FMS EMGZ321 Series User manual

Operating Manual EMGZ321
Digital microprocessor controlled
Double Channel Tension Measuring Amplifier
Version 2.19 10/2015 NS
Firmware Version V2.11 (from S/N 11263xx)
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.

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Table of Contents
1Safety Instructions..................................................................................... 4
1.1 Description Conditions 4
1.2 List of Safety Instructions 5
2System Description.................................................................................... 6
2.1 Functional Description 6
2.2 EMGZ321 Amplifier and its Subunits 7
2.3 EMG321 Sub Types 8
3Quick Installation Guide............................................................................ 9
3.1 Preparations for Set-up 9
3.2 Installation Procedure 9
4Installation and Wiring............................................................................ 10
4.1 Mounting the Force Measuring Roller 10
4.2 Mounting the EMGZ321 10
4.3 Wiring the Tension Monitoring System 11
4.4 Screw Terminal Arrangement 12
4.5 Connection of the Cable Shield 13
4.6 Digital Inputs 13
4.7 Relays Outputs 14
4.8 Opening the Housing 14
5Configuring the System........................................................................... 15
5.1 Description of the Operating Panel 15
5.2 Preparations for System Configuration 16
6Operation.................................................................................................. 18
6.1 Operating the EMGZ321 over the Front Panel 18
6.2 Display Value Selection State 19
6.3 Offset Compensation Procedure 19
6.4 Calibration Methods 20
6.5 Calibration Procedure: 20
7Parameter Setting over the Front Panel ............................................... 22
7.1 Basic Instructions for Parameter Setting 22
7.2 Amplifier Parameter Group 22
7.3 Description of Amplifier Parameters 22
7.4 Outputs Parameter Group 23
7.5 Description of Output Parameters 23
7.6 Relay Parameter Group 25
7.7 Description of Relay Parameters 25
7.8 System Parameter Group 27
7.9 Description System Parameters 27
7.10 Reset to Default Parameters 30
7.11 Complete Parameter List 30
8Parameter Setting via a PC .................................................................... 34
8.1 Parameterisation in an Ethernet Network via Web Browser 35
8.2 Connecting the EMGZ321 Amplifier with a PC (Peer-to-Peer) 38

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9Mechanical Dimensions.......................................................................... 40
10 Trouble Shooting...................................................................................... 42
11 Technical Specification ........................................................................... 43
11.1 Technical Data 43
11.2 Input / Output Configuration 43

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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.

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1.2 List of Safety Instructions
Some of the wire terminals in the power supply board of the EMGZ321W.ACV are
under a tension of 85-264 VAC. Mortal danger! Only specially instructed and
qualified personnel should handle this amplifier unit. In any case the power supply
must be disconnected from the main supply before opening the housing.
Proper function of the FMS tension controllers is only guaranteed with the
recommended application of the components. In case of other arrangement,
heavy malfunction can be the result. 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.
Bad earth connection may cause electric shock to persons, malfunction of the
total system or damage of the control unit. It is vital to ensure a proper earth
ground connection.
The processor board is mounted directly behind the operation panel. 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.

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2System Description
2.1 Functional Description
The EMGZ321 is a double channel strain gauge amplifier for a single measuring
point. The material tension can be measured on both sides of the measuring roller
independently.
The 2 force sensors of the measuring point measure the tension force in the
material and transmit the measuring value as a mV signal to the electronic unit
EMGZ321. The electronic unit amplifies the mV signal of each force sensor
independently. This signal will be fed to the A/D converter. The microprocessor does
then all application specific calculations such as offset, gain, low-pass filter, limit
switches, etc.
A sum value (A+B) and a difference value (׀A-B׀) are calculated from the force
values of the sensors A and B. The resulting feedback values are shown in the
display in [N] or the chosen unit. In addition, the feedback values are provided at the
analogue outputs and can be evaluated by analogue instruments, a PLC or
equivalent devices.
Fig. 1: Application example of EMGZ321 E321004e

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2.2 EMGZ321 Amplifier and its Subunits
As a plug & play unit all functions of the EMGZ321 can be configured very easily via
a user-friendly control panel and two lines LCD. Tension reference values and all
other parameters and functions can be set with keys or remotely via a web browser.
The amplifier is then either connected to a network or via a peer-to-peer
configuration to a laptop or local PC. All parameters are stored in a none-volatile
EEPROM memory.
Automatic offset compensation and calibration, digital signal filtering, function
along with a lot of other features creates a very powerful tension monitoring system.
The fundamental characteristics of the EMGZ321 remain its operation simplicity
and reliability even under challenging operating conditions.
Fig. 2: Block diagram EMGZ321 E321002e
Display and Operation Panel
A dual-line LCD display with 8 characters each line and a well arranged control
panel make the EMGZ321 very easy to set-up and operate. All parameters and
functions are accessible trough the wind rose key pad and three buttons.
Strain gauge amplifier
The build-in strain gauge amplifier delivers a highly accurate supply voltage (5VDC,)
for 2 force sensors. The force sensors can be wired using a 4- wire circuitry.
A highly accurate differential amplifier rises the mV sensor signal up to 10V.

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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 configuration of the strain gauges, the measured value is
proportional to the power supply. EMGZ4321 provides a very accurate power supply
for the wheatstone bridge.
Interface
The EMGZ321 can be embedded in an Ethernet network and the communication is
via a web browser (Ethernet explorer 7 or higher)
2.3 EMG321 Sub Types
EMGZ321.R / .S / .W / .W.ACV
The tension amplifier EMGZ321 series is available in three different housing
options.
EMGZ321.R: Rail mount housing
EMGZ321.S: Panel mount housing
EMGZ321.W / W.ACV Wall mount housing with and without supply unit
Detailed information about the mechanical dimensions refer to the outline drawings
Fig. 30 to 32.
EMGZ321.W.ACV
The tension amplifier type EMGZ321.W.ACV includes a separate power supply that
supports voltage of 85V up to 264V. It transforms the AC input voltage into DC 24V
for the internal system components.

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3Quick Installation Guide
In a Plug & Play configuration the set-up of the EMGZ321 and force sensors is straight
forward and limited to only the offset compensation and the calibration procedure.
3.1 Preparations for Set-up
1. Read the Operation Manual of your force measuring sensors and amplifier
2. Check your requirements such as:
– Desired output configuration 0…10V, ±10V or 0/4… 20mA
– Display unit of nominal force
3. Draw the wiring diagram for your configuration (ref. to “3.5 Wiring the Amplifier“)
4. If required, determine special parameters (ref. to “5.2 Parameterization for
System Configuration”)
3.2 Installation Procedure
1. Mount your force maesuring roller to the machine frame.
2. Wire the force measuring sensors (ref. to “4.3 Wiring the Tension Monitoring
System”)
3. Connect the amplifier to the power supply.
4. The power supply voltage must be in the range 18 to 36V DC.
5. Perform offset compensation and calibration (ref. to paragraphs 4.1 to 4.4)
6. If required, do additional settings (ref. to “5.2 Parameterization for System
Configuration”)

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4Installation 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 FMS tension amplifier is only guaranteed with the
recommended application of the components. Other arrangements, can cause
heavy malfunctions. Installation instructions on the following pages must strictly be
followed.
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.
4.1 Mounting the Force Measuring Roller
Mounting of the force sensors is done according to the FMS installation manual
which is delivered together with the force sensors.
4.2 Mounting the EMGZ321
The EMGZ321 series is available in 3 different housing options. The respective
mechanical dimensions of the different housings can be seen in paragraph 15.

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4.3 Wiring the Tension Monitoring System
Use the original FMS cables to connect the system components together.
The connection between the force sensors and the electronic unit is done with a
2x2x0.25 mm2[AWG 23] cable. The wiring diagrams show how the wiring to the
terminals of the electronic unit is done.
Fig. 3: Wiring diagram EMGZ321 E321001e
Caution
Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the control unit. It is vital to ensure that there is a proper and
secure earth ground connection.

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4.4 Screw Terminal Arrangement
Fig. 4: Screw terminal arrangement on processor board E321003e

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4.5 Connection of the Cable Shield
Cable shields must be
connected as indicated in the
wiring diagram (see Fig. 3 and
4). The shield should be
connected only to the amplifier
side. On the force sensor side,
the shield should stay open.
Other arrangements may
cause ground/earth loops
which may interfere with the
measuring signal. Malfunction
can be the results. If a housing
type with PG glands is used, one must pay heed to a proper connection of the shield. Skinning
of the cable and shield handling are indicated in Fig. 5.
Note
Force sensors deliver a signal of a few mV and are therefore susceptible to external
influences. To increase immunity to interfering use one twisted pair cable for
+signal and –signal. This signal cables must be separated from power lines.
Note
Connecting the shield of the signal cable to the electronic unit and to the force
sensor may cause ground loops which may interfere with the measuring signal.
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.
4.6 Digital Inputs
The EMGZ321 controller provides 2 digital inputs for the special functions of
switching between two different gain factors.
The digital inputs are level triggered. A threshold change activates the gain switch:
•In sensor A from gain factor 1 to gain factor 2
•In sensor b from gain factor 1 to gain factor 2
Signal Name Terminal # Sensor Threshold low Threshold high
Dig. In 1 5 A Gain factor 1 Gain factor 2
Dig. In 2 6 B Gain factor 1 Gain factor 2
Fig. 5: Shield connection E470009e

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4.7 Relays Outputs
The EMGZ321 amplifier provides 2 programmable relay outputs. The outputs are
software controlled. Electrically they are potential-free. Each relay output can
individually be configured to check violations of force limits. The outputs are
configured in the “Relay Parameter Group”.
Following functions can be assigned to each output:
•Indicate if force limit of sensor A has bee violated
•Indicate if force limit of sensor B has bee violated
•Indicate if the sum of the forces of sensor A+B has bee violated
•Indicate if the absolute value of difference ׀A-B׀has bee violated
For more details about the functions refer to paragraph 7.7 “Description Relay
Parameter Group”.
Hardware access via screw terminals (see Fig. 3 and 4)
Signal Name Terminal #
Relay 1/1 7
Relay 1/2 8
Relay 2/1 9
Relay 2/2 10
4.8 Opening the Housing
The amplifier versions EMGZ321.W.ACV is supplied by main supply (85 to 264V AC).
The housings of these controller versions can be opened by removing the front cover
to the screw terminals. This may not be done if the unit is connected to main supply.
Handling of the main supply versions should take place with special care and only
by specially instructed and qualified personnel.
Danger
Some of the wire terminals in the power supply board of the EMGZ321W.ACV are
under a tension of 85-264 VAC. Mortal danger! Only specially instructed and
qualified personnel should handle this amplifier unit. In any case the power supply
must be disconnected from the main supply before opening the housing.

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5Configuring the System
After having mounted and wired the tension controller on the machine, the system
can now be configured to the specific requirements of the application.
5.1 Description of the Operating Panel
Fig. 6: View of the Operating Panel EMGZ309.W C309009
The keys on the operating panel have the following functions:
Key Key function during operation
Enter Offset Compensation Procedure
Enter Calibration Procedure
To enter the Parameter Setting Mode, press the key for longer
than 3 sec. The LED will light and the first parameter group will
appear on the LCD display indicating that you entered the
mode. The State Diagrams (Fig. 12 to 29) in paragraph 7
“Parameter Setting over the Front Panel” will help you to
navigate in the parameter setting mode.
Enter
Changes the parameter selection.
Increases the parameter values. Pressing the button increases
continuously the parameter value.
Decreases the parameter values. Pressing the button reduces
continuously the parameter value.
Fig. 7: Functions of the operation panel keys

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5.2 Preparations for System Configuration
In order to facilitate the configuration of the tension monitoring system it is
advisable to adapt some basic system parameters to the specific requirement of
the application.
1. Adopt password
2. Set the language on the display
3. Set measuring unit
Above features are changed in the 7.8 “System Parameter Group”. Please refer to
Fig. 17 to 19 to visualise the following parameter changing procedures:
A) Adopt Password
The password cannot be changed. It is always 3231. However, it can be adopted or
disabled. If adopted, the system will request the password for every parameter
change. If you wish to adopt the password, follow the following instructions:
1. Hold the key for longer than 3 sec. until you enter the Parametrisation
State.
2. The display shows . Scroll the menu by pressing the key until you
are in the parameter group “System”.
3. Press . The display shows .
4. Press again . The display starts flashing indicating that you can now change
the parameter with the or keys.
5. To confirm your change by pressing the Enter key .
6. Press the key twice, if you want to return to the Operation State. If you
desire to change the language, continue with the steps below.
B) Change Language
The default setting for the language is English.
1. Press to select the Parameter Language
2. Press again . The display starts flashing indicating that you can now change
the parameter with the or keys.
3. To confirm your change by pressing the Enter key .
4. Press the key twice, if you want to return to the Operation State. If you
desire to change the measuring unit, continue with the steps below.
Language
No
/
Yes
Password
No
Amp.
*******

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C) Change the Measuring Units
The default tension measuring unit is N (Newton). The user can, however, select
another unit before the system is calibrated..
1. Press to select the Parameter Unit.
2. Press again . The display starts flashing indicating that you can now change
the unit parameter with the or keys.
3. To confirm your change by pressing the Enter key .
4. Press the key twice to return to the Operation State.
Unit
N

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6Operation
6.1 Operating the EMGZ321 over the Front Panel
The dual channel amplifier EMGZ321 can go in 5 different states:
•Operation State: Amplifier operating
•Display Selection: Selection of force values that are displayed
•Offset Compensation: Automatic procedure to offset the roller weight
•Calibration State: Procedure to calculate the amplifier gain
•Parametrisation State: Set or change parameters
The user can toggle between the different states by pressing a key on the front
panel. Fig. 8 provides an overview about the different Operation States and how to
move from one state to the other.
Fig. 8: Top-level view of operation control E321006e

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6.2 Display Value Selection State
There are several options to display force values the individual channels. The user
can choose between 4 display forms:
S= Sum of sensor A+B or A= Force on sensor A
D= Difference of sensor ׀A-B׀or B= Force on sensor B
6.3 Offset Compensation Procedure
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. Continue with
following steps:
1. Press the key for longer than 3 sec. until you enter the Calibration State.
2. The display shows
3. Press to start the offset compensation for channel A. After pressing the key
this procedure will be executed automatically.
4. The display will indicate
5. Select with key sensor B and repeat step 2 and 3 to do the offset
compensation in sensor A.
6. Press the key to return to the Operation State.
Fig. 9: State diagram offset compensation E321007e
Offset
Sensor
Offset
Running
Offset
Complet
Offset
Sensor A

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6.4 Calibration Methods
The Calibrating procedure (setting the Gain), adjusts
the controller and load cells so that the display gives
you the actual tension value. The method uses a
defined weight. FMS recommends using the method
with the weight (see Fig. 10) since it delivers the most
accurate results.
To set the Gain, load a rope with a defined weight on
the measuring roller. The roller configuration must
correspond to the real material path in the machine
(wrap angle, distances between the rollers etc.).
6.5 Calibration Procedure:
The Calibration Procedure calculates the value for the amplifier gain. The procedure
requests inputs such as the system force and the force corresponding to the
calibration weight. The here determined values are stored in the parameter Gain
and NomForce in the Amplifier Parameter Group. Refer also to Fig. 11 “State
diagram calibration procedure”.
1. Press the key for longer than 3 sec. until you enter the Calibration State.
The display will show:
2. Load the rope with the defined calibration weight as close as possible to the
roller side you want to calibrate first (e.g. left side). The path of the rope must
correspond to the real configuration in the machine (wrap angle, distance of the
rollers etc.).
3. Press to enter the nominal force of the force sensor. The force is indicated
on the label of the installed force sensor.
4. The display will indicate
5. Change the force value with the or keys. Enter the force that has been
installed in this side of the measuring roller.
Fig. 10: Calibrating the measuring amp
l
Adjust
Gain A1
NomForceA
1000.0 N