User Manual

AED9101C
Digital Transducer Electronics
Basic Device for AD103C
with RS232, RS422, RS485

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Content 1

Content

Typographical conventions................................................................................................ 3

Important information ......................................................................................................... 4

Safety instructions .............................................................................................................. 5

1 Introduction and appropriate use ...................................................................................... 6

2 Mechanical construction .................................................................................................... 7

3 Electrical connections ........................................................................................................ 8

3.1 Transducer connection......................................................................................................................... 8

3.2 Connecting the supply voltage.............................................................................................................15

3.3 Connection to a computer ...................................................................................................................16

3.4 Multi-channel measurements (bus mode, RS485) ...............................................................................19

3.5 Connecting the diagnostic bus.............................................................................................................22

3.6 Trigger input........................................................................................................................................24

3.7 AED9101C cable connection via a PG gland .......................................................................................25

Index................................................................................................................................... 26

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2

HBM AED9101C en
Typographical conventions 3

Typographical conventions

For clear identification and improved legibility, the following conventions have been used in
this documentation:

Important paragraphs are marked with a symbol to draw attention to them.

CE Designation

Statutory marking requirements for waste disposal

Italics Points out external documents and files

“File  Open“ All menus and menu commands appear in quotes, here the “File” menu and the “Open”
sub-menu.

“Start” Quotes and italics are used for buttons, input fields and user input.
MSV All commands are set out in a bold font style or as a link to the command description.

AED9101C en HBM
4 Important information

Important information

Neither the design of the device nor any technical safety aspects may be modified without
the express permission of Hottinger Baldwin Messtechnik GmbH. Any modification ex-
cludes Hottinger Baldwin Messtechnik GmbH from any and all liability for any damage re-
sulting therefrom.

It is strictly forbidden to carry out any repairs and soldering work on the motherboards or to
replace any components. Repairs may only be carried out by persons authorized thereto
by Hottinger Baldwin Messtechnik GmbH.

All the factory defaults are stored safe from power failure at the factory, not in the measur-
ing amplifier where they can be deleted or overwritten. They can be reset at any time by
using the command TDD0. For more information, see aed_help_e, AD103C; “Description
of the basic commands”.

The production number is set at the factory and cannot be changed.

The transducer connection must always be assigned.
It is essential for a transducer or a bridge model to be connected up for operation.

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Safety instructions 5

Safety instructions

 There are not normally any hazards associated with the product, provided the notes and
instructions for project planning, assembly, appropriate operation and maintenance are
observed.

 Each time, before starting up the modules, 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.

 It is essential to comply with the safety and accident prevention regulations applicable to
each individual case.

 Installation and start-up must only be carried out by suitably qualified personnel.

 Do not allow the equipment to become dirty or damp.

 During installation and when connecting the cables, take action to prevent electrostatic
discharge as this may damage the electronics.

 The required power supply is an extra-low voltage with safe disconnection from the
mains.

 When connecting additional devices, comply with the local safety requirements.

 All the interconnecting cables must be shielded cables. The screen must be connected
extensively to ground on both sides.
The power supply and digital I/O connection cables only need to be shielded if the ca-
bles are longer than 30 m (32.81 yd) or are routed outside closed buildings
(EN 61326-1).

 The CE mark enables the manufacturer to guarantee that the product complies with the
requirements of the relevant EC directives (the declaration of conformity is available at
http://www.hbm.com/HBMdoc).

 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.
If you need more information about waste disposal, please contact your local authorities
or the dealer from whom you purchased the product.

AED9101C en HBM
6 Introduction and appropriate use

1 Introduction and appropriate use

AED9101C digital transducer electronics are part of the AED component family that digitally
conditions signals from mechanical measurement sensors and networks them with bus ca-
pability. These include digital amplifier motherboards, basic devices with serial interfaces
and intelligent sensors with integrated signal processing. The purpose of these components
is to directly digitize and condition the measurement signals at the transducer location. Using
digital transducer electronics, you can connect SG1) transducers in a full-bridge circuit di-
rectly to a computer or a PC. This enables you to configure complete measurement chains
quickly and with little extra work.

Basic device AED9101C can contain the AD103C amplifier board. It provides mechanical
protection, shields the amplifier board (EMC protection) and allows you to select the serial
interfaces RS422 (factory default), RS485 or RS232.

The AD103C amplifier mother board is not included in the scope of supply of the basic de-
vice and must be ordered separately.

The AD101B amplifier is only required for replacement and will not be considered when new
AED basic devices are ordered.

The PC software AED PANEL 32 is available to facilitate parameter settings, to display dy-
namic measurement signals and for comprehensive analysis of the dynamic system.
The HBM display unit DWS2103 can be connected to all AED basic devices.

All basic devices of the AED family can be connected with the digital display unit DWS2103.
This unit supports all implemented functions of the AED.

All commands are described in the help file aed_help_e.

The abbreviation AED is also used for transducer electronics in the following text.

1)
Strain Gage

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Mechanical construction 7

2 Mechanical construction

The basic device extends the functionality of the AD amplifier boards and provides:

 mechanical protection (IP65)

 the power supply for the amplifier motherboard and transducer excitation

 total transducer bridge resistance 40…4000 

 a choice of serial interfaces RS422, RS485, RS232

 EMC-tested

 Diagnostic bus

(The AED9101A basic device can be replaced by the AED9101C basic device)

The amplifier motherboard is designed as a plug-in board that can be plugged into the carrier
board of the basic device via a 25-pin D-connector. The basic device contains terminals for
the transducer, power pack and interface connections, slide switches for interface selection
and the voltage stabilizer. The connection cables exit the casing via PG glands on the side.

Fig. 2-1: Mechanical construction

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8 Electrical connections

3 Electrical connections

A connection diagram is attached inside the lid of the AED9101C basic device.

When making the connections, please ensure that the wires of the cable do not protrude
beyond the connection terminals (risk that loops may form). Please make sure that the
cable shielding is properly connected to the PG gland.

If it should be necessary, a separate cable can be used to establish potential equalization

between the transducer and the AED and between the AED and the Master control unit
(grounding concept). The cable shielding must not be used for this potential equalization.

3.1 Transducer connection

The transducer connection must always be assigned (connect the transducer).

AED9101C with AD103C

You can connect SG transducers in a full-bridge circuit with a total bridge resistance of
RB = 40...4000 . With a transducer resistance of > 1000 , increased noise (measurement
ripple) must be taken into account. The bridges are supplied with power in the AED9101C
basic device (5 VDC ).

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Transducer connection 9

Fig. 3.1-1: Transducer connection in 6-wire circuitry (HBM color-coding)

The 6-wire connection avoids the effect of a long cable on the measured value. When sev-
eral transducers and a junction box are used, the 6-wire circuitry is routed to the junction
box.

Fig. 3.1-2: Transducer connection in the AED9101C basic device for a 6-wire connection

AED9101C en HBM
10 Transducer connection

There are two methods of connection for transducers implemented in four-wire circuitry:
 Connection via a 6-core extension cable; bridged sensor circuit in the transducer con-
nector.

Plug-in connection

bu
Transducer
bu gn
rd
Cable to
wh wh
transducer electronics
bk gy
bk

Cable shield

Fig. 3.1-3: Transducer connection in 6-wire circuitry via a 6-core cable extension

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Transducer connection 11

 Connection without an extension cable; sensor circuit bridged at the transducer electron-
ics.

Fig. 3.1-4: Transducer connection in 4-wire circuitry without a cable extension (jumpers 2 – 2‘
and 3 – 3‘)

Connection without an extension cable; sensor circuit at transducer electronics. When con-
necting several transducers, it is advisable to use an HBM junction box VKKx. In general, the
feed lines running to the AED should be shielded cables.

When connecting several transducers to the AED, the number of load cells that can be con-
nected (and the resultant bridge resistance) must be taken into consideration with regard to
the external supply voltage, so that the maximum power loss in the basic device is not ex-
ceeded.

AED9101C en HBM
12 Transducer connection

U in (V)

30

24 23 OC [73.4 O
F]
21
16
13 70 OC [158 OF]

Impedance ( )
350 175 87 58 43
1 2 3 4 5 6 7 8 Number of transducers

Fig. 3.1-5: Maximum operating voltage for the AED9101C basic device, with regard to the number of
transducers and the ambient temperature

Notes on type of connection, length and cross-section of cables:

Depending on the bridge resistance of the load cell being used and the length and cross-
section of the load cell connection cable, there may be voltage drops that can reduce the
bridge excitation voltage. The voltage drop at the connection cable is also dependent on
temperature (copper resistance). Likewise, the output signal of the load cell changes in pro-
portion to the bridge excitation voltage.
This is balanced out when connecting in 6-wire circuitry.

6-wire circuit (standard mode of operation):

This will correct all the effects of the load cell cabling up to the feedback points. Even chang-
ing the length of a cable after calibration will not make any difference to the measurement
results.

For load cells with a 6-wire connection, feedback lines 2´ and 3´ are bridged in the load cell
with excitation 2 and 3 (Fig. 3.1-2). For load cells with a 4-wire connection, the feedback
bridges must be implemented directly at the load cell connection (Fig 3.1-3 or 3.1-4).

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Transducer connection 13

4-wire circuit:
As correction through AUTOCAL can only ever take place up to feedback points 2´, 3´, all
the changes of cable resistances affect the measurement result. This means that even if no
further changes are made to the 4-wire cable used for calibration, there will still be meas-
urement errors when there are temperature changes, because the cable resistance and pos-
sibly the contact resistances at the connectors are temperature-dependent. With the 4-wire
circuit, feedback lines 2´ and 3´ are directly connected at connection terminals 2 and 3 in the
AED (see Fig. 3.1-4).

Equivalent circuit of the bridge with bridge resistance RB and supply lines with
line resistances RL1 and RL2:

RL1 = RL2 = (4 pCU /) (I [m] / A [mm2 ])

RL1
pCU = 0,0178 [ mm2 /m] for copper

RB UBR
RL2
 = 3,14 I = Length of cable, A = Cross-section of cable
 RL1 = RL2 = 1,6  at I = 10 m and A = 0,14 mm2

Fig. 3.1-6: Bridge equivalent circuit diagram

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14 Transducer connection

The voltage drop over the bridge feeder cables can be determined from bridge resistance
RB, cable length l, cable cross-section A and the bridge excitation voltage:

UB + URL1 + URL2 = UBR

For
RB = 80 , RL1 = RL2 = 1,6  (l = 10 m) and UBR = 5 V

there is an excitation current of

IBR = UBR/(RL1 + RL2 + RB) = 60 mA

and thus a voltage drop over the two line resistances totaling approx. 0.2V (UBridge = 4.8 V).

For
RB = 80 , RL1 = RL2 = 16  (l = 100 m) and UBR = 5 V

there is an excitation current of

IBR = UBR/(RL1 + RL2 + RB) = 45 mA

and thus a voltage drop over the two line resistances totaling approx. 1.4 V
(UBridge = 3.6 V = 80  0.045).

This is irrelevant for the 6-wire circuit, as the voltage drop over the sensor lines is taken into
account in the measurement signal.

But with a 4-wire circuit, the dependency of the copper resistance of the cables on tempera-
ture goes directly into the measurement result, as the bridge excitation voltage UBridge
changes:

RL(t) = RL20  (1 +   (t –20 °C)),

where RL20 is the line resistance at 20 °C and  is the temperature coefficient of the cop-
per.

RL20 – for calculation, see page 23, CU: = 0.00392 [1/K]

With a cable length of l = 100m and a temperature differential of 10 °C, there is a line resis-
tance of

RL1(t) = RL2(t) = 16  (1 + 0.00392  10) = 16.6 

This changes the bridge excitation voltage of

UBridge = 3.6 V (at 20 °C) to UBridge = 3.53 V.

This change in bridge excitation voltage directly at the transducer changes the measurement
signal of the bridge by 1.9 % (= 100 %  (1 – 3.53 V / 3.6 V)).

This typical calculation shows that if long cables are involved, only 6-wire circuitry should be
used.

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Connecting the supply voltage 15

3.2 Connecting the supply voltage

The power supply must meet the following requirements:

AED9101C with AD103C DC voltage +6...+30 V

current consumption 250 mA (for a 40  bridge)

Calculation the total current consumption:

Fig. 3.2-1: Power supply connection

The voltage feed must be shielded. It can be applied within the interface cable or be imple-
mented as a separate cable.

When supplying several AEDs via one cable, the voltage drop over the cable must be taken
into consideration. The voltage drop depends on the supply current required and on the line
resistance.

AED9101C en HBM
16 Connection to a computer

3.3 Connection to a computer

The basic device can be set up for several interface variants:

Fig. 3.3-1: Pin assignment and settings for the interfaces

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Connection to a computer 17

No bus mode
The RS232 interface allows the AED to be connected directly to a PC. The cable length is
limited to 15 m and bus mode is not possible.

Fig. 3.3-2: Connecting an AED to a computer via the RS232 interface

For the RS232 interface setting, the “bus termination switch must be set to OFF”.

The RS422 interface is a 4-wire interface also with a maximum cable length of 1000 m. To
connect the AED to the COM port of a PC (RS232), you need an interface converter. This in-
terface is not designed for bus mode, as the transmitter is always active.

AED9101C en HBM
18 Connection to a computer

Bus mode
The RS485 interface with a 4-wire connection allows the full range of AED functions with a
maximum cable length of 1000 m. To connect the AED to the COM port of a PC (RS232),
you need an interface converter.The RS485 interface with a 2-wire connection also allows
cable lengths of 1000 m. To connect the AED to the COM port of a PC (RS232), you need
an interface converter
(1-SC232/422B from HBM, with 2-wire mode selected). However, the AED must be operated
in half-duplex mode (command COFxxx must be set). The command MSV?0; must not be
used, as it is not possible to interrupt data output with the STP; command.

Basically, shielded cables should be used for the interface wiring, with the cable shielding
being connected to the AED housing via the PG (see AED9101C cable connection via the
PG gland). The power supply can also be connected via this cable, with a 6-core, shielded
cable being necessary.

If it should be necessary, a separate cable can be used to establish potential equalization

between the bus nodes. The cable shielding must not be used for this potential equalization.
For reasons of electromagnetic compatibility, it is advisable to use a double-shielded cable
(from the HBM program, for example: 3  2  0.14 m², 4-3301.0071).

The shielding of the physical circuit is connected to the AED line (not to the power supply
ground).

UB: 8 V...30 V DC
Interface converter
RS232 - RS485
PC COM port
RxD TxD HBM Wägetechnik GmbH
RS 485-Bus AED 9101C
CONVERTER SC232/422A

TxD RS232
RxD 8...30V
TA TA (blue)
RS485
GND 2/4-wire

GND TB TB (black)

RA RA (green)
SUB-D connector SUB-D female connector
9-pin (PC) 9-pin (converter) RB RB (grey)
PIN PIN
2 = RxD 2 = TxD GND GND (white)
3 = TxD 3 = RxD
5 = GND 5 = GND UB UB (red, 8...30 V DC)

Equivalent
Interface marking:
TA = T- TB = T+
RA = R- RB = R+

Fig. 3.3-3: Connecting an AED (RS422 or RS485 4-wire) to a computer via the interface converter

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Multi-channel measurements (bus mode, RS485) 19

3.4 Multi-channel measurements (bus mode, RS485)

With the RS485 interface, several AEDs can be connected to a common bus line. The bus
cabling for 4-wire mode is shown in Fig. 3.4-1.

With the RS485 interface, up to 32 AEDs can be connected to a common bus line. With the
aid of the RS485 bus driver, it is possible to implement long cables (up to 1000 m
(1,093.61 yd) in length).

AED bus mode is set out as a Master-Slave configuration, with the AED implementing a
slave.

This means that all the AED activities are initiated from the control computer. Each AED is
given a separate communication address (00...89) and can then be activated by an
Sii (ii = 00...89) Select command.

A broadcast command (S98) is implemented for specific communication situations. This

means that after a command of this type, all the AEDs execute the command of the Master,
but none of the AEDs respond. All these communication commands are described with rele-
vant examples in file aed_help_e, AD103C; “Description of the basic commands”.

Fig. 3.4-1: Bus structure 4-wire bus (general)

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20 Multi-channel measurements (bus mode, RS485)

The termination resistances of 500  marked in the above diagram are important for the
electrical function of the bus system. These resistances safeguard the quiescent level for the
receiver on the bus line. The physical circuit must only be connected with these resistances
at the line ends.

For the local bus termination distribution shown in the diagram, the Master and the AED with
address 89 should include the termination resistances. Which is why in this AED, the bus
termination is activated using the “bus termination ON” switch. This bus termination in the
AD103C must also be activated using the commands STR1; and TDD1 (see file aed_help_e,
AD103C; “Description of the basic commands”). If the “bus termination switch is set to OFF”,
the command STR will have no effect, which means that bus termination is deactivated.

The HBM interface converter also includes these bus termination resistances (do not deacti-
vate them).

These terminations must not be activated more than twice in one bus.

The ground of the interface driver is related to the GND terminal. The interface driver of
the master should be also connected to this GND.

The quiescent level on the RS485 physical circuit is produced in 4-wire mode at:

TB - TA > 0.35 V (quiescent level though AED termination resistances)

RB - RA > 0.35 V (quiescent level though Master termination resistances)

As the RS485 is a differential bus interface, the quiescent level is also specified as a differ-
ential voltage between the lines (and not ground-related). Furthermore, please note that this
interface tolerates a maximum common-mode range of ±7 V. If it should be necessary, a
separate cable can be used to establish potential equalization between the bus nodes. The
cable shielding must not be used for this potential equalization.

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Multi-channel measurements (bus mode, RS485) 21

RS485 2-wire mode

Fig. 3.4-2: Bus structure RS485 2-wire bus (general, TB/RB = T/R+, TA/RA = T/R-)

Termination resistances are also necessary for the electrical function of this bus system.
These resistances safeguard the quiescent level for the receiver on the bus line. These ter-
mination resistances are already included in the AED and should be set with the “bus termi-
nation switch” (see 4-wire circuit). The quiescent level on the RS485 physical circuit is pro-
duced in 2-wire mode at:

TB/RB - TA/RA 0.35 V

For the local bus termination distribution shown in the diagram, the Master and the AED with
address 89 should include the termination resistances. Which is why in this AED, the bus
termination is activated using the “bus termination ON” switch. This bus termination in the
AD103C must also be activated using the commands STR1; and TDD1 (see file aed_help_e,
AD103C; “Description of the basic commands”). If the “bus termination switch is set to OFF”,
the command STR will have no effect, which means that bus termination is deactivated.

AED9101C en HBM
22 Connecting the diagnostic bus

3.5 Connecting the diagnostic bus

The diagnostic bus is used to analyze dynamic processes. The bus is set out as an RS485
2-wire bus (lines: TB/RB and TA/RA, GND).

Fig. 3.5-1: Connecting the diagnostic bus via terminal KL4

The interfaces setting of the bus is defined and cannot be changed (38400 bit/s, 8E1).

External bus termination resistances are not necessary for this bus.

The HBM interface converter (1-SC232/485B) can be used to connect the RS485 bus to an
(RS232) COM port of the PC.

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Connecting the diagnostic bus 23

Fig. 3.5-2: Diagnostic RS485 bus

The ground of the interface driver is related to the GNDext terminal. The interface driver of
the master should be also connected to this GNDext.

Only a connecting cable with a screen grounded on two sides should be used as the inter-
connecting cable between the AED 9101C and the bus and the master (see also:
AED9101C cable connection via a PG gland)

The functions and commands of the diagnostic channel are described in the help file
aed_help_e Diagnosis. The address corresponds to the address of the AD103C amplifier,
command ADR (00...89, factory setting: 31), see aed_help_e, Basic Commands). This ad-
dress is independently from the CANOpen address.

The following functions can also be executed via this bus:

Parameters Read only (changes are not possible)

Measured values Reading individual measured values MSV?; (MSV?i not possible)

Results Trigger results and dosing results can be read

The diagnostic functions can be executed using the HBM AED_Panel32 program (as from
Version V3.0.0).

The HBM display unit DWS2103 can be connected with this interface. Than all implemented
functions and parameters are accessible. This is independent from the main communication
channel.

AED9101C en HBM
24 Trigger input

3.6 Trigger input

An external sensor (light barrier, contact, etc.), can be connected to the trigger input of the
AD103C, to drive the trigger measurement function (see file aed_help_e, AD103C; “Descrip-
tion of the signal processing”).
The input is activated as an external trigger by the TRC command.

Fig. 3.6-1: Trigger input

The trigger input has the following properties:

Quiescent level: Low

Active edge: High – Low

High level: 2...30 V

Low level: 0...1 V

Input current: 3 mA (for 30 V), 10 k input resistance

If the input is not required, the input remains unassigned. The GND of the trigger input is
connected to the GND of the supply voltage.

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AED9101C cable connection via a PG gland 25

3.7 AED9101C cable connection via a PG gland

Only a connecting cable with a screen grounded on both sides (and metal connectors)
should be used as the connecting cable between the AED9101C and its partner device.
Bring the screen extensively into contact on both sides at the PG gland (and at the metal
shell of the connector). If the partner device does not have a metal connector, connect the
cable shielding extensively to ground. If there are vast differences between the ground po-
tential of the AED9101C and its partner device, a potential equalization line must be pro-
vided in addition.

Remove outer sheath of cable

to expose required length
wire L.

Slide cable screw

connection with sealing
ring and clamping rings
over the end of the cable.

Fig. 3.7-1: Connecting the transducer, supply voltage and computer to the PG gland

AED9101C en HBM
26 Index

Index

4
4-wire circuitry.................................................................................................................................................10, 11

6
6-wire connection..............................................................................................................................................9, 12

B
basic box ............................................................................................................................................................... 7
bridge excitation voltage .................................................................................................................................12, 14
bridge resistance ......................................................................................................................................12, 13, 14
bus
bus line ............................................................................................................................................................ 19
bus structure ...............................................................................................................................................19, 21
bus mode........................................................................................................................................................16, 19
RS232.............................................................................................................................................................. 17
RS485....................................................................................................................................... 16, 18, 19, 20, 21
bus termination ...............................................................................................................................................20, 21
bus termination RS485 ..................................................................................................................................... 19

C
cable connection.................................................................................................................................................. 17
cable connection - serial interface..................................................................................................................... 16
cable connection supply voltage
cable connection AED9101C .......................................................................................................................15, 25
cable length ....................................................................................................................................................12, 14
computer connection............................................................................................................................................ 16
connection to a computer, AED9101C .............................................................................................................. 16
connecting the diagnostic bus .............................................................................................................................. 22

D
diagnostic bus...................................................................................................................................................... 22

E
electrical connections............................................................................................................................................. 8

I
interface............................................................................................................................................................... 16
interface converter ..........................................................................................................................................16, 18

HBM AED9101C en
Index 27

L
load cell connection ............................................................................................................................................. 12

M
manufacturer’s notes ............................................................................................................................................. 6
mechanical construction......................................................................................................................................... 7
multi-channel measurements ............................................................................................................................... 19

P
PG gland ....................................................................................................................................................8, 16, 25
potential equalization ........................................................................................................................................... 16

Q
quiescent level
RS485.............................................................................................................................................................. 19

R
RS232 ..........................................................................................................................................................6, 7, 16
RS232 serial interface.......................................................................................................................................... 16
RS422 ..........................................................................................................................................................6, 7, 16
RS485 with 2-wire................................................................................................................................................ 16
RS485 with 4-wire................................................................................................................................................ 16

S
serial interface ................................................................................................................................................... 6, 7
RS232............................................................................................................................................................ 6, 7
RS422.......................................................................................................................................................6, 7, 16
RS485.............................................................................................................................................................. 16
supply voltage...................................................................................................................................................... 15
supply voltage AED9101C................................................................................................................................ 25

T
trigger input.......................................................................................................................................................... 24

U
use ........................................................................................................................................................................ 6

AED9101C en HBM
HBM AED9101C en
AED9101C en HBM
Modifications reserved. Hottinger Baldwin Messtechnik GmbH
All details describe our products in general form only.
They are not to be understood as express warranty
and do not constitute any liability whatsoever. Postfach 100151 D-64201 Darmstadt
Im Tiefen See 45 D-64293 Darmstadt
Tel.: +49/6151/803-0 Fax: +49/6151/8039100
I1692-2.0 en E-mail: support@hbm.com · www.hbm.com