively easily by bit manipulation directly at the binary level using the following sequence of operations: First, as described above, the three components of sign bit, exponent and mantissa must be obtained from the four bytes by copying and masking bits. Example: As described above, the bytes 0x3F,0x40,0x00,0x00 become sign=0, exponent=0x7E(126dec), mantissa =100 0000 0000 0000 0000 0000b or...
Dimensioned drawings IP-20 version View from side Rear view View from side IP-65 version View from below Rear view Page 75 of 82 Date: 27.01.06...
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View with fixing clips for rail mounting, type 9221-Z001 Side view View from below Mounting plate 155x100x5 for clips/IP65 enclosure Clip fastening Page 76 of 82 Date: 27.01.06...
Appendix 10.1 Recommendations for use A few recommendations for use are illustrated briefly below for the Sensor Profibus Module type 9221 so as to obtain the best measurement quality. In addition, the examples should make it easier to use the system in practice. Input signal Sensor Profibus Module 9221...
10.2. Display of measurement results 10.2.1 Introduction Unlike analog displays of measurement signals in which the measured quantities are represented continuously as electrical signals, only discrete values representing the result of the quantization (digitization) exist when measurement signals are shown on a digital display. Information loss is inevitable as a result of quantization.
10.2.3 Increasing the resolution by averaging and filtering In measurement mode it is also possible to calculate mean values. This improves the resolution by the factor √ N, where N is the number of single measurements. Let us assume that the force to be measured is again 14 kN, driving the input at 22.4 %, and mean values are being calculated from N=10 single values.
10.3 Factory settings Value Default setting Units string “N” Station name “Station name” Program name “Program name” Instrumentation amp setting 10 mV range Excitation setting 2.5 V Shunt setting Open ( strain gage) Number of averages 100 ( 10/s) Measurement function Input A function None Input B function...
10.4.3 Factory warranty burster präzisionsmesstechnik gmbh & co kg guarantees trouble-free operation of the unit for 24 months after delivery. Any repairs required during this time will be made without charge. If the instrument needs to be returned for repairs, please note the following requirements for packing and shipping: if you have a problem with the instrument, please attach a note to the case summarizing the fault.
Contact details for queries If you have any questions relating to the Sensor Profibus Module type 9221, please contact your representative or go directly to your nearest branch office of burster präzisionsmeßtechnik gmbh & co. kg. Page 82 of 82 Date: 27.01.06...
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