FMS EMGZ473 User manual

Operation Manual EMGZ473/474
Digital microprocessor controlled Tension Measuring
Amplifier with integrated PROFIBUS®interface
Operation Manual Version 2.03 02/03 ff
Firmware Version 1.04 02/03
GSD Version 1.03 05/02
This operating manual is also available in German.
Please contact your local 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.

Operating Manual EMGZ473/474
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1Safety Instructions
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 informations, that, if ignored, could cause heavy mecanical
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.
When putting the housing cover to the bottom you must ensure that the D-Sub
connection in both bottom and cover is in the right position. The cover can only
be mounted in the right position! If the cover is mounted forcibly the electronic
unit may be damaged!
Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the measuring amplifier! It is vital to ensure that proper earth
connection is done.
Improper handling may damage the fragile electronic equipment! Don’t use rough
tools such as screwdrivers or pliers! Touch earthed metal part to discharge static
electricity before touching the electronic unit!

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Table of contents
1Safety Instructions ....................................................................................2
1.1 Description Conditions 2
1.2 List of Safety Instructions 2
2Definitions..................................................................................................4
3System Components..................................................................................4
4System Description....................................................................................5
4.1 Functional Description 5
4.2 Force Sensor 5
4.3 Electronic Unit EMGZ473/474 5
4.4 Block Diagram 6
5Quick Installation Guide..........................................................................7
6Dimensions.................................................................................................8
6.1 Dimensions EMGZ473 8
6.2 Dimensions EMGZ474 8
7Installation and Wiring ............................................................................9
7.1 Mounting the Measuring Amplifier 9
7.2 Mounting the Force Sensors 9
7.3 Setting Elements on the Electronic Unit 10
7.4 Wiring Diagram EMGZ473 11
7.5 Wiring Diagram EMGZ474 11
7.6 Wiring of Power Supply and PROFIBUS Data Cable 12
7.7 Setting the PROFIBUS Address 13
8PROFIBUS Interface Description.........................................................14
8.1 GSD File 14
8.2 EMGZ473/474 DP Slave Functional Description 14
8.3 Initial Parameters 14
8.4 Configuration 15
8.5 Process Data 16
9Calibrating the Measuring Amplifier ...................................................18
9.1 Simulating Method, Calibration within the PLC 18
9.2 Simulating Method, Calibration using Initial Parameters 19
9.3 Simulating Method, Calibration using Control Byte 19
9.4 Mathematical method (Module 1 only) 20
9.5 Configuring the Lowpass Filter 21
10 Trouble Shooting.....................................................................................22
11 Technical Data.........................................................................................23

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2Definitions
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 0V exactly.
Gain: Amplification factor for the measuring signal. Use of proper value will set the
measuring range of the sensor exactly corresponding to the signal output range.
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.
3System Components
The EMGZ473/474 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 EMGZ473/474
•For supplying 1 or 2 force sensors and amplifying the mV signal
•With intergrated PROFIBUS interface for operation and parametrization
•Operates as PROFIBUS DP slave according to EN 50170
•For wall mounting, set off of the force sensor (EMGZ473)
•For control cabinet mounting (EMGZ474)
PROFIBUS master computer
•For operation of the electronic unit EMGZ473/474
•Operates as PROFIBUS DP master according to EN 50170
•Any master computer or PLC suitable
(Italic text indicates a variant or option)

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4System Description
fig. 1: Basic structure of the EMGZ473 Tension Measuring Amplifier E473001e
4.1 Functional Description
The force sensor measures the tension force in the material and transmits the
measuring value as a mV signal to the electronic unit. The electronic unit amplifies the
mV signal depending on configuration. The resulting feedback value can be read by
the PROFIBUS master. The application specific calculations will be done by the
PROFIBUS master.
4.2 Force Sensor
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 wiring of the strain gauges, the measured value is according also to the
power supply. So, the force sensors are supplied from the electronic unit by a very
accurate power supply.
4.3 Electronic Unit EMGZ473/474
Common
The electronic unit contains a microprocessor to handle all calculations and
communications, the highly accurate sensor power supply and the signal amplifier for
the measuring value. In addition, a PROFIBUS interface is integrated to the electronic
unit. The electronic unit can process the signals of two force sensors (sum signal).
EMGZ473: The EMGZ473 is built into a compact aluminium housing according to
IP67. The cover has an electrical function identical to the PROFIBUS standard plug
(connection of the cables and termination). This allows to disconnect the measuring
amplifier from PROFIBUS without cutting the bus line.
EMGZ474: With control cabinet mounting, the EMGZ474 can be used. Connection is
done with the PROFIBUS D-Sub-9 standard plug. This design is less robust against
environmental influences (protection class IP00).

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Strain gauge amplifier
The strain gauge amplifier provides the highly accurate 4V power supply. 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 calculates a standardized signal
from the digitized measuring value, which is fed to the PROFIBUS interface.
PROFIBUS interface
The EMGZ473/474 operates as PROFIBUS DP slave according to EN 50170. All
settings and the entire communication is done by the integrated PROFIBUS interface.
4.4 Block Diagram
fig. 2: block diagram EMGZ473 E473005e

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5Quick Installation Guide
•Check all your requirements such as: configuration of the PROFIBUS interface
(address number, data format, required PROFIBUS cycle time, termination, etc),
calibration mode (ref. to „9. Calibrating the measuring amplifier“)?
•Draw your final wiring diagram according to the wiring diagram (refer to „7.4
Wiring diagram EMGZ473“ / „7.5 Wiring diagram EMGZ474“)
•Install and wire all your components (refer to „7. Installation and wiring“)
•Make settings in the PROFIBUS master computer (DP master) (ref. to
„8. PROFIBUS Interface Description“)
•Set measuring amplifier into operation and calibrize it by PROFIBUS (refer to
„9. Calibrating the measuring amplifier“)
•Turn system on; proceed a test run with low speed
•If required, activate additional application-specific functions of the PROFIBUS
master computer (DP master)
Note
If a real-time control loop is implemented with the PROFIBUS, it has to be ensured
that the application-specific PROFIBUS protocol is timewise short enough to
provide sufficient control dynamics.

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6Dimensions
6.1 Dimensions EMGZ473
fig. 3 Outline drawing EMGZ473 E473003us
6.2 Dimensions EMGZ474
fig. 4 Outline drawing EMGZ474 E474001us

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7Installation and Wiring
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.
Caution
When putting the housing cover to the bottom you must ensure that the D-Sub
connection in both bottom and cover is in the right position. The cover can only be
mounted in the right position! If the cover is mounted forcibly the electronic unit may
be damaged!
7.1 Mounting the Measuring Amplifier
EMGZ473: The housing with the measuring amplifier is mounted to the machine
frame close to the force sensor.
EMGZ474: The measuring amplifier is snapped on a DIN mounting rail in a control
cabinet.
7.2 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. Wiring of the force sensor cables to the terminals is
done according to the wiring diagram (fig. 6 and 7). This means all analogue wiring is done.
Note
If the wiring to the force sensor is modified by the customer: Connecting the shield of
the signal cable to the measuring amplifier 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 measuring amplifier. On the „force
sensor side“, the shield should stay open.

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7.3 Setting Elements on the Electronic Unit
fig. 5: Setting elements on the electronic unit E473010e

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7.4 Wiring Diagram EMGZ473
fig. 6: Wiring and Terminal Schematics EMGZ473 E473009e
7.5 Wiring Diagram EMGZ474
fig. 7: Wiring and Terminal Schematics EMGZ474 E474002e

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7.6 Wiring of Power Supply and PROFIBUS Data Cable
Wiring of the power supply
Wiring of the power supply (24VDC) to the terminals in the housing cover is done
according to the wiring diagram.
Caution
Bad earth connection may cause electric shock to persons, malfunction of the total
system or damage of the measuring amplifier! It is vital to ensure that proper earth
connection is done.
Caution
Improper handling may damage the fragile electronic equipment! Don’t use rough
tools such as screwdrivers or pliers! Touch earthed metal part to discharge static
electricity before touching the electronic unit!
Wiring of the PROFIBUS cables
The standardized PROFIBUS cable type A
(STP 2x0.342) [AWG 22] has to be used
for the PROFIBUS data cable.
EMGZ473: The cables are bared referring
to fig. 8 and connected to the terminals in
the cover according to the wiring diagram.
EMGZ474: The cables are connected to
the D-Sub-9 PROFIBUS standard
connector according to manufacturer’s instructions.
Both cables connected – Termination open
If both cables are connected (Bus in and Bus out), it has to be ensured that the
connection is not terminated.
EMGZ473: The two termination jumpers (J10, J11) must be free (fig. 5).
EMGZ474: Termination is done according to the instructions of the plug
manufacturer.
Only one cable connected – Termination set
If only one cable is connected (Bus in), the connection must be terminated properly.
EMGZ473: The two termination jumpers (J10, J11) have to be set (fig. 5).
EMGZ474: Termination is done according to the instructions of the plug
manufacturer.
Note
The PROFIBUS network has to be terminated properly. Otherwise the installation
cannot be set into operation. It has to be ensured that only the last device of the
PROFIBUS chain is terminated.
fig. 8: Preparation of the PROFIBUS
cables E470010e

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7.7 Setting the PROFIBUS Address
The measuring amplifier requires a
unique PROFIBUS address which
indicates it definitely in the whole
PROFIBUS network. Therefore no
other PROFIBUS device in the
network may use the same address.
The address has to be between
0...125.
The PROFIBUS address is set with
the DIP switch (fig. 9) and referring
to the table below. After switching
the measuring amplifier off an on,
the new address is valid.
Ad DIP
switch Ad DIP switch Ad DIP switch Ad DIP switch Ad DIP switch
0 0000 0000 25 0001 1001 50 0011 0010 75 0100 1011 100 0110 0100
1 0000 0001 26 0001 1010 51 0011 0011 76 0100 1100 101 0110 0101
2 0000 0010 27 0001 1011 52 0011 0100 77 0100 1101 102 0110 0110
3 0000 0011 28 0001 1100 53 0011 0101 78 0100 1110 103 0110 0111
4 0000 0100 29 0001 1101 54 0011 0110 79 0100 1111 104 0110 1000
5 0000 0101 30 0001 1110 55 0011 0111 80 0101 0000 105 0110 1001
6 0000 0110 31 0001 1111 56 0011 1000 81 0101 0001 106 0110 1010
7 0000 0111 32 0010 0000 57 0011 1001 82 0101 0010 107 0110 1011
8 0000 1000 33 0010 0001 58 0011 1010 83 0101 0011 108 0110 1100
9 0000 1001 34 0010 0010 59 0011 1011 84 0101 0100 109 0110 1101
10 0000 1010 35 0010 0011 60 0011 1100 85 0101 0101 110 0110 1110
11 0000 1011 36 0010 0100 61 0011 1101 86 0101 0110 111 0110 1111
12 0000 1100 37 0010 0101 62 0011 1110 87 0101 0111 112 0111 0000
13 0000 1101 38 0010 0110 63 0011 1111 88 0101 1000 113 0111 0001
14 0000 1110 39 0010 0111 64 0100 0000 89 0101 1001 114 0111 0010
15 0000 1111 40 0010 1000 65 0100 0001 90 0101 1010 115 0111 0011
16 0001 0000 41 0010 1001 66 0100 0010 91 0101 1011 116 0111 0100
17 0001 0001 42 0010 1010 67 0100 0011 92 0101 1100 117 0111 0101
18 0001 0010 43 0010 1011 68 0100 0100 93 0101 1101 118 0111 0110
19 0001 0011 44 0010 1100 69 0100 0101 94 0101 1110 119 0111 0111
20 0001 0100 45 0010 1101 70 0100 0110 95 0101 1111 120 0111 1000
21 0001 0101 46 0010 1110 71 0100 0111 96 0110 0000 121 0111 1001
22 0001 0110 47 0010 1111 72 0100 1000 97 0110 0001 122 0111 1010
23 0001 0111 48 0011 0000 73 0100 1001 98 0110 0010 123 0111 1011
24 0001 1000 49 0011 0001 74 0100 1010 99 0110 0011 124 0111 1100
125 0111 1101
fig. 9: Coding of the PROFIBUS address
(Example with address 54) E470007e

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8PROFIBUS Interface Description
8.1 GSD File
The PROFIBUS DP master has to know which devices are connected to the
PROFIBUS network. For this purpose the GSD file is required. The GSD file for the
EMGZ473/474 measuring amplifier can be taken from the following internet address:
http://www.fms-technology.com/gsd
The GSD file can also be supplied on a floppy disk on request. In this case please
contact FMS customer service.
Read in the GSD file into the PROFIBUS DP master
How to read in the GSD file into the control system (DP master) is depending on the
used control system. For further information, refer to the documentation of the control
system.
Note
The GSD file version must match with the firmware version of the measuring
amplifier. Otherwise there may be problems while setup. Version numbers of
firmware and GSD file are printed to the cover page of this operating manual.
8.2 EMGZ473/474 DP Slave Functional Description
The measuring amplifier EMGZ473/474 supports a PROFIBUS link which operates
according to the PROFIBUS DP protocol according to EN 50170. Hereby the
measuring amplifier operates as DP slave and the control system as DP master.
Several parameters have to be set and met by the control system.
8.3 Initial Parameters
Initial parameters are sent from the control system to the measuring amplifier once
while initialization. They are normally set to a fixed value for a machine with the
programming tool of the control system.
The first bytes of the parameter telegram are specified in the EN 50170 standard. An
user segment of 4 bytes is defined manufacturer-specific for the measuring amplifier.
Byte Use Value Meaning
0 Initial parameter 0
1 (Remain Offset unchanged) Find Offset
1 User Gain Reference,
High Byte 0
≠0
2 User Gain Reference,
Low Byte
(Remain Gain unchanged)
Calibrate Gain: Tells the measuring amplifier
the force value which corresponds to the
actual load.
3 Lowpass filter 0
≠0 Filter OFF
Filter ON (ref. to „9.5 Configuring the
Lowpass Filter“)
Byte 0 (Find Offset) has priotity against Byte 1 + 2 (Calibrate Gain).

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8.4 Configuration
The configuration defines how many process data (byte and word) are sent during the
cyclic communication from the control system to the measuring amplifier and from the
measuring amplifier to the control system. It is normally set to a fixed value for a
program with the programming tool of the control system.
To ensure maximum flexibility using the measuring amplifier, there are different
modules supplied. In a single measuring amplifier only one module can be set active at
a time. The terms and structures are referring to the profile for variable speed drives of
the PROFIBUS user organization.
Module 1: Full control
3 bytes (1 byte and 1 word) are transmitted from the control system to the measuring
amplifier and also 3 bytes (1 byte and 1 word) from the measuring amplifier to the
control system in each data cycle.
request telegram
(master →slave) control byte?
(STB) main reference value? (HSW)
response telegram
(slave →master) status byte
(ZSB) main actual value (HIW)
Module 2: Feedback with status
The control system cyclically sends an empty telegram. The measuring amplifier
answers with the actual feedback value and with a status byte which indicates the
quality of the feedback value. This configuration can be used if offset and gain
adjustment are done and no process parameters of the measuring amplifier are read or
modified, or if the whole evaluation of the feedback value (offset, gain, limit value
monitoring) is done by the control system.
request telegram
(master →slave) empty
response telegram
(slave →master) status byte
(ZSB) main actual value (HIW)
Module 2a: Feedback with status
Identical with module 2 but the status byte is transmitted as a 16 bit word. The upper 8
bit are not used and therefore = 0.
request telegram
(master →slave) empty
response telegram
(slave →master) 00000000 + status byte
(ZSB) main actual value (HIW)

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8.5 Process Data
The number of process data specified in the configuration is transmitted cyclically.
There are manin reference value, main actual value, control byte and status byte.
Control byte (STB)
The control byte transmits the required command to the measuring amplifier. (Module
1 only)
Master →Slave
STB HSW
Bit # 7......0
Value Meaning Remarks
00h Default Normal operating mode
09h Read Device Type
21h Read User Offset
23h Write User Offset HSW = User Offset to be written
25h Find User Offset Measuring value will be set to zero
29h Read User Gain
2Bh Write User Gain HSW = User Gain to be written
2Dh Calibrate User Gain HSW = Force value which corresponds to the
actual material tension
F9h Read Firmware
Version
Main reference value (HSW)
The main reference value transmits the actual parameter value. (Module 1 only)
Master →Slave
STB
HSW
Bit # 15......0
The main reference value is a 16 bit word (range ±32767). The high byte is
transmitted before the low byte.
We recommend to set Offset and Gain in a way that loading the sensor at nominal
force will give a feedback value of 10000 (default). (ref. to „9. Calibrating the
measuring amplifier“)

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Status byte (ZSB)
The status byte indicates the status of the measuring amplifier.
Slave →Master
ZSB HIW
Bit # 7......0
Value Meaning Remarks
00h Ok Acquiring of measuring value ok
02h Overflow The allowed measuring range is exceeded
04h Error An error appeared during acquiring of the
measuring value
06h Overload The sensor power source is overload
09h Read Device Type EMGZ473/474: HIW = 2
21h User Offset read HIW = User Offset read
23h User Offset written HIW = User-Offset written
25h User Offset found HIW = User Offset found
29h User Gain read HIW = User Gain read
2Bh User Gain written HIW = User Gain written
2Dh User Gain calibrated HIW = User Gain calculated
F9h Firmware Version HIW = main version (high byte) + sub version
(low byte)
Main actual value (HIW)
The main actual value transmits the actual measuring value.
Slave →Master
ZSB
HIW
Bit # 15......0
The main actual value is a 16 bit word (range ±32767) which transmits the processed
measuring value of the measuring amplifier. The high byte is transmitted before the
low byte.

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9Calibrating the Measuring Amplifier
To get correct measuring values, offset and gain have to be determinated while setting
into operation. There are several methods for this task:
Method Use with Advantage
Simulating method
calibration within the PLC Module 1+2 No settings required for the measuring amplifier
Simulating method
calibration using initial
parameters
Module 1+2 Can be done without
programming
Simulating method
calibration using control byte Module 1 Highest flexibility
Mathematical method Module 1 Less accurate than simulating
method
9.1 Simulating Method, Calibration within the PLC
The following instructions are referring
to a setup and calibration on-site. The
material tension will be simulated by a
weight (fig. 10). Offste and Gain
calibration is done within the PLC or the
master computer.
•Insert material or a rope loosely to
the machine.
•The offset corresponds to the actually
transmitted main actual value (HIW):
HIWoffset=
•Load material or rope with a defined
weight (fig. 10)
•The gain factor now is calculated
from the actually transmitted main
actual value (HIW):
()
offsetHIWF F
gain
alNo
Calib
−⋅
⋅
=
min
10000
•The determined values for gain and
offset are used by the control system
to calculate the actual material tension in [N] from the main feedback value:
()
offsetHIW
F
gainF alNo
Beff −⋅⋅= 10000
min
Definition of symbols:
FCalib applied calibration load [N or lbs] (refer to fig. 11)
FNominal nominal force of sensor [N or lbs]
FBeff actual material tension [N or lbs]
HIW main actual value
fig. 10: Calibrating the measuring
amplifier C431011e

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9.2 Simulating Method, Calibration using Initial Parameters
The following instructions are referring to a setup and calibration on-site. The material
tension will be simulated by a weight (fig. 10).
Offste and Gain calibration is done in the measuring amplifier using the initial
parameter (ref. also to „8.3 Initial Parameter“).
•Insert material or a rope loosely to the machine.
•Set initial parameter byte 0 to „1“. The measuring amplifier calculates
automatically the new offset value.
•Reset initial parameter byte 0 to „0“.
•Load material or rope with a defined weight (fig. 10)
•Set initial parameter byte 1+2 to a measuring value corresponding to the applied
weight (ref. to „8.3 Initial Parameter“). The measuring amplifier calculates
automatically the new gain value.
•Reset initial parameter byte 1+2 to „0“.
•Offset and Gain are now fail safe stored in the measuring amplifier.
Note
The main actual value (HIW) must also be capable to show overload values correctly.
Therefore the calibration must be done in a way that the HIW range (±32767) is not
fully used at nominal load. We recommend to set Offset and Gain so that loading the
sensor at nominal force will give a feedback value of 10000.
9.3 Simulating Method, Calibration using Control Byte
The following instructions are referring to a setup and calibration on-site. The material
tension will be simulated by a weight (fig. 10).
Offste and Gain calibration is done in the measuring amplifier using the control byte
and the main reference value (module 1 only; ref. also to „8.5 Process Data“).
•Insert material or a rope loosely to the machine.
•Set control byte of a request telegram to „25h“. The measuring amplifier calculates
automatically the new offset value. The new offset value is transmitted in the
related response telegram (ref. to „8.5 Process Data“).
•Load material or rope with a defined weight (fig. 10)
•Set control byte of a request telegram to „2Dh“ and the main reference value
(HSW) to a measuring value corresponding to the applied weight (ref. to „8.3
Initial Parameter“). The measuring amplifier calculates automatically the new gain
value. The new gain value is transmitted in the related response telegram (ref. to
„8.5 Process Data“).
•Offset and Gain are now fail safe stored in the measuring amplifier.
•If required you can switch now to module 2 (feedback with status) (ref. to „8.4
Configuration“). These telegrams are 3 bytes shorter which allows faster cycle
times.

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9.4 Mathematical method (Module 1 only)
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 has to
be done as described
under „Simulating
method, calibration using
control byte“.
•The Gain value will be calculated by the following formula:
Definition of symbols:
αangle between vertical and
measuring web axis FBmaterial tension
βangle between vertical and FMF
Groller weight
γwrap angle of material FMmeasuring force resulting from FB
γ1entry angle of material FMeff effective measuring force
γ2exit angle of material n number of force sensors
δAngle between measuring web
axis and FM
•Set control byte of a request telegram to „2Bh“ and the main reference value
(HSW) to the calculated gain value (ref. to „8.5 Process Data“). The measuring
amplifier stores the gain value. The new gain value is transmitted in the related
response telegram (ref. to „8.5 Process Data“).
•Offset and Gain are now fail safe stored in the measuring amplifier.
•If required you can switch now to module 2 (feedback with status) (ref. to „8.4
Configuration“). These telegrams are 3 bytes shorter which allows faster cycle
times.
fig. 11: Force vectors in the FMS force measuring
bearing C431012e
()
n
ckGainFeedba ⋅⋅ =2/sinsin 1
γδ