Tensiometer Manual JT-9050

TENSION
MEASURING SYSTEM
MANUAL
PROCESS LINE
Vishay Precision Group Canada ULC (KELK)
48 Lesmill Road, Toronto, Ontario, M3B 2T5, CANADA
T: +1 416 445 5850 F: +1 416 445 5972 kelk@vpgsensors.com www.kelk.com

TENSION
MEASURING SYSTEM
MANUAL
CONTENTS
PART
WARRANTY
A: TENSIOMETERS
B: ELECTRONICS
FOR: CN STEEL PLANT ENGINEERING CO. LTD.
APPLICATION: PT. ALUMINIUM EXTRUSION INDONESIA

PT ALEXINDO, INDONESIA
CONTINUOUS GALVANIZING LINE
CUSTOMER P.O. #: 17B203-I-004
KELK JOB #: JT-9050
SHIPPING DATE: MAY 2019

WARRANTY
KELK products are warranted against defects in materials

and workmanship for one year from the date of installation
or eighteen months from the date of shipment, whichever
comes first. Our obligation, should the equipment prove
defective during the warranty period, is limited to repair or
replacement at our Plant, or, at our option, at the premises
of our designated agent. Should our customer not wish to
return the equipment to our factory for repair or
replacement, we will perform the necessary work at his
premises free of charge, provided that he agrees to pay
our standard hourly rates for travel time, transportation
costs and living expenses of our personnel.
We are not liable for consequential damages. Shipping

charges and insurance on material returned to the factory
to be prepaid. We will prepay surface transport charges
and insurance on return shipment.
WrntyStd (101) 1999-01

PART A
KELK TENSIOMETER
KELK MONOBLOC TENSIOMETER
CONTENTS
Section
1 Introduction & System Description
2 Specifications
3 Installation
4 Calibration
5 Maintenance
Installation Drawings
Monobloc(209) 2010/09
A
KELK TENSIOMETER
1.0 INTRODUCTION
Kelk Monobloc Tensiometers are specifically designed to measure tension in metals

processing lines and in the paper and textile industries.
The information presented in the following pages is of a general nature and may vary to
meet specific requirements.
1.1 System Description
The system measures tension in processing lines by sensing the force exerted by the
moving strip on a roll. This is achieved by using two Monobloc Transducers, one at each
end of the roll, which produce signals accurately proportional to strip tension.
Monobloc model and capacity are selected depending on the magnitude and direction of
the force, Fn or Fp, to be measured. Two distinct sensors are available; one, designated
by MDN0020-01model number, measures only Fn, force normal to the mounting surface
(see Fig. 1.1) ; the second, designated by MDP0020-01model number, measures only Fp,
i.e., force parallel to the mounting surface in the longitudinal direction (see Fig. 1.2).
1.2 Monobloc Description
Kelk Monoblocs are strain gage transducers machined from a one-piece forged steel
block. The geometry of the block is such that the sensor has very low hysteresis,
excellent linearity and is insensitive to forces other than in the sensing direction. The
sensors are hermetically sealed, with cables protected by hydraulic hoses, to withstand
harsh mill environments.
1.3 Electrical Equipment
To complete the system, a Kelk amplifier is required to provide excitation and signal
amplification for the sensor. The system calibration depends on the strip to roll geometry
and outputs are normally provided scaled to represent strip tension directly.
Monobloc(209) 2010/09
A
KELK TENSIOMETER
FIG. 1.1 SYSTEMS SENSING FORCES ACTING NORMAL TO THE

MOUNTING SURFACE
Sensing Direction
T1 T2
Fn
   
Fn
T1 T2
Fn = T1 sin a + T2 sin b - w Fn = T1 sin a + T2 sin b + w
w = Roll Weight + Bearing & Pillow Block Weight
FIG. 1.2 SYSTEMS SENSING FORCES ACTING PARALLEL TO THE

MOUNTING SURFACE
Sensing Direction
T2
Fp 
 Fp
 
T1
T1
T2
Fp = T1 cos a - T2 cos b Fp = T1 cos a - T2 cos b
Monobloc(209) 2010/09
A
KELK TENSIOMETER
2.0 MONOBLOC SPECIFICATIONS
Capacity Per Outline Drawing.
Sensitivity approx.1.0 mV/V at rated capacity.
Overload Per Outline Drawing (500 to 1000% of rated

tension).
Excitation Voltage 10 V nominal, 20V maximum AC or DC.
Hysteresis and Linearity Error Less than 0.1% of full scale output for hysteresis
and linearity combined.
Repeatability Error Better than 0.05% of full scale output.
Zero Drift With Temperature: Less than 0.005% of full scale /oC.
Operating Temperature Temperature compensated to 100oC.

Maximum operating temperature 150oC.
Dimensions Per Outline Drawing.
Leads Teflon, shielded - protected by steel reinforced

Buna N hydraulic hose.
Calibration Cell calibration traceable to National Institute of

Standards and Technology, Washington, D.C.
Monobloc(209) 2010/09
A
KELK TENSIOMETER
3.0 INSTALLATION
For mechanical details, refer to the load cell installation drawing; for electrical details,
refer to the general system drawing and the cabinet wiring diagram, if supplied
3.1.1 Cables and Load Cell Identification
Each load cell is supplied with a calibration card attached to its cable. A copy of this
card is also in the manual. The load cell is identified by a model and serial number.
IT IS MOST IMPORTANT TO REMOVE AND RETAIN THE CALIBRATION

CARD.
IT IS MOST IMPORTANT TO RECORD THE LOCATION OF EACH LOAD CELL

BY MODEL AND SERIAL NUMBER; FOR EXAMPLE, MARK THESE NUMBERS
ON THE MILL STAND IN A LOCATION THAT IS VISIBLE AFTER COMPLETE
INSTALLATION.
Caution
The cables are sealed in the cells and their replacement requires factory
service. In most cases, the load cell is supplied with a hydraulic hose to
protect the cable from mechanical damage and the environment. The
cable and hose must be routed to avoid mechanical damage; installation in
metal conduit is preferred. If the load cells are mounted on a retractable
support, the provision must be made to control the movement of the cable
and hose assemblies. The cables are composed of Teflon-coated wires for
chemical protection and are not easily spliced.
For this reason, cables should be fitted in the junction boxes before
cutting. A special splicing kit Part No. 045696 is available for splicing
cables which are damaged in service.
3.2 Mounting Arrangement
Monoblocs are designed to be bolted to the top of a frame usually supplied by the
customer. The sensor mounting faces have been drilled and tapped to facilitate mounting
to such a frame and for the mounting of the roll and bearing assemblies to the sensor.
The electrical connection of the sensor leads to the junction boxes completes the
installation.
Monobloc(209) 2010/09
A
KELK TENSIOMETER
3.2.1 Mounting Sequence
1. Test load cell and cable for continuity. Using an ohmmeter with a resolution of
0.1 ohms, measure:
(a) the input resistance between the green and black conductors,
(b) the output resistance between the red and white conductors,
and compare both values with those given on the calibration card. The values should
correspond.
2. Test the load cell cable for leakage resistance.
Caution
Do not use any insulation tester with test voltages in excess of 50V.
Permanent damage to the load cell may result if this voltage is exceeded.
Measure leakage resistance between any conductor and the load cell body, any
conductor and the cable shield, and the shield and the load cell body; the result in
each case should be greater than 100 megohms.
3. Locate the Monobloc on the respective frame. The polarity of the output depends on
the direction of the applied force. It is most important, therefore, to orientate the
sensors in accordance with the information given on the Signal polarity diagram for
this type.
4. The tension signal is dependent upon geometry, therefore, check that the installation
of the sensors in relation to the strip angles is as detailed on the Tensiometer
application data forms #858.
Caution: If sensors are not correctly installed, as detailed in items 3 and 4 above,
incorrect tension indication will result.
5. Note the location of each sensor, identifying by serial number.
Monobloc(209) 2010/09
A
KELK TENSIOMETER
6. Lower the rolls with bearings on to the sensors; additional wear or mounting plates
may be used. Check that the rolls are correctly aligned and positioned to provide the
specified geometry. Adjust, if necessary, with shims.
NOTE: TENSIOMETER ROLLS MUST BE DYNAMICALLY BALANCED IN

THE TWO BEARING PLANES TO MAGNITUDE OF 6.3mm/s (A GRADE
OF 6.3 PER ISO 1940) OR BETTER TO AVOID A CYCLIC FORCE ON
THE SENSORS THAT WOULD BE REFLECTED IN THE TENSION
MEASUREMENT.
3.3 Wiring
A general system drawing, figure 1.3, is included in this manual illustrating the main
components of a tension measuring system and their interconnecting cabling. More
specific information may be obtained from the cabinet wiring diagram if supplied.
The load cell is fitted with a 4 conductor shielded cable of suitable length. Typically this
cable is permanently attached to the load cell and protected from mechanical damage by
a hydraulic hose.
When the load cell is equipped with two bridges, the bridge 1 cable is labelled.
The hydraulic hose, protecting the cables, should be routed for minimum exposure to
danger of crushing during plant maintenance.
Load cell wires should be fitted with spade or ring type terminal lugs.
When load cell cable termination is required, it must be provided in a vapour-proof

junction box. One junction box, equipped with barrier terminal strips usually serves two
cells.
The preferred location for the Electronic enclosure and junction box if used is one that
provides easy accessibility and precludes the accumulation of water or oil.
It is advisable to repeat the continuity and insulation test given in 3.2.1 upon completion
of each stage of the wiring.
To facilitate calibration, when connecting wiring between the junction box and the
readout amplifier, identify each bridge circuit both at the amplifier and junction boxes, by
cell model number, serial number and location, e.g., MDN0020-01, Serial 24, Location
XYZ, operator side.
In the most cases integral load cell cable run directly to the electronic enclosure. When
the junction box is used, interconnection cables should be run by themselves in metallic
conduit, and discretion used in routing the conduit in relation to heavy current cables. It
Monobloc(209) 2010/09
A
KELK TENSIOMETER
has been found satisfactory to maintain at least 1 m spacing between load cell cables and
heavy power cables where a parallel run of up to 30 m (100 ft) exists.
If a longer parallel run exists, separation should be increased to 2 m. The recommended

interconnection cable sizes are:
#18 AWG for up to 90m (300 ft)

Cables should be four conductor twisted shielded cable with an insulating jacket overall,
which must insulate the shield from the metal conduit to avoid circulating currents.
THE SHIELD IS CONNECTED AT THE AMPLIFIER ONLY. Four conductor cable of
this type is available from Kelk (AWG#16 Part No. 28280 and AWG#14 Part No.
43899).
THE IMPORTANCE OF GOOD CONNECTIONS AND DRY JUNCTION BOXES

CANNOT BE OVER-EMPHASIZED. Any additional junction boxes introduced
between the mill stand and readout amplifier must be vapour-proof.
Monobloc(209) 2010/09
A
ELECTRONIC
KELK
Monobloc(209) 2010/09
INTERCONNECTION
CABLE AND CONDUIT
(IF USED)
JUNCTION BOX
(IF USED)
ANALOG / DIGITAL
OUTPUTS
AND LOGIC INPUT
TENSION ROLL
A
ASSEMBLY
CABLE & HOSE
STANDARD LENGTH 6m (20FT.)
MOUNTING
SCREWS
ADAPTER
120/240 VAC SUPPLY PLATE
(IF USED)
FIG. 1.3 MONOBLOC TENSION MEASURING SYSTEM

MONOBLOC
TENSIOMETER
70659A
KELK LOAD CELLS
4.0 OPERATION
When installation is complete, it is necessary to calibrate the load measuring system prior
to actual operation.
4.1 General Purpose Amplifier
To gain a basic understanding of the operation and use of the General Purpose Amplifier,
Model GPA2, read Section B of this manual (Sections 1 through 6) before proceeding.
4.2 System Set-Up
The GPA2, as supplied from the factory, is setup in terms of functionality and features
either with a default setup or a specific setup as defined at the time of order. This is fully
described in Section B, Appendix A. The user is advised to check that the supplied setup
is correct for the specific application. The procedure for doing this check is given in
Section B, Part 4 of this system manual.
To fully configure the GPA2 for measurement operation, the user must enter data,
including the load cell calibration target load and system parameters such as analog
outputs setting and load limits. The user is guided through this process in Section B,
Parts 4 and 5.
4.3 Calibration
Every KELK load cell is supplied with a calibration card giving the full load output stated
in millivolts per volt of bridge excitation.
For convenient system calibration, the card also specifies (in percent of rated load) the bridge
output resulting from the application of a precision shunt resistor across one bridge arm.
4.3.1 Force and Pressure Measurement Systems
In KELK load cell systems, a simulated load, produced by precision resistors, is used to
calibrate the load measuring system. The value of the precision resistor is given on the
calibration card and a resistor of that value is available in the GPA2. The user must select
the same value when required during GPA2 Channel Configuration process described in
Section B, Part 5.4.
Also in Part 5.4 of Section B, the user is prompted to enter a 'Calibration Target Load' for
each load cell. This figure is the simulated output expressed as a percent of rated load.
LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
If the calibration card gives a figure of 79.73% of rated load as the figure to be used for
"Full Routine Mill Calibration of the Load Metering System", this is the Calibration
Target Load to be entered into the GPA2.
4.3.2 Tension Measurement Systems
Note: During calibration, the metal (or paper) strip, the tension of which is being
measured, must be removed from the tensiometer roll.
The design of KELK Tensiometers is such that calibration is accomplished through the
trimming of the transducer amplifiers alone. Field calibration of the tensiometer sensors
by means of dead weights is not required since the necessary transfer reference in the
form of shunt calibration resistance has been established at the factory for each sensor.
For load cells incorporated into tensiometers, the simulated load is converted to a
simulated tension and expressed as a percentage of the full rated tension for that location.
The conversion of tension to load is illustrated on the Tension Application Data Sheet
Form 858. The resulting calibration data is given on the Tensiometer Calibration Data
Sheet, Form 855. Both forms are given at the end of Section A of this manual. A
complete explanation of the Forms 855 and 858 is given in Appendix C in Section B of
this manual.
In Part 5.4 of Section B, entering a 'Calibration Target Load' for each load cell is
described. Refer to the Tensiometer Calibration Data Sheet for the value of simulated
tension, expressed as a percentage, for the appropriate load cell. As an example, if this
value is 81.53%, then this is the Calibration Target Load to be entered into the GPA2.
It is important to note that the calculation of simulated tension is carried out based on
fixed tensiometer geometry and specific strip angles. If the geometry of the system, as
installed, does not correspond to that on the Tensiometer Application Data Sheet, then
consult George Kelk Corporation to obtain new forms and percentage values.
4.4 The Effect of Cable Length
The value of the calibration constant given on the calibration card is measured with only
short cables linking the cell to its amplifier. Installation in the mill sometimes involves
the use of long interconnecting cables. The additional resistance added by long cables
affects the cell output in response to the application of the shunt resistance and correction
of the 'Calibration Target Load' may be required.
LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
4.4.1 Calibration Constant Correction
In installations involving long interconnecting cables, where correction is required,

proceed as follows:
1. Determine the resistance of one conductor of the interconnecting cable. This can be
done using Figure 1 if the length and gauge of wire are known or, by direct
measurement as follows:
(a) Disconnect the interconnecting cable at the amplifier.
(b) Using an ohmmeter with 0.1 Ohm resolution, measure the resistance between the
interconnection cable leads corresponding to red and white wires of the load cell
cable with either:
The interconnection cable leads shorted at the junction box,
or
The interconnection cable connected to the load cell at the junction box. In
this case subtract the value of 'Output Resistance' given on the load cell
calibration card from the measurement.
For both cases, divide the result by 2 to obtain a value, RL, which is the
individual lead resistance.
c) Using Figure 2 and the value of RL obtained above, determine the Cable
Correction Factor, ‘Cf'.
If the value of RL is beyond the range of Figure 2, or the system is a 6 wires

arrangement, the value of Cf can be calculated as follows:
For a four conductor connecting cable (the case given in Figure 2)
Cf = 1 + 4 RL where RBR is the output resistance

RBR given on the calibration card
For a six conductor connecting cable where 2 conductors are used for remote
sensing of excitation voltage (typically done in weighing systems),
Cf = 1 + 2 RL
RBR
LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
2. Correct the Calibration Target Load using
CTL1= Cf x CTL
Where:
CTL is the output obtained from the calibration shunt resistor being applied during
factory calibration, expressed as a percentage of the full scale output for force and
pressure (found on the Calibration Card). For Tension applications, it is the
percentage of the full scale tension from the Tensiometer Calibration Data Sheet;
and
CTL1 is the Calibration Target Load corrected for the interconnecting cable resistance.
Example:
For a load cell with a bridge resistance of 240 ohms, connected to the amplifier by
90 meters of 16 AWG cable
From Figure 1 RL = 1.2 ohms
From Figure 2 Cf = 1.02
If the calibration card gives a figure of 79.73% of rated load as the figure to be
used for "For Routine Mill Calibration of Load Metering System", then the
corrected calibration constant to be used to accurately calibrate the load measuring
system is:
CTL1 = 1.02 x 79.73%
= 81.3%
This value compensates for any errors introduced by the 90 meters of

interconnecting cable.
4.5 System Check and Simulation
The GPA2 has a diagnostic feature that allows the user to conduct a Load Simulation,
forcing the unit to output a known value. This feature facilitates a check of external
connections. It is strongly recommended that this check be carried out before putting the
complete system into operation. Refer to Parts 6.7 of Section B for full details.
LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
CABLE LENGTH CORRECTION FACTOR

LEAD RESISTANCE - RL (Ω)
2 WIRE CROSS SECTIONAL AREA

2 -3
IN x 10 mm2
G
AW 18 AWG 1.28 0.82
18 16 AWG 2.03 1.31
14 AWG 3.23 2.08
G
AW
1 16 1 FT = 0.3045 METERS
WG
14 A RL
RL
RL
RL
0 LOAD CELL
0 30 m 60 m 90 m 120 m 150 m
(100ft) (200ft) (300ft) (400ft) (500ft)
CABLE LENGTH - L
Figure 1 Determination of Lead Resistance, RL
1.10
RBR = LOAD CELL OUTPUT BRIDGE RESISTANCE
1.09
CABLE CORRECTION FACTOR - Cf*
* CORRECTED CALIBRATION
1.08 VALUE = GIVEN SHUNT
RL CAL. x Cf
Cf = 1 + 4
RBR
R)
1.07
B
(R
Ω
0
12
1.06
1.05
Ω
1.04 240
1.03 Ω
360
1.02 480 Ω
720 Ω
1.01
1.00
0 1 2 3
INDIVIDUAL LEAD RESISTANCE - R L (Ω)
Figure 2 Determination of Cable Correction Factor, Cf

LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
5.0 MAINTENANCE
5.1 Mechanical
KELK load cells are typically mounted in locations where regular inspection is not
practical, for example, above a screwdown nut. The load cell itself requires no
mechanical maintenance but it is important for reliable operation of the cell that the
conditions and tolerances given on the installation drawing are maintained. Additional
maintenance notes may be contained in this manual.
5.2 Electrical
Electrically, the load cell is a simple circuit containing only passive devices. The load
measuring system, including the cell, connecting cable and amplifier can be checked by
observing the stability of the output with no load applied and checking the repeatability
and stability of the output when the shunt resistor used to calibrate the system is engaged.
If instabilities of zero, shunt resistor generated output, or indicated load are experienced,
then the tests given in 5.2.1 and 5.2.2 should be carried out.
5.2.1 Insulation Resistance
A potential source of faults in a load measuring system is the occurrence of leakage paths
to ground in the load cell to electronics wiring. The most common cause is moisture in
the load cell cable and/or junction box. Related preventive measures are listed in
Section 3.
The presence of excessive leakage will usually reveal itself by causing drift in the zero
reading under conditions of no load.
Caution
Do not use any insulation tester with test voltages in excess of 50V.
Permanent damage to the load cell can result if this voltage is exceeded.
To check for leakage, disconnect all load cell leads and their shield from the electronics
and measure the resistance from any lead to ground (refer to Part 3, Installation). A ten
megohm leakage would introduce a maximum error of about 0.3%. However, such a
reading suggests a condition that should be corrected.
LC/GPA2 (318)
Revised 2008/04
A
KELK LOAD CELLS
To localize the leakage, open the junction box at the mill stand and, having disconnected
all leads, pinpoint the source by taking individual readings from each terminal. If there
are other junction boxes in the cable circuit, repeat the procedure for each of them.
5.2.2 Bridge Resistance and Continuity
To check bridge resistance, disconnect load cell leads at the junction box and, using an
ohmmeter with a resolution of 0.1 Ohms, measure
(a) the input resistance between the black and green conductors
(b) the output resistance between the red and white conductors.
The values obtained should correspond to those given on the cell calibration card. If the
measurement is made at the amplifier to check the condition and continuity of the
interconnecting cable, then allowance must be made for the additional cable resistance
when comparing with the values on the calibration card.
5.3 Cable Repairs
Load cell cables are fixed and sealed to the load cell. In the event of damage to the cable
near to the load cell body (within 6 inches, or 150 mm), the cell should be returned to
KELK for service. If the cable is damaged at some point further along its length, then a
repair can be performed using the KELK Splicing Kit, part number 20311. This kit is
specifically for splicing teflon cables and is the only method recommended.
LC/GPA2 (318)
Revised 2008/04
A
LOAD CELL CALIBRATION CARD
MODEL No. MDN0012-15 SERIAL No. 11
VISHAY PRECISION GROUP CANADA ULC
TORONTO, ONTARIO, CANADA

RATED FULL SCALE
12 kN 0.9378 mV/V*
CAPACITY SENSITIVITY AT RATED CAPACITY
48 LESMILL ROAD
OUTPUT WITH 300,000 [W] SHUNT RESISTOR 0.8340 mV/V*
APPLIED ACROSS BLACK AND WHITE LEADS
FOR ROUTINE MILL SHUNT RESISTOR

% of RATED
CALIBRATION SIMULATES 88.93 CAPACITY
OF LOAD METERING SYSTEM APPLICATION OF
INPUT RES. 1003.1 [W] AT 23° C OUTPUT RES. 1003.1 [W] AT 23° C
GREEN (+), BLACK(-) (77° F) RED (+), WHITE(-) (77° F)
* OPEN CIRCUIT MEASUREMENT (AMPLIFIER DISCONNECTED) DATE: 25-Oct-2018
BY: RM
KELK Form# 887
Rev. 2016-07-15 Work Order: JT9050

RATED FULL SCALE
12 kN 0.9218 mV/V*
48 LESMILL ROAD

% of RATED
BY: RM
KELK Form# 887

RATED FULL SCALE
12 kN 0.9363 mV/V*
48 LESMILL ROAD

% of RATED
BY: RM
KELK Form# 887

RATED FULL SCALE
12 kN 0.9133 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
12 kN 0.9497 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
12 kN 0.9277 mV/V*
48 LESMILL ROAD

% of RATED
BY: RM
KELK Form# 887

RATED FULL SCALE
12 kN 0.9136 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887
MODEL No. MDP0020-05 SERIAL No. 11

RATED FULL SCALE
20 kN 1.0222 mV/V*
48 LESMILL ROAD

% of RATED
BY: RM
KELK Form# 887

RATED FULL SCALE
20 kN 1.0171 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
20 kN 1.0073 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
20 kN 0.9872 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
20 kN 1.0175 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887

RATED FULL SCALE
20 kN 0.9544 mV/V*
48 LESMILL ROAD

% of RATED
BY: EP
KELK Form# 887
PART B
GENERAL PURPOSE AMPLIFIER
MODEL GPA2, REVISION E

USER'S MANUAL
Manual # 90472
Revision C
July 2018
Vishay Precision Group Canada ULC (KELK)

48 Lesmill Road, Toronto, Ontario, M3B 2T5, CANADA
T: +1 416 445 5850 F: +1 416 445 5972 kelk@vpgsensors.com

www.kelk.com
KELK Copyright
Copyright © 2018 Vishay Precision Group Canada ULC (“KELK”)
All rights reserved. No part of this manual may be reproduced or stored as data,
in whole or in part, without the prior written permission of KELK. No license,
express, implied, or otherwise, to any intellectual property rights is granted by
this document, or by any conduct of KELK.
This manual is provided solely as a convenient guide to the operation and

maintenance principles of the accompanying KELK instrumentation device and
software. For purposes of explanation, the text and illustrations have been
simplified or represent typical installations and, therefore, do not represent nor
replace the approved engineering drawings and documentation that accompany
each unit. It is the customer’s responsibility to ensure that all operation and
maintenance is performed with reference to the approved engineering drawings
and documents.
KELK disclaims any and all liability for errors or omissions in this manual or their
consequences. KELK makes no warranty, representation or guarantee other than
as set forth in the terms and conditions of purchase.
KELK Warranty
WARRANTY
The KELK General Purpose Amplifier, Model GPA2, is warranted

against defects in materials and workmanship for one year from
the date of installation or eighteen months from the date of
shipment, whichever occurs first. This warranty is independent of
the KELK Rollmax Load Cell Five Year Conditional Warranty.
Should the equipment prove defective during the warranty period,

KELK’s obligation is limited to module replacement. Should the
customer not wish to return the product to the KELK factory or
local agent for replacement, KELK will, if feasible, perform the
necessary work at a suitable location in the customer’s premises
free of any charges for replaced materials or components
providing that he agrees to pay KELK’s standard hourly service
rates for site and travel time, plus transportation costs and living
expenses at cost.
Products submitted for a warranty claim shall be shipped prepaid

by the customer to and from our factory where they will be
replaced.
Under no circumstances shall KELK be liable for consequential

damages.
WrntyStd (101) 1999-01

KELK Table of Contents
Table of Contents
Part 1 About This Manual ......................................................................................... 1
Part 2 GPA2 Description ........................................................................................... 2

2.0 Introduction ................................................................................................................................ 2
2.1 Features 3
2.2 Hardware Configuration ............................................................................................................. 4
2.3 Function Overview ..................................................................................................................... 5
2.3.1 Sensor Inputs .................................................................................................................... 5
2.3.2 Configuration ..................................................................................................................... 6
2.3.3 Zero Adjustment ................................................................................................................ 6
2.3.4 Analog Data Outputs for Control Purposes ....................................................................... 7
2.3.5 Digital Data Outputs for Control Purposes ........................................................................ 7
2.3.6 System Setup, Monitoring and Diagnostics ....................................................................... 7
2.4 Interfaces ................................................................................................................................... 8
2.4.1 Sensor Ports ...................................................................................................................... 9
2.4.2 Analog Ouputs ................................................................................................................... 9
2.4.3 Logic Inputs ....................................................................................................................... 9
2.4.4 Logic Outputs .................................................................................................................... 9
2.4.5 Fieldbus Interface ............................................................................................................ 10
2.4.6 Serial Communications Interface .................................................................................... 10
2.4.7 Front Panel Interface ....................................................................................................... 10
2.4.8 User Access Program ..................................................................................................... 10
Part 3 Installation .................................................................................................... 11

3.1 Introduction .............................................................................................................................. 11
3.2 Enclosures ............................................................................................................................... 11
3.3 AC Power Wiring ..................................................................................................................... 12
3.4 Sensor Wiring .......................................................................................................................... 15
3.5 Analog Output Wiring .............................................................................................................. 17
3.6 Logic I/O Wiring ....................................................................................................................... 19
3.7 Serial Communications Wiring ................................................................................................ 21
3.8 Ethernet Wiring ........................................................................................................................ 22
3.9 Profibus Wiring ........................................................................................................................ 22
3.10 PROFINET Wiring ................................................................................................................... 22
3.11 Ferrite Chokes Installation ....................................................................................................... 22
Part 4 User Interfaces.............................................................................................. 24

4.1 Introduction .............................................................................................................................. 24
4.2 User Access Program .............................................................................................................. 24
4.3 Front Panel Interface ............................................................................................................... 25
4.4 Changing the Communication Mode ....................................................................................... 31
Part 5 Setup and Configuration .............................................................................. 32

5.1 Introduction .............................................................................................................................. 32
5.2 Checks Prior to Power-Up ....................................................................................................... 32
5.3 Setup 33
GPA2-E Manual 90472 RevC
July 2018
5.3.1 Excitation Voltage............................................................................................................ 33

5.3.2 Analog Outputs and Scaling ............................................................................................ 34
5.3.3 Load Alarm Source and Threshold.................................................................................. 34
5.3.4 Signal Filtering................................................................................................................. 34
5.3.5 Communication ............................................................................................................... 36
5.4 Configuration of Input Channels .............................................................................................. 37
5.4.1 Sensor Calibration Data .................................................................................................. 37
5.4.2 Analog-to-Digital Conversion (ADC) of Input Signals ...................................................... 39
5.5 Serial Communications Interface Connection and Setup ........................................................ 41
5.5.1 Setup and Configuration.................................................................................................. 41
5.5.2 Processing and Configuration ......................................................................................... 42
5.5.3 Measurement Data .......................................................................................................... 44
5.5.4 Communications .............................................................................................................. 45
5.6 Modbus/TCP Interface Connection and Setup ........................................................................ 48
5.6.1 Connection and Setup ..................................................................................................... 48
5.6.2 Data Formats for Communications .................................................................................. 50
5.6.3 Modbus-TCP Memory Map ............................................................................................. 52
Part 6 Operation ...................................................................................................... 53

6.1 Introduction .............................................................................................................................. 53
6.2 Load Display ............................................................................................................................ 53
6.3 Load Level Alarm ..................................................................................................................... 54
6.4 System Status.......................................................................................................................... 54
6.4.1 Online Diagnostics .......................................................................................................... 54
6.4.2 Status Messages ............................................................................................................. 55
6.5 Channel Configuration ............................................................................................................. 55
6.6 Zero 57
6.7 Channel Test / Load Simulation .............................................................................................. 58
6.8 Single Sensor Operation ......................................................................................................... 59
Part 7 Diagnostics & Troubleshooting .................................................................. 60

7.1 Overview .................................................................................................................................. 60
7.2 User Set Fault Conditions ........................................................................................................ 63
7.2.1 Channel Test / Load Simulation (Error code 80) ............................................................. 63
7.2.2 Single Sensor Operation (Error code 40) ........................................................................ 63
7.3 Faults Detected by Continuous Monitoring (Error codes 20 and 10) ...................................... 64
7.4 Faults detected by Auxiliary Function Checks (Error codes 08, 04, 02, 01) ........................... 65
7.4.1 Channel Zero Fault (Error code 08) ................................................................................ 65
7.4.2 Channel Configuration CFG Faults (Error codes 04, 02, 01) .......................................... 65
7.5 Troubleshooting the System .................................................................................................... 67
7.5.1 System Test .................................................................................................................... 67
7.5.2 Interconnecting Cable Test ............................................................................................. 68
7.5.3 Sensor Test ..................................................................................................................... 69
Part 8 Maintenance .................................................................................................. 70

8.1 Introduction .............................................................................................................................. 70
8.2 Power Supply Module Replacement ....................................................................................... 70
8.3 GPA2 Module Replacement .................................................................................................... 70
July 2018
Part 9 Specifications ............................................................................................... 72

9.1 Performance ............................................................................................................................ 72
9.2 Sensor Excitation Supply......................................................................................................... 72
9.3 Sensors Strain Gauge Bridge Type ...................................................................................... 73
9.4 Logic Inputs ............................................................................................................................. 73
9.5 Logic Outputs........................................................................................................................... 73
9.6 Analog Outputs ........................................................................................................................ 74
9.7 Filtering 74
9.8 Serial Communication Port ...................................................................................................... 74
9.9 Ethernet (Modbus/TCP) ........................................................................................................... 75
9.10 Profibus Communications (option) .......................................................................................... 75
9.11 PROFINET Communications (option) ..................................................................................... 75
9.12 User Access Program .............................................................................................................. 75
9.13 Physical 75
9.14 Dimensions .............................................................................................................................. 76
Appendix A GPA2 Model Numbering Scheme ..................................................... 77
Appendix B User Access Program ....................................................................... 81

B.1 Introduction .............................................................................................................................. 81
B.2 Features 81
B.2.1 Operating Modes ............................................................................................................. 82
B.3 Installation................................................................................................................................ 82
B.4 Communication ........................................................................................................................ 83
B.4.1 GPA2 Communication Setup .......................................................................................... 83
B.4.2 Host Computer Communication Setup ............................................................................ 83
B.5 Using the UAP ......................................................................................................................... 85
B.5.1 Using the UAP to Set Up and Configure a GPA2 ............................................................ 85
B.5.2 Using the UAP to Monitor a GPA2 .................................................................................. 86
B.6 UAP Panels ............................................................................................................................. 86
B.6.1 Operations 87
B.6.2 Configure & Set ............................................................................................................... 88
B.6.3 Diagnostics 96
B.7 Additional Features .................................................................................................................. 99
B.7.1 GPA2 Setup and Configuration Summary Printout ......................................................... 99
B.7.2 UAP System Setting ........................................................................................................ 99
B.7.3 Help 99
Appendix C Tensiometer Calibration Information Sheets, Forms 858 and 855101

C.1 Introduction ............................................................................................................................ 101
C.2 Form 858, Tensiometer Application Data Sheet ................................................................... 102
C.3 103
C.4 Form 855, Tensiometer Calibration Data Sheet .................................................................... 103
Appendix D Fieldbus - Profibus Protocol ........................................................... 106

D.1 Introduction ............................................................................................................................ 106
D.2 Setup and Configuration ........................................................................................................ 106
July 2018
D.2.1 Connections .................................................................................................................. 107

D.2.2 Termination ................................................................................................................... 109
D.2.3 Node Address ................................................................................................................ 109
D.2.4 Indicators 110
D.3 Processing ............................................................................................................................. 111
D.4 Communications .................................................................................................................... 112
D.4.1 Data Formats ................................................................................................................. 112
D.4.2 Memory Map ................................................................................................................. 114
Appendix E PROFINET Fieldbus Protocol ......................................................... 115

E.1 Introduction ............................................................................................................................ 115
E.2 PROFINET............................................................................................................................. 115
E.3 HMS Anybus Communicator for PROFINET ......................................................................... 116
E.3.1 PROFINET Connector (Ethernet) .................................................................................. 117
E.3.2 PC Connector ................................................................................................................ 117
E.3.3 Subnetwork (aka GPA2) Connector .............................................................................. 120
E.3.4 Power Connector ........................................................................................................... 123
E.3.5 Indicators 123
E.4 Setup and Configuration of Anybus Communicator Gateway ............................................... 125
E.5 GSDML File ........................................................................................................................... 127
E.6 Installing and Removing the Module ..................................................................................... 128
E.6.1 Installing the Anybus Communicator Module ................................................................ 128
E.6.2 Removing the Anybus Communicator Module .............................................................. 128
E.7 Communications .................................................................................................................... 129
E.7.1 Data Formats ................................................................................................................. 129
E.7.2 Memory Map ................................................................................................................. 131
Appendix F Recommended Spares .................................................................... 132

July 2018
Table of Figures
Figure 2.1 GPA2-12 (NEMA 12) with Profibus Option 3
Figure 2.2 Main Module Functionality 5
Figure 3.1 GPA2 Enclosure 12
Figure 3.2 GPA2 Wiring 13
Figure 3.3 Main Module Connections 14
Figure 3.4 Analog Output Circuit 18
Figure 3.5 Zero Function Input Circuit 19
Figure 3.6 System Healthy and Load Level Relay Circuits 20
Figure 3.7 Serial Communications Connections for RS232 21
Figure 3.8 Serial Communications Connections for RS485 21
Figure 3.9 Ferrite Chokes Installation 23
Figure 4.1 Front Panel Interface 25
Figure 4.2 FPI Menu 27
Figure 4.3 Function Setup Loop 28
Figure 4.4 Operation Loop 29
Figure 4.5 Modbus Mode Setting 31
Figure 5.1 Digital Filter Response 35
Figure 5.2 Working Range Definition 40
Figure 5.3 GPA2 Web Page 49
Figure 8.1 GPA2 Module removal from DIN Rail 71
Figure 9.1 Dimensions of GPA2 Enclosures 76
Figure A.1 GPA2 Ordering Form 80
Figure B.1 Communication Action Selection 83
Figure B.2 Serial Communication Setup Panel 84
Figure B.3 Directory Path Panel 84
Figure B.4 Navigation Panel 86
Figure B.5 Operations Panel 87
Figure B.6 Configure & Set Panel 89
Figure B.7 Input Configuration Panel 90
Figure B.8A Mode of Data Entry 90
Figure B.9 Cable Calculator 92
Figure B.10 Application Wizard Image 93
Figure B.11 Setup Panel 94
Figure B.12 Status Panel 96
Figure B.13 Configuration Data Panel 97
Figure B.14 Simulation and Output Test Panel 98
Figure B.15 UAP System Setting Panel 99
Figure B.16 Sample of ‘Print GPA2 Configuration Report’ 100
Figure C.1 Example of a Calibration Card 101
Figure C.2 Form 858, Tensiometer Application Data Sheet 102
Figure C.3 Form 855, Tensiometer Calibration Data Sheet 104

July 2018
KELK Precautions
Precautions
Intended Use
The General Purpose Amplifier, Model GPA2, is intended for use only with factory
calibrated KELK strain gage sensors in load measuring systems. Do not use the
GPA2 in a manner not expressly described in this manual or approved by
authorized KELK personnel or their agents. The outputs and the alarms will be
unpredictable, both the GPA2 and the equipment to which it is connected may be
damaged and the protection provided by the GPA2 may be impaired.
Installation, Setup and Configuration
The GPA2 must be installed, setup and configured as specified in Part 3,

Installation, and Part 4, Setup and Configuration. If not properly installed, setup
and configured, the outputs and alarms will be unpredictable, both the GPA2 and
the equipment to which it is connected may be damaged and the protection
provided by the GPA2 may be impaired.
Accessibility
The GPA2 enclosure is tool accessible and should only be opened by qualified
service personnel. Always disconnect the GPA2 from the power source before
removing the cover. Do not reconnect power until the cover has been replaced
and secured. The only permissible user service, the replacement of printed
circuit boards, does not require the application of power while the cover is
removed.

July 2018
KELK Precautions
Warnings and Cautions
The GPA2 is marked with IEC 61010 symbols to warn the user of items requiring
particular attention for safety reasons.
Caution, refer to accompanying documents.
Caution, risk of electric shock.
Protective Enclosure ground
Cautions are included in this manual to advise of hazards to which equipment

may be exposed.
Persons undertaking the installation, commissioning, operation and service of the

GPA2 must pay careful attention to these Warnings and Cautions.
Electrostatic Damage
Electrostatic discharge (ESD) can damage static sensitive

components used in the GPA2. To prevent ESD, follow
the guidelines given in Part 8, Maintenance, when
handling, removing and installing printed circuit boards.

July 2018
KELK GPA2 Description
Part 1 About This Manual
Information is provided for installing, operating and servicing the General

Purpose Amplifier, Model GPA2-E, as part of a KELK Roll Force, Pressure or
Tension Measuring System in metals rolling mills, or KELK Load Measuring
System in metals and ore processing applications.
Users of this manual must pay particular attention to the Precautions section at
the front of the manual and to all Warnings and Cautions contained herein.
If additional technical assistance is required, contact KELK at the address given

on the title page or our designated agent.
Translation of this manual into another language may result in loss of meaning
and content; in all cases, the content of the English version upon which the
translation was based prevails.

July 2018 1
Part 2 GPA2 Description
2.0 Introduction
The General Purpose Amplifier Model, GPA2-E, is a two channel strain gage
sensor signal conditioner for use in industrial applications. The GPA2-E is
referred as GPA2 throughout this manual.
The GPA2 is used together with KELK strain gage sensors for:
 Tension measurement, particularly in metals process lines and paper
machines
 Force measurement
 Weight measurement
 Pressure measurement
The GPA2 comprises:
A mill worthy enclosure, NEMA 12 or optional NEMA 4X, containing
 A Power supply module

 A main module for sensor excitation and signal conditioning
 Power ON/OFF circuit breaker
 Optional Fieldbus modules
Figure 2-1 illustrates the enclosure with modules installed.
To service the wide variety of applications and sensors, the main module can be
supplied with either the standard excitation voltage of 10 VDC or the optional 20
VDC. The higher excitation voltage is provided for applications requiring sensors
providing higher than the standard 500% overload ratings.

July 2018 2
Figure 2-1: GPA2-12 (NEMA 12) with Profibus Option
2.1 Features
KELK measuring systems employ strain gage technology to ensure fast

response, excellent linearity and low hysteresis, and to permit the design and
construction of very robust sensors incorporating a one piece load sensing
element. The GPA2 supports two sensors, and is specifically designed for
systems that require measurement data from two sensors simultaneously. It
features:
 Sensor excitation and signal conditioning

 Analog outputs, user selectable as current or voltage
 Modbus/TCP interface
 Load level indication for the sum of the two channels
 Calibration via selectable shunt resistors
 Tare correction
 Remote zero (both channels simultaneously)
 Online diagnostics with fault indication
 Single sensor cell operation

July 2018 3
2.2 Hardware Configuration
The GPA2 is an electronics unit comprising DIN rail mounted modules contained
within a steel enclosure. NEMA 12 and NEMA 4X enclosures are available.
Figure 2.1 illustrates the NEMA 12 option. The enclosure contains a circuit
breaker serving as an ON/OFF switch and all the necessary terminals for AC
connection. The user must provide power and signal exit holes. Sensor entries
to fit KELK load cell cables with 1/2” NPT hose adapter are provided. The basic
configuration consists of:
Power Supply Module

The module is CE compliant and converts standard AC power, 110/220 VAC, to
24 VDC to power the main module and any additional modules designed for use
with the GPA2.
GPA2 Module
This provides the sensor excitation, signal conditioning, a direct user interface
including an eight-button keypad, and an LCD panel for manual monitoring and
setup. The LCD panel can display 2 lines by 8 alphanumeric characters. Sensor
connections and system inputs and outputs are located on the side of the
module. Additional connections are also provided for interfacing with a PC or an
optional Fieldbus module (see Figure 3-2).
Optional Profibus Module

The optional Profibus module is available for users requiring process
measurement and status data in digital format at a rate suitable for process
control.
Figure 2-2 details the functions of the main module, in addition to the inputs and
outputs.
Optional PROFINET Module

The optional PROFINET module is available for users requiring process
measurement and status data in digital format at a rate suitable for process
control.

July 2018 4
Figure 2-2 Main Module Functionality
2.3 Function Overview
2.3.1 Sensor Inputs

There are two input channels for strain gage sensors (load cells). Each channel
must be setup and configured using load cell calibration data to yield
measurement data with the required scaling and zero reference. Strain gage
sensors present a resistive load in the form of a Wheatstone Bridge. The main
module provides a regulated voltage supply for bridge excitation for the two
isolated channels. As previously described, there are 2 excitation levels, 10 VDC
or 20 VDC. In the hardware designation field of the GPA2 model number, ‘1’
represents 10 VDC (standard) and ‘2’ represents the optional 20 VDC (see
Appendix A).

July 2018 5
2.3.2 Configuration
Channel Calibration
Every KELK load cell is supplied with calibration data giving the cell full load
output (sensitivity) stated in millivolts per volt of bridge excitation. The data also
includes the bridge output resulting from the application of a precision shunt
resistor across one bridge arm (in percent of rated load), used for calibration of
load measuring systems. For tension measurement applications, KELK provides
additional information to assist the user in the setup and calibration of individual
sensor channels; refer to Appendix C for details.
To allow field calibration of a sensor and its corresponding signal conditioning

channel, a network of sensor bridge shunt resistors, selectable via the Front
Panel Interface or the User Access Program, is available. A Calibration Target
Load entered via the Front Panel Interface (FPI) defines the load to be simulated
by the application of a selected shunt resistor. This in turn defines the
measurement Full Scale Input. A Calibration Target Load is used to establish the
channel input working range when the Configuration function is initiated.
Configuration
The Configuration function uses data input by the user for each channel to:
a) Establish the input working range to ensure the best measurement
resolution while providing adequate zero compensation and over range.
b) Correct for any tare load not included in the measurement range.
c) Establish a measurement zero reference.
d) Set the channel fine gain in accordance with the load cell calibration data.
The Configuration function must be applied before the channels can be

considered operational. Configuration can be initiated via the Front Panel
Interface, the User Access Program, Modbus/TCP interface or the optional
Profibus or PROFINET modules.
2.3.3 Zero Adjustment

The Zero function compensates for small changes in tare weight, without
affecting other measuring system settings. User initiated, it adjusts the fine
offsets to set both channel outputs to zero and indicates if a detected offset falls
outside a range of 20% of the defined channel input range.
Zero adjustment can be made via the Front Panel Interface, the Logic Input, the
User Access Program, Modbus/TCP interface or the optional Profibus module.
July 2018 6
2.3.4 Analog Data Outputs for Control Purposes
Two programmable, group isolated analog outputs are provided which can be
configured for either current or voltage mode. These outputs can be user-
programmed to represent either the loads of the two individual sensors or the
sum and difference of the two sensors (i.e. either as A and B or A+B, A-B). Each
output can be scaled to represent a user selected percentage of Full Scale Input
defined by the calibration parameters.
2.3.5 Digital Data Outputs for Control Purposes

Digital data output for control is available through the on-board Ethernet
connection (Modbus/TCP) or any of the optional Fieldbus modules for Profibus or
PROFINET.
2.3.6 System Setup, Monitoring and Diagnostics

The Front Panel Interface (FPI) and/or a PC using the KELK supplied User
Access Program (UAP) can be used to setup the amplifier and monitor its
operation. The UAP provides extended configuration access and troubleshooting
tools. The FPI and the UAP both use simple menu structures for system setup
and configuration. The UAP utilizes the GPA2 module serial port that provides
an RS232/RS485 serial communications link.
Internal routines monitor the measuring system performance continuously during

on-line operation. System status is provided:
 For operational purposes, by the logic outputs, and through the user and
communications interfaces as described in Part 7.
 For troubleshooting purposes, through the user and communications
interfaces as described in Part 7.

July 2018 7
2.4 Interfaces
The interfaces, and their functions, are listed in Table 2-1.
Interface
Serial Communications
User Access Program
Front Panel Interface

Analog Outputs
Logic Outputs
Sensor Ports
Logic Inputs
Fieldbus 1
Function
Inputs
Sensors x
Load Outputs (for control) x x
Load Alarm Indication x x x x
Operations
Load Monitoring and Display x x x x
Status Indication - System Healthy x x x x
Status Indication - Channel A Fault x x x
Status Indication - Channel B Fault x x x
Status Indication - Single Sensor Operation x x x
Single Sensor Operation Function x x x x
2
Zero Function x x x x x
Configuration (span and zero reference) x x x x 2
Diagnostics
System Status x x x x
Calibration Data x
Load Simulation x x
Hardware and Firmware Data x
Table 2-1 Functions and Interfaces
1
Accurate for the following GPA2 Fieldbus interfaces Modbus, Profibus, PROFINET
2
Factory enabled, access may be disabled by User Access Program

July 2018 8
2.4.1 Sensor Ports

The sensor Ports connect directly to the GPA2 module, which provides sensor
excitation, signal amplification and conditioning, and analog-to-digital (A/D)
conversion.
2.4.2 Analog Ouputs

There are two groups of isolated analog outputs, which can be independently
configured as follows:
Output 1 and 2 to represent a percentage of individual loads, Channel A and

B, programmable as either 0-10 VDC or 4-20 mA
or
Output 1 as a percentage of the sum of the two channels (A+B)

(programmable as either 0-10VDC or 4-20 mA), and Output 2 as a defined
percentage difference of the two channels (programmable as either ±10 VDC
or 4-12-20 mA).
Note that only the UAP, not the FPI, can be used to select between current or
voltage outputs. However, another option is for the output type to be specified at
the time of order via the model number choice. As such, the GPA2 main module
will be programmed accordingly at KELK (see Section 0).
2.4.3 Logic Inputs

One active logic input is provided for remote activation of the Zero function.
The Zero function is applied simultaneously to both input channels and is initiated
by the rising edge of a customer supplied voltage (see Section 9.4).
2.4.4 Logic Outputs

There are two logic outputs provided (refer to Section 9.5):
 One Form A relay indicates that a user defined load (Sum of both channels)
has been exceeded. The relay changes state from open to close when the
threshold is exceeded.
 One Form C relay to indicate ‘System Healthy’ as determined by the GPA2
internal diagnostics routines.

July 2018 9
2.4.5 Fieldbus Interface
The Fieldbus interfaces available are: Ethernet (Modbus/TCP), Profibus or
PROFINET. These interfaces:
 Provide access to the load measurement set at a rate suitable for mill control.
 Provide access for monitoring and controlling unit operation.
The Ethernet (Modbus/TCP) is described in Section 5.6, and the Profibus DP

Interface is described in Appendix D and PROFINET is described in Appendix
E.
2.4.6 Serial Communications Interface

The Serial Communications Interface provides access for setup, monitoring, and
control.
There are two serial communications modes available: RS232 and RS485.
The load data output over this interface are intended for data logging and
monitoring purposes only. For mill control, the Fieldbus Interface is
recommended.
The Serial Communications Interface is described in Section 5.5.
See Section 3.7 for connection details.
2.4.7 Front Panel Interface

The Front Panel Interface (FPI) provides access for system setup, monitoring
and control. It comprises an alphanumeric display, keypad, and status indicators.
It is described in Section 4.3.
2.4.8 User Access Program

The User Access Program (UAP) is provided to allow the user greater access to
the unit configuration, to facilitate setup, and for monitoring and diagnostic
purposes. Refer to Appendix B for details.

July 2018 10
KELK Installation
Part 3 Installation
3.1 Introduction
KELK load measuring systems are designed, and have been proven over many
years, to provide excellent performance in the demanding environments of the
metals industry. However, to achieve their full potential for high accuracy and
long service life, they must be properly installed.
Following installation, the system must be set up and configured before being
placed in online service (see Part 5: Setup and Configuration).
Caution
If the system is not properly set up and configured, the digital and
! analog outputs, and the load alarm are unpredictable and their use
for control purposes may cause the production of off-specification
product or equipment damage.
The General Purpose Amplifier, Model GPA2 must be installed:
 In an operating environment with the characteristics specified in Section 9.13.

 If mounted in a cabinet or other enclosed space, ensure that the temperature
adjacent to the GPA2 enclosure does not exceed 55 oC (131 oF) and provide
adequate clearance for airflow.
 At a minimum of 75 mm (3 in.) above heat generating equipment
 Such that the amplifier modules, the cabinet in which they are installed and all
connecting wiring must be installed in compliance with all applicable codes,
regulations and standards.
3.2 Enclosures
The GPA2 is normally supplied with a NEMA 12 enclosure as shown in Figure

3.1. See Section 9.12 for dimensional details. Terminals for AC line connection
and a circuit breaker acting as a power ON/OFF switch are included in the
enclosure. If modules are purchased without an enclosure, the user is
responsible for all power and signal connections.

July 2018 11
KELK Installation
In any industrial environment it is always recommended that the GPA2 main

module and power supply be mounted in a suitable sealed enclosure or cabinet.
When installing a GPA2 enclosure:
 Secure to a wall or other supporting structure. KELK Enclosures (‘12’, ‘4X’)

are supplied with four mounting flanges; refer to Section 9.14 for holes sizes.
 Provide sufficient clearance for the door to open. A standard KELK enclosure
cover opens 180° to allow access for service.
All conduit entries should be caulked to prevent dust from entering the enclosure.
Figure 3-1 GPA2 Enclosure
3.3 AC Power Wiring
The AC power required is specified in Section 9.13. The power supply module
adjusts automatically to the voltage range, typically 120 or 240 VAC, to which it is
connected. It must be properly grounded.
Figure 3-2 shows the complete main module connection wiring.

Figure 3-3 illustrates the recommended wiring within the enclosure.

July 2018 12
KELK Installation
Figure 3-2 GPA2 Wiring

July 2018 13
KELK Installation
Figure 3-3 Main Module Connections

July 2018 14
KELK Installation
3.4 Sensor Wiring
The amplifier enclosure can be mounted close to the measurement location

provided that the environment is within the parameters provided in Section 9.13.
In such cases the sensor cables can be terminated directly at the GPA2 main
module inside the enclosure.
For more remote locations it is recommended to terminate the sensor cables in a

vapor proof junction box and to complete the connection to the main module via
a suitable interconnection cable run either in conduit or signal wiring trays (see
cable specification later in this section).
For a new measuring system, recommended wiring practices and instructions are
included in the documentation supplied with the system.
For existing systems, it is strongly recommended that the sensor wiring be

checked against KELK recommendations and serviced, if necessary, to ensure
optimum system performance.
Sensor wiring must be rated for at least 300V. Terminations must be clean so as
not to introduce contact resistance or leakage to ground. Cables must be routed
to avoid exposure to power cables and other potential sources of electromagnetic
interference. Good wiring practices and a dry environment are essential. Typical
sensor wiring is shown in Figure 3-2 and the connections in Figure 3-3;
connector pin-outs are listed in Table 3-1.
GPA2 CONNECTOR-PIN SIGNAL

 (5) Sensor A Shield
S- (4) Sensor A -Signal
SENSOR A S+ (3) Sensor A +Signal
INPUT E- (2) Sensor A -Excitation
E+ (1) Sensor A +Excitation
 (5) Sensor B Shield
S- (4) Sensor B -Signal
SENSOR B S+ (3) SensorB +Signal
INPUT E- (2) Sensor B -Excitation
E+ (1) Sensor B +Excitation
Table 3-1 Sensor Connectors

July 2018 15
KELK Installation
When installing, note the following:

1. The sensor cable hose assemblies must be free of damage and kinks.
2. If the GPA2 is remote from the sensor installation then a junction box and
interconnecting cable are to be used. Note the following:
 The junction box must be vapor proof. The junction box should be
mounted on a vertical surface, with the sensor cable/hose entries at
the bottom, in a location that precludes the accumulation of fluids and
provides good accessibility.
 Periodically, open the junction box and inspect all connections.
Replace all dirty and corroded terminal blocks and lugs. Ensure that
the box and all internal components are dry. If moisture is seen or
suspected, dry with alcohol.
 Ensure that the cable shields are electrically isolated from the box
ground. Ensure that there are no frayed wires to cause momentary
shorts to ground.
 Check the cable entry points; reseal, if necessary.
 When replacing the junction box cover, ensure that the gasket is
properly positioned. Tighten the bolts sequentially, in two steps
(snug, then tight) to prevent distortion or damage of the cover and
gasket.
3. Check the wiring from the junction box to the Main Module:
 The minimum wire gage must be:
18 AWG (1.0mm2) for up to 90m (300 ft) runs,

16 AWG (1.5mm2) for up to 150m (500 ft) runs,
14 AWG (2.5mm2) for up to 240m (800 ft) runs.
 A four conductor twisted (in pairs or all together) shielded cable, with
insulating jacket is recommended; 16 AWG (1.5mm2) cable is available
from KELK, Part Number 28280.
 The preferred routing is through metal conduit. However, the cable
may, after leaving the junction box in a conduit, be run in low signal
cable trays. When run parallel to heavy power cables, a minimum
separation of 1 m (3.3 ft) is required for runs of up to 30 m (100 ft). For
longer runs, a minimum separation of 2 m (6.6 ft) is required.
4. With the interconnecting cable not connected to the main module, check
the sensor and interconnecting cable wiring for:
 Continuity. Using an Ohmmeter with a resolution of 0.1 Ohm, measure
the input resistance between the green and black conductors and the
output resistance between the red and white conductors. The
measured values should be within 1 Ohm of those given on the
July 2018 16
KELK Installation
calibration card supplied with the sensor, plus the resistance of the
interconnecting cable.
The resistance of the interconnecting cable can be determined by

direct measurement or from:
Wire Gage Resistance - each conductor

14 AWG (2.5mm2) 0.0084 Ohm/m (0.0026 Ohm/ft.)
16 AWG (1.5mm2) 0.0133 Ohm/m (0.0041 Ohm/ft.)
18 AWG (1.0mm2) 0.0209 Ohm/m (0.0064 Ohm/ft.)
 Leakage Resistance:
Measure leakage resistance between any conductor and the cable
shield, between any conductor and ground, and between the cable
shield and ground. The result should be greater than 100 M in each
case.
Caution
! Do not use an insulation tester with test voltages in excess of 50V.

Higher voltages may damage the sensor.
If any problems are encountered, test the interconnecting and sensor

cables (see Section 7.5).
3.5 Analog Output Wiring
The Main Module provides two analog outputs, Out1 and Out2 that can be
connected for voltage or current; both are shown in Figure 3.4. An output must
not be connected for both current and voltage at the same time. Outputs
are to be connected in accordance with the mode selection made, as described
in Appendix B, or as defined by the model number ordered (refer to the model
numbering scheme in Appendix A). Connector pinouts are listed in Table 3-2.
Connecting cables must be rated for at least 300V.

July 2018 17
KELK Installation
The following cables, or their equivalents, are recommended:

 2 channels: Belden 8723, 22 AWG. 2 twisted pairs, individually shielded
OR
 2 x 1 channel: Belden 9451, 22 AWG. 1 twisted pair, shielded.
Figure 3-4 Analog Output Circuit
GPA2 CONNECTOR-PIN SIGNAL

COM C (pin6) Return 2
OUT2 I (pin 5) Current Out 2
OUT2 V (pin 4) Voltage Out 2
COM C (pin 3) Return 1
OUT1 I (pin 2) Current Out 1
OUT1 V (pin 1) Voltage Out 1
Table 3-2 Analog Output Connector

July 2018 18
KELK Installation
3.6 Logic I/O Wiring
Logic I/O connections are illustrated in Figure 3-3.
Connections include:
Input: Zero function input; see Figure 3-5
Outputs: System Healthy relay; see Figure 3-6
Load Level Relay; see Figure 3-6
Connecting cables must be rated for at least 300V. The following cable, or its
equivalent is recommended:
 4 x 1 channel: Belden 9501, 24 AWG. 1 twisted pair, shielded.
NOTE: 24 AWG is equivalent to 0.21-0.24 mm2.
For the logic input, a user supplied voltage of 10-24 VDC and contact closure, or
equivalent, is required.
NOTE: System Healthy relay is de-energized for a fault condition.
Figure 3-5 Zero Function Input Circuit

July 2018 19
KELK Installation
Figure 3-6 System Healthy and Load Level Relay Circuits

July 2018 20
KELK Installation
3.7 Serial Communications Wiring
The serial communications wiring is shown in Figure 3-7 and Figure 3-8.
The COM1 connector pinouts are listed in Table 3-3.
Figure 3-7 Serial Communications Connections for RS232
Figure 3-8 Serial Communications Connections for RS485

July 2018 21
KELK Installation
GPA2 SIGNAL
CONNECTO
R-PIN RS232 RS485
1 No Connection No Connection
2 TXD -TXD
3 RXD -RXD
5 Serial Common Serial Common
7 No Connection +RXD
8 No Connection +TXD
Table 3-3 Com 1 Pin Assignments
3.8 Ethernet Wiring
Connect the CAT5 Ethernet network cable to the RJ45 connector on top of the
GPA2 module.
3.9 Profibus Wiring
Refer to Appendix D for Profibus wiring.
3.10 PROFINET Wiring
Refer to Appendix E for PROFINET wiring.
3.11 Ferrite Chokes Installation
Upon completing the connections to GPA2 main module, place one ferrite choke
across each of the following cables: Sensor Inputs A&B, Analog Output, and
Ethernet (if this function is available). The ferrite chokes can be found in a
ziplock bag inside GPA2 enclosure.
Refer to Figure 3-9: Ferrite Chokes Installation, for details on applying the ferrite
chokes.

July 2018 22
KELK Installation
Figure 3-9: Ferrite Chokes Installation

July 2018 23
KELK User Interfaces
Part 4 User Interfaces
4.1 Introduction
The GPA2 has two user interfaces used to set up the load, tension, or pressure
measuring system:
 The User Access Program (UAP)
 The Front Panel Interface (FPI)
The GPA2 module can be set up, configured and monitored using either the FPI
or the UAP.
The UAP provides full access to all functions and parameters.
The FPI provides limited access and is used primarily for load cell input
configuration and monitoring.
4.2 User Access Program
The User Access Program (UAP) is a software application for use with any PC
operating in a Windows environment. It communicates with the GPA2 via the
serial port of the main module. The UAP, together with a copy of the GPA2-E
User’s Manual in PDF format, is supplied on the Load Cell Electronics Utilities
CD.
Features
The UAP permits the setup of:

a) Input channels
b) Output channels
c) Load alarm
d) Filtering
e) Communications
f) FPI Zero and CFG accessibility

July 2018 24
The UAP has the following features:

 A full screen to monitor the load outputs from each channel and to determine
the status of the system.
 A full diagnostics screen to provide the user with readout of the system status
plus an indication of any faults detected.
 The program uses standard conventions and menu structure for its operation.
Each screen is self-explanatory. Areas on any screen not available to the
user are shown in gray. Edited data is displayed with a yellow background
until the “Apply to GPA2” button is clicked in the ‘CONFIGURE AND SET’
screen.
 When the computer is connected to a GPA2 via the serial connection, UAP
automatically assesses the setup and channel configuration.
 An existing setup and channel configuration can be read back from a
connected unit.
 A new or revised setup and channel configuration can be downloaded to a
connected unit.
 The UAP provides additional user access not provided by the FPI.
 On-screen help and access to this manual is available.
Refer to Appendix B for full details.
4.3 Front Panel Interface
The FPI comprises an alphanumeric display, LED indicators and keypad as

shown in Figure 4-1. It is used primarily for the display of active loads and
system status, and for the implementation of operational functions including
Configuration and Zero.
Figure 4-1 Front Panel Interface

July 2018 25
Navigation via the FPI is accomplished using a structured menu. The FPI menu
is divided into two loops; the Function Setup Loop and the Operation Loop, as
shown in Figure 4-2.
The Function Setup Loop displays the current setup of the unit as shown in
Figure 4.3. This loop allows these setting changes: Filter, Modbus address
(same as Serial Communication Address), and Modbus mode. All other settings
can be as supplied from the factory or as set by the user via the UAP (refer to
Appendix A: GPA2 Model Numbering Scheme).
The Operation Loop (Figure 4-4) is used to define the operational mode of the
unit, to display load data and status information, and for the input and selection of
the sensor Calibration Target Load and shunt resistor values, respectively.

July 2018 26
Figure 4-2 FPI Menu

July 2018 27
Figure 4-3 Function Setup Loop

July 2018 28
Figure 4-4 Operation Loop

July 2018 29
The FPI is also used for the following operation functions:

Selection of sensor operation mode, normal A & B, Single sensor 2xA or 2xB
Channel Configuration
Channel Zero
Load Simulation
The keypad contains eight input keys and they have the following functions:
Navigation of the menu structure

In edit mode: select a parameter value or press and
hold key to accelerate increment or decrement of a value
Navigate the menu structure laterally

In operation loop, switch between A and B value
To enter and exit Edit mode
Load simulation by shunt resistor (ON/OFF)

This also serves as a calibration check
Initiate the Zero function. Zero both A and B channels
Initiate the Configuration function. Establish zero reference,

set span and calibrate both A and B channels.

July 2018 30
4.4 Changing the Communication Mode
The GPA2 main module is equipped with a serial port for communication with a
PC or PLC in one of two modes: RS232 or RS485. The factory default is RS232.
RS485 is used when it is desired to have multiple main modules connected to the
PC at the same time. To change the mode of operation for communication port:
1. Make sure that FPI is in Function Setup Loop by pressing the SET A or SET
B button (Figure 4-3).
2. Use the  or  key to go down or up the Function Setup loop until the
Modbus Mode setting is displayed as shown in Figure 4-5.
3. To enter edit mode, press the SET A and SET B keys at the same time. Note
that in edit mode, the setting is blinking.
Figure 4-5 Modbus Mode Setting
4. Use the  or  key to select the applicable setting (RS485 or RS232).

5. To exit edit mode, press the SET A and SET B keys at the same time again.
6. To return to the main KELK GPA2 display, press the SET A or SET B key.
Note that the mode change takes effect immediately and does not requires
power cycling.

July 2018 31
KELK Setup and Configuration
Part 5 Setup and Configuration
5.1 Introduction
Prior to operating the tension, load, or pressure measuring system, the GPA2
and sensors must be correctly set up and configured to provide accurate
measurement data in the required format.
All GPA2 Modules are supplied with factory default settings or in accordance with
customer specifications at the time of order. The user is directed to Appendix A
for the full range of options available.
A clear understanding of the effects of configuration, calibration, scaling and

signal filtering on the digital and analog outputs and the load alarm is essential
for a properly functioning system.
Read Section 5.3: Setup and Section 5.4: Configuration of Input Channels,
before attempting setup and configuration.
5.2 Checks Prior to Power-Up
Before turning on the GPA2, check that:
 The sensors and wiring are properly installed and connected to the correct
sensor ports
 All analog outputs are correctly connected to the appropriate current or
voltage terminals
 Logic I/O, and Fieldbus cables are correctly installed
 Any equipment in the mill that responds automatically to the outputs is not
active.
Caution
Prior to and during setup and configuration, the Digital and

Analog Outputs and the Load Alarms are unpredictable. Ensure
that they are not connected to any active mill control system as
this may cause the production of off-specification product or mill
damage.

July 2018 32
5.3 Setup
The GPA2 setup defines the functionality of the unit. The user is advised to
check the settings of the GPA2 module, described in the following sections, prior
to system calibration. They can be checked using the Front Panel Interface or
checked and modified as required via the User Access Program. Instructions for
using these interfaces are provided in Part 4: User Interfaces.
To use the FPI, refer to Section 4.3, Figure 4-3 and Figure 4-4.
To use the UAP, refer to Section 4.2, Appendix B, and Section B.6.2.2: Setup.
Refer to Appendix A, for details of the model numbering scheme as it relates to

the setup.
5.3.1 Excitation Voltage
Two factory-set excitation voltage options, 10 VDC and 20 VDC, are available for
the GPA2 main module. The standard is 10 VDC, whereas 20 VDC is a
customized excitation used in cases when a load cell is designed to have a lower
output for a given application (in most cases, a tensiometer application). GPA2
modules with the 20 VDC option must only be used for applications that require
this higher level of excitation. After powering up the GPA2, measure the
excitation voltage at terminals E+ and E- of sensor inputs A and B to ensure it is
correct for the application.
NOTE:
The GPA2 20 VDC excitation option is for designated applications only.
It must not be connected to load cells with strain gage bridges under 350.
If it is necessary to change the excitation level, please contact KELK for

instructions.

July 2018 33
5.3.2 Analog Outputs and Scaling
A full description of the Analog Outputs is given in Section 2.4.2.
Setup of the analog outputs includes:
 Selection of the data source for each output: A, B, A+B, or A-B.

 Selection of output mode: Current 4-20 mA, or 4-12-20 mA,
Voltage 0-10V or +/- 10V
 Selection of scaling: percentage of the full scale input represented by the full
scale output (which is +10V or 20 mA, depending on output mode selected
above); user can select from:
5, 10, 20, 25, 40, 50, 100, or 200 % of Full Scale (FS) input.
Default settings:
Data Source: Output 1=‘A’, Output 2=‘B’
Output Mode: 0-10V
Scaling: 100%
5.3.3 Load Alarm Source and Threshold

One logic output is assigned as a load alarm. The data source is fixed as A+B,
the sum of both input channels.
Although the data source cannot be changed, the user can select the threshold
at which the alarm is asserted. The threshold is expressed as a percentage of
A+B in a range from 1-327%. The user is advised to choose a value within the
defined working range (see section 5.4.2). The recommended range is 1-110%.
Default setting:
Threshold 100%
5.3.4 Signal Filtering
The amplifier has both fixed and user-selectable filtering available. Fixed anti-
aliasing input filtering, with a cut off frequency of 2.8 kHz, is applied to each input
signal to ensure signal quality. The input signal is sampled at a rate of 78.125
kHz and processed at 9.765 kHz. In addition, there is an analog output
smoothing filter with a bandwidth of approximately 1.5 kHz.

July 2018 34
A further filtering option is available to the user by the application of a running

average filter after the signal is transferred to the digital domain. The user may
select a filter coefficient in the following frequencies:
700 Hz, 300 Hz, 150 Hz, 75 Hz, 40 Hz, 20 Hz, 10 Hz, 5 Hz
Default setting:
Cut off frequency: 10 Hz
This coefficient sets the number of samples to be averaged prior to the

application of offset and gain adjustments and the subsequent formulation of
values to be transferred to the measurement set; A, B, A+B and A-B. Figure 5-1,
shows a filter response with all available settings of the filter, from 0 to 7, where:
0  700 Hz
1  300 Hz
2  150 Hz
3  75 Hz
4  40 Hz
5  20 Hz
6  10 Hz
7  5 Hz
Figure 5-1 Digital Filter Response

July 2018 35
The time response for a step rise to 98% of the full scale input with the selected
filter is given by the following formula:
Trise98%  0.74  2FilterCoeff.  0.82 [ms]
This filter signals the source data for the analog outputs and load alarm relay.
5.3.5 Communication
The factory default address for serial communication is 15. The GPA2 FPI
displays the address in decimal format. The address can be changed to any
integer value in the range of 1-15 using the FPI or UAP. The new address does
not become active until the GPA2 is reset (power OFF then ON).
Important to note is that if using either the Profibus or PROFINET fieldbus

interfaces for communication, the address must remain as 15. The baud rate is
not configurable, fixed at 19200 baud, no parity, 8 bits of data, with one stop bit.
The user must select to use either an RS232 or RS485 protocol; see section 4.4
for details to change the communication mode.

July 2018 36
5.4 Configuration of Input Channels
5.4.1 Sensor Calibration Data

Each sensor is calibrated against a high precision, traceable standard at KELK.
A sensor is placed under load, ranging from zero to full scale load (sensor
capacity) while the sensor output is measured. Then, with no load applied, a
high accuracy shunt resistor is temporarily placed across one arm of the sensor’s
strain gage bridge to force an output, thereby simulating a load on the sensor.
For sensors used in force and pressure applications, the ratio of this forced
output to the full load output is referred to as a Calibration Target Load (CTL),
and is in the range 20.1 to 150.0. The user must program this value into the
GPA2, which uses it to calibrate the force or pressure measuring system onsite.
The CTL, along with the value of the calibration shunt resistor, appears on the
sensor calibration card, which is attached to the sensor when shipped. A
complete list of information appearing on the calibration card appears below.
Each sensor is supplied with a calibration card (see Appendix C, Figure C-1)
listing:
 Model number
 Serial number
 Bridge number (where applicable)
 Sensor capacity
 Sensitivity - sensor output, in millivolts per volt of applied excitation, at
sensor capacity
 The value of the shunt resistor
 Output with shunt resistor, in millivolts per volt
 Calibration Target Load
 Input resistance
 Output resistance
In tension measuring systems, the CTL is not based solely on the sensor output
from a directly applied load, as is the case for the force and pressure sensors
previously described. This is because the magnitude of the load applied to the
sensor is dependent on strip tension and the angles at which the strip
approaches and leaves the tensiometer roll. These ‘wrap angles’ must be
accurately known as they are factored into the calibration of the system. KELK
uses the user-defined wrap angles and the geometry of the tensiometer
assembly, in addition to the output measured during the sensor factory
calibration, to compute a Calibration Target Load for the tensiometer.

July 2018 37
In addition, the shunt resistor used for system calibration is referred to as the
application shunt resistor, and may be different from the shunt resistor used
during factory calibration of the sensor.
The application shunt resistor value and the tension measurement CTL are listed
in a separate Tensiometer Calibration Data Sheet, Form 855, supplied with each
tensiometer (refer to Appendix C). Individual sensor calibration cards, as
described above, are also supplied with the tensiometer. Typically, such systems
are calibrated such that Full Scale Input for each channel represents 100% of the
user-defined rated tension, not the sensor capacity.
Caution
If a tensiometer is operated in a geometry different from that

specified on the Calibration Data Sheet, the Digital and Analog
Outputs and the Load Alarms will be unpredictable and use of
the system for mill control purposes may cause the production
of off-specification product or mill damage.
The shunt resistor value and Calibration Target Load (from the calibration cards
for roll force, pressure and load measuring applications, and from the Calibration
Data Sheets for tension measuring applications) must be entered into the GPA2
prior to system calibration (for reference, the factory default setting for the shunt
resistor is 300 K, while the Calibration Target Load default is 99.9). The user-
selectable shunt resistor values are in a range between 50 and 800 K, in 50 K
steps. Both the resistor and the CTL can be entered via the FPI or the UAP;
refer to Figure 4.4 or Appendix B, respectively. Using the UAP simplifies the
correction of the CTL if long interconnecting cables are used (refer to Appendix
B).
After entering the resistor and CTL values, the user must initiate the
Configuration function, causing the GPA2 to compute and set the tare correction,
offset, and the analog and fine gains for the sensor signals, thereby providing a
calibrated output for the force, tension, or pressure measuring system. It is
important that there is no active load (besides the tare load) on the sensor prior
to applying the Configuration function.
Caution
If Configuration is not performed after parameter change, the measuring system
is not calibrated. The Digital and Analog Outputs and the Load Alarms are
unpredictable and use of the system for mill control purposes may cause the
production of off-specification product or mill damage.

July 2018 38
This procedure must also be invoked whenever changes are made to the shunt
resistor value or the Calibration Target Load, or if a sensor has been replaced.
After performing the Configuration function, it is advised that the system be

checked for correct operation by measuring the analog outputs with the Test
function invoked. This Test function involves the application of the shunt resistor
to produce the analog outputs corresponding to the CTL. For more details, see
Section 6.7.
A number of internal operations are performed by the GPA2 when the

Configuration function is initiated. The following section describes these
operations, specifically the adjustment of Analog-to-Digital conversion
parameters for the sensor input signals.
5.4.2 Analog-to-Digital Conversion (ADC) of Input Signals
Tare Correction
In many applications, there is force applied to the sensor that the user does not
want to measure. One example is the weight of ancillary equipment supported
by the sensor. It is advantageous to cancel out the sensor offsets caused by
such static loads to maximize the system measurement range. This is referred to
as ‘correction’ and uses the same principle as the shunt resistor to create an
opposing offset.
During the GPA2 Configuration function, a resistor network automatically applies

different magnitudes of resistance to one arm of the load cell bridge to find the
resistor setting that corrects the tare load. Which arm of the bridge that the
GPA2 applies the resistor to depends on the polarity of the offset. In this manner,
both negative and positive offsets can be corrected. Application of tare
correction is used to bring the input signal to the correct level relative to an
Analog-to-Digital (ADC) center point in order to maximize ADC utilization. After
application of tare correction, any remaining zero offset is corrected by software.
Additional information on the optimization of the ADC working range is provided
in the following section.
Working Range Definition

As previously mentioned, the signal inputs to the GPA2 are analog. The signals
are amplified and fed to an Analog-to-Digital Converter (ADC) for transfer to the
digital domain. The ADC has a defined range, which is to be utilized for the
active input, plus over range, plus zero correction allowance and a safety margin.
The objective is to maximize the utilization of the ADC to provide optimum output
resolution without saturation.

July 2018 39
The ADC utilization is organized such that there is a working range that is defined
for both the positive and negative directions from a zero reference point:
In the positive direction:

 Full scale input, FSI (or CTL, whichever is greater) + 10% for
analog output dynamic over range +
 20% zero adjustment + 5 % safety margin
In the negative direction:

 Zero (offset) reference+ 20% zero adjustment + 5% safety
margin.
32767 MAX MAX
135% or CTL+25%
whichever is greater
10%+20%+5%
100% 100%
WORKING RANGE:
+20%+5%
GAIN < 65280
Working range
MAX > 135% (100% +10% + 20%+ 5%= 135%) shunt CTL
MAX > CTL + 25% (20%+ 5%= 25%)
MIN < -25% (-20% - 5%= -25%)
0
Where:
GAIN = CTL/(shunt - offset)*32768
MAX = 32767 * GAIN - offset
MIN =-32768 * GAIN - offset
+10% - analog output dynamic range offset 0% 0%
±20% - zero allowance
± 5% - overhead -20%-5%
- 25%
-32768 MIN MIN
Figure 5-2 Working Range Definition

July 2018 40
NOTE:
The safety margin and zero allowances are in % of FSI, therefore, the selection
of hardware gain and the setting of tare correction have a significant impact on
the ADC utilization. The working range relative to the ADC range is illustrated in
Figure 5-2.
The GPA2 determines the practical ADC working range by stepping through eight
hardware gain selections, starting with maximum gain. The largest gain that
produces a working range within the limits described above is deemed the
optimal gain and is used by the GPA2 for application to the input signals. If even
the minimum available gain setting does not produce a working range within the
above limits, the minimum gain is still applied by the GPA2, however, part of the
working range will be truncated.
5.5 Serial Communications Interface Connection and Setup
The Serial Communications Interface (SCI) can be used to monitor and control
the General Purpose Amplifier, model GPA2.
Caution
Load measurement data accessed through the Serial Communications Interface
are intended for monitoring purposes only. For process control, there is a
dedicated serial port is used to transfer data over an external communicator to
Ethernet, Profibus or PROFINET Fieldbus Interfaces.
5.5.1 Setup and Configuration

Connect the GPA2 to the control computer, Section 3.7. All GPA2’s employed in
a system can be connected in parallel, in RS485 mode, to the computer.
To configure the GPA2 for serial communication, make sure that:

 Set the communication mode to RS232 or RS485 in accordance with the
procedure in Section 4.4.
 Address in the range 1 to 15, with factory default set at 15. When configured
over SCI, the Slave Address does not become active until the GPA2 ‘power
ON ‘ is reset.
 Bit Rate (not configurable) is fixed at 19200 baud, no parity, 8 bits of data,
one stop bit data.

July 2018 41
5.5.2 Processing and Configuration

The Modbus communications protocol (PI-MBUS-300 Rev.J, Modicon Modbus
Protocol Reference Guide, Modicon Inc., June 1996) is used for data exchange
on the SCI. This section describes its implementation; many of the terms used
are drawn from the Modbus specification.
The SCI interface functions as a Modbus slave device. Once the SCI is
configured, it waits for a query (message) from a Modbus master. The GPA2
processes the request and, if required, returns an appropriate response. While
processing a query, the GPA2 ignores any new query.
If RS485 mode has been selected, the GPA2 normally configures the port
hardware for receive, switching to the transmission configuration only when
sending a response.
The GPA2 supports the remote terminal unit (RTU) serial transmission mode of
the Modbus protocol only. The GPA2 always requires a ‘silent time’ of at least 3.5
character times as an indication of the end of a query. Characters received with
less than this time separating them will be deemed part of a single query.
Only queries containing 25 characters (10 registers) or less are supported. Any
query longer than this is ignored.
Characters that have a framing error are ignored. This will typically cause any
associated query to be rejected (as missing characters will normally cause the
CRC validation check to fail).
The table of Modbus registers is given in Section 0.
The following function codes are supported:
Value Name Notes

(Hex)
3 Read Holding Registers Used to read up to ten (10) (contiguous) registers.
Equivalent to the “Read Input Registers” function code.
4 Read Input Registers Used to read up to ten (10) (contiguous) registers.
Equivalent to the “Read Holding Registers” function code.
6 Preset Single Register Used to write a single register. The value written becomes
effective immediately.
Table 5-1 Serial Communication Function Codes
Write errors generally result in the return of an exception response.

July 2018 42
Caution
Reads of undocumented registers will return indeterminate
values. Writing to undocumented registers may cause the
Digital and Analog Outputs and the Load Alarms to be
unpredictable and use of the system for mill control purposes
may cause the production of off-specification product or mill
damage.
NOTE
During certain IO functions such as pressing a key on the FPI or
requesting remote Zero, all read/write operations to Modbus
registers are delayed for 200 ms.
The following is an example of the use of the ‘read holding registers’ function to
read Load and/or Load Alarm. Note that these parameters have been grouped in
the memory map (Table 5-5) so that data for both sensors may be obtained with
a single command.
Value Field Name Notes

(Hex)
03 Slave Address
03 Function Code Using the “Read Input Registers” function code would yield
identical results
00 Starting Address Hi Starting address = 0000 Hex
00 Starting Address Lo
00 Number of Points Hi Number of points = 0002 Hex
02 Number of Points Lo
C5 CRC Lo
E9 CRC Hi
Table 5-2 Read Holding Register Master Query

July 2018 43
Value Field Name Notes

(Hex)
03 Slave Address Echo of query
03 Function Code Echo of query
04 Byte Count Number of (data) bytes that follow
27 Data Hi (Register Load (Percentage) = 2710 (Hex) = 10000 = 100.00%
0000)
10 Data Lo (Register
0000)
27 Data Hi (Register Load (Percentage) = 2710 (Hex) = 10000 = 100.00%
0001)
10 Data Lo (Register
0001)
C8 CRC Lo
BE CRC Hi
Table 5-3 GPA2 Response
5.5.3 Measurement Data
The Measurement data available are loads A, B, A+B, A-B.
Resolution is 10000 counts for full scale reading.
The maximum available data range is ±327.67% (±32767 counts).
Measurement data saturation will be indicated by ±327.67% reading only.

July 2018 44
5.5.4 Communications
5.5.4.1 Data Formats

The following table defines the formats of data that have been reconstructed after
transmission.
Name Description Detail
Signed Integer Types

16I2 16 bit, signed integer, two decimal digits Example -123.45 stored as -12345
Bitmapped Types
Bit 4 - System Healthy
Bit 5 - Load Level Alarm
4B0 Relay outputs (status and alarm)
Bit 6 - Output Spare 1
Bit 7 - Output Spare 2
Bit 0 - Input Spare 1
3B1 Logic Inputs Bit 1 - Input Spare 2
Bit 2 - Remote Zero
Bit 1 - B Fault
4B2 System Status
Bit 2 - A Fault
Bit 3 - Single Sensor
Bit 0 - Channel B: Shunt or FS out of range
Bit 1 - Channel B: Zero out of range
Bit 2 - Channel B: Gain out of range
Bit 3 - Channel B: Zero out of margin
Bit 4 - Channel B: Saturation +/-
Bit 5 - Channel B: Excitation current overload
Bit 6 - Channel B: Single Sensor Operation
(Double A)
Bit 7 - Channel B: Simulation
16B3 Channel A&B Measurement Status
Bit 8 - Channel A: Shunt or FS out of range
Bit 9 - Channel A: Zero out of range
Bit 10 - Channel A: Gain out of range
Bit 11 - Channel A: Zero out of margin
Bit 12 - Channel A: Saturation +/-
Bit 13 - Channel A: Excitation current overload
Bit 14 - Channel A: Single Sensor Operation
(Double B)
Bit 15 - Channel A: Simulation
Bit 0 - Zero
2B4 Configuration, Zero
Bit 1 - Configuration
0 - Normal operation
Bit 0 - Simulate A
4B5 Load Simulation
Bit 1 - Simulate B
Bit 2 - Shunt A
July 2018 45

Bit 3 - Shunt B
Enumerated Type
0- A &B
Single Sensor Operation (Load 1- 2*B
2E1
doubling) 2- 2*A
3- B &A
Table 5-4 Serial Communication Data Formats
Numeric values are decimal (base 10) unless stated otherwise.
For bitmapped formats, the condition is enabled (or ‘on’) when the bit is set and
disabled (or ‘off’) when the bit is clear, unless stated otherwise.
The nomenclature used for each format reflects the basic type and size (in eight-
bit bytes) of the format. The size of each format is always an integral multiple of
one byte. Regardless of their size, data are interpreted as ‘big-endian’ (i.e., the
least significant bit is bit 0 and the most significant bit is the highest-numbered bit
for the format).
For formats that do not use all of the available bits, the unused bits are ignored
by the format and are set to zero during transmission.
Format names are in the form SSS TTT AAA, where:

 SSS is the Data Size. For the GPA2, this is always 16 bits.
 TTT is the Format Type:
I - Signed Integer
U - Unsigned Integer
B - Bitmapped
 AAA is Additional Format Information
For signed/unsigned integer types, this is the number of implied decimal
digits:
0 - No decimal digits (no decimal point appears)
1 - One decimal digit (decimal point before last digit)
2 - Two decimal digits (decimal point before last two digits)
Etc.
Example: 16I2 is 16 bits, signed integer, 2 decimal points. For a bitmap, this
is a bitmap order number.

July 2018 46
5.5.4.2 GPA2 ModBUS and System Addresses

ModBUS
Min Max
Address Name Format Units
Value Value
(HEX)
Process Variables
00 Input A Load 16I2 % -327.67 327.67
01 Input B Load 16I2 % -327.67 327.67
System Status (System

02 Healthy, A&B faults, 4B2 - - -
Single Sensor)
Channels A&B
03 16B3 - - -
Measurement Status
04 Input Sum Load (A+B)/2 16I2 % -327.67 327.67
05 Input Difference Load A-B 16I2 % -327.67 327.67
Logic Inputs/Outputs
07 Relay Outputs 4B0 - - -
08 Logic Inputs 3B1 - - -
0A Configuration, Zero 2B4 - - -
Load Simulation
0B Load Simulation 4B5 - - -
0C Simulated Load Value 16I2 % -327.67 327.67
Configuration Parameters
Single Sensor Operation
0F 2E1 - - -
(Load doubling)
Serial Control Communication
22 Slave Address 4U0 - 1 15

Table 5-5 Serial Communication Memory Map
Notes:
1. The Zero and Configuration register is normally in 0 state. The Zero (1) or
Configuration (2) instruction is required to initiate a function. When the
function is complete, the register is automatically set to 0 by the GPA2.

July 2018 47
2. Sensor Input Configuration register set to value 3 will invert inputs A and B
and the ‘Single sensor operation measurement status code’ will be
triggered for both A and B channels.
5.6 Modbus/TCP Interface Connection and Setup
The Modbus/ TCP (Ethernet) Interface provides the process control computer
with access to:
 Load measurement data at the rate necessary for process control.
 System and Measurement Status.
 Monitor and control the GPA2.
The RJ45 Ethernet connector on the GPA2 allows the host computer to access
the GPA2 using the Modbus/TCP protocol.
Ethernet communication for the GPA2 has the following features:

 10/100 Mbps, automatic speed and cable detection
 Maximum two Modbus TCP/IP simultaneous connections on port 502
 Modbus UDP/IP service on port 502
 Web server page for setting the IP address and the network mask
 Default IP address is 10.37.0.2 ; default net mask: 255.255.0.0
Note: All registers are accessible through the Ethernet interfaces: Modbus
TCP/UDP. Maximum polling interval for Modbus TCP/IP is 4 seconds. The
communication must be reopened after this interval.
5.6.1 Connection and Setup

Connect the network cable from the process control computer to the Ethernet
RJ45 connector on the top of the GPA2.
To change the IP address or netmask of the GPA2:
1. Verify that the GPA2 module is ON.

2. Check the IP address displayed on the FPI (Figure 4-3). If it is not the
default of 10.37.0.2, make a note of it for later step.
3. Configure the client computer network setting so that its IP address is
10.37.0.1 and netmask is 255.255.0.0.

July 2018 48
4. At the client computer, start up an Internet browser such as Firefox.

5. Enter the IP address of the GPA2 from step 2 in the web address field
(URL) of the Internet browser.
6. Verify that the KELK GPA2 web page appears as shown in Figure 5-3.
7. Enter the applicable new IP address and Netmask assigned by the network
administrator into the IP Address and Netmask field.
8. Click the Submit button.
9. Power the DPA2 off and then ON so that the new IP address takes effect.
Figure 5-3 GPA2 Web Page

July 2018 49
5.6.2 Data Formats for Communications

The following table (Table 5-6) defines the formats of data that have been
reconstructed after transmission. Numeric values are decimal (base 10) unless
stated otherwise.
For bitmapped formats, the condition is enabled (or “on”) when the bit is set to 1
and disabled (or “off”) when the bit is 0, unless stated otherwise.
The nomenclature used for each format reflects the basic type and size (in eight-
bit bytes) of the format. The size of each format is always an integral multiple of
one byte. Regardless of their size, data are interpreted as “big-endian” (i.e., the
least significant bit is bit 0 and the most significant bit is the highest-numbered bit
for the format).
For formats that do not use all of the available bits, the unused bits are ignored
by the format and are set to zero during transmission.

I - Signed Integer
B - Bitmapped
For signed/unsigned integer types, this is the number of implied decimal
digits:
Etc.
Example: 16I2 is 16 bits, signed integer, 2 decimal points.
For a bitmap, this is a bitmap order number.

July 2018 50

16 bit, signed integer, two
16I2 Example -123.45 stored as -12345
decimal digits
Unsigned 8 bit Integer
8U0 8 bit, unsigned integer

Bitmapped Types
Bit 1 - B Fault
4B2 System Status
Bit 2 - A Fault
Bit 6 - Channel B: Single Sensor Operation
(Double A)
Channel A&B Measurement
16B3 Bit 8 - Channel A: Shunt or FS out of range
Status
Bit 13 - Channel A: Excitation current
overload
(Double B)
Bit 0 - Zero
Enumerated Type
0- A &B
Sensor Input Configuration 1- 2*B
2E1
(Load doubling) 2- 2*A
3- B &A
Table 5-6 Modbus-TCP Communication Data Formats

July 2018 51
5.6.3 Modbus-TCP Memory Map
The following table defines the data that may be accessed via the Fieldbus
interface. The grouping of the data reflects the manner in which it is treated by
the GPA2. Process variables are updated from the GPA2 to the Fieldbus
memory at 50 Hz. Configuration parameters are updated and could be changed
at a rate of 5 Hz.
Host
Host Write
Read Min Max
Address Name Format Units Notes
Address Value Value
(Hex)
(Hex)
Process Variables (Read-Only, Volatile)
Input A Load
0000 16I2 % -327.68 327.67 1
Input B Load
0001 16I2 % -327.68 327.67 1
System Status
0002 4B2 - - - 1
Channel A&B Measurement
0003 16B3 - - - 1
Status
Receive /Transmit Statistic (Read-Only, Volatile)
Relay Outputs Transmit 8U0
- - -
0004 Count 1
Logic Inputs Receive Count 8U0
Configuration Parameters (Read-Write, Nonvolatile)
0005 0005 Configuration, Zero 2B4 - - - 2
Sensor Input Configuration
0006 0006 2E1 - - - 2
(Load doubling)
Table 5-7 Modbus-TCP Communication Memory Map
Notes:
1. These variables are updated by the GPA2 every 20 ms.

July 2018 52
KELK Operation
Part 6 Operation
6.1 Introduction
The General Purpose Amplifier GPA2, provides the user with the following
features for system monitoring and control:
 Load display
 Load level alarm
 Single sensor operation
 Channel configuration
 Zero
 Channel test & load simulation
 System status and online diagnostics
6.2 Load Display
Measured loads are displayed via the Front Panel Interface (FPI) alphanumeric
display and the User Access Program (UAP) Operations screen. (Throughout
the rest of this section, any descriptor in parentheses indicates how the
parameter is shown on the FPI, i.e. uppercase or lowercase.)
During normal operation (when both Sensors A and B are operational), the
individual A and B, sum S) and difference d) loads can be displayed on the
FPI as follows:
Axxx.x Individual load ‘A’ in % of F.S.

bxxx.x Individual load ‘B’ in % of F.S.
xxx.x total load = (A+B) in % of F.S.
xxx.x differential load = A-B in % of F.S.
Loads A, B, S and d are in the numerical range -327.60 to 327.60, the limits
representing negative and positive input saturation. The display range is limited
such that the negative values are limited to -0.1 to -199.9. Numbers below -
199.9 do not have a preceding negative sign.
During Single Sensor Operation (i.e. 2 x Sensor A or 2 x Sensor B), the load
values will be based on the single operational sensor selected.
The user can select the load parameter to be displayed from the Operations
Loop menu by using the keys.

July 2018 53
KELK Operation
6.3 Load Level Alarm
The load alarm activates when the user-set load threshold of the SUM load is
exceeded. The condition is indicated by:
 Logic Output indicator on the UAP Operations screen.

 An alarm message at the Modbus/TCP, Profibus or PROFINET interfaces
(see Section 5.6, Appendix D or Appendix E, respectively).
Refer to Section 9.5 for more details regarding the alarm relay.
6.4 System Status
System status includes status of the signal processing electronics, the sensor
excitation currents, and the input signals, which are all continuously monitored.
System status is indicated by:
 System Healthy, Channel A Fault, Channel B Fault and Single Sensor

Operation LED’s on the GPA2 front panel and in the UAP Operations screen.
 Error messages at the FPI.
 status messages at the Modbus/TCP, Profibus or PROFINET interfaces (see
Section 5.6, Appendix D or Appendix E, respectively).
 status messages on the System Status Panel of the Operations screen in the
UAP (see Appendix B).
 the System Healthy Logic Output relay (Section 9.5).
6.4.1 Online Diagnostics

The input signal level and the sensor excitation are continuously monitored
during operation of the GPA2.
The sensor excitation voltage is monitored to ensure that it is within defined

limits. Any deviation will affect system calibration.
The input signal level is monitored, and if it is high enough in either the positive
or negative direction to cause saturation, a fault condition and error message are
displayed.

July 2018 54
KELK Operation
6.4.2 Status Messages

These can be viewed directly in the Operation Loop Status field on the FPI or by
using the UAP. The format of the message is:
Status: xxyy
where xx is a hexadecimal number code for Channel A

yy is a hexadecimal number code for Channel B.
Note the hexadecimal code can represent a single error code or the sum of error
codes. If a fault is indicated, refer to Part 7: Diagnostics & Troubleshooting, or
the UAP system status list panel for details of error codes.
For further information regarding status messages in the UAP, see Appendix B.
6.5 Channel Configuration
During input channel configuration, as detailed in Section 5.4, the user enters the
value of Calibration Target Load and selects an application shunt resistor. When
the Configuration command is invoked, this value and shunt resistor are used to
set the gain of each channel, a process that determines the relation between full
scale input and full scale output for each channel.
Channel configuration establishes both the channel gain and the channel zero
reference. This function is typically applied immediately following the sensor
parameter (CTL) entry procedure as described in Part 5 of this manual. It is
recommended that the CFG button, and its equivalent in the UAP, only be used
to re-configure the channel when initializing a sensor or in the event of a fault
indication. It can be invoked at any time, however, when the system is not online
to re-establish the zero reference and to confirm the internal gain settings.
A successful CFG is indicated for each channel when activation of the CFG
command does not return an error indication for either channel. The absence of
an error confirms that the span for each channel has been set and both channels
are at zero.
Channel Configuration is initiated

 By pressing the front panel CFG key.
 Through the UAP - ‘CONFIGURE AND SET’ screen.
 Through the Fieldbus Interface.

July 2018 55
KELK Operation
Caution
During a Configuration (CFG) operation, the digital and analog
outputs, and the load alarm continue to function normally.
Ensure they are not in use for control as this may cause the
production of off-specification product or equipment damage.
To prevent against unwanted Configuration under load, FPI access to the CFG
function may be disabled using the UAP (see Appendix B, sub-section B.6.3.3).

July 2018 56
KELK Operation
6.6 Zero
Zero adjusts the fine offset of both channels to set their outputs to zero. It is
normally used to compensate for small changes in tare load.
Configuration (CFG) establishes a zero reference at the input stage. The Zero
command will successfully zero the outputs provided that the total offset, relative
to the zero reference established during CFG, does not exceed ±20% of the full
scale input. This limit serves to advise the user of the accumulation of small
offsets successively corrected or to alert the user to a single large change in
offset. Exceeding the 20% limit results in a ‘zero out of margin’ error. It is
recommended that in the event of a ‘zero out of margin’ error message, the
cause be investigated prior to further operation. To continue operation, invoke
Configuration by pressing CFG to establish a new zero reference. See Part 7:
Diagnostics & Troubleshooting, for further assistance with troubleshooting.
Zero can be initiated:

 By pressing the front panel ZERO key.
 Through the UAP - Operations screen.
 Through the Fieldbus Interface (Modbus/TCP, Profibus or PROFINET).
 By a voltage input at the Logic Input 1. The zero function is initiated by the
rising edge of the applied voltage (see Section 9.4).
To prevent against performing an unwanted Zero function under load, FPI access
to the Zero function may be disabled using the UAP (see Appendix B, sub-
section B.6.3.3).
Caution
During a Zero operation, the digital and analog outputs, and the
load alarm continue to function normally. Ensure they are not in
use for control as this may cause the production of off-
specification product or equipment damage.

July 2018 57
KELK Operation
6.7 Channel Test / Load Simulation
Channel Test / Load Simulation is a feature provided to check the GPA2 setup
and the load output (analog or digital) to the user’s control system interface. It
can be invoked via the FPI or the UAP.
As this is a non-operational condition, the following occurs when it is invoked:

 The channel fault LED illuminates
 An error code is displayed
 The System Healthy logic output changes state to indicate a fault condition.
With Channel Test / Load Simulation initiated, the shunt resistor previously
applied during the Configuration is now applied to the sensor bridge. The level of
the load output will correspond to the Calibration Target Load (including any
corrections for interconnecting cable resistance entered during Configuration).
Caution
During Channel Test / Load Simulation, the digital and analog
outputs, and the load alarms are forced to user selected levels
until normal operation is resumed. Ensure that they are not in
use for control during this time as this may cause the production
of off-specification product or equipment damage.
Channel Test / Load Simulation via the FPI

To test Channel A using the FPI, navigate to the load A and load B display and
press the TEST A button. The load displayed should equal the Calibration Target
Load entered if GPA2 is zeroed for Channel A. This value will also be shown at
the analog and digital outputs. This feature checks the calibration and allows the
user to test and verify connections to their equipment. Note that the Channel A
fault will be set by this action, indicating that the system is not in normal
operation. Press TEST A again to remove the shunt resistor and to return to
normal status.
Channel Test / Load Simulation via the UAP

Using the UAP, the user can apply a fixed load level simulation using the shunt
resistor in the same manner as over the FPI or Fieldbus, or can enter a selected
percentage value as shown in Figure B-15.
Note that if the Calibration Target Load or the selected value is greater than
110% and if the analog output scale factor is equal to or smaller than 100, the
analog outputs may saturate.
July 2018 58
KELK Operation
6.8 Single Sensor Operation
If there is a problem with a sensor or an input channel, Single Sensor Operation

can be invoked. Single Sensor Operation, otherwise known as load doubling,
connects both Channel A and B registers in the load measurement set to the
same input sensor channel.
When invoked:
 Both individual outputs show the same value as the source selected, A or B.
 The sum load (A+B) is twice the selected sensor load and the difference load
(A-B)
is zero.
 The front panel ‘Single Sensor’ LED indicator is illuminated and the
appropriate Sensor Fault indicator will be set. These responses will also be
indicated in the UAP and through the Fieldbus.
Single Sensor Operation can be invoked:

 Through the FPI:
 Using  or  in the Operations loop (see Figure 4.4), select Load
DBL.
 Press SET A + SET B at the same time to enter edit mode
 Using  or  to select either A A (single sensor A) for a sensor B
fault condition or B B (single sensor B) for a Sensor A fault condition.
 Press SET A + SET B at the same time to exit edit mode and return to
the normal display.
 Through the UAP - Operations screen.
 Through the Fieldbus Interface (Modbus/TCP, Profibus or PROFINET).
Note 1. Single Sensor Operation is not automatically invoked. If a fault is

detected, user intervention is required.
Note 2. Note that the Single Sensor Operation condition is non-volatile and
is, therefore, retained even if the GPA2 power is cycled off and on.
To cancel Single Sensor Operation:

 FPI – reset the Load DBL to A B under Operations loop.
 UAP – through the UAP - Operations screen
 Fieldbus – through the Modbus/TCP, Profibus or PROFINET interfaces.

July 2018 59
KELK Diagnostics & Troubleshooting
Part 7 Diagnostics & Troubleshooting
7.1 Overview
Internal diagnostic routines monitor the measuring system performance

continuously and respond to:
 User set conditions, Channel Test / Load Simulation, and Single Sensor
Operation that directly affect system operation and output integrity.
 Internal diagnostic testing.
 The activation of the auxiliary functions routines, ZERO and Configuration
(CFG), that includes validity tests to ensure correct system operation.
When a fault is detected, indicators are set to alert the user and status messages
are posted to assist in identification and correction of the fault condition.
Note 1 The GPA2 is supplied with channel and system fault indicators
asserted. The user must apply valid channel configurations to
remove the fault indications prior to placing the unit into operation.
Note 2 Single Sensor Operation is the only fault condition under which the
system can remain operational.
System status is indicated using two categories:

 Measurement channel faults
Channel 'A' fault and Channel 'B' fault.
An error has been detected that may influence the quality and
accuracy of the measurement data. See Table 7.1
 System Healthy indication.
This is a composite system status indication that includes both
System status is provided:

 For operational purposes, by a logic output (see Sections 2.3.5 and 2.4.4),
and through the user and communications interfaces as follows:
 Channel Fault LED set on FPI
 System Healthy logic output de-asserted
 Error status code posted at the FPI.
 Status codes over the Serial Communications Interface (SCI) (can be
observed in the UAP)
 Status codes over the Modbus/TCP, Profibus or PROFINET interface

July 2018 60
 For troubleshooting purposes, error codes can be obtained through the user
and communications interfaces.
Status and Error Codes

GPA2 Measurement Status, as displayed on the FPI and UAP, is a 16-bit number
that is a combination of the status for the two channels A and B. The status for
channel A is given by 8 upper bits (xx) and for channel B by 8 lower bits (yy).
The status is presented by a hexadecimal number representing the combined
measurement status.
Status is displayed on the FPI in the Operations Loop as:

Status
xxyy
These are referred to as the Error Codes and they are presented in the following
locations:
 In the UAP Diagnostics Status screen (Figure B-13 Status Panel)
 In the Serial Communications Interface (Section 5.5) and Fieldbus Interface
(Section 5.6 and Appendix D) by bitmapped messages (Table 7-1)
 In the FPI as Hex sums of individual faults (Table 7-1)
Error Code
Fault Mode Set condition or test Fault Condition
[HEX]
Simulation active Test condition 80
User Set condition Single Sensor Operation A or B input data disabled 40
active
Sensor excitation test Excitation OFF 20
GPA2 Monitoring
Channel input condition test Input Saturation +/- 10
Zero Zero out of margin 08
Auxiliary Function- Gain out of range 04
User activated Zero out of range 02
Configuration
Shunt input or FSI out of 01
range
Table 7-1: Fault Conditions and Resulting Error Codes

July 2018 61
To decipher the FPI status messages:
 From the displayed fault number, subtract the largest Error Code number (in
Hex format), identified in the table above, which is equal to or less than the
displayed number. That error for that largest Error Code is present.
 Repeat the above, subtracting next largest Error Code from the remainder,
until the remainder is reduced to zero.
 Note that the Error Code is a number in hexadecimal format.
Example:
For Status Message 0630:
Channel A error code is 06
06-04 (Gain out of range) = 02

02-02 (Zero out of range) = 0
Channel A has two faults, 04 and 02.
Channel B error code is 30
30-20 (Excitation current overload) = 10

10-10 (Saturation) = 0
Channel B has two faults, 20 and 10.
For status messages transmitted over the SCI or the Fieldbus,

faults are directly identified by bit position as indicated in the tables:
1 = fault detected, 0 = fault not detected.
Important Note
A single fault condition can result in several error codes combining to produce a
Status message. When deciphering a status code into its component error
codes, the faults are revealed in descending identification number order. This
indicates the order of importance of the fault. The user is advised to identify the
cause of each component error and apply corrective action. Correction of the
larger numbered fault conditions may automatically remove those with smaller
identifying numbers.

July 2018 62
7.2 User Set Fault Conditions
The GPA2 has user selectable conditions that result in fault indication.
7.2.1 Channel Test / Load Simulation (Error code 80)

Channel Test / Load Simulation is provided to facilitate checking the unit setup,
configuration and the load output (analog or digital) to the user’s control system
interface, see Section 6.7. It can be invoked via the FPI, or the UAP. When
invoked, the following error codes are posted to indicate Simulation active.
Sensor A 8000
Sensor B 0080
Corrective action: Press TEST A or TEST B to cancel the respective channel

test via the FPI or click the ‘Off’ selection in the pull down menu that appears
directly under “Load Simulation” in the Simulation/Test window of the UAP.
Note this condition is canceled during unit reset (Power OFF/ON).
7.2.2 Single Sensor Operation (Error code 40)
Single Sensor Operation, otherwise known as load doubling, connects both

Channel A and B registers in the load measurement set to the same sensor
channel. Refer to Section 6.8 for details.
When invoked:
 Both individual outputs show the same value as the source selected, A or B.
 The sum load (A+B) is twice the selected sensor load and the difference load
(A-B) is zero.
 The front panel Single Sensor indicator is illuminated; the appropriate Sensor
Fault indicator will be set. These responses will also be indicated on the UAP
and through the Fieldbus.
Error codes posted are:

Sensor A 4000
Sensor B 0040
Note that System Healthy indication is not affected by this fault (which can only
be applied to one channel at a time). The active error code is masked by the
System Healthy logic.

July 2018 63
This allows the amplifier to be operated under this fault condition but the user is
advised that any differential signal will show zero.
Note the Single Sensor Operation condition is non-volatile and is, therefore,
retained even if the GPA2 power is cycled off and on.
7.3 Faults Detected by Continuous Monitoring (Error codes 20 and 10)
The channel input signal levels and the sensor excitation supplies are
continuously monitored and, in the event of problems, fault indications are set.
These indications are volatile; existing only while the fault is detected.
Excitation OFF (Error code 20)
This fault occurs if the sensor excitation supply is not within specification: 10
VDC for models E1 or 20 VDC for models E2.
It is typically caused by an excitation supply over current due to a short and a

subsequent failure or shutdown of the supply. After 100 milliseconds the circuit
attempts a recovery.
Error Codes: Sensor A 2000, Sensor B 0020

Causes: Sensor connection fault, sensor fault, excitation supply
failure or shutdown (short circuit detected).
Corrective action: Check connections and excitation output.
Signal Saturation (Error code 10)

This error is caused by the sensor input magnitude being too high (positive or
negative). As such, it is out of the analog-to-digital (A/D) conversion range, a
condition that can cause saturation of the outputs or an incorrect output,
depending on the output scaling selected. Note that a cut, or disconnected wire
at the sensor input can trigger this error condition.

Causes: Sensor load condition, sensor connection fault, sensor fault,
incorrect channel configuration.
Corrective action: Check sensor load, condition and connections.
Check channel configuration, including shunt resistor
selection and parameter entry. If changes to the input
parameters are made, the user must apply the Configuration
(CFG) function before placing the unit in operation.

July 2018 64
7.4 Faults detected by Auxiliary Function Checks (Error codes 08, 04, 02, 01)
The application of auxiliary functions, ZERO and Configuration (CFG), initiates

some internal diagnostic routines to ensure that there is a successful outcome
from these functions. If a problem is detected then a fault condition will be
displayed.
Note that fault conditions resulting from these diagnostics are non-volatile. The
fault indications will remain until corrected even if the GPA2 power is cycled off
and on. A successful application of the auxiliary function, CFG or ZERO, is
required to clear the fault.
7.4.1 Channel Zero Fault (Error code 08)

The ZERO function is user-initiated via a logic input, the FPI, the UAP, or the
Fieldbus. It causes a comparison between the fine offset of each channel and
the reference point defined by the previously completed CFG with the set limit of
±20% of FSI. If both channel offsets are within ± 20% of the reference, then both
channel outputs are set to zero; if any is greater than ±20%, then the following
error can result.
Zero out of margin
In this case, offset is not adjusted, the fault indicator is illuminated, and an error
message is displayed for that channel:
Causes: Sensor load condition, sensor connection fault, sensor fatigue.
Corrective action:
 Check load condition
 Check sensor and sensor connections
 If the zero offset is permanent, then apply CFG to adjust the
tare correction and re-establish the zero reference point
7.4.2 Channel Configuration CFG Faults (Error codes 04, 02, 01)
These faults would occur after a channel configuration (CFG), which is user-
initiated via the FPI, the UAP or the Fieldbus.
This Configuration function checks that the sensor working range, as defined in
Section 5.4.2 and illustrated in Figure 5-2, is within the operating range of the
internal Analog-to-Digital (A/D) converter and that the resolution of the defined
full scale input (FSI) is acceptable.

July 2018 65
The following error conditions can result:
Gain out of range (04)

This error indicates that the FSI is too small, resulting in unacceptable resolution.

Cause: Sensor fault, excitation supply problems, and/or incorrect
channel configuration.
Corrective action:
 Check the sensor and its connections; see Section 7.5
 Check the excitation supply
 Check the Calibration Target Load value set
 Check the Shunt resistor value selected
 Reapply CFG
Zero out of range (02)
The existing tare and gain settings place the working range zero allowance
outside the A/D operating range in the negative direction.
Error Codes: Sensor A E0200, Sensor B E0002

Corrective action:
 Check the Calibration Target Load value set
 Check the shunt resistor value selected
 Reapply CFG.
Shunt input or Full Scale Input (FSI) is out of range (01)
In this case, the working range has been checked and found to exceed the
positive limit of the operating range of the A/D converter. The cause is incorrect
channel configuration.
Corrective action:
 Check the excitation supply.
 Check the Calibration Target Load value set.
 Check the shunt resistor value selected.
 Reapply CFG.

July 2018 66
7.5 Troubleshooting the System
7.5.1 System Test
Note
This test assumes that the interconnecting cable and sensor

wires are the same color. If different colored interconnecting
wires are used, ensure that the test connections correspond to
the sensor wire colors. It also assumes that the GPA2 is
functional.
1. Ensure the suspect channel is either not loaded or only tare loaded.
2. Switch off the GPA2.
3. Disconnect the red and white interconnecting cable wires. Switch on the
GPA2.
4. With a digital voltmeter (DVM) or multimeter, measure the excitation
voltage between the GPA2 terminals that the green (+) and black (-) wires
are connected to. This should be 10 VDC ±0.5 VDC or 20 VDC ±0.5 VDC
depending on the model type (‘D1’ is the identifier in the GPA2 model
number for 10 VDC excitation, whereas ‘D2’ is for the 20 VDC excitation
model). A low reading indicates current leakage in the cable or sensor, or
an excitation supply problem.
5. With the DVM set to millivolts, measure between the red (+) and white (-)
wires. The reading will normally be less than 3 mV. Values above 15 mV
are unusual. If the value is high, it may be beyond the range of the zero
control. A reading of ±5V (or ±10V for ‘D2’ type) indicates sensor failure.
6. Switch off the GPA2, disconnect the green (+) and black (-) wires (this
completely disconnects the cable from the main module) and conduct the
following tests in order:
a) Input resistance: using an Ohmmeter with a resolution of 0.1 measure
between the green and black wires. The reading should be within 1  of
the resistance specified on the sensor calibration card, plus the
resistance of the interconnecting cable.
b) Output resistance: repeat (a) between the red and white wires.
High or low readings for tests (a) - (b) indicate cable problems or a
damaged sensor.
c) Using a DVM set to millivolts, measure between any wire and ground.
The reading should be less than 5 mVDC.
d) Repeat (c) between any wire and the internal cable shield.
July 2018 67
e) Repeat (c) between the internal cable shield and ground.

Any reading above 5 mVDC for tests (c) - (e) indicates moisture in the
sensor or cable which will result in unstable readings and, more
noticeably, zero drift.
f) Using a DVM or mega-ohmmeter with a test voltage of less than 50V,
measure bridge to ground resistance, i.e., any sensor wire to ground.
Caution
Do not use an insulation tester with test voltages in excess of

50V. Higher voltages may damage the sensor.
g) Measure bridge to shield resistance by repeating (f) for any sensor wire to
the cable shield.
If all readings were normal for tests 5 and 6, then the excitation supply is faulty.
Replace the GPA2 module and/or power supply.
If any readings were abnormal for tests 5 and 6, the problem is caused by the
interconnecting cable or the sensor.
7.5.2 Interconnecting Cable Test
1. Disconnect the cable at the junction box and at the main module.
2. Test all conductors for continuity.
3. Measure the resistance to ground of all conductors.
4. Measure the resistance to shield of all conductors.
5. Measure shield to ground resistance.
6. When reconnecting the cable:
 Replace all dirty and corroded terminal blocks and lugs. Ensure that there
are no frayed wires to cause momentary shorts to ground.
 Ensure that the box and all internal components are dry. If moisture is
seen or suspected, dry with alcohol.
 Ensure that the cable shield is electrically isolated from the box ground.
 Ensure, when closing, that the box is properly sealed, checking the cover
and all cable entry points.
A reading of 20 M or less for tests 3 - 5 indicates cable damage or moisture in

the cable. If values below 20 M are measured or if any conductor is found not
to be continuous, the cable must be replaced.

July 2018 68
7.5.3 Sensor Test
1. Disconnect the sensor cable from the junction box.

2. Repeat tests in Step 5 of the System Test, Section 7.5.1.
3. If a problem is encountered it could be in either the sensor cable or the
sensor itself. Remove the sensor for a complete inspection; see the
measuring system User’s Manual.
4. Inspect the full length of the cable for damage, including crushing or
kinking. If it is damaged near its point of entry into the sensor, the sensor
should be replaced. If it is damaged at some point along its length, it can
be repaired using a KELK Splicing Kit (Part Number 20311). All
necessary instructions are included in the kit. This is the only
recommended method.
5. If the cable is not damaged, the problem is probably in the sensor itself.
Return the sensor to KELK for evaluation and repair.
Note: KELK load cells can be returned to the KELK factory for evaluation and
repair. KELK also offers a full range of after-sales services to assist
customers in the maintenance of their systems and troubleshooting should
problems arise.

July 2018 69
KELK Maintenance
Part 8 Maintenance
8.1 Introduction
The GPA2 requires no routine maintenance.
Service is only required if a failure occurs. Repair of the GPA2 main module on-
site is not possible. In the event of a failure, the GPA2 module must be sent to
KELK for inspection and repair if possible. Module that cannot be repaired will
be replaced as per warranty.
8.2 Power Supply Module Replacement
The following procedure is recommended:

1. Turn off the AC power either to the enclosure or by using the supplied circuit
breaker.
2. Remove all connectors from the Power Supply module and remove the
module from the DIN rail.
3. Install new Power Supply Module and reconnect.
If process conditions permit, after replacing a Power Supply Module, it is

recommended, to complete the checks given in Section 6.7 and Section 7.5 to
ensure correct operation.
8.3 GPA2 Module Replacement
The following Precaution is recommended:.
Caution
Electrostatic discharge (ESD) can damage static sensitive

components used in the GPA2. To prevent ESD, follow
the guidelines given below when handling and setting
switches on the Main Module printed circuit boards.
To minimize the probability of electrostatic damage when handling printed circuit

boards:
 Do not touch any components on the PCB; handle the board by the edges
only.

July 2018 70
KELK Maintenance
 Wear a grounded wrist strap when handling boards.

 Do not place boards on any surface other than a properly grounded static
dissipative mat.
To remove the GPA2 Module:

1. Turn off the AC power either to the enclosure or by using the supplied circuit
breaker.
2. Remove all connectors from the GPA2 Module.
3. To release the Module from the DIN rail, insert a small screwdriver into the
latch as shown in Figure 8.1 and pull the latch away from the module while
lifting the module away from the rail.
4. Install new module and reconnect.
Note that a new GPA2 Module means that all previous Setup and Configuration
has been lost. It is necessary to configure the new GPA2 Module; refer to Part 5:
Setup and Configuration, for setup and configuration and Part 6: Operation for
operation use.
Figure 8-1 GPA2 Module removal from DIN Rail

July 2018 71
KELK Specifications
Part 9 Specifications
9.1 Performance
Tare correction: ± 50-300% of full scale, dependent on sensor

bridge resistance and sensitivity
Input range: 0-50 mV
Common mode rejection: 100 db @10 Hz
Zero correction: ± 20 % of full scale
Calibration accuracy: ± 0.01% of full scale
Gain drift at the analog outputs: 0.01% of full scale per degree C
Zero drift at the analog outputs: 0.01% of full scale per degree C
Ripple and noise:
At isolated analog voltage output 5 mV RMS for 10 kHz noise bandwidth
At isolated analog current output 10 µA RMS for 10 kHz noise bandwidth
Resolution: 0.01% of full scale, front panel display 0.1%

Linearity: 0.05% of full scale
9.2 Sensor Excitation Supply
Quantity 2, DC group isolated, regulated and short circuit proof.
GPA2- -E1 10 VDC

GPA2- -E2 20 VDC
*Note: Spaces in above model number (“ ”) denote enclosure type and are
not related to GPA2 performance.
See Section 9.12 for enclosure specification

July 2018 72
KELK Specifications
9.3 Sensors Strain Gauge Bridge Type
Resistance range: GPA2- -E1 120-1000 Ohms

GPA2- -E2 350-2000 Ohms
Sensitivity range: GPA2- -E1 0.50 - 5.0 mV/V per volt full
scale.
GPA2- -E2 0.25 - 2.5 mV/V per volt full
scale.
9.4 Logic Inputs
Qty 1 Function: Zero both measurement channels, A and B,

simultaneously. (Zero)
Form: Voltage sense (rising edge) 10 VDC to 24 VDC at
10 mA max.
Sampling rate: 100 per second.
9.5 Logic Outputs
Qty 1 System Fault Indication2, Form ‘C’ (normally closed) :

Imax = 1 amp (resistive load), Vmax = 30 VDC/VAC
Qty 1 Load Level Alarm2 Form ‘A’ 2 activation when threshold exceeded.
Threshold can be specified at the time of order via the model number
and programmed at KELK, or can be programmed by the user with
the UAP only (default 100.0%) exceeded
Imax = 80 mA, Vmax = 30 VDC/VAC

July 2018 73
KELK Specifications
9.6 Analog Outputs
Qty 2
Measurement data: A, B, A+B, A-B, selectable via UAP only, can be
defined at the time of order by model number
choice.
Mode: Current or voltage selectable via UAP only, can
be defined at the time of order by model
number choice as:
±10VDC into a resistive load of 2000 ohms
minimum
or
4-20 mA into a resistive load not exceeding 500
ohms
Saturation: 110% for voltage (11VDC) and 105% for
current (21mA)
Scaling: 5-200% of Full Scale Input
Isolation: group (2)
External connections: screw terminal for signal and shield. Voltage
and current output share common ground
terminal.
Resolution: 16 bit
9.7 Filtering
Input signal: 5 kHz, no selectable filtering

Output signal: Selectable corner frequencies:
5, 10, 20, 40, 75, 150, 300, or 700 Hz.
Selection is via the UAP or FPI.
Default is 10 Hz
9.8 Serial Communication Port
Type: RS232/RS485 user selectable

Address: 1-15, user selectable (factory default - 15)
Baud Rate: 19200 fixed

July 2018 74
KELK Specifications
9.9 Ethernet (Modbus/TCP)

Connection: RJ45 (on-board)
Speed: 10/100 Mb/s
9.10 Profibus Communications (option)

Type: Profibus DP protocol
Baud Rate: Detected automatically up to 12 Mb/s
9.11 PROFINET Communications (option)

Type: PROFINET IO protocol
9.12 User Access Program
Minimum Computer Requirement Pentium III, 128 MB RAM with

10 MB available hard drive space, 800 x 600 video adapter, CD ROM drive
Operating Systems: Windows 98, Windows XP, Windows 7
Format CD
9.13 Physical
Power requirements 100 - 240 VAC, 50 VA, 50-60 Hz
Power Supply Module Input 85 - 264 VAC, 0.65 - 0.25 A, 45-65 Hz
Power Supply Module Output 24 VDC, 1.3A
Main Module Input 24 VDC, 300 mA
Profibus Communication Module 24 VDC, 300 mA
PROFINET Communication Module 24 VDC, 280 mA
Ambient Operating temperature -10°C to +55 °C
Operating Humidity 90% at 55 °C
Storage temperature -20 °C to +80 °C
Storage humidity 70% at 40 °C
Weight 33 lbs. (15 kg)

July 2018 75
KELK Specifications
9.14 Dimensions
Figure 9-1 Dimensions of GPA2 Enclosures

July 2018 76
KELK GPA2 Model Numbering Scheme
Appendix A
GPA2 Model Numbering Scheme
To simplify ‘on site’ setup, the model number includes extensions to allow customers to
order GPA2 units preset to specific requirements.
The model number includes information defining:

 GPA2 Hardware Identifier
 Enclosure type
 Hardware revision
 Excitation voltage
 Functionality Setup

 Analog Output scaling
 Load Alarm Threshold
 Digital filter
The format is:

GPA2 - aa - yz - Model identifier (Hardware identification)
o(nm)1(nm)2 - Functionality setup
C(nm)1(nm)2
P0031
tnnn.n
F000n
where ‘a’ denotes an alphanumeric character and ‘n’ or ‘nm’ denotes single and
double-digit numbers, respectively. Subscripts, when included, identify the
specific analog output. Leading characters ‘o’, ‘C’, ‘P’, ‘t’, and ‘F’ identify
parameters as specified below in detailed Functionality Setup.
Note that the order of the model number component parts must be maintained.
Hardware Identification
Enclosure: - aa
- 12 Nema 12 - Painted Steel
- 4X Nema 4X - Stainless Steel
- 00 Cabinet Mounting Kit
- RE P640 to GPA2 conversion kit. Applicable only if a P655
cabinet was previously supplied by KELK.

July 2018 77
Hardware Description: - yz
-y E - Hardware Revision (on the FPI displayed ‘E’)
-z 1 - 10VDC excitation voltage, standard
2 - 20VDC excitation voltage, option
Functionality Setup
Analog outputs, data source and mode: - o(nm)1(nm)2
-o Parameter identifier for Data Source and Operational Mode for Analog
Output #1 -(nm)1 and Analog Output #2 -(nm)2 .
-(nm) 10 - Individual A (1); Output Mode ±10V (0)

11 - Individual A (1); Output Mode 4-20 mA (1)
20 - Individual B (2); Output Mode ±10V (0)
21 - Individual B (2); Output Mode 4-20 mA (1)
30 - Sum A+B (3); Output Mode ±10V (0)
31 - Sum A+B (3); Output Mode 4-20 mA (1)
40 - Difference A-B (4); Output Mode ±10V (0)
42 - Difference A-B (4); Output Mode 4-12-20 mA (2)
Analog Output Scaling: -C(nm)1(nm)2
-C Parameter identifier for the scale factor for Analog Output #1 -(nm)1 and
Analog Output #2 -(nm)2 .
-(nm) 01 = 200%
02 = 100%
04 = 50%
05 = 40%
08 = 25%
0A = 20%
14 = 10%
28 = 5%
Load Alarm
-P0031 Alarm triggered by SUM(A+B) factory set; closed above user-set
threshold, as described below
Load Alarm Threshold: -tnnn.n
-t Parameter identifier for Alarm Threshold.

-nnn.n Selected threshold expressed as a percentage of full scale.

July 2018 78
Digital filter: -F000n
-F000 Parameter identifier for Digital Filter.

-n Corner frequency selected from 0 = 700 Hz
1 = 300 Hz
2 = 150 Hz
3 = 75 Hz
4 = 40 Hz
5 = 20 Hz
6 = 10 Hz
7 = 5 Hz
Default Model Definition:
GPA2-12-E1 - Standard GPA2 Hardware in a Nema 12 enclosure
o1020 Programmed for Individual Analog outputs in voltage mode

C0202 Individual Analog outputs scaled to 100%
P0031 Alarm triggered by SUM(A+B); relay closed above threshold
t100.0 Alarm threshold, asserted at 100.0%
F0006 Low pass filter corner frequency 10Hz.
This setup will be factory applied in the event that the customer does not request
a specific setup at the time of order.
To define a specific setup, use the GPA2 Ordering Form #881; see Figure A-1.
NOTE: In the event that any component is not fully defined by the customer
when ordering, the default for that component will be applied.

July 2018 79
Figure A-1 GPA2 Ordering Form

July 2018 80
KELK User Access Program
Appendix B
User Access Program
B.1 Introduction
The General Purpose Amplifier (GPA2) is designed to function with a large range
of strain gage type sensors throughout various applications. Many features and
options are available and the amplifier can be set up to operate in a number of
distinct modes depending on the application. The main module of the amplifier is
normally ordered fully setup to match the user defined operation mode. The
model number includes extensions to allow the customer to order the unit
specifically preset as per their requirements.
The function setup, as defined by the model number, is applied to the unit at the
factory since the Front Panel Interface (FPI) has limited functionality and,
therefore, factory definition is preferred to ‘on site’ setup. A User Access
Program (UAP) has been developed to provide the user with friendly and more
comprehensive tools by which to set up, configure and monitor the GPA2. In
addition, it permits the user to change the SETUP of the unit for a different
application or set of circumstances, if required.
The User Access Program (UAP) is supplied on a CD together with a copy of the
GPA2 Manual in portable document format (.pdf). The program is designed for
use with any PC operating in a Windows environment; connection to the amplifier
is through the serial port connector on the main module.
B.2 Features
The UAP permits the setup of:

a) Input Channels
b) Analog Output Channels
c) Load Alarm
d) Filtering
e) Communication
f) FPI Zero and CFG accessibility
It also has the following features:
 A full panel to monitor the load outputs from each channel and determine the
status of the system.
 A full diagnostics panel to provide the user with instant readout of the system
status plus an indication of any faults detected.

July 2018 81
 Standard conventions and menu structure for its operation. Each panel is self
explanatory. Areas on any panel not available to the user are shown in gray
while edited data is displayed with a yellow background until applied to the
GPA2.
 Automatic access to the unit Setup and Configuration upon establishing a
connection.
 An existing Setup and configuration can be read back from the amplifier.
 Additional tools to the user not provided by the FPI, such as:
a) Calculation of Cable Correction factor.
b) Internal configuration data.
c) Factory calibration information.
d) Force and wrap angle calculation spreadsheet.
B.2.1 Operating Modes

The UAP can be used when connected to one or more GPA2s. The
communication setup for the host computer and the GPA2s must be compatible.
See Section B.4.
The UAP can also be used without a connection to the GPA2. This mode, using
a default GPA2 configuration file, allows the user to familiarize themselves with
the program and its navigation.
B.3 Installation
For use with Windows 98, ME, 2000, or XP. Refer to Section 9.12 for minimum
computer requirements.
Insert the KELK Load Cell Electronic Utilities CD in the CD drive and follow the
'NEXT' prompts to complete installation of the program.
If the CD does not automatically start the installation process, open the CD icon
and double click on SETUP.EXE. Load Cell Electronic Utilities menu will appear
with options to install the GPA2UAP program and to view the GPA2 User’s
Manual. To display the GPA2 User’s Manual, the Acrobat Reader available on
this CD is required.
NOTE: If there is already an earlier version of the program installed on the PC,
the installation program will prompt you before uninstalling it. When the uninstall
is complete, remove and re-insert the CD to start the install process.
Once the program is installed, navigate through: Start\Programs\GPA2UAP and
click on GPA2UAP to launch the program.

July 2018 82
B.4 Communication
B.4.1 GPA2 Communication Setup
The GPA2 must be suitably configured for communication with the host
computer. Communication is via the main module serial port.
The GPA2 supports two communication protocols: RS232 and RS485. The
default communication protocol is RS232. To change the communication
protocol to RS485, refer to the procedure in Section 4.4. The GPA2 default
address is 15; this can be changed to any value in the range of 1 to 15 after
communication has been established with the host computer via the UAP. Note
that the new address, applied via the SETUP Panel will not be valid until the
GPA2 is reset by Power OFF/ON.
B.4.2 Host Computer Communication Setup

The user must first access the Communication Panel to identify the host
computer and GPA2 communication parameters. The procedure is as follows:
1. Start UAP.
2. The UAP automatically searches for an attached device.
If no GPA2 has been detected the following panel is displayed.
Figure B-1 Communication Action Selection
3. Selecting ‘Attach Device”, the Serial Communication Setup Panel (see

Figure B-2) will appear:

July 2018 83
Figure B-2 Serial Communication Setup Panel
The right hand portion of this panel is for the host computer setup. Select the
COM port to be used for the GPA2 connection and select the GPA2 address.
Ensure the GPA2 is connected to the computer and press scan to search for the
unit.
If the address is correctly configured, the UAP will recognize the device, extract
its assigned serial number and function Setup, and return the panel shown in
Figure B-3. This panel indicates the directory path for Configuration files and
prompts the user to select a Configuration file from the list or to name a new file
*.[GPA2serial#].cfg.
Figure B-3 Directory Path Panel

July 2018 84
Assign a name to the indicated file and click OK. Ensure to keep the
*.[GPA2serial#].cfg extension in the name of the file (ie. Tension.26.cfg). The
panel shown in Figure B-2 will be displayed again with row 1 completed with the
GPA2 communications data and file name.
Alternatively, if an existing configuration file is to be used, then it can be selected

from the list. Select ‘Exit’ to go directly to the ‘Operations’ panel, Figure B-5; see
under Section B.6: UAP Panels. If the user now exits and then re-enters the
program, the UAP will locate the GPA2 directing the user to the ‘Operations’
panel. Once a serial communication is established, a Serial Communication text
with a blue light will be illuminated on the bottom left of the UAP Window.
NOTE: To open multiple files for more than one unit (RS485 Connection) the
user can open each subsequent file using ‘Open Configuration File’ and use
‘Communication Setup’ under the ‘File’ of the Menu bar similar as above.
B.5 Using the UAP
Active communication with an operational GPA2 gives the user access to all the
UAP features and panels. All panels include the Navigation Panel to assist the
user.
NOTE: Data entry into any data field in any panel will result in the background
of that field changing color to yellow to indicate that the field has been edited.
The field background will remain yellow until the data is applied to the GPA2
using the ‘Apply to GPA2’ command on the GPA2 ‘CONFIGURE & SET’ Panel.
Data entered via the ‘Input Configuration’ panel become active after the ‘CFG’
command is executed from the FPI or from the ‘CONFIGURE & SET’ Panel.
Changes entered via ‘Setup’ Panel are made active immediately after the ‘Apply
to GPA2’.
B.5.1 Using the UAP to Set Up and Configure a GPA2

Part 4 and Part 5 of this manual describe the steps necessary to set up and
configure a GPA2 for operation. The UAP can be used to perform all of those
functions. The user can review the following sections for descriptions of the
features and panels available for this purpose. The main steps are summarized
as follows:
 Establish communication.
 Check the GPA2 SETUP via the ‘Setup’ panel to confirm functionality is as
required.
 Under the ‘Input Configuration’ panel, enter input channel related data or
parameters.
 Use the Cable Calculator to determine a correction factor, if required.

July 2018 85
 Use the Application Wizard to determine application related parameters and
Apply Corrections.
 Transfer configuration related data to the GPA2 and apply CFG.
 Review the ‘Operations’ panel for ‘System Status’.
 Use the ‘Diagnostics’ panel to identify any problems.
 Access the ‘Simulation/Test panel to check operation and external
connection.
 Under ‘UAP Setting’ in the top menu bar, choose ‘UAP System Setting’ to
assign names to the input channels and to set a logging rate for error
conditions.
 Save the Configuration file.
 Print a copy of the Configuration file.
B.5.2 Using the UAP to Monitor a GPA2

The OPERATIONS panel displays the current measurement status and system
status. The user can select single sensor operation and apply ‘Zero’ from this
panel.
A diagnostic log file with data time and error code records can be automatically
created on the hard drive, see Section B.7.2. This feature is active when the
Status Logging is selected and the GPA2 connected to a host computer.
B.6 UAP Panels
All panels available are summarized in the Navigation Panel to assist and guide
the user.
Navigation Panel
The Navigation panel, Figure B-4, displays a list, headed by the GPA2
*.[serial#].cfg file name, of the UAP Main panels and sub-panels that can be
accessed by the user as shown below.
Figure B-4 Navigation Panel

July 2018 86
All main panels and sub panels can be selected and directly accessed by the
user and always include the Navigation Panel.
B.6.1 Operations
Selection of either ‘GPA2: (name)’ or ‘OPERATIONS’ will display the Operations
panel, Figure B-5.
‘Name’ is user applied for a connected GPA2, otherwise the ‘name’ field contains
a file name.
Figure B-5 Operations Panel
The GPA2 Operations panel displays the following operational details:

a) the channel output levels on a bar graph percent of Full Scale or numerically
in load units of the users choice (see SETUP)
b) the load alarm condition
c) the system status
July 2018 87
A series of buttons are available for the user to access any one of the following
four operations:
1) Load Units [#], switch the channel output level on the bar graph from percent
of Full Scale to Load Units of the users choice.
2) Status List, see Part 7
3) Single Sensor Operation, see Section 6.8
4) Zero, see Section 6.6
Activation of any button changes the dialogue box to reference the chosen
operation and displays further options for invoking that operation.
B.6.2 Configure & Set

This panel, Figure B-6, shows the current status of each parameter module. Any
changes made over the UAP will cause the appropriate box to change colour to
yellow. Changes include those induced by selecting a .cfg file that does not
reflect the current SETUP of the GPA2. The color indicates that UAP file has not
yet been applied to a GPA2 or saved to file.
The buttons displayed are:

 Read from GPA2: allows user to read back an existing SETUP from a
connected GPA2 (does not include related data such as Model, S/N, etc).
 Apply to GPA2: data as entered into the UAP fields is applied to the GPA2.
Data can be applied at any time the UAP is in use.
 CFG: uses data entered to configure and zero the Input channels.
 Read from File: loads data into the UAP from a designated configuration file.
 Save to File: saves UAP data to the currently opened configuration file.
 Save as: saves UAP data to be named to a new configuration file.

July 2018 88
Figure B-6 Configure & Set Panel
B.6.2.1 Input Configuration

Before using this panel, the user is advised to read Part 5 of the manual to have
a full understanding of the process of configuration of input channels for accurate
measurement; Figure B-7 illustrates the panel.

July 2018 89
Figure B-7 Input Configuration Panel
The procedure is as follows:

Select mode of data entry - either Basic or Extended Entry; see Figure B-8.
Figure B-8: Mode of Data Entry

July 2018 90
Basic Entry
In this mode the user cannot access most of the features on this panel. Load
Cell Calibration Card Information is largely for record only and is not accessible
under ‘Basic Entry’ with the exception of ‘Input Bridge Resistance’. The principal
purpose of this panel is an alternate method to using the FPI to enter the
Calibration Target Load value. A default value is first displayed. The user can edit
this value, go to the previous panel and select ‘Apply to GPA2’ followed by ‘CFG’.
Extended Entry
This is the recommended mode of data entry as it makes all features available to
the user. This is particularly useful for applications such as Tension Measurement
where Application Calibration Target Load is different from that given on the Load
Cell Calibration Card. The user is directed to Appendix C for a description of
Application related Form 855.
Extended Entry provides access to:
 Load Cell Calibration Information fields to be manually completed

 Application
Figure B-9: Application
Using Application, Figure B-9, the user can select the type of application for
which the sensors are used. With Tension selected, the user can access the
Application Wizard to calculate the strip and roll geometries and sensor
arrangements.
 Cable Calculator
This feature is provided for CTL correction in the case of long interconnecting
cables.

July 2018 91
Figure B-10 Cable Calculator
 Application Wizard
This feature is for tension applications, refer to Appendix C for further details.
The Wizard includes libraries of strip to roll geometries and various KELK sensor
arrangements. This feature can be used to calculate wrap angles, derive Force/
Tension relationships and calculate parameters Application Calibration Target
Loads; see Figure B-11.
This feature is particularly useful when changes are made to the geometry of the
strip/roll/sensor system.
 Apply Corrections.
Activation of this feature applies Corrections derived using the Cable Calculator
and the Application Wizard.

July 2018 92
Figure B-11 Application Wizard Image

July 2018 93
B.6.2.2 Setup
This panel, Figure B-11, represents the Function Setup Loop (Refer to Section
4.4) of the Front Panel Interface. Using this panel the user can select and
define all programmable functions of the GPA2. Pull down menus are provided
to simplify the process.
Figure B-12 Setup Panel

July 2018 94
Analog Outputs
For each of two analog outputs the user can select
 Data source
 Mode, current or voltage
 Scaling
Load Alarm
The Load Alarm is preconfigured to represent the SUM of both channels in the
case of a Force application or the average of the two channels for Tension or
Pressure applications.
The user can enter a “Load Alarm Threshold Limit’ value at which the alarm will
be asserted in the range of ±327%. If the value entered is out of the GPA2
range it will not be accepted.
The user is advised to select a value within the operating range of the ADC as
determined during Channel Configuration
Input Filter Corner Frequency

Refer to Section 5.3.4 for a full explanation.
Serial Communications Address

This panel is for changing the unit serial communications address.
The user may enter a new address value in the range of 1-15.
The factory set default value is 15.
UAP Display
The OPERATIONS panel includes two bar graphs showing active loads. The
default display is as a percentage of defined Full Scale. Using UAP Display the
user can define Full Scale in terms of ‘load units’ of their choice.

July 2018 95
B.6.3 Diagnostics
B.6.3.1 Status
The Diagnostics Status panel, Figure B-13, displays the current status of the
GPA2.
Figure B-13 Status Panel
See Part 7: Diagnostics & Troubleshooting for a full explanation of all displayed
fault conditions.

July 2018 96
B.6.3.2 Configuration Data

The Configuration Data Panel, Figure B-14, is for reference only and illustrates
and explains the Input Channel Configuration Parameters. These parameters
are not editable and can be displayed via this panel or FPI. The values are
derived and set by unit auxiliary functions, 'CFG' and 'ZERO', and represent the
internal settings of the electronic unit for each of the input channels.
Figure B-14 Configuration Data Panel
The parameters displayed can be useful in diagnosis of problems beyond the

scope of those detailed in the manual.

July 2018 97
B.6.3.3 Factory Setting

This panel is for reference only. It shows the main module identification details
and Factory settings. ‘Zero’ and ‘CFG’ functions’ accessibility via FPI can be
controlled over this panel and access disabled when usage of these functions
should be performed under special circumstances only.
B.6.3.4 Simulation and Output Test

This panel, shown in Figure B-15, allows the user to simulate loads on each input
channel individually or on both channels at the same time. The load can be user
selectable or by applying the shunt resistor directly to the sensor. The simulation
is indicated at the analog outputs and, if applicable, at the Logic Output Relay.
Figure B-15 Simulation and Output Test Panel

July 2018 98
B.7 Additional Features
B.7.1 GPA2 Setup and Configuration Summary Printout

A printout of the complete GPA2 functionality and Channel Setup is available.
The ‘Print GPA2 Configuration Report’ command is accessible through the Main
Menu bar in the drop down menu of ‘File’. An example is given by Figure B-17.
B.7.2 UAP System Setting

Configuration and diagnostic log file Directory Path is defined by ‘UAP System
Setting” Panel accessible through the ‘UAP Setting’ Menu bar.
A diagnostic log file is automatically created on the hard drive. Log file created is
a text file that records date time and error code. This file will have same name as
unit configuration file with .log extension and can be accessed independently of
the UAP using Notepad.
Note that this feature is only active when the Status Logging is selected and the
GPA2 connected to a host computer.
Figure B-16 UAP System Setting Panel
B.7.3 Help
A full copy of the GPA2 manual in .pdf format is included with the GPA2 UAP and
it is accessible through the ‘Help’ on the Main Menu bar or independently
navigated through Windows: Start\Programs\GPAuap.

July 2018 99
Figure B-17 Sample of ‘Print GPA2 Configuration Report’

July 2018 100
KELK Tensiometer Calibration Information Sheets
Appendix C
Tensiometer Calibration Information Sheets, Forms 858 and 855
C.1 Introduction
KELK load cells can be used to measure force or tension. Each load cell is
factory calibrated to determine its full load sensitivity, or output at its rated
capacity. Following this, a precision resistor of known value (calibration shunt
resistor) is placed across one arm of the load cell bridge to force a fixed and
repeatable output. The forced output is expressed as a percentage of the full
scale output for force, pressure or tension, depending on the application. This
provides a precise transfer reference that allows the system to be calibrated on-
site, effectively removing the need to use dead weight or auxiliary calibration
equipment that may be difficult to apply in the actual installation.
Onsite, a field reference value is inputted by the user into the GPA2, which is
then used during the ‘Configuration’ operation to adjust GPA2 offset and gain to
provide the expected output for the rated load or tension (see Section 5.4 and 6.5
or Appendix B, Section B.6.2).
Each KELK load cell is supplied with a calibration card giving details of the model
and serial number, its full load sensitivity, and the value of field transfer reference
and the value of shunt resistor applied to create it. An example of a calibration
card is given in Figure C-1: Example of a Calibration Card.
Figure C-1: Example of a Calibration Card

July 2018 101
Load cell systems that require outputs in terms of force or load can be calibrated
directly using the information given on the calibration card. In the cases of
systems designed to measure tension, however, additional information is
required to assist the user to calibrate the system.
In tension measurement systems, the load cells measure load directly

proportional to tension. The constant of proportionality is related to the overall
system geometry and the wrap angles of the strip over the tensiometer roll. The
accuracy of the system depends on the precise knowledge of the system
geometry and the wrap angles.
With each tension measurement system, KELK provides a ‘Tensiometer

Application Data Sheet’, Form 858, and a Tensiometer Calibration Data Sheet,
Form 855.
C.2 Form 858, Tensiometer Application Data Sheet
Copies of this form corresponding to each application can be found in Section A

of the Tension Measurement System manual.
Figure C-2: Form 858, Tensiometer Application Data Sheet

July 2018 102
This form is generated by KELK by inputting application wrap angles and specific
system parameters, as given on the application installation drawing, into the
GPA2 User Access Program (UAP) supplied with the system. An example is
given in Figure C-2: Form 858, Tensiometer Application Data Sheet.
This feature of the UAP can be accessed by clicking on the ‘Application Wizard’
button in the ‘Input Configuration’ screen (Note: the ‘Application Wizard’ button is
only active if the ‘Tension’ application and ‘Extended Entry’ selections are
chosen). Refer to Appendix B for full details.
The wizard permits the following:
 Selection of tensiometer format from a library of system types

 Selection of strip to roll geometry from a library of known applications
 Accurate determination of wrap angle using the selected strip to roll condition
and dimensional parameters
 Determination of the maximum normal and parallel forces due to tension that
are applied to the measuring system
 The maximum force on the load cell at maximum rated tension
 The constant of proportionality between tension and the resulting force on the
load cell
 The Utilization Factor; the ratio of cell capacity to force at rated tension
All above information is displayed, and can be readily interpreted, using the
comprehensive legend.
KELK generates Form 858 using the user supplied data. In the event of system
changes, the user can use the UAP feature to update the system information and
generate new data.
C.3
C.4 Form 855, Tensiometer Calibration Data Sheet
This form, supplied for each application, uses the data derived using Form 858
and the load cell calibration card to determine the Calibration Target Load to be
entered into the Main Module to correctly calibrate each sensor channel. As a
result, the amplifier outputs a signal directly representing tension.

July 2018 103
Figure C-3 Form 855, Tensiometer Calibration Data Sheet
The form also includes information to assist the user in the setup of each input
channel as follows:
Application information
Row 1. Location in mill
2. Sensor position; for example, Drive or Operator side
3. Rated tension for the application
4. KELK reference information (installation drawing number)

July 2018 104
Load cell Calibration Card Information

Row 5. Load cell model number
6. Load cell serial number for each sensor position (see Row 2 above)
7. Load cell capacity
8. Load cell sensitivity (S) in mV/V at full rated capacity
9. Shunt resistance used at factory calibration (note this may not be the
same value as for the application, see Row 15)
10. Output in mV/V with shunt resistor applied
11. Sensor bridge resistance in Ohms
Correction Factors (that are applied)

Row 12. Cable correction factor (Cf); to compensate for additional
interconnecting cable resistance (obtained by manual calculation; see
section 5.2 of this manual, or by using the Cable Calculator feature
accessed from the ‘Input Configuration’ screen of the UAP).
13. Utilization factor (Uf); the ratio of load cell capacity to force on the
sensor at full rated tension (from Form 858)
Application Data and GPA2 Settings

Row 14. Load cell output at full rated tension, Sr (equal to S/Uf), in mV/V
15. GPA2 shunt resistance selected for this application
16. Sensor output, OS (mV/V), with shunt resistor (Row 15) applied
Where OS = OC * (Shunt Resistance at Calibration (Row 9)
(Application Shunt Resistance ( Row 15)
17. Calibration Target Load (CTL) for each sensor channel
(CTL = 100 * OS / SR)
18. Calibration Target Load corrected for cable resistance (CTL * Cf)
IMPORTANT NOTE
The content of Forms 855 and 858, as supplied with the manual, is derived from the
information given on the installation drawing and/or supplied by the customer. This data
should be checked against the ‘as built’ or ‘as installed’ situation at the time of system
calibration. If the data on the forms do not correspond to the ‘as installed’ situation, a
new Tensiometer Calibration Data Sheet should be created. This can either be done by
KELK or by the customer using the UAP Input Configuration screen and the Application
Wizard.

July 2018 105
KELK Profibus DP
Appendix D
Fieldbus - Profibus Protocol
D.1 Introduction
The optional Fieldbus Interface provides the mill control computer with access to:
 Load measurement data at the rate necessary for mill control.
 System and measurement status
 Monitor and control the GPA2.
GPA2 uses an Anybus Communicator (ABC) Gateway to connect to the fieldbus. This
appendix describes the Profibus DP protocol version.
D.2 Setup and Configuration
Configure GPA2 device address to 15 (factory default) using UAP or FPI (see
Appendix B or Figure 4-3)
The Anybus Communicator Gateway provided by KELK is loaded with necessary

configuration to connect the GPA2 to a Profibus network

July 2018 106
KELK Profibus DP
D.2.1 Connections
Anybus Communicator
A. Profibus Connector
This connector is used to connect the ABC to the fieldbus.
B. PC Connector
This connector is used to connect the ABC to a PC for configuration and
monitoring purposes.
C. GPA2 connector
This connector is used to connect the ABC to GPA2.
D. 24V Power connector
Use this connector to apply power to the ABC.
E. DIN Rail connection
The din rail connector is internally connected to PE.

July 2018 107
KELK Profibus DP
Connect the GPA2 fieldbus cable between the ABC’s GPA2 connector and GPA’s
fieldbus connector. The cable connections are described in the next picture.
Connect the Anybus Communicator Gateway for Profibus to the fieldbus as indicated
below.
Pin Name Function

Housing Shield Connected to PE
1 Not Connected -
2 Not Connected -
3 B-Line Positive RxD/TxD according to RS485
specification
a
4 RTS Request to Send
b
5 GND BUS Isolated GND from RS 485 side
b
6 +5V BUS Isolated +5V from RS 485 side (80mA max)
7 Not Connected -
8 A-Line Negative RxD/TxD according to RS 485
specification
9 Not Connected -
a. RTS is used in some equipment to determine the direction of transmission.

However, in normal applications, only A-Line, B- Line and Shield are used.
b. +5V BUS and GND BUS are used for bus termination. Some devices, like optical
transceivers (RS485 to fiber optics) might require external power supply from
these pins.
Connect the 24V power supply to ABC as shown below.
Pin Description
1 +24V DC
2 GND

July 2018 108
KELK Profibus DP
D.2.2 Termination
If the AnyBus Communicator is the last node on a Profibus segment, it is necessary to
use an external termination.
• The termination switch should be set to ‘ON’ if

 The ABC module is the last physical node on a network segment
 No other termination is used at this end of the network
• The termination switch should be set to ‘OFF’ if
 There are no other nodes on both sides of the ABC module in the network
segment
D.2.3 Node Address
The configuration switches are used to set the Profibus node address.
Normally, these switches are covered by a plastic hatch. Note that the node address
cannot be changed during runtime, i.e., the ABC requires a reset for any changes to
have effect.
The configuration is done using two rotary switches as follows:

Profibus Node Address = (Switch B x 10) + (Switch A x 1)
The node address range is: 1-99.
Example: If the node address should be 42, set switch A to 2 and switch B to 4
Note: When removing the hatch, avoid touching the circuit boards and components.
If tools are used when opening the hatch, be cautious.

July 2018 109
KELK Profibus DP
D.2.4 Indicators
Number Description Indication Status

1 Fieldbus online Off Not online
Green Online
2 Fieldbus offline Off Not offline
Red Offline
3 Not used - -
4 Fieldbus Diag Off No diagnostics present
Red, flashing 1Hz Error in configuration
Red, flashing 2Hz Error in user parameter data
Red, flashing 4Hz Error in initialization
5 GPA2 Link status* Off Power off
Green, flashing Initializing and not running
Green Running
Red Stopped or subnet error or time-out
6 Device Status Off Power off
Alternating Red/Green Invalid or missing configuration
Green Initializing
Green, flashing Running
Red, flashing Fatal error
NOTE: At 'power ON', the GPA2 Link Status will be red, changing to green after all transactions
have been active at least once. This includes any transactions using “change of state” or
“change of state on trigger” (read or write commands performed to all registers).
Uninitialized registers will not influence communication. Communication will be correct while
the GPA2 Link Status is red.

July 2018 110
KELK Profibus DP
D.3 Processing
Because the AnyBus Communicator Gateway functions are implemented as two

sections of dual port RAM, one Read and the other Write, it is not possible to
implement Read/Write registers directly on the fieldbus and a workaround is used. All
registers that are written by the host are mirrored in the space read by the host.
The ABC cannot determine exactly which variable has been updated by the host in the
dual port memory so it operates by identifying changes in variable values sent by the
host.
Normally, this is completely transparent to the host but there are two cases where care
must be taken:
At startup the current value buffer, used to identify changes, is set to 0. If the host
tries to write a zero to a GPA2 register, no action will be taken and the GPA2
register will remain at its default power-on value.
If the host tries to write the same value twice to a GPA2 register, no action will be
taken and the GPA2 register will remain unchanged. This is only a problem if the
register has been changed by the UAP between the first and second writes.
Functions such as Configuration and Zero, that are initiated by changing a register
value from 0 to 1 and indicate completion by the GPA2 changing the value back to
zero, must be handled as follows:
At startup, the value of the host write register will be 0.

The host must write 1 to the host write register, changing it from 0 to 1 to request a
function.
While the function is in progress, the host will read 1 from the mirrored read
register.
When the function is completed, the host will read 0 from the mirrored read
register.
The host must write 0 to the host write register to enable a subsequent function
request to change value from 0 to 1.

July 2018 111
KELK Profibus DP
D.4 Communications
D.4.1 Data Formats

The following table defines the formats of data that have been reconstructed after
transmission.

16I2 16 bit, signed integer, two Example -123.45 stored as -12345
decimal digits
8U0
8 bit, unsigned integer
Bitmapped Types
4B2 System Status Bit 0 - System Healthy
Bit 1 - B Fault
Bit 2 - A Fault
16B3 Channel A&B Measurement Bit 0 - Channel B: Shunt or FS out of range
Status Bit 1 - Channel B: Zero out of range
Bit 6 - Channel B: Single Sensor Operation (Double
A)
Bit 8 - Channel A: Shunt or FS out of range
Bit 14 - Channel A: Single Sensor Operation (Double
B)
2B4 Configuration, Zero Bit 0 - Zero
Enumerated Type
2E1 Sensor Input Configuration 0- A &B
(Load doubling) 1- 2*B
2- 2*A
3- B &A
Numeric values are decimal (base 10) unless stated otherwise.

For bitmapped formats, the condition is enabled (or “on”) when the bit is set to 1 and
disabled (or “off”) when the bit is 0, unless stated otherwise.
The nomenclature used for each format reflects the basic type and size (in eight-bit
bytes) of the format. The size of each format is always an integral multiple of one
July 2018 112
KELK Profibus DP
byte. Regardless of their size, data are interpreted as “big-endian” (i.e., the least
significant bit is bit 0 and the most significant bit is the highest-numbered bit for the
format).
For formats that do not use all of the available bits, the unused bits are ignored by the
format and are set to zero during transmission.

I - Signed Integer
E - Enumerated
B – Bitmapped

For signed/unsigned integer types, this is the number of implied decimal digits:
Etc.
Example: 1 6I2 is 16 bits, signed integer, 2 decimal points.

For a bitmap, this is a bitmap order number.

July 2018 113
KELK Profibus DP
D.4.2 Memory Map

The following table defines the data that may be accessed via the Fieldbus interface.
The grouping of the data reflects the manner in which it is treated by the GPA2.
Process variables (A, B, A+B, A-B) are updated from the GPA2 to the Fieldbus
memory at 50 Hz, other variables are updated at approximately 5 Hz.
Byte based addressing is used.
Each GPA2 variable occupies two bytes (MSB:LSB).
Profibus DP Memory Map
Host Read Host Name Format Units Min Max Notes

Address Write Value Value
(Dec) Address
(Dec)
0001:2 Input A Load 16I2 % -327.68 327.67 1
0003:4 Input B Load 16I2 % -327.68 327.67 1
0005:6 System Status 4B2 - - - 1
0007:8 Channel A&B 16B3 - - - 1

Measurement Status

0009 Relay Outputs Transmit 8U0 - - - 1
Count
0010 Logic InputsReceive 8U0 - - - 1
Count

0011:12 0011:12 Configuration, Zero 2B4 - - - 2
0013:14 0013:14 Sensor Input Configuration 2E1 - - - 2
(Load doubling)
Notes:

July 2018 114
KELK PROFINET
Appendix E
PROFINET Fieldbus Protocol
E.1 Introduction
The optional PROFINET Fieldbus Interface provides the mill control computer with
access to:
 Load measurement data at the rate necessary for mill control
 System and measurement status
 Monitor and control the GPA2
The GPA2 uses an Anybus Communicator protocol converter gateway to connect to
the GPA2 to the PROFINET fieldbus. This appendix describes the Anybus
Communicator Gateway converter used by the GPA2 to provide an interface to the
PROFINET fieldbus.
E.2 PROFINET
PROFINET is the open Industrial Ethernet standard for Automation from PROFIBUS
International. The AnyBus Communicator Gateway for PROFINET currently supports
the following protocol features:
 Soft Real-Time (RT) communication
 Cyclic data exchange (10 ms cycle time)
 Acyclic Data exchange (Record Data Requests)
 Up to 64 slots / 1 subslot
 Up to 512 bytes of I/O in each direction
 TCP/IP Configuration via DCP (Discovery and Configuration Protocol)

July 2018 115
KELK PROFINET
E.3 HMS Anybus Communicator for PROFINET
Figure E-1: HMS Anybus Communicator for PROFINET
Reference Description
PROFINET Connector (Ethernet):

A This connector is used to connect the HMS Anybus Communicator for PROFINET
to the fieldbus; refer to section E.3.1: PROFINET Connector (Ethernet)
Status LEDs:
B
Refer to section E.3.5: Indicators.
PC Connector:
This connector is used to connect the HMS Anybus Communicator for PROFINET
C
to a PC for configuration and monitoring purposes; refer to section E.3.2: PC
Connector.
Subnetwork (aka GPA2) Connector:

This connector is used to connect the HMS Anybus Communicator for PROFINET
D
to a serial subnetwork, such as the GPA2; refer to section E.3.3: Subnetwork (aka
GPA2) Connector.
Power Connector:
E This connector is used to apply power to the HMS Anybus Communicator for
PROFINET; refer to section E.3.4: Power Connector.
DIN-rail Connector:
F This connector is used to mount the HMS Anybus Communicator for PROFINET to
a DIN-rail and connects the module to ground, refer to
Table E-1: HMS Anybus Communicator for PROFINET External Features

July 2018 116
KELK PROFINET
E.3.1 PROFINET Connector (Ethernet)
Figure E-2: PROFINET (Ethernet, RJ-45) Connector
Pin Signal
Housing Cable Shield
1 TD+
2 TD-
3 RD+
4 Termination
5 Termination
6 RD-
7 Termination
8 Termination
Table E-2: PROFINET Connector Pinout Details
E.3.2 PC Connector
Figure E-3: Example of Cable to Connect PC to HMS Anybus Communicator 3
3
Provided with HMS Anybus Communicator for PROFINET module.

July 2018 117
KELK PROFINET
DB-9 Female RJ-9

(PC) (Anybus Converter)
Pin 2 Pin 4
Pin 3 Pin 3
Pin 5 Pin 2
N/C Pin 1
Cable
Shield
Figure E-4: Schematic for Cable to Connect PC to HMS Anybus Communicator
Figure E-5: RJ-9 Connector Pin Out
Pin Signal
1 Signal Ground
2 Signal Ground
3 RS232 RX
4 RS232 TX
Table E-3: RJ-9 Connector Pin Out Details

July 2018 118
KELK PROFINET
Figure E-6: DB-9 Connector Pin Out
Pin Signal
Housing Shield, connected to PE
1 N/C
2 RS232 Rx (Input)
3 RS232 Tx (Output)
4 N/C
5 Signal Ground
6-9 N/C
Table E-4: DB-9 Pin Out Details for PC Connection Cable

July 2018 119
KELK PROFINET
E.3.3 Subnetwork (aka GPA2) Connector

The GPA2 PROFINET fieldbus cable (PL044014-6IN) is used to connect the GPA2 to
the HMS Anybus Communicator for PROFINET module via a serial interface. The
subnetwork interface from the Anybus module can provide for RS232, RS422 and
RS485 communication modes but the factory default configuration for the GPA2’s
fieldbus interface is set to the values found in Table E-5 (except for Unit Address,
which is configurable).
Setting Value
15
Unit Address
(factory default)
Mode RS232
Bit Rate 19200 baud
Parity None
Data 8 bits
Stop 1 bit
Table E-5: GPA2 Fieldbus Configuration, Factory Defaults
The subnetwork connector (refer to Figure E-1, ‘D’) on the HMS Anybus
Communicator for PROFINET uses a DB9-female connector. The pinout and details
for this connector is shown in and Table E-6, respectively.
Figure E-7: DB-9 Female Connector Pin Out on PROFINET Module

July 2018 120
KELK PROFINET
Pin Signal
Housing Shield, Connected to PE
1 +5 VDC
2 RS232 Rx
3 RS232 Tx
4 N/C
5 Signal Ground4
6 RS422 Rx+
7 RS422 Rx-
8 RS485+ / RS422 Tx+
9 RS485- / RS422 Tx-
Table E-6: DB-9 Female Connector Pin Out Details on PROFINET Module
The subnetwork connector (refer to KELK Drawing 46799) on the HMS Anybus
Communicator for PROFINET uses a 5-position terminal block style plugin connector.
The pinout and details for this connector is shown in Figure E-8 and Table E-7,
respectively.
Figure E-8: GPA2 Fieldbus Connector Pin Out
4
Connecting this signal directly to Protective Earth (PE) of other nodes may, in case of grounding loops etc., cause damage to the on-board serial
transceivers of the HMS Anybus module. It is therefore generally recommended to connect it only to Signal Ground (if available) of other nodes.

July 2018 121
KELK PROFINET
Pin Signal
1 RS232 Tx
2 N/C
3 Signal Ground
4 N/C
5 RS232 Rx
Table E-7: GPA2 Fieldbus Connector Pin Out Details
The schematic for the GPA2 PROFINET fieldbus cable (PL044014-6IN) is shown in
Figure E-9.
DB-9 Female 5-Pos Plugin

(Anybus Converter) (GPA2 Fieldbus)
Pin 2 Pin 1
Pin 5 Pin 3
Pin 3 Pin 5
Cable
Shield
Figure E-9: GPA2 PROFINET Fieldbus Cable Schematic

July 2018 122
KELK PROFINET
E.3.4 Power Connector

Power is provided to the HMS Anybus Communicator for PROFINET module via a 2-
pin plug-in style connector, as seen in Figure E-1, item ‘D’ and Figure E-10.
Figure E-10: Power Connector Pin Out for PROFINET Converter
Pin Signal
1 +24 VDC
2 GND
Table E-8: Power Connector Pin Out Details for PROFINET Converter
E.3.5 Indicators
Figure E-11: HMS Anybus Communicator for PROFINET Status LEDs

July 2018 123
KELK PROFINET
LED Name State Status

Off Line:
Off There is no connection with HMS Anybus
Communicator for PROFINET
On Line (Running):
A connection with the HMS Anybus Communicator
Communication Green
1 for PROFINET is established and the device is in
Status
‘RUN’ state
On Line (Stop):
A connection with the HMS Anybus Communicator
Green, Flashing
for PROFINET is established but the device is in
‘STOP’ state
Off No Power or Not Initialized
Green Initialized, No Errors
Green, 1 Flash Diagnostic Data Available
Blink:
Green, 2 Flash
Used by engineering tools for identification
2 Device Status
Configuration Error:
Red, 1 Flash Too many modules and/or the I/O size and/or
Configuration mismatch
Red, 3 Flash No Station Name or No IP Address Assigned
Red, 4 Flash Internal Error
Off No Link or Power Off
3 Link / Activity Green Link Established
Green, Flashing Receiving / Transmitting Data
4 Not Used
Off Power Off
Green Running
5
5 Subnet Status Running correctly, but one or more transaction
Green, Flashing
error(s) have occurred
Red Transaction Error / Timeout or Subnet Stopped
Off Power Off
Alternating Red / Invalid or Missing Configuration
Green
Green Initializing
Green, Flashing Running
6 Device Status 6
Red Bootloader Mode
If the Device Status LED is flashing in a sequence
starting with one or more red flashes, please note
Red, Flashing
the sequence pattern and contact the HMS support
department.
Table E-9: HMS Anybus Communicator for PROFINET Status LED Details
NOTE: At 'power ON', the GPA2 Link Status will be red, changing to green after all transactions have been
active at least once. This includes any transactions using “change of state” or “change of state on
trigger” (read or write commands performed to all registers).
5
This LED turns green when all transactions have been active at least once. This includes any transactions using “change of state” or “change of state on
trigger”. If a timeout occurs on a transaction, this LED will turn red.
6
If the gateway is in bootloader mode, then firmware must be restored in order for it to work properly. Start up the Anybus Configuration Manager and
connect to the Anybus Communicator. Choose Tools/Options/Module. Click “Factory Restore” to restore firmware.

July 2018 124
KELK PROFINET
E.4 Setup and Configuration of Anybus Communicator Gateway
This series of steps are only required if the Anybus Communicator Gateway must be
reconfigured. The Anybus Configuration Manager is a Windows-based application
used to supply the Anybus Communicator Gateway with a description of the sub-
network protocol.
1. From the KELK Utilities CD (044303-1), navigate to the \GPA2\PROFINET

subdirectory to install the Anybus Configuration Manager called hms-scm-1204-
169.zip.
2. Power off the GPA2 system, including the Anybus Communicator Gateway
module.
3. After installing the Anybus Configuration Manager application, connect the Anybus
Communicator Gateway serial cable (refer to section E.3.2) to the serial port on the
PC (that will be used to configure the PROFINET module) and the Anybus
Communicator Gateway module’s PC port (refer to Figure E-1: HMS Anybus
Communicator for PROFINET, item ‘C’).
4. Power on the GPA2 system, including the Anybus Communicator Gateway
module.
5. Start the Anybus Configuration Manager application. Once open, the application
will open a “Configuration” window – select cancel and proceed on; refer to Figure
E-12
Figure E-12: Anybus Configuration Manager at Start Up

July 2018 125
KELK PROFINET
6. Verify that the COM port settings on the PC; select the appropriate serial port from
the Tools menu in the Anybus Configuration Manager application; refer Figure
E-13.
Figure E-13: COM Port Setting in the Anybus Configuration Manager Tool Menu
7. Connect to the Anybus Communicator Gateway module by selecting the

highlighted icon shown in Figure E-14.
Figure E-14: Connect Icon
8. The Anybus Communicator Gateway provided by KELK is loaded with necessary

configuration to connect the GPA2 to the AnyBus Communicator Gateway and
then to the PROFINET network.
A copy of this configuration file (44433-3.cfg) can be found on the KELK Utilities
CD (044303-1) by navigating to the following subdirectory: \GPA2\PROFINET\.
Select this configuration by using the File Open icon, as seen in Figure E-15.
Figure E-15: File Open

July 2018 126
KELK PROFINET
9. Then download the configuration to the AnyBus Communicator Gateway by

selecting the icon shown in Figure E-16
Figure E-16: Download Icon
10. Once the configuration file has been downloaded, disconnect and close the
Anybus Configuration Manager application
E.5 GSDML File
On PROFINET, all devices are associated with a GSDML file. The GSDML file is the
equivalent of the PROFIBUS GSD file, and is based on the EXtensible Markup
Language (XML). This file holds information about the device (in this case the Anybus
Communicator), its features, and possible I/O configurations.
A version of the GSDML file for the Anybus Communicator can be found on the KELK
Utilities CD (044303-1) by navigating to the following subdirectory:
\GPA2\PROFINET\; the latest version can also be downloaded from the HMS website,
www.anybus.com.

July 2018 127
KELK PROFINET
E.6 Installing and Removing the Module
E.6.1 Installing the Anybus Communicator Module

11. Press the module downwards (1), to compress the spring in the DIN-rail
mechanism
12. Then push (2) the module against the DIN-rail, in order to make it snap into place.
E.6.2 Removing the Anybus Communicator Module

1. Push the module downwards (1), to compress the spring in the DIN-rail
mechanism
2. Then pull the module outwards (2), in order to snap the module off.

July 2018 128
KELK PROFINET
E.7 Communications
E.7.1 Data Formats

Table E-10 defines the data formats that have been reconstructed after transmission.

16 bit, signed integer, two
16I2 Example -123.45 stored as -12345
decimal digits
8U0 8 bit, unsigned integer
Bitmapped Types
Bit 1 - B Fault
4B2 System Status
Bit 2 - A Fault
Bit 6 - Channel B: Single Sensor Operation (Double
A)
Channel A&B Measurement Bit 7 - Channel B: Simulation
16B3
Status Bit 8 - Channel A: Shunt or FS out of range
(Double B)
Bit 0 - Zero
Enumerated Type
0- A &B
Sensor Input Configuration 1- 2*B
2E1
(Load doubling) 2- 2*A
3- B &A
Table E-10: GPA2 PROFINET Data Formats

July 2018 129
KELK PROFINET
Data Format Notes:
1. Numeric values are decimal (base 10) unless stated otherwise.
2. For bitmapped formats, the condition is enabled (or “on”) when the bit is set to 1
and disabled (or “off”) when the bit is 0, unless stated otherwise.
3. The nomenclature used for each format reflects the basic type and size (in eight-bit
bytes) of the format. The size of each format is always an integral multiple of one
byte. Regardless of their size, data are interpreted as “big-endian” (i.e., the least
significant bit is bit 0 and the most significant bit is the highest-numbered bit for the
format).
4. For formats that do not use all of the available bits, the unused bits are ignored by
the format and are set to zero during transmission.
5. Format names are in the form SSS TTT AAA, where:
o SSS is the Data Size (for the GPA2, this is always 16 bits)
o TTT is the Format Type, where:
I Signed Integer
U Unsigned Integer
E Enumerated
B Bitmapped
o AAA is additional format information, such as for signed/unsigned integer

types, this is the number of implied decimal digits:
0 No decimal digits (no decimal point appears)
1 One decimal digit (decimal point before last digit)
2 Two decimal digits (decimal point before last two digits)
Etc.
Example:
6U2 is 16 bits, unsigned integer, 2 decimal points.
6. For a bitmap, this is a bitmap order number.

July 2018 130
KELK PROFINET
E.7.2 Memory Map

Table E-11 defines the data that may be accessed via the Fieldbus interface. The
grouping of the data reflects the manner in which it is treated by the GPA2. Process
variables (A, B, A+B, A-B) are updated from the GPA2 to the Fieldbus memory at 50
Hz, other variables are updated at approximately 5 Hz.
Byte based addressing is used.
Each GPA2 variable occupies two bytes (MSB:LSB).
Host
Host Read
Write Min Max
Address Name Format Units Notes
Address Value Value
(Dec)
(Dec)
Input A Load
0001:2 16I2 % -327.68 327.67 1
Input B Load
0003:4 16I2 % -327.68 327.67 1
System Status
0005:6 4B2 - - - 1
Channel A&B
0007:8 16B3 - - - 1
Measurement Status
Relay Outputs Transmit
0009 8U0 - - - 1
Count
Logic InputsReceive
0010 8U0 - - - 1
Count
0011:12 0011:12 Configuration, Zero 2B4 - - - 2
Sensor Input Configuration
0013:14 0013:14 2E1 - - - 2
(Load doubling)
Table E-11: PROFINET DP Memory Map
Notes:

July 2018 131
KELK Recommended Spares
Appendix F
Recommended Spares
Select from the following list of recommended spares:
Complete GPA2 System GPA2- -E1 or GPA2- -E2,
where is to contain “12” or “4X”, denoting a

painted or stainless steel NEMA enclosure,
respectively
General Purpose Amplifier Assembly GPA2-RE-E1 or GPA2-RE-E2

GPA2 Core System and Rail Assembly GPA2-00-E1 or GPA2-00-E2
Power Supply Module *07970
Main Module PL046800
Circuit Breaker *01263
Profibus (spare or option) *07202
PROFINET Spare *09112
The modules and circuit breaker shown above are interchangeable, allowing
them to be used as spares in any GPA2 electronics system.
Important Note: The main modules that are supplied alone and the ones
contained within the Complete GPA2 System are set up in
terms of functionality and features at the factory as
described in Appendix A. When ordering spares, customer
must identify the specific requirements of the spare using the
model number designators. KELK Form #881 GPA2
Ordering Form is available for this purpose.

July 2018 132

Tensiometer Manual JT-9050

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tensiometer Manual JT-9050

Uploaded by

Copyright:

Available Formats

TENSION

Vishay Precision Group Canada ULC (KELK)

48 Lesmill Road, Toronto, Ontario, M3B 2T5, CANADA

T: +1 416 445 5850 F: +1 416 445 5972 kelk@vpgsensors.com www.kelk.com

FOR: CN STEEL PLANT ENGINEERING CO. LTD.

APPLICATION: PT. ALUMINIUM EXTRUSION INDONESIA

CUSTOMER P.O. #: 17B203-I-004

KELK JOB #: JT-9050

SHIPPING DATE: MAY 2019

KELK products are warranted against defects in materials

We are not liable for consequential damages. Shipping

WrntyStd (101) 1999-01

KELK MONOBLOC TENSIOMETER

1 Introduction & System Description

Kelk Monobloc Tensiometers are specifically designed to measure tension in metals

1.1 System Description

1.2 Monobloc Description

1.3 Electrical Equipment

FIG. 1.1 SYSTEMS SENSING FORCES ACTING NORMAL TO THE

w = Roll Weight + Bearing & Pillow Block Weight

FIG. 1.2 SYSTEMS SENSING FORCES ACTING PARALLEL TO THE

Fp = T1 cos a - T2 cos b Fp = T1 cos a - T2 cos b

2.0 MONOBLOC SPECIFICATIONS

Capacity Per Outline Drawing.

Sensitivity approx.1.0 mV/V at rated capacity.

Overload Per Outline Drawing (500 to 1000% of rated

Excitation Voltage 10 V nominal, 20V maximum AC or DC.

Repeatability Error Better than 0.05% of full scale output.

Operating Temperature Temperature compensated to 100oC.

Dimensions Per Outline Drawing.

Leads Teflon, shielded - protected by steel reinforced

Calibration Cell calibration traceable to National Institute of

3.1.1 Cables and Load Cell Identification

IT IS MOST IMPORTANT TO REMOVE AND RETAIN THE CALIBRATION

IT IS MOST IMPORTANT TO RECORD THE LOCATION OF EACH LOAD CELL

3.2 Mounting Arrangement

3.2.1 Mounting Sequence

2. Test the load cell cable for leakage resistance.

5. Note the location of each sensor, identifying by serial number.

NOTE: TENSIOMETER ROLLS MUST BE DYNAMICALLY BALANCED IN

When load cell cable termination is required, it must be provided in a vapour-proof

If a longer parallel run exists, separation should be increased to 2 m. The recommended

#18 AWG for up to 90m (300 ft)

THE IMPORTANCE OF GOOD CONNECTIONS AND DRY JUNCTION BOXES

FIG. 1.3 MONOBLOC TENSION MEASURING SYSTEM

4.1 General Purpose Amplifier

4.2 System Set-Up

4.3.1 Force and Pressure Measurement Systems

4.3.2 Tension Measurement Systems

4.4 The Effect of Cable Length

4.4.1 Calibration Constant Correction

In installations involving long interconnecting cables, where correction is required,

(a) Disconnect the interconnecting cable at the amplifier.

If the value of RL is beyond the range of Figure 2, or the system is a 6 wires

For a four conductor connecting cable (the case given in Figure 2)

Cf = 1 + 4 RL where RBR is the output resistance

2. Correct the Calibration Target Load using

From Figure 1 RL = 1.2 ohms

From Figure 2 Cf = 1.02

CTL1 = 1.02 x 79.73%

This value compensates for any errors introduced by the 90 meters of

4.5 System Check and Simulation

CABLE LENGTH CORRECTION FACTOR