FMS EMGZ Series User manual

Operating Manual EMGZ611A...614A
Digital microprocessor controlled
Tension Measuring Amplifier
Version 1.35 01/2011 ff
Firmware Version: ab 2.01
Hardware Rev. D
This operation manual is also available in German, French and Italian..
Please contact your local representative.
Diese Bedienungsanleitung ist auch in Deutsch, Französisch und Italienisch erhältlich.
Bitte kontaktieren Sie die Vertretung im zuständigen Land.
Ce mode d'emploi est également disponible en Français, en Italien et en Anglais.
Veuillez contacter la représentation locale.
Queste manuale d’installazione è disponibile anche in lingua italiano, inglese e francese.
Vogliate cortesemente contattare la locale rappresentanza.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Table of Contents
1 Safety Instructions .................................................................................. 4
1.1 Description conditions 4
1.2 List of safety instructions 4
2 Definitions ............................................................................................... 5
3 System Components ............................................................................... 5
4 System Description ................................................................................. 7
4.1 Functional Description 7
4.2 Force Sensors 7
4.3 Electronic Units EMGZ611A...614A 8
5 Quick Installation Guide ....................................................................... 10
6 Dimensions ........................................................................................... 11
7 Installation and Wiring ......................................................................... 12
7.1 Mounting the Electronic Unit 12
7.2 Wiring Diagram 14
7.3 Mounting the Force Sensors 15
8 Operating ............................................................................................... 16
8.1 View of the Operating Panel 16
8.2 Configuring the Electronic Unit 17
8.3 Calibrating the Measuring Amplifier 18
8.4 Additional Settings 21
9 Parametrisation .................................................................................... 22
9.1 State Diagram Parametrisation 22
9.2 List of the System Parameters 23
9.3 List of the Parameters EMGZ611A...614A 23
9.4 Description of the System Parameters 24
9.5 Description of the Parameters EMGZ611A...614A 25
9.6 Service Mode 28
10 Serial Interface (RS232) ...................................................................... 29
11 PROFIBUS Interface Hardware Description ........................................ 30
11.1 Wiring of the PROFIBUS Data Cable 30
11.2 Setting the PROFIBUS Address 30
12 PROFIBUS Interface Description .......................................................... 32
12.1 GSD File 32
12.2 EMGZ611A/612A/630A DP Slave Functional Description 32
12.3 Initial Parameters 32
12.4 Configuration 33
12.5 Function Code 34
12.6 Error Code 34
13 Interface CAN-Bus ................................................................................. 35

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14 Technical Reference ............................................................................. 36
14.1 Additional Setting Elements 36
14.2 Setting Elements on the Extension Board 37
14.3 Technical Data 38
15 Trouble Shooting ................................................................................... 39

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1 Safety Instructions
1.1 Description conditions
High danger of health
injury or loss of life
Risk of damage
to machines
Notice for
proper function
Danger
This symbol refers to high
risk for persons to get
health injury or loss life. It
has to be followed strictly.
Caution
This symbol refers to risk
of heavy mecanical
damage. This warning has
to be followed absolutely.
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 electronic unit 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 electrical equipment. They are not
taken into consideration in this operating manual. However, they have to be followed
strictly.
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.
The processor board is mounted to the housing cover. Improper handling may
damage the fragile electronic equipment! Don’t use rough tools such as screwdrivers
or pliers! Operators handling the processor board must wear a well earthed bracelet
in order to discharge static electricity.

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2 Definitions
Offset: Correction value for compensation of the zero point difference. Thanks to
the offset, it is ensured that a force of 0N will generate a signal of zero exactly.
Gain: Amplification factor for the measuring signal. Use of an appropriate value
will adjust the force sensor signal to the tension feedback value exactly.
Strain gauge: Electronic component that will change its resistance while its length
has changed. Strain gauges are used in the FMS force sensors for acquisition of
the feedback value.
Subprint: Electronic extension module which can be plugged to the main board of
the electronic unit if required. That way, the possibilities of the electronic unit can
be extended easily.
3 System Components
An EMGZ611A...614A system consists of the following components
(refer also to fig. 1):
Force sensors
 For mechanical/electrical conversion of the tension force
 Force measuring bearing
 Force measuring roller
 Force measuring journal
 Force measuring bearing block
Electronic unit EMGZ611A/612A/613A/614A
 For supplying the force sensors and amplifying of the mV signal
 1...4 channels for 1...4 measuring points
 With operation panel for parametrization
 Digital inputs and outputs freely programmable
 LED’s freely programmable
 With robust aluminium housing
 Supports connection of external feedback displays
 Interface RS232
 Interface CAN-Bus, PROFIBUS, DeviceNet

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(Variant or option in italic text)

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4 System Description
fig. 1: Basic structure shown with the EMGZ612A Double Channel Tension
Measuring Amplifier E612001e
4.1 Functional Description
The force sensors of each measuring point measure the tension force in the
material and transmit the measuring values as mV signals to the electronic units
EMGZ611A...614A. The electronic unit amplifies the mV signals depending on
configuration. The resulting feedback values are shown in the display in [N] (lbs if
required) for each channel. In addition, the feedback values are provided at the
analog outputs and various interfaces and can be evaluated by analog
instruments, a PLC or equivalent devices.
4.2 Force Sensors
The force sensors are based on the flexion beam principle. The flexion is
measured by strain gauges and transmitted to the electronic unit as mV signal.
Due to the Wheatstone Bridge wiring of the strain gauges, the measured value is
depending also to the power supply. So, the force sensors are supplied from the
electronic unit by a very accurate power supply.

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4.3 Electronic Units EMGZ611A...614A
Common
The electronic unit is mounted to a robust aluminium housing. It contains a
microprocessor to handle all calculations and communications, the highly
accurate sensor power supply and the signal amplifiers for the measuring values
of up to four measuring points. The electronic unit has no trimmers and only few
Dip-switch, jumpers to keep most accurate long-time and temperature stability.
Operation
The large backlit display with 2x16 characters, 4 LED’s and large keys guarantee
simple operation. All information is in plain text with the following languages
selectable: English, German, French and Italian. Most of the functions may be
paramterized. The parametrization can be done via the keys or the interfaces. All
inputs are fail-safe stored in an EEPROM.
Strain gauge amplifier
The strain gauge amplifier provides the highly accurate power supply (5VDC, or
10VDC) for 1 or 2 force sensors per channel. The force sensors can be wired using
4 wire circuit or 6 wire circuit. This allows accurate control of the bridge excitation
even with very long cabling.
The power supply is equipped with current control. This allows to detect short
circuit or cable break automatically and to output an error message if required.
A highly accurate, fixed difference amplifier rises the mV signal up to 10V. This
signal will be fed to the A/D converter. The microprocessor then does all
application specific calculations with the digitized measuring value (such as offset,
gain, lowpass filter, limit switches, etc). The resulting feedback value is provided
as both tension and current signal at the same time.
Using digital inputs, the amplifier can be switched easily between 2 different gain
values (for ex. to process different operating conditions). There is no
reconfiguration required to switch the gain values.
The strain gauge amplifier section written above is integrated separately for each
channel to provide independent evaluation of each measuring point.
Type Number of
channels
Sensors per
channel
Feedback signals
EMGZ611A 1 1 or 2 Sum A+B
EMGZ612A 2 1 or 2 Sum A+B
EMGZ613A 3 1 or 2 Sum A+B
EMGZ614A 4 1 or 2 Sum A+B

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Interface
As an option, there are RS232, PROFIBUS, CAN-Bus or DeviceNet interfaces
available.
fig. 2: Block diagram of the electronic unit EMGZ614A E614001e

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5 Quick Installation Guide
 Check all your requirements such as:
– configuration of the analog outputs (signal level)?
– gain switching required?
– digital input / output assignment?
– linking by interface etc.?
 Draw your final wiring diagram according to the wiring diagram (refer to „7.2
Wiring diagram“)
 Install and wire all your components (refer to „7. Installation and wiring“)
 Parametrize and calibrate the measuring amplifier for each channel (refer to
„8. Operating“)
 Put system into operation; proceed a test run with low speed
 If required, do additional settings (refer to „8.4 Additional settings“)

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6 Dimensions
fig. 3: Dimensions E611002e

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7 Installation and Wiring
Caution
Proper function of the electronic unit 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 electrical equipment. They
are not taken into consideration in this operating manual. However, they have to
be followed strictly.
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.
7.1 Mounting the Electronic Unit
The housing can be mounted in a control cabinet or directly beside the machine.
All connections are led into the housing through glands and are connected to the
plug-in screw terminals according to the wiring diagram (fig. 7).
fig. 4: Wiring path inside the housing E600011e

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Caution
The processor board is mounted to the housing cover. Improper handling may
damage the fragile electronic equipment! Don’t use rough tools such as
screwdrivers or pliers! Touch processor board as little as possible! Touch earthed
metal part to discharge static electricity before open the housing!
fig. 5: Screw terminal arrangement on the electronic unit E600012e
fig. 6: Screw terminal arrangement on the extension board (EMGZ613A/614A only)
E600009e

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7.2 Wiring Diagram
fig. 7: Wiring diagram EMGZ614A. The versions EMGZ611A...613A may vary in
the number of sub-boards. E614014e

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7.3 Mounting the Force Sensors
Mounting of the force sensors is done referring to the FMS Installation manual
which is delivered together with the force sensors. The connection between the
force sensors and the electronic unit is done using 2x2x0.75mm2 [AWG 18]
shielded twisted pair cable. (With cable length below 15m, 2x2x0.25 mm2 [AWG
23] is also suitable.) The cable must be installed separate from power lines.
Wiring to the terminals of the electronic unit is done according to the wiring
diagram (fig. 7). If two force sensors are used per measuring point, the cables are
wired parallel (ref. to wiring diagram, channel 1).
Note
The force sensor signal consists of only a few mV and is therefore susceptible to
external influences to the cable. To increase immunity to interfering use one pair
of the twisted pair cable for +signal and –signal.
Note
Connecting the shield of the signal cable to the electronic unit and to the force
sensor may cause ground circuits which may interfere the measuring signal
massively. Malfunction can be the result. The shield should be connected only to
the electronic unit. On the „force sensor side“, the shield should stay open.

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8 Operating
8.1 View of the Operating Panel
fig. 8: Operating panel EMGZ611A...614A E614013e
fig. 9: Main operating menu EMGZ614A E614010e

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8.2 Configuring the Electronic Unit
Prior to the first calibration, the following settings must be done for each channel
(ref. to „9. Parametrization“):
Global parameters
Language Required display language
Measuring system Metric (default) or US standard
Channel parameters
Force of sensor Ref. to nameplate of the force sensor
Unit of sensor Ref. to nameplate of the force sensor
Sensitivity FMS force sensors = 1.8mV/V (default)
1 or 2 sensors 1 or 2 per channel
Scale output Which tension feedback refers to 10V resp.
20mA?
Config. output 0-10V and 0...20mA (default)
or 0-10V and 4...20mA
or -10V...+10V
Notice: With a tension signal 0...10V, tension
and current output are active at the same time.
Jumpers for the analog outputs (ref. also to „14. Technical Reference“)
Channels 1 / 2 / 3 / 4 0...10V (Default) or ±10V,
corresponding to parameter Config. output
Note
Wrong setting of the parameters may cause malfunction of the electronic unit!
Setting of the parameters must be done carefully prior to setting into operation!

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8.3 Calibrating the Measuring Amplifier
The calibration is done for each channel separately. It can be calibrated using the
„simulating method“ or the „mathematical method“:
Simulating Method (recommended)
The following instructions are referring to a
setup and calibration on-site. The material
tension will be simulated by a weight (fig.
10).
Check force sensors
 Connect the first force sensor (ref. to
wiring diagram).
 Check if a positive value is displayed
when loading the sensor in measuring
direction. If not, exchange terminals
+signal and –signal on the measuring
amplifier.
 If used, connect the second force sensor.
 Check if a positive value is displayed
when loading the sensor in measuring
direction. If not, exchange terminals +signal and –signal on the measuring
amplifier.
Find offset
 Insert material or a rope loosely to the machine.
 Press MODE key. Search and select the module Spec.F EMGZ614 11) and the
special function Find offset with the    keys (fig. 9).
 Find offset by pressing the  key for 3 seconds (fig. 9). The electronic unit
calculates automatically the new offset value. The display will return to the
main operating menu.
(The offset may also be determined alternatively with the digital input Find Offset;
refer to wiring diagram.)
Find gain
 Load material or rope with a defined weight (fig. 10)
 Press MODE key. Search and select the module Spec.F EMGZ614 11) and the
special function Calibration with the    keys (fig. 9).
 Set the force referring to the applied weight into the display with the   keys
and confirm with  key (fig. 9). The electronic unit calculates automatically the
new gain value. The display will return to the main operating menu.
fig. 10: Calibrating the measuring
amplifier C431011e

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EMGZ612A...EMGZ614A
The calibration of the measuring amplifier written above applies to module 1. It
must be done also for module 2...4. For that purpose use the special functions
from module
Spec.F EMGZ614 2 / Spec.F EMGZ614 3 / Spec.F EMGZ614 4 (ref. to fig. 9).
1) Depending on the electronic unit used the modules are named as follows:
Spec.F EMGZ611 n / Spec.F EMGZ612 n / Spec.F EMGZ613 n / Spec.F
EMGZ614 n
Mathematical method
If the material tension cannot be simulated, calibration has to be done by
calculation. This way of calibrating is less accurate because the exact angles are
often unknown and the effective mounting conditions, which usually deviate from
the ideal, are not taken into account.
 Offset adjustment is done as written under „Simulating method“.
 The Gain value will be calculated by the following formula and then inputted in
the parameter Gain (refer to „9.5 Description of the parameters
EMGZ611A...614A“).
fig. 11: Force vectors in the FMS force measuring bearing C431012e

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Definition of symbols:
 angle between vertical and
measuring web axis
FB material tension

angle between vertical and FM FG roller weight

wrap angle of material FM measuring force resulting from FB
1 entry angle of material FMeff effective measuring force
2 exit angle of material n number of force sensors
 Angle between measuring web axis
and FM
 
n
ckGainFeedba  2/sinsin
1
