FMS RTM X42.IO Technical Document

RTM X42.IO Installation Manual and Operating
Instructions
Telemetry System for Wire Tension Monitoring in Cage and
Tubular Stranders – with analogue outputs up to 10 channels
Document version 3.60
Published/author 01/2020 NS
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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1Content
1CONTENT................................................................................................................................................... 2
2SAFETY INFORMATION ........................................................................................................................... 3
2.1 Presentation of Safety Information..................................................................................................... 3
2.1.1 Danger that Could Result in Minor or Moderate Injuries ............................................................... 3
2.1.2 Note Regarding Proper Function ................................................................................................... 3
2.2 General Safety Information ................................................................................................................ 3
3PRODUCT INFORMATION........................................................................................................................ 5
3.1 Functional Description........................................................................................................................ 5
3.2 Main Components .............................................................................................................................. 5
3.3 Scope of Supply ................................................................................................................................. 6
4INSTALLATION AND ELECTRICAL CONNECTIONS ............................................................................. 7
4.1 Installation of Force Sensor for Core ................................................................................................. 7
4.2 Installation of the Force Sensor in the Rotating Part of the Machine ................................................ 7
4.3 Installation of the Electronics Components in the Rotating Part of the Machine ............................... 8
4.4 Electrical Connection ......................................................................................................................... 9
4.4.1 EMGZ482T Receiver Module (with battery) .................................................................................. 9
4.4.1 EMGZ482T.24VDC Receiver Module (version without battery, with 24VDC power supply via slip
rings on the strander)................................................................................................................................ 10
4.5 EMGZ484T Channel Extension Module .......................................................................................... 12
4.5.1 EMGZ482R Receiver Module...................................................................................................... 13
4.5.1 EMGZ48R Extension Modules .................................................................................................... 14
5OPERATION AND DISPLAY OF THE RECEIVER MODULE EMGZ482R ............................................ 16
5.1 Offset Compensation of the Force Sensors..................................................................................... 17
5.2 Force Sensor Calibration ................................................................................................................. 18
5.3 Charger ............................................................................................................................................ 19
6CONFIGURATION.................................................................................................................................... 20
6.1 Quick Start........................................................................................................................................ 20
6.2 Menu and navigation........................................................................................................................ 20
6.3 List of System Parameters ............................................................................................................... 20
6.4 List of channel 1 to 10 and core parameters.................................................................................... 23
6.5 List of relay output parameters ........................................................................................................ 24
6.6 Reset to default parameters............................................................................................................. 25
7CONFIGURATION VIA WEB BROWSER ............................................................................................... 26
8DIMENSIONS ........................................................................................................................................... 31
9TECHNICAL DATA .................................................................................................................................. 33
9.1 EMGZ482T Transmitter Module ...................................................................................................... 33
9.2 EMGZ482R Receiver Module .......................................................................................................... 33
9.3 EMGZ484T Channel Extension Module (max 2 pcs.) ..................................................................... 34
9.4 Certifications .................................................................................................................................... 34
9.5 Lloyd's Register Type Approval ....................................................................................................... 35

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2Safety Information
All safety information, operating and installation regulations listed here ensure proper
function of the device. Safe operation of the system 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
2.2 General Safety Information
Flying parts
If the battery is not secured correctly, it can be ejected in the case of
rotating machines.
Secure the battery using the knurled screws
Changes or modification to this device that have not been expressly
approved by FMS AG, will result in the FCC approval for operation of
this device being voided.
This device complies with the FCC Rules Part 15 as well as the RSS
standards issued in Canada not requiring approval. Operation is

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subject to the following two conditions:
-The device may not cause any harmful interference, and
-This device must accept any interference received, including
interference that may cause undesired operation of the
device
Information about radio frequency radiation
This device complies with the FCC limit values for an uncontrolled
environment. This device should be installed and operated such that
a minimum distance of 20 cm is maintained between radiation
source and your body. This transmitter must not be operated near or
in connection with another antenna or transmitter
The function of this system is only ensured with the components in
the specified layout to one another. Otherwise, severe malfunctions
may occur. Thus, the installation information on the following pages
must be followed.
The local installation regulations ensure the safety of electrical
systems. They are not considered in these operating instructions.
However, they must be met.
Poor grounding can result in electric shocks for persons,
malfunctions of the overall system or damage to the control
electronics! Proper grounding must always be ensured.
It is of utmost importance to compensate for the centrifugal forces
generated through the rotation of the strander. Non-compensated
force-measuring rollers lead to faulty measurements.
Electrical connections must be implemented by an expert.
All system components are sensitive components that can be
damaged in the case of improper installation! Installation must be
performed by trained service personnel!

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3Product Information
3.1 Functional Description
The RTM X42 IO Telemetry System provides the tension value of single strands or wires
in cage or tubular type stranding machines. All personnel involved in the production
environment gain easy access to the to these important process parameters. For
controlling purposes a PLCcan be interfaced via analogue outputs. Many OEMs currently
deliver their new machines with preinstalled RTM X42 IO systems, but due to the
modular concept and the compact components, retrofitting our system to your existing
machinery is also straightforward. Reliable radio transmission of the data and optional
battery-packs make slip rings obsolete. The typical RTM X42 IO system can handle the
measurement of up to 10 individual wires or strands, but it is also possible to
interconnect multiple telemetry systems to allow for an unlimited number of force
sensors.
3.2 Main Components
Figure 1: RTM X42 main components RTM_X42_IO_BA_Manual.ai
Main component designations
Item Description
1a to 1f Telemetry system RTM X42 IO
1a Force sensor(s), according to your specifications
1b Channel extension module(s) (max 2)
1c Transmitter module
1d Receiver module
1e Force sensor (for core)
1f Dig. input for production length (e.g. proximity switch)
not shown Battery for transmitter module and charger for battery
not shown Connection cable from force sensors to transmitter module resp.

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extension modules
1g Measuring amplifier for core
Table 1: Main Components
3.3 Scope of Supply
Scope of supply:
Force sensors, model and size according to specification; transmitter module(s) with 20
Ah battery/ies and charger, channel extension module(s); receiver module(s); pre-
fabricated connection cables, force sensor to channel extension module and/or to
receiver module; pre-fabricated connection cables of the channel extension modules to
transmitter module
Options:
Transmitter module with 24VDC power supply instead of battery
The following is not included in the scope of supply:
Pulleys, installation material; 24VDC power supply for receiver module, cable for power
supply
Accessories:
Patch cable for web browser

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4Installation and Electrical Connections
4.1 Installation of Force Sensor for Core
Core measurement in static part of machine
The following information describes the installation of the core
sensor when installed outside the rotating part of the machine
The red point should be aligned in the direction of the resulting force. Further
installation information can be found in the installation manual of the force sensor.
Figure 2: Force sensor alignment in static area RTM_X42_Modbus_BA_Manual.ai
4.2 Installation of the Force Sensor in the Rotating Part of the Machine
In rotating applications, the force sensors are installed such that the centrifugal forces
are compensated.
Note
It is of utmost importance to compensate for the centrifugal forces
generated through the rotation of the strander. Non-compensated
force-measuring rollers lead to faulty measurements,
In the case of FMS force sensors of the RMGZ series, this is achieved by aligning the
force sensor such that the measuring direction is exactly parallel to the axis of rotation
of the strander. The red point of the force sensor points in the direction of the positive
force component.
Correct alignment of the red point can be tested after offset compensation and
calibration. If the display of an unloaded force sensor is always 0 N in all positions (e.g.,
in 12 o’clock or 6 o’clock position), the force measuring roller is aligned correctly.

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Figure 3: Force sensor alignment, here RMGZ200
RMGZ200_NEU_2017_BA_Manual.ai
Parallel alignment
The exact, parallel alignment of the measuring direction to the axis
of rotation of the machine is decisive for achieving precise measured
data.
Otherwise, measured value fluctuations occur during machine
operation due to the high sensitivity of the FMS force sensors. These
interfere with the assessment of the product quality later.
Due to irregularities in the installation surfaces, the alignment may have to be
readjusted very precisely. Some FMS force sensors feature an integrated mechanism
facilitating this fine adjustment. For force sensors without such features, we
recommend the use of shims or thin metal strips.
4.3 Installation of the Electronics Components in the Rotating Part of
the Machine
The transmitter module and the channel extension modules should be mounted as
closely as possible to the axis of rotation of the strander. This reduces the influencing
centrifugal forces.
During installation of the transmitter module, make sure that the centrifugal forces do
not act in the direction of the fastening screws of the battery.
Make also sure that the transmission path to the receiver module is free from obstacles.
Mount the receiver as high as possible.

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Abbildung 4: Installation RTM_X42_Modbus_BA_Manual.ai
4.4 Electrical Connection
4.4.1 EMGZ482T Receiver Module (with battery)
The connection cables are pre-fabricated with respective connectors.

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Figure 5: EMGZ482T electrical connection RTM_X42_Modbus_BA_Manual.ai
4.4.1 EMGZ482T.24VDC Receiver Module (version without battery, with 24VDC
power supply via slip rings on the strander)
The connections between the force measuring rollers and transmitter are realized using
a 2x2x0.25 mm2 [AWG 23] cable with 2 shielded, twisted pairs of strands.
The cables have connectors on both sides to facilitate installation.

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Figure 6: EMGZ482T.24VDC electrical connection
RTM_X42_Modbus_BA_Manual.ai

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4.5 EMGZ484T Channel Extension Module
Figure 7: EMGZ484T electrical connection RTM_X42_Modbus_BA_Manual.ai
Bus Termination Plug
All Bus & Power Socket have to be connected. Otherwise errors in
communcaiton may occure.
Always insert the included bus termination plug to last channel
extension module in the row (out).

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4.5.1 EMGZ482R Receiver Module
Figure 8: EMGZ482R electrical connection RTM_X42_IO_BA_Manual.ai
EMGZ482R pin assignment
Pin(s) Description
1 24 VDC+
2 24 VDC
-
3 PE
10, 11 24 VDC output
12 GND for 24 VDC
13 Digital input for production length
14 Analog input for force sensor core
16, 26 Relay 1/1 – 1/2 Configurable relay outputs 1 to 4:
Tension value limits channel 1, 2; tension value
17, 27 Relay 2/1 – 2/2

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18, 28 Relay 3/1 – 3/2 limits collective alarm, limit pre alarm collective
alarm, radio connection, battery state of charge,
core tension value
19, 29 Relay 4/1 – 4/2
Table 2: EMGZ482R pin assignment
The RTM X42 system has pre-configured relay outputs. The respective alarm output is
activated if the assigned function condition occurs.
4.5.1 EMGZ48R Extension Modules
Figure 9: EMGZ482R electrical connection RTM_X42_IO_BA_Manual.ai
Pin assignment EMGZ484R
Pin (s) Description

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1 bis 3 Output 0 to 10 VDC; 0/4 to 20 mA
4 bis 6 Output 0 to 10 VDC; 0/4 to 20 mA
7 / 19 Relay 1/1 – 1/2
8 / 20 Relay 2/1 – 2/2
9 / 21 Relay 3/1 – 3/2
10 / 22 Relay 4/1 – 4/2
13 bis 15 Output 0 to 10 VDC; 0/4 to 20 mA
16 bis 18 Output 0 to 10 VDC; 0/4 to 20 mA
Table 3: EMGZ484R pin assignment

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5Operation and Display of the receiver module
EMGZ482R
Figure 10: Receiver module operation and display
RTM_X42_IO_BA_Manual.ai
Operation and Display
Pos. Description
1 Display, 2 x 8 Digits
2 Start offset compensation
3 Cal – Calibration
4 Para – access to parameter menu
5 Main operating field with
Navigation button (scroll within a menu)
Change button (change values up or down)
Confirmation button (confirm a selection, select)
10 Battery status of transmitter module EMGZ482T
5 bar segments – 100% charge
4 bar segments – 80% charge
3 bar segments – 60% charge
2 bar segments – 40% charge
1 bar segments – 20% charge, exchange / re-charge battery
11, 12 LED bars of tension values channels 1 and channel 2

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13 to 16 Additional, optional LED bars for max. of 10 channels, depending on
system size.
Table 4: Receiver module operation and display
5.1 Offset Compensation of the Force Sensors
Offset compensation is used to compensate for the weight of the pulley on the force
sensor. The measuring system is practically “zeroed.”
Observe the following:
-The force sensor may only be loaded with the pulley (no wire on the pulley)
-Rotate the lay-plate until the desired force sensor, for which the offset compensation
is performed, is vertically over the axis of rotation (12 o’clock position)
Figure 11: Lay-plate alignment RTM_X42_Modbus_BA_Manual.ai
-Press and hold the button >0< for min. 3 sec.
-Force sensor number is displayed
-Select the desired number by pressing the navigation buttons
-Press confirmation button to select the desired channel
-The display shows "Offset running" and "Offset complete"
-The calculated offset value is stored automatically
-For other channels, repeat the steps
Press to return to the main menu
Please note
The offset compensation must be carried out individually for each
channel on the 12 clock position of the base plate.
The offset compensation of the force sensor for the core strand can either be done via
the measuring amplifier connected to this force sensor or the EMGZ482R. If you do it

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via the amplifier, please follow the instruction of the operating manual of the measuring
amplifier.
5.2 Force Sensor Calibration
Calibration is used for matching the measuring amplifier with the force sensor. The so-
called gain factor is determined. After calibration, the displayed force corresponds to
the force effectively affecting the material. Two calibration methods are possible; one
computational method and calibration with a defined weight force. The defined weight-
based calibration method is simple and delivers more accurate results as it replicates
the material profile and considers the actual circumstances in the machine.
Figure 12: Application of a defined weight force to the force sensor
RTM_X42_Modbus_BA_Manual.ai
To adjust the gain, load the measuring roller with a rope or wire with a defined weight
attached to its end. The cable must correspond to the real material course in the
machine (wrap angle, distances between the rollers, etc.). The displayed/determined
digit value must now be assigned in the PLC to the weight force corresponding to the
calibration weight.
Please note that the force sensor which is to be calibrated shall be on the 12 o'clock
position.
-Press and hold the button "Cal" for min. 3 sec.
-Channel number and Gain is displayed
-Select the desired number by pressing the < or > buttons
-Press confirmation button to select the desired channel
-The display shows "NomForce" and respective channel number. Enter the nominal
force in N of the force sensor. This value can be found on product label of the sensor.
-Adjust the value with the Change button and press the confirmation button.
-"Calibra" is displayed now. Here you enter the defined weight in the displayed unit
that is attached to the rope or wire on the force sensor.
-Adjust the value with the Change button and press the confirmation button.
-The calibration start and shows "Calibra complete" if it is finished.

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-The calculated gain value is stored automatically
-For other channels, repeat the steps
Press to return to the main menu
For the calibration of the force sensor for the core can either be done via the measuring
amplifier connected to this force sensor or the EMGZ482R. If you do it via the amplifier,
please follow the instruction of the operating manual of the measuring amplifier.
5.3 Charger
Figure 13: Charger with battery RTM_Ladegerät_Akku_10Ah_01.png
-Connect battery to charger
-The state of charge LED lights up red if the battery is discharged
-The safety circuit protects the batteries from overcharging.
-Charging is finished as soon as the battery pack reached its maximum charge
capacity. The charging process takes 3-4 hours.
-The state of charge LED lights up green if the battery is charged
-The battery must be connected in the battery compartment of the EMGZ482T prior
to start-up.
-If a battery is not needed for the moment, it may remain in the charger
Flying parts
If the battery is not secured correctly, it can be ejected in the case of
rotating machines.
Secure the battery using the knurled screws. Tighten the knurled screws
sufficiently.

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6Configuration
6.1 Quick Start
-Insert the battery into the EMGZ482T transmitter module and secure with both
knurled screws. The screws must be tightened sufficiently otherwise, the centrifugal
forces caused by cage rotation could eject the battery.
oConnect the 24VDC power supply of the machine if a version without battery
is used
-Connect the EMGZ482R.Modbus receiver module to the power supply 24 (18 bis 36)
VDC
-Switch on the power supply
-The radio connection of the RTM X42 system is established automatically. This can
take approx. 5 to 10 seconds.
-After system start and establishment of the radio connection, the display in the
receiver module, e.g., shows “RTM X42 V 3.60”. This describes the currently loaded
firmware.
-The RTM X42 system is now ready and can be configured.
6.2 Menu and navigation
All configuratable paramters are defined in multiple levels.
To acces the navigation, follow these steps:
-Press and hold the Para button for min. 3 sec.
-Press the navigation buttons to the point System
-Press the confirmation button
System parameters
The system parameter group contains the general parameters that control the
operation of the RTM X42 system, but do not influence the actual measurement.
Channel parameters 1 to 10
Configuration of the force sensors in the machine
Core parameters
Configuration of the core force sensor
Parameters for relay outputs
Configuration of the relay outputs
Default
reset the system to factory setting
6.3 List of System Parameters
System Parameters
Parameter Description
Language Language on the display of the operating panel
Unit [-]