FMS EMGZ 490 User manual

Operating Manual
EMGZ 490
Tension Amplifier with integrated PROFINET Interface
Version 1.3 09/2015 NS
Firmware Version V1.16
GSDML file V2.3
This operation manual is also available in German.
Please contact your local FMS representative.
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie Ihren nächstgelegenen FMS Vertreter.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved

Operation Manual EMGZ 490
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Table of Content
1Safety Instructions................................................................................ 4
1.1 Description Conditions .....................................................................................................4
1.2 List of safety instructions.................................................................................................4
2Product Description.............................................................................. 6
2.1 Product Range...................................................................................................................6
2.2 Block Diagram EMGZ 490...............................................................................................6
2.3 System Description EMGZ 490.......................................................................................6
3Quick Installation Guide ...................................................................... 7
3.1 Preparations for Set-up ....................................................................................................7
3.2 Installation Procedure ......................................................................................................7
3.3 Installation and Wiring.....................................................................................................7
3.4 Mounting the Force Sensors............................................................................................7
3.5 Wiring the Amplifier..........................................................................................................8
4Calibration of the Measuring System ................................................ 9
4.1 Offset Compensation........................................................................................................9
4.2 Calibration..........................................................................................................................9
4.3 Calibration Procedure.................................................................................................... 10
4.4 Gain .................................................................................................................................. 10
4.5 Limit Violations............................................................................................................... 11
4.6 Description of Signal-LEDs ........................................................................................... 12
5Integration in a PROFINET-network..................................................13
5.1 PROFINET Interface ...................................................................................................... 13
5.2 MAC - Address................................................................................................................. 13
5.3 Assignment of MAC - Addresses.................................................................................. 13
5.4 TCP/IP Configuration..................................................................................................... 14
5.5 System Start-up.............................................................................................................. 15
5.6 Data Exchange................................................................................................................ 15
6Configuration.......................................................................................16
6.1 Description of Parameters............................................................................................ 16
6.2 Cyclic Data Traffic .......................................................................................................... 18
6.3 Acyclic Data Traffic ........................................................................................................ 19
7PROFINET Communication ...............................................................21
7.1 General Function ............................................................................................................ 21
7.2 Services and Protocols .................................................................................................. 21
7.3 Limitations ...................................................................................................................... 22
7.4 Functional Blocks, Example ......................................................................................... 22
7.5 Data Blocks..................................................................................................................... 23
7.6 Trigger Read-/Write-instructions.................................................................................. 24
7.7 Configuration File GSDML............................................................................................. 25
7.8 Tools ................................................................................................................................. 25
8Web Interface......................................................................................26
8.1 Access to the Amplifier over a Web Interface ........................................................... 26

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8.2 Parameter Setting.......................................................................................................... 28
8.3 Offset Compensation and Calibration over the Web Browser ................................ 29
8.4 Ethernet Settings .......................................................................................................... 30
8.5 System Settings ............................................................................................................. 31
9Mechanical Dimensions ....................................................................32
10 Technical Specification ......................................................................34
10.1 PROFINET Characteristics............................................................................................. 34
10.2 Technical Features ......................................................................................................... 34
10.3 Hardware Specification................................................................................................. 35

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1Safety Instructions
All safety related regulations, local codes and instructions that appear in the manual or
on equipment must be observed to ensure personal safety and to prevent damage to
the equipment connected to it. If equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
Do not stress the equipment over the specification limits neither during assembly nor
operation. To do so can be potentially harmful to persons or equipment in the event of a
fault to the equipment.
1.1 Description Conditions
a) Danger of health injury or loss of life
Danger
This symbol refers to high risk for persons to get health injury or loss life. It has to be
followed strictly.
b) Risk of damage of machines
Caution
This symbol refers to information, that, if ignored, could cause heavy mechanical
damage. This warning has to be followed absolutely.
c) Note for proper function
Note
This symbol refers to an important information about proper use. If not followed,
malfunction can be the result.
1.2 List of safety instructions
Proper function of the Tension Measuring Amplifier is only guaranteed with the
recommended application of the components. In case of other arrangement, heavy
malfunction can be the result. Therefore, the installation instructions on the following
pages must be followed strictly.
Local installation regulations are to preserve safety of electric equipment. They are not
taken into consideration by this operating manual. However, they have to be followed
strictly.

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Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the electronic unit! It is vital to ensure that proper earth
connection is done.
Improper handling of the electronic boards may cause damage to the fragile
equipment! Don’t use rough tools such as screwdrivers or pliers! Operators handling
the electronic boards must wear a well earthed bracelet in order to discharge static
electricity.
In order to improve the natural convection and keep the temperature of the amplifiers
that are mounted in a cabinet, to a minimum, a distance of at least 15mm (0.6”)
between the devices must be kept.
During operation the use of not-PROFINET related services such as port scanning, web
services, load testing, and other services and protocols should be avoided. There is the
possibility of a system overload, if such a service is nonetheless used. The
consequence is a connection interruption between EMGZ490 and PLC. The
interruption usually lasts between 3-5 seconds. Afterwards, a new connection is
automatically established again.
The web interface may only be used in the test mode since data communication can
interfere with the PLC. Moreover, one link can be established via a web browser at the
same time.

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2Product Description
2.1 Product Range
The tension amplifier EMGZ 490 series is available in three different housing options.
●EMGZ 490.R DIN-rail mount housing
●EMGZ 490.Ro DIN-rail mount open version
●EMGZ 490.W Wall mount housing
For detailed information about the mechanical dimensions refer to the outline drawings
in chapter 9.
2.2 Block Diagram EMGZ 490
Fig. 1: Block Diagram EMGZ 490 force measuring amplifier E490004e
2.3 System Description EMGZ 490
The microprocessor-controlled amplifiers of EMGZ 490 series are used to amplify,
process and transmit force sensor signals to devices connected in a suitable network.
The measured force values are accessible via the PROFINET bus and on an analog
voltage output. The amplifiers are suitable for tension measurement with all FMS force
sensors. Either one or two sensors can be connected to one amplifier.
Device information, parameters or system settings can be accessed via a web browser.
Offset compensation and calibration of the system is realized through the web browser
which allows you to adjust the amplifier to the most demanding system requirements.

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3Quick Installation Guide
The set-up of the EMGZ 490 and force sensors is limited to only the installation procedure,
offset compensation and the calibration.
3.1 Preparations for Set-up
1. Read the Operation Manual of your force measuring sensors
2. Check your requirements such as:
– required measuring units in the system
–Used outputs (0…10V and Bus)
–Filter settings for analogue output
3. Draw the wiring diagram for your configuration (ref. to 3.5 “Wiring the Amplifier“)
3.2 Installation Procedure
1. Mount the force maesuring sensors to the machine frame (ref. to chapter 3.4)
2. Wire the Force Measuring Sensor(s) (ref. to Fig. 2)
3. Connect the amplifier to the power supply.
4. The supply voltage must in the range between 18 and 36V DC.
5. Perform offset compensation and calibration (ref. to chapters 4.1 to 4.3)
4. If required, do additional settings (chapter 8.2)
5. In tegrate the amplifier in the PROFINET-network (chapter 5)
3.3 Installation and Wiring
Caution
In order to improve the natural convection and keep the temperature of the amplifiers
that are mounted in a cabinet, to a minimum, a distance of at least 15mm (0.6”)
between the devices must be kept..
Caution
Proper function of the Tension Measuring Amplifier is only guaranteed with the
recommended application of the components. In case of other arrangement, heavy
malfunction can be the result. Therefore, the installation instructions on the following
pages must be followed strictly.
Caution
Local installation regulations are to preserve safety of electric equipment. They are not
taken into consideration by this operating manual. However, they have to be followed
strictly.
3.4 Mounting the Force Sensors
Mounting of the force sensors is done according to the FMS Installation manual which is
delivered together with the force sensors.

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3.5 Wiring the Amplifier
One or two force sensors can be connected to the measuring amplifier. When using two
force sensors, the sensors are internally connected in parallel. The connection between
force sensors and measuring amplifier has to be done using a 2x2x0.25mm2[AWG 23]
shielded twisted-pair cable. The cable must be installed separate from power lines.
Fig. 2: Wiring Diagram EMGZ 490
Color scheme (IEC60757) and pin codes are valid for FMS components, only!
Caution
Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the electronic unit! It is vital to ensure that proper earth
connection is done.
Note
The shield should be connected only to the electronic unit. On the force sensor side the
shield should stay open.

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4Calibration of the Measuring System
The system calibration can be performed in two ways:
A) over the web interface (see chapter 8.3)
B) directly in the PLC
4.1 Offset Compensation
With the Offset Compensation one can compensate the roller weight. This procedure is
always performed before the calibration. The force measuring roller should not be
loaded while the Offset Compensation is being done.
4.2 Calibration
The Calibrating procedure (setting the Gain),
adjusts the controller and load cells so that the
display gives you the actual tension value. There
are two methods of calibrating the system. The
first method uses a defined weight. The second
method is based on a calculation method in
conjunction with the FMS Calculator. This
Calculator can be down loaded from the FMS web
page. FMS recommends using the method with the
weight (see Fig. 3) since it delivers the most
accurate results.
To set the Gain, load a rope with a defined weight
on the roller. The roller configuration must
correspond to the real material path in the
machine (wrap angle, distances between the
rollers etc.).
Fig. 3: Calibrating the measuring
amplifier C431011e

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4.3 Calibration Procedure
1. Activate web interface (ref. to chapter 8.1) and call web page „Offset/Calibration
over the web browser” (see chapter 8.3).
2. Connect volt meter to the voltage output (Fig. 2, terminal 4/5)
3. Connect first force sensor to the amplifier (see Fig. 2).
4. Check whether a load in measuring direction (red point) results in a positive volt
reading. If the reading is negative, change signal wires in the corresponding sensor
(Fig. 2, terminals 12/13).
5. If applicable, connect second force sensor.
6. Check whether a load in measuring direction (red point) results in a positive volt
reading. If the reading is negative, change signal wires in the second sensor (Fig. 2,
terminals 22/23).
7. Unload measuring roller by removing material or rope from it.
8. Click the key „Adjust Offset“.
9. Load the rope with the defined calibration weight (Fig. 3).
10. Click the key „Calibrate Gain“. With that the calibration is completed.
4.4 Gain
Depending on the wrap angle of the material on the measuring roller the prevailing
force is not passed one-to-one to the sensors, with the result that the measured
material tension does not correspond to the effective force. In order to account for this
error, the measured force is amplified by multiplier (the Gain). The correction adapts the
measured force with the effective material force. The Gain Factor (V) is calculated with
following formula:
Variables:
Fsys N= Installed system force in Newton. This is determined by the number of used
force sensors in the measuring roller. With one force sensor, the system
force is equal to the nominal force mentioned on the label of the sensor. If
the measuring roller contains two sensors the force is twice as large.
Fsys Digit= System force as a binary value (max. output of A/D-converter). Here it is a
constant with the value 5945. It is independent from the number of used
sensors. From a user perspective, the value corresponds to an input signal of
9mV.
Fist N= Acting force on the measuring system in Newton.
Fist Digit= Force measured on the system as binary value (output of A/D-converter).
From a user perspective, the value corresponds to a voltage in mV, that the
amplifier will receive as an input from the force sensors.
F
sys Digit * Fist N
V =
F
sys N * Fist Digit