FMS EMGZ622A User manual

Operating Manual EMGZ622A/642A
Digital Tension Measuring Amplifier
for Double Range Force Sensors
Version 1.13 02/2007 ff
Firmware Version 2.00
Hardware Rev. D
This operation manual is also available in German,
Please contact your local representative.
Diese Bedienungsanleitung ist auch in Deutsch, erhältlich.
Bitte kontaktieren Sie die Vertretung im zuständigen Land.
Ce mode d'emploi est également disponible en Allemand.
Veuillez contacter la représentation locale.
Queste manuale d’installazione è disponibile anche in lingua tedesco.
Vogliate cortesemente contattare la locale rappresentanza.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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1Safety 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! Touch
processor board as little as possible! Touch earthed metal part to discharge static
electricity before opening the housing!
Wrong setting of the jumpers and solder bridges may cause malfunction of the electronic
unit or the total system! Setting of the solder bridges and jumpers must be checked
carefully prior to power on! Setting of the solder bridges should be carried out by trained
personnel only!

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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 Double Range Force Sensors 5
4.3 Electronic Units EMGZ622A/642A 5
5Quick Installation Guide..........................................................................7
6Dimensions.................................................................................................8
7Installation and Wiring ............................................................................9
7.1 Mounting the Electronic Unit 9
7.2 Wiring Diagram 11
7.3 Mounting the Force Sensors 12
8Operating .................................................................................................13
8.1 View of the Operating Panel 13
8.2 Configuring the Electronic Unit 14
8.3 Calibrating the Measuring Amplifier 15
8.4 Simulating Method (recommended) 16
8.5 Mathematical Method 17
8.6 Additional Settings 18
9Parametrization.......................................................................................19
9.1 Schematic Diagram of Parametrization 19
9.2 Parameter List: System Parameters 20
9.3 List of the Parameters EMGZ622A/642A 20
9.4 Description of the Parameters: System Parameters 21
9.5 Description of the Parameters EMGZ622A/642A 22
9.6 Service Mode 25
10 Serial Interface (RS232) .........................................................................26
11 PROFIBUS Interface Description.........................................................27
11.1 Wiring of the PROFIBUS Data Cable 27
11.2 Setting the PROFIBUS Address 27
12 PROFIBUS Interface Description.........................................................29
12.1 GSD File 29
12.2 EMGZ622A DP Slave Functional Description 29
12.3 Initial Parameters 29
12.4 Configuration 30
12.5 Function Code 30
13 Interface CAN-Bus..................................................................................31
14 Interface DeviceNet.................................................................................32
15 Technical Reference................................................................................33
15.1 Additional Setting Elements 33
15.2 Dip-switch for the Analogue Inputs / Outputs 34
15.3 Technical Data 36
16 Trouble Shooting.....................................................................................37

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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 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.
3System Components
An EMGZ622A/642A system consists of the following components (refer also to fig. 1):
Force sensors
•Double range force measuring bearings
•For mechanical/electrical conversion of the tension force
Electronic unit EMGZ622A/642A
•For supplying the force sensors and amplifying of the mV signal
•2...4 channels for 1...2 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 CAN-Bus, PROFIBUS, DeviceNet, Interface RS232
(Variants and options in italic text)

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4System Description
fig. 1: Basic structure shown with the EMGZ612A Tension Measuring Amplifier
E622001e
4.1 Functional Description
The double range 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
EMGZ622A/642A. The electronic unit amplifies the mV signals of each measuring range
depending on configuration. The resulting feedback values are shown in the display in [N] (lbs
if required) for each measuring range. In addition, the feedback values are provided at the
analogue outputs and various interfaces and can be evaluated by analogue instruments, a PLC
or equivalent devices.
4.2 Double Range 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 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.
4.3 Electronic Units EMGZ622A/642A
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 two 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.
Additional settings can be made with Dip switch, jumpers or solder bridges.

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Strain gauge amplifier
The strain gauge amplifier provides the highly accurate power supply (5VDC or 10VDC) for 1
or 2 force sensors per measuring point. 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
breaks 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 range of each measuring point.
Type Number of
channels Sensors per channel Feedback signals
EMGZ622A 1 2 channel 1 = range 1A
channel 2 = range 1B
EMGZ642A 2 2 channel 1 = range 1A
channel 2 = range 1B
channel 3 = range 2A
channel 4 = range 2B
Interface
As an option, there are RS232, PROFIBUS, CAN-Bus or DeviceNet interfaces available.
fig. 2: Block diagram of the electronic unit EMGZ642A E642001e

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5Quick Installation Guide
•Check all your requirements such as:
– configuration of the analogue inputs (power supply, 4 wire or 6 wire circuit)?
– configuration of the analogue 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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6Dimensions
fig. 3: Dimensions E611002e

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7Installation 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. 6).
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 (EMGZ642A only)
E600009e

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7.2 Wiring Diagram
fig. 7: Wiring diagram EMGZ642A. The version EMGZ622A has only channels 1 and 2.
E642002e

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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 4x2x0.75mm2[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. 6).
If two force sensors are used per measuring point, the cables are wired parallel (ref. to wiring
diagram). If wiring is made using 6 wire circuit the Dip-switch, solder bridges must be
modified (ref. to „8.2 Configuring the electronic unit“).
Force sensor excitation can be made using 5VDC (default) or 10VDC (ref. to
„8.2 Configuring the electronic unit“).
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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8Operating
8.1 View of the Operating Panel
fig. 8: Operating panel EMGZ622A/642A E642006e
fig. 9: Switching between the tension feedback values E642003e

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8.2 Configuring the Electronic Unit
The use of the input channels provided is as follows:
Input Channel assignment (ref. also to wiring diagram)
EMGZ622A EMGZ642A
Channel 1 Range 1A (low force range) Range 1A (measuring point 1, low
force range)
Channel 2 Range 1B (high force range) Range 1B (measuring point 1, high
force range)
Channel 3 – Range 2A (measuring point 2, low
force range)
Channel 4 – Range 2B (measuring point 2, high
force range)
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)
Scale output Which tension feedback refers to 10V resp. 20mA?
Config. output 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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fig. 10: Switching between the tension feedback values E642007e
8.3 Calibrating the Measuring Amplifier
The calibration is done for each channel separately.
Channel assignment
Channel 1 Range 1A (measuring point 1, low force range)
Channel 2 Range 1B (measuring point 1, high force range)
Channel 3 Range 2A (measuring point 2, low force range)
Channel 4 Range 2B (measuring point 2, high force range)
It can be calibrated using the „simulating method“ or the „mathematical method“:

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8.4 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. 9).
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 EMGZ642 1/2 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 EMGZ642 1/2 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. 11: Calibrating the measuring
amplifier C431011e

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8.5 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: EMGZ622A/642A“).
fig. 12: Force vectors in the FMS force measuring bearing C431012e
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
()
n
ckGainFeedba ⋅⋅ =2/sinsin 1
γδ

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8.6 Additional Settings
Setting the low-pass filters
The measuring amplifier provides 1 low-pass filter for the display and 1 low-pass filter for the
output signal of each channel. They are used to prevent noise which is added to the signals.
The low-pass filters are configured by setting its cut off frequency to an appropriate value.
The cut off frequency is set in the parameter Lowpass display resp. Lowpass output (ref. to „9.
Parametrization“). Signal variations which are faster than the cut off frequency are then
suppressed. The lower the cut off frequency, the more sluggish the display value resp. the
output signal will be.
Note
If the cut off frequency is set to a value too low, the output signal will become sluggish. It may
be that the feedback value is no longer suitable for control loop applications. You have to pay
attention that the cut off frequency is set to a suitable value.
Setting the limit switches
The measuring amplifier provides a min and a max limit switch per channel. The threshold
values may be set freely using the channel parameters Min. limit / Max. limit (ref. to „9.5
Description of the parameters: EMGZ622A/642A“). If the electronic unit detects exceeding of
the values set, it can switch on an LED and / or a dig. output.
Tapping of the limit switches is done according to the wiring diagram (fig. 6).
Gain switching
If a measuring point is operated with varying measuring conditions (i.e. different material
paths), the gain value of each channel may be switched between two values depending on the
material path. The additional gain values must be calibrated also during setup (ref. to „9.5
Description of the parameters: EMGZ622A/642A“, parameter function Calib. gain 1).
Switching is done using a digital input.
Wiring of the dig. inputs is done according to the wiring diagram (fig. 6).
Digital inputs
The digital inputs may be used for various purposes. Wiring is done according to the wiring
diagram (fig. 6).
Digital outputs
The digital outputs may be used for various purposes. Configuration is done by setting the
channel parameters dig. output 1&2for each channel to an appropriate value (ref. to „9.5
Description of the parameters: EMGZ622A/642A“).
The dig. outputs are operated as „open collector“ outputs. Wiring is done according to the
wiring diagram (fig. 6).
LED on the operating panel
The LED on the operating panel may be used for various purposes. Configuration is done by
setting the channel parameters Config. of LED to an appropriate value (ref. to „9.5 Description
of the parameters: EMGZ622A/642A“).

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9Parametrization
9.1 Schematic Diagram of Parametrization
fig. 13: Parametrization EMGZ642A E642005e

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9.2 Parameter List: System Parameters
Parameter Unit Min Max Default Selected
Language English, French, Italian, German
Measuring System Metric, US standard Metric
Lowpass Display Hz 0.1 10.0 1.0
Identifier [-] 0 255 0
Baud rate 2400, 4800, 9600, 19200 9600
9.3 List of the Parameters EMGZ622A/642A
Channel assignment
Channel 1 Range 1A (measuring point 1, low force range)
Channel 2 Range 1B (measuring point 1, high force range)
Channel 3 Range 2A (measuring point 2, low force range)
Channel 4 Range 2B (measuring point 2, high force range)
Parameter Unit Min Max Default Selected
Offset A/B [Digit] –8000 8000 0
Gain A/B [-] 0.100 9.000 1.000
Gain 1 A/B [-] 0.100 9.000 1.000
Force of sensor A/B [N, kN, cN] 1 9999 1000
Unit of sensor A/B N, kN, cN N
Sensitivity A/B [mV/V] 0.1 5.0 1.8
Min. limit A/B 1) 2) 0
Max. limit A/B 1) 2) 1000
Config LED A/B Min., Max., Error, Okay Max.
Dig. Out 1 A/B Min., Max., Error, Okay Min.
Dig. Out 2 A/B Min., Max., Error, Okay Max
Lowpass output [Hz] 0.1 200.0 10.0
Scale output A/B 1) 2) 1000
Config. Output A/B 0–10V and 0...20mA,
0–10V and 4...20mA, –10V...+10V 0–10V and 0...20mA
1) [N, cN, kN] if measuring system = metric
[lb, clb, klb] if measuring system = US standard
2) A force value can be input. The value consists of 4 digits. The
position of the decimal point depends on the parameter
Force of sensor