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.

Operating Manual EMGZ622A/642A
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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!

Operating Manual EMGZ622A/642A
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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

Operating Manual EMGZ622A/642A
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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

Operating Manual EMGZ622A/642A
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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