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QGPR 104 and QGPR 102 load cells are mainly used in applications where the load to be measured or the available space in the installation is smaller than what is suitable or required for the smallest PFVL141R load cell. Examples of such installations are tube mills and smaller edger mills.

Standard sizes and cable lengths

Load cells are manufactured in the standard range as below. Dimensions can be designed to order on request.

Select as follows:

• Determine the load for which the load cell is to be used and choose from the table the next higher value in the standard range. We can customize load cells if a standard load cell is not suitable for a particular application.

• To calculate the load F for non-standard load cells:

F = ( D3 2 π 4 – D2 2 π 4 ) × 0.0001 MN.

Load cells Data and definitions

Nominal load (Fnom) is the load for which the load cell is dimensioned and calibrated, i.e. the sum of the stationary load and the maximum measured load in the measuring direction.

Accuracy class is defined as the maximum deviation and is expressed as a percentage of the sensitivity at nominal load. This includes linearity deviation, hysteresis and repeatability error.

Linearity deviation is the maximum deviation from a straight line drawn between the output values of zero and nominal load, related to the nominal load

Hysteresis is the maximum deviation of the output signal at the same load during a cycle from zero to nominal load and back to zero, related to the sensitivity at nominal load. The hysteresis is proportional to the cycle.

Repeatability error is defined as the maximum deviation between repeated readings under identical conditions

It is expressed as a percentage of the sensitivity at a nominal load.

Compression is the total reduction in the height of the load cell when the load is increased from zero to nominal load.

Zero point drift is defined as the drift in the output signal when there is no load on the load cell.

Sensitivity drift is defined as the drift in the output signal at nominal load, excluding the zero point drift.

Control unit Millmate Controller 400

The control unit supplies the load cells with power, processes the signals from the load cells and communicates the result to other systems. Communication can take place via digital inputs/outputs, analog inputs/outputs, TCP/ IP-communication, RS-232 and as an option, via high-speed fieldbus.

The control unit can be manually operated using the Millmate Operator Unit 410 and by external units via a serial interface or digital/analog inputs. Setup and commissioning are easy following step-by-step menus.

Measured values are displayed on the operator unit, connected to analog outputs or transmitted via a serial interface to an external display or to other external units.

Features

The Millmate Controller 400 has been designed to offer a lot of functionalities and at the same time very easy to use.

The control unit covers most mechanical arrangements. This means the user only has to follow the step-by-step menus in order to set up the control unit and to obtain correct roll force measurement.

Some examples of the built-in functionalities:

• Predefined standard measurement modes

• Built-in load cell tables

• Filter times from 1 up to 2000 ms

• Easy configurable analog/digital inputs/outputs

• Level detectors

• Unit selection (N, kN, MN, kp, t, lb, T)

• Self-diagnostics test system including transducer test

• Simulation mode for easy check of system

integration

Millmate Controller 400

Version Number of load cells Communication

PFVA 401 2 PFVL141 VIP

PFVA 401 S 4 PFVL141 VIP

PFVA 401 F 2 PFVL141 VIP + Profibus

PFVA 401 SF 4 PFVL141 VIP + Profibus

PFXA 401 2 QGPR 104/102 VIP

PFXA 401 S 4 QGPR 104/102 VIP

PFXA 401 F 2 QGPR 104/102 VIP + Profibus

PFXA 401 SF 4 QGPR 104/102 VIP + Profibus
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The Tie point allows the auxiliary encoder inputs to be used as single-ended inputs. This terminal is internally connected to a 2.5 Vdc source through a 1 kΩ current limiting resistor. Typically, the Tie point is connected to the IN_A- and IN_B- input terminals to bias the line receiver. Note that on the SSI216, SSI228, and SSI420 models, this terminal is located on the Pulse Input connector on the bottom of the controller. For single-ended open collector encoder signals, a 470 Ω pull-up resistor is required. The internal schematic for the tie terminal is shown below.

Encoder Output (Out_A, Out_B, Index)

The S2K controller is typically used to control the position of the motor based on programmed commands. The encoder output buffers either the motor feedback or auxiliary encoder signals and makes them available as quadrature (A-Channel, B-Channel and Index) signals to another S2K controller for master/slave or cam following or to a host controller.

The S-Series motor encoder resolution is 2,500 pulses per revolution, so the feedback to the host controller supports 10,000 quadrature counts/revolution. For MTR-Series motors, the resolver-based S2K derives quadrature encoder signals from the resolver feedback with a maximum resolution of 1,024 pulses per revolution (4,096 quadrature counts per revolution). This maximum resolution can be scaled down to one of several predefined lower resolution values using the Encoder Output Type (EOT) register.

The encoder output is a differential output source (see Section 2.1.7 for specifications) with user selectable source via the Encoder Output Type (EOT) parameter. The EOT parameter determines whether this output tracks the auxiliary encoder input or the motor encoder input:

When EOT=0 (default), the encoder output buffers the auxiliary encoder input pulse-forpulse. If the auxiliary input is a quadrature encoder the output will be quadrature. If the auxiliary input is CW/CCW pulses, the output will be in this same format

When EOT is non-zero, the output tracks the motor encoder input up to the full resolution of 2,500 lines/rev for encoder feedback controllers or 1,024 lines/rev for resolver feedback models; and the setting of the EOT register determines the output resolution. The allowed values for this resolution are:

Encoder Feedback Controller: 0; 500; 625; 1,000; 1,250; 2,000, 2,500

Resolver Feedback Controller: 0; 250; 256; 500; 512; 1,000; 1,024

The marker pulse width is fixed at 1/5,000th of the source encoder revolution (auxiliary or motor encoder based on setting of EOT). This implies that the marker pulse output width will vary with encoder speed and the smallest width will occur at the highest speed. For example, if the source encoder is rotating at 1000 RPM or 16.667 rev/sec then the encoder takes 0.06 seconds per revolution. Therefore, 1/5000th of this value, or 12 µS, represents the marker pulse width at that speed.

The encoder output is connected on the Auxiliary I/O connector. For best results, wiring connections should use 20-28 AWG twisted-pair wires with individual shields on each wire pair and an overall shield. For best noise immunity, connect the cable shield to one of the common inputs on the Auxiliary I/O connector. Connect the cable and shield as shown in Section 3.6.10, Connection Diagrams. The auxiliary encoder inputs are labeled with “Out_” prefix (such as Out_A+) and Index prefix (such as Index +) on these diagrams.

The typical internal schematic for each of the encoder output circuits is shown below.

It is possible to daisy chain a master encoder signal by connecting the master encoder signal to the auxiliary encoder input and then repeating this signal on the Encoder Output for use by downstream controllers. The propagation delay is approximately 50 ns for each daisy-chained S2K controller. For example, daisy-chaining eight controllers would result in approximately 400 ns (0.4 microseconds) encoder propagation delay on the final controller. For a 1,000 line (4,000 quadrature count) master encoder rotating at 6,000 RPM this represents an insignificant delay of 16% of the width of a single master encoder count.

High Speed Position Capture (Registration) Input

The S2K servo controllers support a high speed position capture input that can be used for registration applications to latch both the axis encoder and the auxiliary encoder positions with a 30 µS response time. The motor encoder position is stored in the Axis Position Capture (PCA) register while the auxiliary encoder position is stored to the Auxiliary Position Capture (PCX) register. The capture input is identified in the following table and depends on the controller model. This same input also functions as the auxiliary encoder index input. (See Section 3.6.10, Connection Diagrams.)

The controller inputs are not rated for 24Volts, so for registration devices operating at 24VDC, use one of the circuits diagrammed below:

Cables and Connector Mates

Cables in several lengths are available from GE Fanuc for motor to controller connections and various other controller functions. It is strongly recommended that you use the cables available from GE Fanuc as shown in Table 3-13. GE Fanuc does not provide mating connectors for the MTRSeries motors or S-Series motors along with the motor; you can, however, purchase the S-Series and MTR-3T Series motor connector kits, shown in table 3-14, from GE Fanuc.

Note:GE Fanuc cables and connectors shown are not rated for IP67 environments, or washdown applications. GE Fanuc cables are not designed for high flex or cable track applications.

S2K Series Cable GE Fanuc Catalog Number Description

IC800SKCI010 Interface Cable, S2K Auxiliary I/O to 44A726268-001 Terminal Board Assembly,

IC800SKCI030 Interface Cable, S2K Auxiliary I/O to 44A726268-001 Terminal Board Assembly,

IC800SKCFLY010 Interface Cable, S2K Auxiliary I/O to flying leads, 1m (flying leads labeled with corresponding connector pin number) Aux. I/O Interface

IC800SKCFLY030 Interface Cable, S2K Auxiliary I/O to flying leads, 3m (flying leads labeled with corresponding connector pin number) Serial

IC800SKCS030 S2K Serial Communication Cable (DB1), 3 m

IC800SKCEZ050 Encoder Cable, S2K to 200-750 W S-Series Motor, 5 m

IC800SKCEZ100 Encoder Cable, S2K to 200-750 W S-Series Motor, 10 m

IC800SKCEV050 Encoder Cable, S2K to 1 kW-5 kW S-Series Motor, 5 m S-Series Servo Motor Encoder

IC800SKCEV100 Encoder Cable, S2K to 1 kW-5 kW S-Series Motor, 10 m

IC800SKCPZ050 Power Cable, S2K to 200 – 750 W S-Series Motor, 5 m

IC800SKCPZ100 Power Cable, S2K to 200 – 750 W S-Series Motor, 10 m

IC800SKCPV050 Power Cable, S2K to 1 kW-2.5 kW S-Series Motor, 5 m

IC800SKCPV100 Power Cable, S2K to 1 kW-2.5 kW S-Series Motor, 10 m

IC800SKCPVL050 Power Cable, S2K to 4.5 kW-5 kW S-Series Motor, 5 m

IC800SKCPVL100 Power Cable, S2K to 4.5 kW-5 kW S-Series Motor, 10 m

IC800SKCBV050* Power/Brake Cable, 1 kW-2.5 kW S-Series Motor with Brake, 5 m

IC800SKCBV100* Power/Brake Cable, 1 kW-2.5 kW S-Series Motor with Brake, 10 m

IC800SKCBVL050* Power/Brake Cable, 4.5 kW-5 kW S-Series Motor with Brake, 5 m S-Series Servo Motor Power

IC800SKCBVL100* Power/Brake Cable, 4.5 kW-5 kW S-Series Motor with Brake, 10 m

IC800SLCBZ050 Brake Cable, 200 – 750 W S-Series Motor with Brake, 5 m S-Series Servo Motor Brake Power (200-750 W Motors)

IC800SLCBZ100 Brake Cable, 200 – 750 W S-Series Motor with Brake, 10 m

*The 1kW-5kW S-Series and MTR-3T Series servo motors incorporate the brake power and motor power into a single cable. When a brake is required, this cable (see Table 3-13) should be used in place of the standard motor power cable. The 30–750 W S-Series, MTR-3N, and MTR3S Series servo motors require a separate brake cable as listed in Table 3-13 for motor brake power when the brake option is required. ** Stepping motor encoder feedback cables terminate in flying leads on the controller end. The S2K stepping motor controller encoder interface is included on the Auxiliary I/O connector. The TRM-JAUX-03 (3 ft. cable) or TRM-JAUX-10 (10 ft. cable) auxiliary I/O breakout terminal board can be used to provide a screw terminal interface for the encoder feedback signals.
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The Auxiliary I/O connector on these models is a standard screw terminal connector and is wired according to the pin-out shown in Table 3-11 and in section 3.6.10, Connection Diagrams (note that these models are available with either DeviceNet or Profibus network connectivity). Because the connections are made to screw terminals, no prefabricated cable is offered for Auxiliary I/O connections for these models.

Detailed descriptions for each signal on the Auxiliary I/O connector are shown in the following table.

Auxiliary I/O Break Out Terminal board (part #44A726268-001) can be used to provide screw terminal interface for the connections. (Applies to 4A and 7A servo models and 5A stepper model only.)

Analog Output (AO)

The hardware analog output is primarily used as a process input to the controller programs, but it can also be used a diagnostic output for various signals used in the tuning and debugging process. The Analog Common pin is used for the signal return. The Analog Output (AO) software parameter allows you to configure this output to represent one of the following signals:

• Actual velocity (AO = VLA)

• Actual output current (AO = CMD)

• Following error (AO = FE)

The output can also be forced to a specific voltage value by setting the AO parameter to the desired voltage from a program, PC terminal emulator, or Motion Developer terminal window. The analog Output value can be queried in the terminal window using the “?” command.

Use 20-28 AWG twisted-pair wire with an overall shield for this signal interface. For best noise immunity connect the shield to the Analog Common pin on the Auxiliary I/O connector. The internal schematic for the analog output circuit is shown below.

Enable Input

The Enable discrete input allows the host controller to enable or disable the power output stage of the controller and reset faults. The Enable input must be active to run the servo motor. This Enable hardware input works in tandem with a logical (software) enable register called the Power Output Stage Enable (POE) register. The POE register will allow current to flow into the motor only when set true and no faults are present on the controller. Since a Lost Enable (LE) fault is generated when this hardware enable input is false, ensure that POE=1, the hardware enable input is true, and all faults have been cleared (RSF register) to activate the power stage of the controller.

The current state of the Enable input can be queried using the Fault Code (FC) register in the terminal window. The Enable input should be connected as shown in the connection diagrams in Section 3.6.10. The internal schematic for the enable input circuit is shown below.

OK Output

The OK discrete output allows the S2K to communicate status information to the host controller. The OK output is active when the controller is enabled and no faults are present. The S2K LED status register will display OK when this output is active. The internal schematic for the OK output circuit is shown below.

Analog Inputs

There are two 12-bit differential analog inputs that support an operating voltage range of ± 10Vdc. These general-purpose inputs can be read as a voltage value in user programs using the AI command. The analog input values can also be queried in the terminal window using the “?” command. Wiring connections should use twisted shielded cable for best noise immunity. Connect the cable and shield as shown in Section 3.6.10, Connection Diagrams.

Auxiliary Encoder Input

The auxiliary encoder input is a flexible input that can be used as a master input for cam or electronic gearing applications, a secondary position monitor, a remote axis position feedback or as secondary position feedback for dual position loop control for the S2K servo controllers. The auxiliary encoder is selected as the master position source for camming by setting the Cam Shaft Position Type (CAT) equal to PSX. The auxiliary encoder is the default command source when gearing is enabled (GRE=1). If the Handwheel Input is enabled (HWE=1), digital inputs 5 and 6 are used for connecting an A/B type hand wheel for use as the gearing command source instead of the auxiliary encoder.

If the Position Feedback Enable is set (PFE=1), the axis position (PSA) is updated from the auxiliary encoder rather than the motor encoder. In addition, when the Position Feedback Numerator (PFN) is non-zero the S2K controller uses a dual position loop mode where the motor encoder is used for the primary position loop and the auxiliary encoder is used for secondary position loop. In this case the auxiliary encoder should be connected to the load to allow the S2K to accurately control the load position without the effects of lost motion from the mechanics. This dual loop arrangement is a very powerful feature that provides excellent servo stability while eliminating the inaccuracy caused by backlash and compliance in the system mechanics. The auxiliary encoder input is connected on the Auxiliary I/O connector for the STI105, SSI104, SSI107, and SSI407 models and to the Pulse Input connector for the SSI216, SSI228, and SSI420 models. Wiring connections should use twisted shielded cable for best noise immunity. Connect the cable and shield as shown in Section 3.6.10, Connection Diagrams. The auxiliary encoder inputs are labeled with “IN_” prefix on these diagrams.

The S2K controller includes an electronic gearing mode that allows the motor to follow a master encoder (follower) or pulse command source (stepper emulator). The Auxiliary Encoder Type (QTX) register configures this input for one of the following signal types:

• Pulse/Direction input

• CCW/CW pulse input

• Quadrature (encoder) input

If an Auxiliary Encoder Input is being driven by a 26LS31 or equivalent differential line driver, it is recommended that a 120-ohm parallel termination resistor be used (please see specifications for RS422 communications for details). If being used in a singled-ended circuit, see the section called “Tie” below.

Note that the S2K Primary Encoder feedback receivers have internal termination resistors.

Note that on the SSI216, SSI228, and SSI420 models, the auxiliary encoder input and the +5Vdc output are located on the Pulse Input connector on the bottom of the controller. The internal schematic for the encoder input circuit is shown below.

NOTE: when the Auxiliary Encoder input is used with a single-ended signal source, see the next section titled “Tie” below.
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Resolver feedback cables as shown in Table 3-13 are available from GE Fanuc for the S2K Series resolver-based controllers used with MTR-Series motors. Plug the motor end of the resolver cable into the connector on the motor and the DB-type connector end of the cable into the DB-15 socket labeled Position Feedback on the front of the controller. The best system reliability is achieved when the encoder cable is returned in a separate conduit from that housing the motor power cable. The feedback cable should use 24-28 AWG twisted pair wire and must be shielded. The shields must be terminated to the isolated ground pins on the Position Feedback (DB-15) connector on the S2K controller as shown in Table 3-9. The maximum cable length for resolver feedback cables is 50 meters. See Section 3.6.10, Connection Diagrams, for additional wiring detail.

Serial Port Wiring

The S2K controller includes an RS-232 serial port that is used for programming and monitoring functions in addition to providing an interface for an Operator Interface Terminal. While the Motion Developer software uses normal ASCII communications, the S2K controllers also support an RTU protocol on this port allowing communication with any RTU-compliant OIT or device (see Chapter 9, “Using Serial Communications” for more details). The RTU register is used to enable/disable the RTU mode. A +12 VDC supply is available on pin 4 that can be used to power the display. This supply is also available on the I/O connector and can source a maximum of 0.5 amp combined load current.

Default settings for the serial port are 9,600 baud, 7 bits and odd parity. XON/XOFF flow control is used.

Prefabricated serial cables are available from GE Fanuc as part number IC800SKCS030 (3 meters) or you can build your own cable using the following S2K connection information. Cable should be Belden 8723 shielded cable or equivalent. To meet the requirements of EN61000-4-5 and CE mark, serial communication cables shall be shielded and shall not exceed 30 meters in length. Pin-out for the serial cable is shown in the following table.

Discrete I/O Wiring

The discrete inputs and outputs may be wired for either sinking or sourcing operation. The operational voltage range is 12 to 24 volts DC. The outputs can sink or source 100 mA maximum. The connection diagrams in Section 3.6.10 show proper connection for sourcing and sinking configurations. Points labeled as “IN_xx” are inputs only while points labeled “I/O_xx” can be used as either inputs or outputs.

The wiring to this connector should be of appropriate size and insulation quality for the application. To meet the requirements of EN61000-4-5 and CE mark, discrete I/O cables shall be shielded and shall not exceed 30 meters in length.

The discrete I/O are general purpose except for the Enable Input and the OK output. Three of the other general purpose inputs are used to connect a home switch and hardware overtravel switches when required by the application.

Connecting Homing and Overtravel Switch Inputs

Many applications require the use of a home position sensor to define the reference or “home” position of the axis. The S2K controllers have a number of home reference commands that can be used to home the axis to various reference points such as the encoder marker (RMF, RMR), a home switch (RHF, RHR) and the overtravel switches (ROF, ROR). When a home sensor is used, it must be wired to the Discrete Input 1 (DI1) terminal. When the controller executes one of the Run To Home Input commands (RHF, RHR), it will look for a state change on this physical input.

When the controller executes a Home To Overtravel Input command (ROF, ROR), it will look for a state change on the respective overtravel switch. The forward overtravel switch must be connected to Discrete Input 2 (DI2), and the reverse overtravel switch must be connected to Discrete Input 3 (DI3). To use these end-of-travel switches as a home sensor, it is not necessary to have the hardware overtravel inputs enabled (OTE=1). However, if the application requires end-of-travel protection, you must enable the hardware overtravel inputs by setting the Overtravel Enable register true (OTE=1).

Connecting Handwheel Encoder Inputs

The controller has a special function that enables the connection of a handwheel encoder, typically used to jog the axis at a low speed, to two of the discrete inputs. When the Handwheel Enable register is set to true (HWE=1), Discrete Input 5 (DI5) is used to connect the A-channel of the handwheel, and Discrete Input 6 (DI6) is used to connect the B-channel. The handwheel encoder inputs are limited to a maximum pulse rate of 500 pulses/second. The axis will follow the handwheel input based on the values of the Gearing Ratio Numerator (GRN) and Gearing Ratio Denominator (GRD) as shown below:

This additional encoder input can be used as a master source, within the maximum pulse rate limitation stated above, when the auxiliary encoder input is used for dual loop servo control.

Auxiliary I/O Wiring and Functional Descriptions

The Auxiliary I/O connector includes a number of diverse signals used to interface the S2K controller to your motion controller and machine. The functions available include:

• Analog Command Input (AI1)

• Analog Output (AO)

• +5 Vdc Output (for auxiliary encoder) (on the Pulse Input on SSI216, SSI228, & SSI420 models)

• +12 Vdc Output (for Enable input)

• Enable Input

• OK Output

• Encoder Output

• Auxiliary Encoder Input (on the Pulse Input on SSI216, SSI228, & SSI420 models)

The SSI216, SSI228, & SSI420 models have a different configuration for the Discrete I/O and Auxiliary I/O connections as shown on the connection diagrams in Section 3.6.10.

The Enable input and OK output may be wired for either sinking or sourcing operation. The operational voltage range is 12 to 24 volts DC. The OK output can sink or source 100 mA maximum. The wiring to the Auxiliary I/O connector should be of appropriate size and insulation quality for the application. To meet the requirements of EN61000-4-5 and CE mark, Auxiliary I/O cables shall be shielded and shall not exceed 30 meters in length.

SI105, SSI104, SSI107 and SSI407 Models

The Auxiliary I/O connector on these models is a standard 25-pin female D-shell connector and is wired according to the pin-out shown in Table 3-11 and in section 3.6.10, Connection Diagrams, for the 4.3 and 7.2 amp servo controller models and 5 amp stepper controller model.

GE Fanuc offers prefabricated connection options for the Auxiliary I/O signals:

A breakout terminal board assembly (44A726268-001) and associated “plug-and-go” interface cables (IC800SKCIxxx) make all of the signals available on screw terminals from a compact terminal block that can be panel or DIN-rail mounted.

Flying lead cables (IC800SKCFLYxxx) have a connector on one end and marked, stripped wires on the other end. The stripped ends can be wired to a user-supplied terminal strip or to the machine controller’s terminal strip. Each wire on the stripped end is marked with the pin number it connects to on the connector end.
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