FMS RTM X42.Modbus Technical Document

RTM X42.Modbus Installation Manual and
Operating Instructions
Telemetry System for Wire Tension Measurements in Cage
and Tubular Type Stranders
Document version 3.20
Published/author 12/2019 NS
Diese Bedienungsanleitung ist auch in Englisch 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 System Extensions to the RTM X42 Measuring System ................................................................... 5
3.3 Main Components .............................................................................................................................. 6
3.4 Scope of Supply ................................................................................................................................. 7
4INSTALLATION AND ELECTRICAL CONNECTIONS ............................................................................. 8
4.1 Installation of Force Sensor for Core ................................................................................................. 8
4.2 Installation of the Force Sensor in the Rotating Part of the Machine ................................................ 8
4.3 Installation of the Electronics Components in the Rotating Part of the Machine ............................... 9
4.4 Electrical Connection ....................................................................................................................... 10
4.4.1 EMGZ482T.Modbus Receiver Module (with battery) .................................................................. 10
4.4.1 EMGZ482T.Modbus.24VDC Receiver Module (version without battery, with 24VDC power
supply via slip rings on the strander) ........................................................................................................ 11
4.5 EMGZ484T.Modbus Channel Extension Module ............................................................................ 13
4.5.1 EMGZ482R.Modbus Receiver Module........................................................................................ 13
5OPERATION AND DISPLAY ................................................................................................................... 15
5.1 Offset Compensation of the Force Sensors..................................................................................... 16
5.2 Force Sensor Calibration ................................................................................................................. 16
5.3 Charger ............................................................................................................................................ 17
6CONFIGURATION.................................................................................................................................... 18
6.1 Quick Start........................................................................................................................................ 18
6.2 System Parameters.......................................................................................................................... 19
6.3 System Parameter Overview ........................................................................................................... 21
7GATEWAY................................................................................................................................................ 23
7.1 Electrical Connection ....................................................................................................................... 23
7.2 Summary of Gateway Installation and Start-up ............................................................................... 24
7.3 RTM X42 Gateway Technical Data.................................................................................................. 24
7.4 Data Exchange between RTM and PLC .......................................................................................... 24
7.5 ANYBUS Gateway AB9001 Register............................................................................................... 31
8MAINTENANCE ....................................................................................................................................... 34
9DIMENSIONS ........................................................................................................................................... 35
10 ERROR CAUSES AND TROUBLESHOOTING ...................................................................................... 36
11 TECHNICAL DATA .................................................................................................................................. 37
11.1 EMGZ482T.Modbus Transmitter Module......................................................................................... 37
11.2 EMGZ482R.Modbus Receiver Module ............................................................................................ 37
11.3 EMGZ484T.Modbus Channel Extension Module ............................................................................ 38
11.4 Certifications .................................................................................................................................... 38
11.5 Lloyd's Register Type Approval ....................................................................................................... 39

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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 telemetry system RTM X42 uses force sensors for measuring the wire tension of
strands and wires. It radio-transmits the measured values from the rotating to the static
part of the machine. The telemetry system RTM X42 with its components is an
integrated system. The individual components are optimally aligned to one another.
Thanks to its modular and space-saving design, it can be ideally used in confined
conditions of tubular type stranding machines, and cage type stranders with up to 42
spools. The machine efficiency is increased as well as the production yield during wire
and cable production.
3.2 System Extensions to the RTM X42 Measuring System
RTM X42.CC Control Center – Master controller with pre-installed RTM Monitoring &
Control Software
-Clear presentation of measured values
-Storage, printing of measured data, quality documentation for your customers
-Integrated solution with user-friendly interface
-Storage of recipes, fast setup/conversion to other products
-Wide database for analysis, sound statements regarding system performance as
basis for process improvements
RTM X42.BC Brake control – Brake actuators on every spool carrier
-Integrated solution, fully automated control of the pull-off force
-For belt and rope type friction brakes, continuous production with highest quality
-Simple design, maintenance-free, robust, easy to retrofit, highest reliability
-Proven battery technology, ease of operation, long lifetime, highest efficiency

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3.3 Main Components
Figure 1: RTM X42 main components RTM_X42_Modbus_BA_Manual.ai
Main component designations
Item Description
1a to 1f Telemetry system RTM X42
1a Force sensor(s), according to your specifications
1b Channel extension module(s)
1c Transmitter module
1d Receiver module
1e Force sensor (for core)
1f Dig. input for production length
not shown Battery for transmitter module and charger for battery
not shown Connection cable from force sensors to transmitter module resp.
extension modules
not shown Patch cable for gateway or PLC connection
not shown Measuring amplifier for core
Table 1: Main Components

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3.4 Scope of Supply
Scope of supply:
Force sensors, model and size according to specification; transmitter module(s) with
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; RTM X42 system installation manual and operating instructions
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:
Gateway; switch; patch cable for the connection of receiver module and gateway resp.
PLC

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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.Modbus Receiver Module (with battery)
The connection cables are pre-fabricated with respective connectors.

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Figure 5: EMGZ482T.Modbus electrical connection
RTM_X42_Modbus_BA_Manual.ai
4.4.1 EMGZ482T.Modbus.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.Modbus.24VDC electrical connection
RTM_X42_Modbus_BA_Manual.ai

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4.5 EMGZ484T.Modbus Channel Extension Module
Figure 7: EMGZ484T.Modbus 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).
4.5.1 EMGZ482R.Modbus Receiver Module

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Figure 8: EMGZ482R.Modbus electrical connection
RTM_X42_Modbus_BA_Manual.ai
EMGZ482R.Modbus 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
limits collective alarm, limit pre alarm collective
alarm, radio connection, battery state of charge,
core tension value
17, 27 Relay 2/1 – 2/2
18, 28 Relay 3/1 – 3/2
19, 29 Relay 4/1 – 4/2
Table 2: EMGZ482R.Modbus pin assignment
The RTM X42 system has pre-configured relay outputs. The respective alarm output is
activated if the assigned function condition occurs.

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5Operation and Display
The EMGZ482R.Modbus receiver module features buttons and a display for the
configuration.
The >0< and Cal buttons have no function.
System parameters can be adjusted via the operating panel
Figure 9: Receiver module operation and display RTM_X42_Modbus_BA_Manual.ai
Operation and Display
Item Description
1 LED
2 Main operating panel with navigation buttons and confirmation button
3 “PARA” button for access to the configuration
4 Battery indicator in the EMGZ482T.Modbus transmitter module
5 bars – 100% charged
4 bars – 80% charged
3 bars – 60% charged
2 bars – 40% charged
1 bar – 20% charged, battery replacement recommended
5 Visual indicator of the quality of the radio connection
Full indicator – 100 %
No indicator – 0 %
6 Without function
Table 3: Receiver module operation and display

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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 (do not place a wire)
-Turn the lay-plate until the force sensor, for which the offset compensation is
performed, is vertically over the axis of rotation (12 o’clock position)
-The force indicate due to the weight of the lay plate must be compensated in the
PLC so that the outputted value is “0.”
Figure 10: Lay-plate alignment RTM_X42_Modbus_BA_Manual.ai
For the offset compensation of the force sensor for the core observe the operating
manual of the measuring amplifier connected to this force sensor.
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.

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Figure 11: 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 cable 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.
For the calibration of the force sensor for the core observe the operating manual of the
measuring amplifier connected to this force sensor.
5.3 Charger
Figure 12: 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.Modbus 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 and the gateway using a patch
cable.
-Connect the gateway to the power supply (24 VDC)
-Connect the EMGZ482R.Modbus receiver module to the power supply (24 VDC)
-Switch on the power supply for both devices
-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 “Modbus V3.15”. This describes the currently loaded
firmware.
-The RTM X42 system is now ready and can be configured.

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6.2 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.
Figure 13: System parameter 1 RTM_X42_Modbus_BA_Manual.ai

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Figure 14: System parameter 2 RTM_X42_Modbus_BA_Manual.ai