FMS EMGZ492.EIP Series User manual

Operating Instructions
EMGZ492.EIP
Dual-channel measuring amplifier for ETHERNET/IP
EMGZ492.R.EIP for mounting on DIN rail
EMGZ492.W.EIP for wall mounting
Document Version 1.0 09/2019 NS
Firmware Version V 2.0.0
EDS Datei FMS_TensionAmpilfier_EMGZ492_EIP_V1_1.eds
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie Ihre lokale FMS Vertretung.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – Alle Rechte vorbehalten.

Operating Instructions EMGZ492.EIP
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1 Table of Contents
1 TABLE OF CONTENTS ............................................................................................................................. 2
2 SAFETY INFORMATION ........................................................................................................................... 4
2.1 Presentation of Safety Information ..................................................................................................... 4
2.1.1 Danger that Could Result in Minor or Moderate Injuries ............................................................... 4
2.1.2 Note Regarding Proper Function ................................................................................................... 4
2.2 General Safety Information ................................................................................................................ 5
3 PRODUCT DESCRIPTION ........................................................................................................................ 6
3.1 Block Diagram .................................................................................................................................... 6
3.2 System Description ............................................................................................................................ 6
3.3 Scope of Delivery ............................................................................................................................... 6
4 QUICK GUIDE/QUICK START .................................................................................................................. 8
4.1 Preparations for Parameterization ..................................................................................................... 8
4.2 Mounting Sequence ........................................................................................................................... 8
4.3 Mounting and Electrical Connections ................................................................................................. 8
4.4 Force sensor Mounting ...................................................................................................................... 9
4.5 Electrical Connections ........................................................................................................................ 9
4.5.1 EMGZ492.R.EIP ............................................................................................................................ 9
4.5.2 EMGZ492.W.EIP ......................................................................................................................... 10
4.5.3 Ethernet Anschlüsse .................................................................................................................... 11
5 CALIBRATION OF THE MEASURING SYSTEM .................................................................................... 12
5.1 Offset Compensation ....................................................................................................................... 12
5.2 Calibration (Adjusting the Gain Factor) ............................................................................................ 12
5.3 Calibration ........................................................................................................................................ 13
5.4 Gain .................................................................................................................................................. 13
5.5 Limit Value Violations ....................................................................................................................... 14
5.5.1 Overload Test .............................................................................................................................. 14
5.5.2 Overflow and Underflow Test ...................................................................................................... 15
5.6 Description of the LEDs ................................................................................................................... 15
6 INTEGRATION INTO THE ETHERNET/IP NETWORK ........................................................................... 16
6.1 EtherNet/IP Interface ........................................................................................................................ 16
6.2 TCP/IP Configuration ....................................................................................................................... 16
6.3 Data Exchange ................................................................................................................................. 16
7 CONFIGURATION .................................................................................................................................... 17
7.1 Modify IP address with RLLinx ......................................................................................................... 17
7.2 Parameter Description ..................................................................................................................... 19
7.3 Cyclic Data Traffic ............................................................................................................................ 22
7.4 Acyclic Data Traffic .......................................................................................................................... 26
8 ETHERNET/IP COMMUNICATION .......................................................................................................... 33
8.1 General Function .............................................................................................................................. 33
8.2 Services and Protocols .................................................................................................................... 33
9 WEB INTERFACE .................................................................................................................................... 34
9.1 Amplifier Access via Web Interface ................................................................................................. 34
9.2 Parameter Settings .......................................................................................................................... 35
9.3 Offset Adjustment and Calibration via Web Browser ....................................................................... 35
9.4 Ethernet Settings .............................................................................................................................. 36

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9.5 System Settings ............................................................................................................................... 36
10 DIMENSIONS ........................................................................................................................................... 37
11 TECHNICAL DATA .................................................................................................................................. 38

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2 Safety Information
All safety information, operating and installation regulations listed here ensure proper
function of the device. Safe operation of the systems requires compliance at all times.
Noncompliance with the safety information or using the device outside of the specified
performance data can endanger the safety and health of persons.
Work with respect to operation, maintenance, retrofit, repair, or setting the device
described here must only be performed by expert personnel.
2.1 Presentation of Safety Information
2.1.1 Danger that Could Result in Minor or Moderate Injuries
Danger, warning, caution
Type of danger and its source
Possible consequences of nonobservance
Measure for danger prevention
2.1.2 Note Regarding Proper Function
Note
Note regarding proper operation
Simplification of operation
Ensuring function

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2.2 General Safety Information
The function of the measuring amplifier is only ensured with the
components in the specified layout to one another. Otherwise, severe
malfunctions may occur. Thus, observe the mounting information on
the following pages.
Observe the local installation regulations.
Improper handling of the electronics module can lead to damage to
the sensitive electronics!
Do not work with a blunt tool (screw driver, pliers, etc.) on the
housing!
Use suitable grounding (grounding wrist strap, etc.) when working on
the electronics.
The devices should have a distance of at least 15 mm to one another
in the control cabinet for proper cooling.

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3 Product Description
3.1 Block Diagram
Figure 1: block diagramEMGZ492.EIP EMGZ492_EIP_BA_Manual.ai
3.2 System Description
The microprocessor-controlled measuring amplifier EMGZ492.EIP series is used in
processing, amplifying, and relaying sensor signals in suitable form to downstream
devices. The measured force values are available via ETHERNET/IP and an analog
voltage output.
The measuring amplifiers are suitable for tension measurements using all FMS force
sensors. Two force sensors A and B can be connected to the device. Both measuring
values are available as individual signal (A and B), as sum signal (A + B), as differential
signal |A – B|or as average value (A + B)/2 for the master controller.
Furthermore, device information, parameters, and system settings can be accessed via
a web browser. Offset compensation and system calibration can also be performed via
the web browser.
3.3 Scope of Delivery
The following is included in the scope of delivery
- Measuring amplifier
- Mounting and operating instructions
The following is not included in the scope of delivery
- AC/DC power supply, minimum requirement: EMC immunity specifications
EN61000-4-2, 3, 4, 5; EN55024 light industry level, criteria A, e.g., TRAKO TXL 035-
0524D
- Cable for power supply

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The following is not included in the scope of delivery, but are available as accessories
from FMS
- Patch cable with RJ45 plug (straight or 90°)
- Sensor cable for the connection of force sensor and measuring amplifier
- M12 plug, D-coded

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4 Quick Guide/Quick Start
In these operating instructions, commissioning of the EMGZ492.EIP amplifier is limited
to the installation procedure, offset compensation, and system calibration.
4.1 Preparations for Parameterization
- Read the operating instructions of the selected force sensor carefully.
- Check your requirements on the system, such as:
o Used units in the system
o Used outputs (0 to 10V and bus)
- Filter settings for actual force value and analog output
- Create the connection diagram for your specific system layout (see chapter
“Electrical Connection”)
4.2 Mounting Sequence
- Mount the force sensors (mounting details can be obtained from the mounting
instructions of the force sensors)
- Connect the force sensors to the amplifier (see 4.5)
- Connect the amplifier to the supply voltage. The voltage supply must be in the range
of 18 to 36 VDC. (See 4.5)
- Perform offset compensation and calibration (see 5 and Fehler! Verweisquelle
konnte nicht gefunden werden.)
- Change the parameter settings as needed (see 9.2)
- Amplifier integration into the ETHERNET/IP network (see 9.5)
4.3 Mounting and Electrical Connections
Warning
To improve natural convection and keep heating of the amplifiers as
low as possible, the devices installed in a cabinet should have a
minimum distance of 15 mm.
Warning
The function of the measuring amplifier is only ensured with the
components in the specified layout to one another. Otherwise,
severe malfunctions may occur. Thus, the mounting information on
the following pages must be followed
Warning
The local installation regulations ensure the safety of electrical
systems. They are not considered in these operating instructions.

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However, they must be met.
4.4 Force sensor Mounting
The force sensors are mounted in line with the mounting instructions of the respective
products. The mounting instructions are included with the force sensors.
4.5 Electrical Connections
Two or four force sensors can be connected to the EMGZ492.EIP. When four sensors are
used, two of them have to be connected in parallel. The force sensors and amplifier are
connected using a 2x2x0.25 mm2 [AWG 23] shielded, twisted cable.
4.5.1 EMGZ492.R.EIP
Figure 2: EMGZ492.R.EIP electrical connections EMGZ492_EIP_BA_Manual.ai
Color specifications (per IEC60757) and coding apply to FMS components only!
For easier installation, the terminal blocks can be detached from the main housing.

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Figure 3: Detachable terminal blocks: use a small slotted screwdriver as a lever
4.5.2 EMGZ492.W.EIP
The 4 screws of the cover with the PG glands and the M12 plug must be loosened for
board access. You can slide out the board by approx. 2 cm (1 in.) and loosen the
terminal blocks for easier connection of the wires.
Figure 4: Pc board with removable terminal blocks EMGZ491_W_EIP_16-11.30.FCStd
Figure 5: EMGZ492.W.EIP electrical connections EMGZ492_EIP_BA_Manual.ai

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4.5.3 Ethernet Anschlüsse
Tabelle 1: Pin Belegung Ethernet Anschluss EMGZ492_EIP_BA_Manual.ai
Warning
Poor grounding can result in electric shocks for persons,
malfunctions of the overall system or damage to the measuring
amplifier! Proper grounding must always be ensured.
Note
Cable shielding may only be connected to one side of the measuring
amplifier. On the side of the force sensor, shielding must remain
open.

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5 Calibration of the Measuring System
There are two options for performing the calibration:
- Via the web browser (see 9)
- Directly in PLC
5.1 Offset Compensation
Using offset calibration, the weight of the measuring roller and the roller bearings is
compensated and the measuring system “zeroed”.
Offset compensation must always be executed prior to the actual calibration. The
measuring roller must not be loaded during the procedure.
5.2 Calibration (Adjusting the Gain Factor)
Calibration is used for matching the gain factor with the force sensors. After calibration,
the displayed force corresponds to the force effectively affecting the material. Two
calibration methods are available. The first calibration method described here uses a
defined weight. There is also a calculation method for the gain. The weight-based
calibration method is simple and delivers more accurate results as it replicates the
material profile (see the figure below) and considers the actual circumstances in the
machine.
If the material tension in the machine cannot be replicated using the weight method
(e.g., for space reasons), the gain can be calculated using the “FMS-Calculator”. This tool
can be downloaded from the FMS homepage.
Figure 6: Replication of the material profile using a defined weight
Tension_Control_Solutions.ai

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5.3 Calibration
- Activate the web interface (see 9) and click on “Offset/Calibration” from the menu
(see 9.3).
- Connect the first force sensor (see 4.5).
- The measuring signal must become positive for loads in measuring direction. If it is
negative, the signal lines of the affected force sensors must be switches at the
terminal block (see 4.5).
- Connect the second force sensor.
- The measuring signal must become positive for loads in measuring direction. If it is
negative, the signal lines of the affected force sensors must be switched at the
terminal block (see 4.5).
- Click on “Adjust Offset” in the web browser.
- Insert material or rope into the machine.
- Load material or rope with a defined weight (see 5.1).
- Click on “Calibrate Gain” in the web browser.
5.4 Gain
Depending on the material wound around the measuring roller, the applied force is not
relayed to the sensors 1:1. Thus, the measured force does not correspond to the
effectively applied force. To correct for this error, the measured force is amplified using
a factor. The factor that is referred to as gain or gain factor is calculated such that the
resulting force corresponds to the applied force. The gain is calculated per the following
formula:
F
Nom
Digit * F
act
N
Gain =
F
Nom
N * F
act
Digit
Explanations
Variable Description
FNom Digit Is the nominal force as binary value after the A/D converter. This
value is a constant with value 11’890. From the user’s point of view,
this value corresponds to an input signal of 9 mV.
The amplifier can measure up to an overload of 37 %.
Fact N Effectively applied force at the measuring system in Newtons.
FNom N Is the nominal force of the measuring system in Newtons.
Fact Digit Measured force at the measuring system as binary value after the
A/D converter. From the user’s point of view, this value corresponds
to a voltage in mV, which is relayed by the measuring system to the
amplifier.

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Example
- Nominal force at 9 mV = 11‘890 digit
- 1 force sensors with 500 N nominal force, as per type plate; Fsys N = 500 N
- Use of a defined weight of 50 kg (corresponds to approx. 500 N); Fact N = 500 N
- Obtain measured force with suspended weight from the PLC, e.g., Fact Digit = 4‘980
11‘890 * 500N
Gain = = 2.388
500N * 4980
Note
The gain factor needs to be calculated for both of the channels
individually.
Note
This calculation is not required when calibrating via web browser.
This calculation type is also used by the FMS Calculator. It is thus possible to directly
copy the gain calculated in FMS Calculator in the gain parameter. Thus, calibration at
the system is not required. However, calibration at the system is preferred over
calibration using FMS Calculator, as it delivers more accurate gain results.
5.5 Limit Value Violations
The amplifier checks the analog input and output for limit value violations. At the input,
it is checked using the input voltage, whether the force sensor is mechanically
overloaded (overload test). The measuring amplifier can measure an overload of 37 %.
At the output, it is checked, whether the output voltage depending on the amplified
input signal will be above or below the physically possible value. In this case, an
overflow and/or underflow is present.
5.5.1 Overload Test
The overload test is performed using the raw value read on the ADC. It is thus not
related to any force and can be applied independently from the nominal force to every
force sensor.
Test rule:
The FMS force sensors deliver 9 mV at the output under nominal force load. In the case
of a load up to the mechanical stop, approx. 12.4 mV are output. These values apply, if
the force sensor is loaded in normal operating direction (red point). In reverse direction,
the values are respectively negative. The amplifier checks overload in both directions.
The limit value for overload is fixed set to 12 mV and/or -12 mV. If one of these limit
values is reached, the overload status bit of the respective force sensors is set. The bit is

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removed again, as soon as the raw value is 0.5 mV below and/or above the triggering
limit value.
5.5.2 Overflow and Underflow Test
The overflow and underflow test is performed with the output value that is relayed to the
DAC, calculated from the gain. If the output value exceeds the maximum possible value,
an overflow is present. If it undercuts the minimum possible value, an underflow is
present.
Test rule
The output voltage is between 0 and +10 V. A hysteresis of +/-10 digits is used for the
test so that the error bits do not trigger for every small over- and/or underflow. Thus, the
overflow triggers, when the theoretically calculated output value of 10.05 V is reached.
For underflow, the value is 0.05 V. When these limit values are reached, the respective
bits are set in the status. The bits are removed, as soon as the output value is within the
valid range again (above 0.05 V and below 9,95 V).
5.6 Description of the LEDs
.R-Version .W-Version
LED Description
PORT1 Port 1 Ethernet cable 1 connected and
linked with counter point
PORT2 Port 2 Ethernet cable 1 connected and
linked with counter point
MS
Green, on: in operation, ok
Green, flashing: standby
Green, red flashing: self-test
Red, flashing: simple error
Red, on: severe error
NS
Green, on: connected
Green, flashing: not connected
Green, red flashing: time-out
connection
Red, on: dual IP
RDY
Illuminates in green as soon as the
voltage supply is connected and the
processor is started.
Figure 7: Signal LEDs on EMGZ492.EIP EMGZ491_EIP_Grafik.ai

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6 Integration into the EtherNet/IP Network
The measuring amplifiers of the EMGZ492.EIP series can operate in an EtherNet/IP
network. Here, the amplifier operates as EtherNet/IP-adapter with the PLC which has
the role of a EtherNet/IP-scanner.
6.1 EtherNet/IP Interface
EtherNet/IP is supported. The respective communication profile is selected by the
controller (master) via the EDS file. The EMGZ492.EIP transfers the actual value in digit
and the status/error byte. In addition, parameters, such as offset actual value, gain
actual value, filter actual value, filter analog output, as well as scaling analog output can
be adjusted.
6.2 TCP/IP Configuration
The Ethernet settings must be known for PLC or web browser to communicate with the
amplifier in an EtherNet/IP network. The system developer configures the address for
every device and has thus a general overview of the address allocation in the network.
The IP address of the amplifier is factory pre-set to 192.168.0.90.
6.3 Data Exchange
The EMGZ492.EIP uses the communication types typical for EtherNet/IP. Cyclic data
traffic is used for the fast transmission of measured data. Acyclic data traffic is used for
parameterization. Cyclic data traffic is used for transmitting the limit value violations.

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7 Configuration
The EMGZ492.EIP can be configured either via the web interface or via ETHERNET/IP.
The parameters “Low-pass filter active” and “Low-pass filter analog output active”
cannot be accessed via the web interface.
7.1 Modify IP address with RLLinx

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7.2 Parameter Description
Access data with RSLogix 5000
Parameter
Name Description
Unit Here you select which unit of measurement is used. The
label located on the sensor will indicate the nominal
force in Newtons.
Note:
This input will also affect the unit of the cyclic process
data.
If lb (pound) is selected, the system switches from metric
to imperial measuring units.
Selection N, kN, lb, g, kg
Specified value N

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Low
-
pass filter active A Here, the status of the low
-
pass filter active value for the
force sensor A is indicated.
This parameter cannot be accessed via the web interface.
Min. 0
Max. 1
Specified value 1
0 = no, inactive, 1 = yes, active
Offset A The values determined with the “Offset Compensation”
procedure are stored in the form of a digital value in the
[Offset] parameter. The value is used for compensating
for the roller weight of force sensor A.
Min. -16’000
Max. 16’000
Specified value 0
Gain A The gain factor ensures that the displayed force matches
the effective force on sensor A.
Min. 0.100
Max. 20.000
Specified value 1.000
Nominal force A The nominal force indicates the measuring capacity of
force sensor A. E.g., if a 500 N force sensors is installed
500 N must be entered.
Unit N
Min. 1.00
Max. 200‘000.00
Specified value 1‘000.00
Limit frequency low
-
pass filter actual value
A
The amplifier features a low
-
pass filter that filters the
measured value is relayed via ETHERNET/IP. This filter is
used for suppressing undesired interference signals that
are superimposed on the measuring signal. Using this
parameter, the limit frequency of the filter of force sensor
A is adjusted. The lower the limit frequency, the slower
the measuring value.
This low-pass filter is independent from the output filter.
Unit Hz
Min. 0.1
Max. 200.0
Specified value 10.0