© Copyright 2003 by ABB Automation Products GmbHWe reserve the right to technical amendments

This document is protected by copyright. Information in this document isintended only to assist the user in safe and efficient operation of theequipment. Its contents are not to be reproduced in full or part withoutprior approval of legal owner.

ABB Automation Products GmbHBorsigstr. 2, 63755 Alzenau, GermanyTel: +49 551 905-534Fax: +49 551 905-555CCC-support.deapr@de.abb.com

TGU 5, TGU 5-Ex Transmitter forangular position

42/1432 EN Rev. 04Operating manual

Subject to technical changes.Printed in the Fed. Rep. of Germany

42/1432 DE Rev. 04Edition 12.03

2 42/14-32 DE

Table of contents Page

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Mounting and connection instructions . . . . . . . . . . . . 75.1 Unpacking the instrument . . . . . . . . . . . . . . . . . . . . . . 75.2 Mounting location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.3 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.4 Mounting the transmitter . . . . . . . . . . . . . . . . . . . . . . . 75.5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 85.6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.7 Protection against overvoltage transients . . . . . . . . . . 9

6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 Setting the lower range value (zero adjustment) . . . . . 96.2 Setting the upper range value (span adjustment) . . . 10

7 Changing the output signal, measuring range or direction of action 107.1 Changing the out signal . . . . . . . . . . . . . . . . . . . . . . . 107.2 Changing the measuring range . . . . . . . . . . . . . . . . . 117.3 Changing the direction of action . . . . . . . . . . . . . . . . 117.3.1 Transmitters with adjustable span . . . . . . . . . . . . . . 137.3.2 In transmitter with adjustable span . . . . . . . . . . . . . . 13

8 Explosion-protected version . . . . . . . . . . . . . . . . . . . . . 148.1 Data of explosion protection . . . . . . . . . . . . . . . . . . . 148.2 Utilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

12 Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Important Instructions!They must absolutely be read and obeyed!

Proper and safe operation of the TGE 5 (-Ex) transmitter prosupposesthat it is correctly transported and stored, installed and commissionedby experts and carefully operated and maintained.

Only those persons conversant with the installation and commission-ing of similar equipment and who possess the necessary qualifica-tions may work on the apparatus. They must observe the contents ofthis Operating Instruction and the relevant safety regulations for instal-lation and operation of electrical apparatus.

This apparatus has been designed and tested in accordance with DINVDE 0411, Part 1, „Safety Requirements for Electronic MeasuringEquipments“ and has been supplied in a safe condition. To retain theapparatus in safe condition, the safety instructions with the title „Cau-tion“ in this Operating Instruction must be observed. Failure to complywith these safety instructions can result in death, severe bodily injuriesand considerable damage to the apparatus ifself or to other equip-ment.

Should be the information given in the Operating Instruction prove tobe inadequate at any time please consult ABB in your area.

The industrial standards and regulations (e.g. DIN, VDI, VDE) as wellas the directives, specifications and requirements governing explo-sion protection (e.g. ElexV, EX-RL, VDE, DIN EN) referred to this Op-erating Instruction are applicable in Germany. When using this deviceoutside the German Federal jurisdiction, the relevant specifications,standards and regulations applicable in the country where the deviceis used must be observed.

Technical description1 ApplicationThe transmitter types TGU5 and TGU5-Ex are used for the analog mea-surement of angular positions. The angular position is converted into aproportional load-independent direct current so that the measured val-ues can be transferred without line balancing, even over large dis-tances.

The type TGU5 or TGU5-Ex is particularly suitable for attachment toangular position sensors producing only a small torque, e.g. scales orfloat flowmeters. Evens small length changes can be measured bymeans of a coupling lever.

2 Technical dataMeasuring rangesStandard measuring ranges

0... 10° adjustable to 0... 9/ 11°0... 30° adjustable to 0... 27/ 33°0... 60° adjustable to 0... 54/ 66°0... 90° adjustable to 0... 81/ 99°0...180° adjustable to 0...162/198°0...270° adjustable to 0...224/280°

Special measuring rangesFinal value adjustment rangefrom 0... 7,5°/ 16° 1) from 0... 15° / 71° 1) from 0... 60° /165° 1) from 0...150° /280° 2) v0...220° /310° 2)

Shaft ∅ 3 mm, can be freely rotatedTorque required ca. 0,15 NcmZero approx. ± 5% adjustable 3)

1) rechts- und linksdrehend (Blickrichtung auf die Welle) steigender Ausgangsstrom2) Rechtsdrehend steigender Ausgangsstrom, für linksdrehend Code-Nr. 3103) bezogen auf die Ausgangsspanne

Output and Power supply

Jum

per

Br3

open

clos

edcl

osed

clos

edop

en

clos

edcl

osed

clos

edop

en

clos

edcl

osed

clos

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clos

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5 m

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0...2

0 m

A4.

..20

mA

3)

0...

5 m

A0.

..10

mA

0...2

0 m

A4.

..20

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3)

0...

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0...2

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2-w

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4...2

0 m

A

– – – 4...

20 m

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– – – – – – – – – – – –

Max

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600

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600

Ω

Max

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rent

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pply

24 m

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24 m

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24 m

A

100

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100

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12...

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DC

13.2

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14,

×

42/14-32 DE 3

Non-linearity< 1 % (referred to the output span)

Response time< 50 ms (jump 0 %...100 %)

Long-term influence< 0.2 % / year

Residual ripple (peak-peak)Output signal < 1 %Power supply < 1.5 V

Environment conditionsApplication class acc. to DIN 40040

TGU5 HQETGU5-Ex HSE

Ambient temperature -25... +80 °CTGU5-Ex -25... +70 °C

Transportation and storage temperature: -40... +80 °C

Relative atmospheric humidity< 75 % annual average, condensing permitted, occasional

Mechanical stress capabilitiesTested to DIN IEC 68-2-27 and 68-2-6

Impact: 50 g/11 msVibration: 5 g/± 10 mm/5...150 Hz

Interferenc proofInterference proof acc. to NAMUR Recommendation for industri-al standard in 2-wire circuit

Connection, housing, mounting and safety

Electrical connections4-conductor ribbon cable 150 mm long

Mounting orientationany

Test voltage to DIN VDE 04110.5 kV

Material of housingSalt-water-proof cast aluminiumSurface anodizedplastic cover

Weightapprox. 0.2 kg

Explosion protectionSee page 14.

4 42/14-32 DE

4 ConstructionThe transmitter for angular position consists of the independing measu-ring modules and case:

The measuringmodule comprises the subassemblies:– Differential capacitor (capacitor)– Electronics circuit board (electronics) with 4-wire connecting line and

extra printed circuit board for strain relief.The subassemblies are mounted on a plastic flange by means of 3 setsrews.

Differential capacitorDepending on the adjustable measuring range (see table 1) there are 5standard capacitor tapes K1...K5.The rotor (lug) of the differential capacitor has ball bearings.The free end of the shaft has a diameter of 3 mm and projects from theflange.The lug turns between the two circular-shaped stator plates of the capac-itor. The angular position is pecked up contactlessly by the lug anmdtransferred to the electronics by a coupling capacitor which can be rotat-ed.

Table 1 Adjustable measuring range

The electrinics contain:– The potentiometer for adjusting the lower range value (zero R24) and

end of measurement (span R25).– The jumpers Br3 and Br/R10 for adjusting the output current.

– The resistors R39, R40 for matching the electronics to the selectedmeasuring range (capacitor type).

– The 4-wire, 150 mm long connecting line with an extra pcb for strainrelief.

The components for power limitation are situated on the extra pcb in thecase of instruments protected against explosions.

Housing with coverThe housing consists of a cylindrical cup, on the bottom of which the freeshaft end of the measuring module, which is securedwith 3 screws,projects. The power transistor of the electronics is srewed for coolingpurposes by means of a single screw on the housing side.The potentiometer for lower range value (zero) and upper range value(span) are accessible through hole in the housing cover which is fittedinto a circumferential groove.The transmitter can be fastenedto the angular position sensors bymeans of brackets in the circumferential groove on the housing bottomor by means of 3 screws to threade holes which are situated on the frontside, offset by 120°.

Fig. 2 Transmitter construction

K1 from 0... 7,5° bis 0... 16°

K2 from 0... 15° bis 0... 71°

K3 from 0... 60° bis 0...165°

K4 from 0...150° bis 0...280°

K5 from 0...220° bis 0...310°

6 42/14-32 DE

Fig. 3 Marking the lower range value (zero) on the case

NoteThe transmitter shaft is balanced out. Balancing out the coupling isrequired in the case of the angular position sensors wit low controllingtorque.

When securing the couling, minimal strain should be imposed onthe transmitter shaft.The start of scale (zero) of the transmitter is marked on the shaft andhousing .Fasten the coupling so that both markings coincide in the desired hous-ing position (see Fig. 3). A plastic nipple is situated on the other shaftside (take off housing cover) to facilitate adjustment. The zero positioncan be recognized from 2 arrows.In the case of transmitter with span up to 71° (differential capacitors K1and K2), the zero is available repeatedly for the given direction of rota-tion but is marked only at one position (see section 7.3).

Fig. 4 Lower range value (zero) markingh at shaft end

5.5 Electrical connectionElectrical connection is made at the 4-wire connecting line.The direct voltage source must dipose of adequate filtering (permissibleresidual ripple < 1.5 V peak-peak) of the supply voltage.

Fig. 5 Connection diagrambr = brown / gn = green / ws = white / sw = black

Markedelectric „zero“

Start of scale if arrowsin alignment

2-wire connection 4-wire connection3-wire connection

8 42/14-32 DE

Fig. 6 Position of Br/R10, Br3, R40, R39

open Jumper Br3 repluggable

closed

7.2 Changing the measuring rangeThe rating plate gives the measuring range set when the instrument isdelivered. The given measuring range final value can be changed by ap-prox. ± 10% with the potentiometer for upper range value (seesection 6).

Measuring ranges outside the adjustment limits but within the measuringlimits of the differential capacitor given in table 1 can be implemented asfollows:– Bring potentiometer for final value to the center position– Remove printed circuit board with connecting line.– Unsolder resistor R40 and replace by resistance decade (adjustment

range to 60 kΩ).– Set start of scale acc. to section6.1..– Turn shaft to the desired angle and set the output signal to 100%,

using the resistance decade.– Read resistance value from teh decade and solder on as fixed resitor

(metal-film resistance, ± 1%, Gr. 0207) instead of R40. Set upper range value exactly with potentiometer .

Position of R40 see Fig. 6.

7.3 Changing the direction of actionThe start of scale position is marked depending on the direction of rota-tion of the transmitter when delivered (turning right or left loocking at theshaft, increasing output current).

As shown inn Figs. 7, 8, 9, 10, 11 and 12 the transmitters have, depend-ing on the measuring renge of the built-in., differential capacitor (see ta-ble 1) up to 6 action and reverse actioncharacteristics.

Connection lines to the capacitor differential.Ilustrated, turning reight,if turning left (K4 an K5)the lines are crossed.

42/14-32 DE 11

8 Explosion-protected version

8.1 Data of explosion protection

Only with 2-wire connection

Certificate of conformityPTB 03 ATEX 2118

DesignationII 2 G EEx ib IIC T6 orII 2 G EEx ib IIC T4

Temperature classT6 for max. -25°C...40 °C ambient temperatureT4 for max. -25°C...70 °C ambient temperature

Mounting of the unitWithin hazardous areas of Zone 1 or Zone 2

Supply and signal current circuitFor connection to a certified intrinsically safe current circuitwith the following maximum valuesUi = 20 V, Ii = 35 mA, Pi = 700 mW

Effective internal inductance LiNegligibly low

Effective internal capacitance Ci between the connectionsNegligibly low

Effective internal capacitance Ci between the connections and case (ground)

≤ 6 nF

Transmitter TGU5-Ex must be powered from an intrinsically safer certi-fied current source, suitable for connection to the transmitter’s powersupply circuit. In the case of a 2-wire connection, the output signal is shown as achange of the current consumption.

Power supply circuitWith type of protection „intrinsic safety“ II 2 G EEx ib IIC

Rated valuesVoltage 12...20 V DC

CurrentWith 2-wire connection up to 20 mA

Output circuitWith type of protection „intrinsic safety“II 2 G EEx ib IIC

The power supply circuit and output circuit are identical for the 2-wire connection. In the event of a fault, the maximum values of thepower supply circuit will also occur in the output circuit.

If active, intrinsically safe circuits are connected to the output circuit,the sum total of the maximum values of the active, intrinsically safecircuits, connected to the output circuit, including the maximum val-ues of the power supply circuit may not exceed the following values:

Voltage to 20 VCurrent to 35 mAPower to 0.7 W

14 42/14-32 DE

8.2 UtilizationWhen mounting the transmitter TGU5-Ex the „Specifications for elctricalequipment in hazardous areas (ElexV)“, The „Requirements for erectionof electrical equipment in hazardous aresa“ (VDE 0165) and the Certifi-cate of conformity PTB 03 ATEX 2118 must be observed.

Mounting in hazardous areas is permissible if power is taken from a volt-age source having a certified intrinsically-safe circuit. Fig. 13 gives anapplication example in 2-wire connection.

Warning!Befor operating the unit, computational or measuring proof of the intrin-sic safety of such a circuit must be produced.

Work on an explosion-protected device may be performed after eliminat-ing the risk of explosion.

However, befor the equipment can be placed back in operation, it mustbe tested and certified by an authorized inspector.

This is not necessary if the work has been performed by authorized per-sonnel of thje equipment manufacturer. The person conducting repairsmust have appropriate credential. After repairs are completed, the dateand identification code of the person conducting repairs must be affixedto the repaired equipment.

Exempted from these requirements are operations to adjust the start andend of scale.These operations can also be performed by the user, even on the haz-ardous area, taking into consideration the locally required safety mea-sures.

Remarks concerning Fig. 13The transmitter supply unit isolates the intrinsically safe loop to the trans-mitter from the subsequent control room device.

Standard versions of the equipment can be connected to the ouput of thetransmitter supply unit.

Fig. 13 Operation of the angular position transmitter in 2-wire connection

Supply from the transmitter supply unit Contrans I with electrical isola-tion.Connection of the supply unit to the potential equalisation is not neces-sary.

RA

UH

Ex “i”Ex “i”

Contrans ITGE5-Ex

Non-hazardous areaHazardous areaZone 1

42/14-32 DE 15

12 Dimensional drawing

Bild 16 Dimensional drawing (all dimensions in mm)

5.5

43

120°

M 3 x 5

3 x 120°=360°

A

7

5.5

252

39

∅56

∅3h

8

∅54

f8

∅60

Z-138081

175

88(11)

13.5 20

.3~61.5°

Z-13808/2

Connectiondiagram

Ribbon cable2 cord 150 long

View A

42/14-32 DE 19