FMS EMGZ480 User manual

Operating Manual
EMGZ480
EMGZ480.M16
Digital microprocessor controlled Tension Measuring
Amplifier with integrated CAN-BUS®interface
Operating Manual Version 1.10 10/2007 ff
Firmware Version 1.01
GSD Version 1.00 08/06
This operating 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.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

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Table of contents
1Safety Instructions ....................................................................................4
1.1 Warnings 4
1.2 List of Safety Instructions 4
2Definitions..................................................................................................4
3System Components..................................................................................5
4System Description....................................................................................6
4.1 Functional Description 6
4.2 Force Sensor 7
4.3 Electronic Unit EMGZ480, EMGZ480.M16 7
5Quick Installation Guide..........................................................................8
6Dimensions.................................................................................................9
6.1 Dimensions EMGZ480 9
6.2 Dimensions EMGZ480.M16 10
7Installation and Wiring ..........................................................................11
7.1 Mounting the Force Sensors 11
7.2 Mounting the Measuring Amplifier 12
7.3 Connector Configuration and Setting Elements 12
7.4 Wiring Diagrams 14
8Calibrating the Measuring Amplifier ...................................................16
8.1 Simulating Method, Calibration with the PLC or PC 16
8.2 Mathematical Method 17
8.3 Scaling of Analogue Output 18
8.4 Configuring the Lowpass Filter 18
9Parameter Setting....................................................................................19
9.1 List of System Parameters 19
9.2 List of Parameter EMGZ 480 / 480.M16 19
9.3 Description of the System Parameters 20
9.4 Description of Parameters EMGZ480 / 480.M16 21
10 Specification of the CAN-Bus Interface (Devise profile)...................24
10.1 General Remarks 24
10.2 Summary of Objects (application specific) 24
10.3 Device Identification 25
11 CAN Bus Object Catalogue....................................................................26
11.1 Object 2001: Parameter Offset 26
11.2 Object 2002: Parameter Gain 28
11.3 Object 2003: Parameter Force of Sensor 30
11.4 Object 2004: Parameter Unit of Sensor 32
11.5 Object 2005: Parameter Lowpass Filter 34
11.6 Object 2006: Parameter Limit value 1 min or max 36
11.7 Object 2007: Parameter Limit value 1 38
11.8 Object 2008: Parameter Limit value 2 min or max 40
11.9 Object 2009: Parameter Limit value 2 42

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11.10 Object 2040: Parameter scaling analogue output 44
11.11 Object 2051: Parameter Find offset 46
11.12 Object 2052: Parameter Calibration 47
12 CAN-BUS Catalogue System Parameter Objects................................48
12.1 Object 2080: System Parameter Language 48
12.2 Object 2081: System Parameter Measuring System 50
12.3 Object 2082: System Parameter Baudrate 52
12.4 Object 2083: System Parameter Cycle time PDO 54
13 CAN-BUS Catalogue Operating System Objects.................................56
13.1 Object 7100: Cross values A/D-Converter 56
13.2 Object 7130: Feedback value 57
14 CAN-BUS Catalogue Action Objects....................................................58
14.1 Object 2210h: Parameter Set Default Parameters 58
15 CAN-BUS Catalogue Status Objects.....................................................59
15.1 Object 2100: Operating status 59
15.2 Object 6150: Analogue Input Status 60
15.3 Object 6508: Alarms 61
16 Communication Profile...........................................................................62
16.1 PDO_0 (1800 / 1A00) ID: 180h + Node ID 62
16.2 PDO_1 (1801 / 1A01) ID: 280h + Node ID 62
17 Complete Object Overview ....................................................................63
18 Non-Volatile Data Memory (EEPROM)...............................................64
19 Technical Reference................................................................................65
19.1 Other Elements for Settings of EMGZ 480 65
19.2 Function of the CAN-Bus LED (red) 65
20 Trouble Shooting.....................................................................................66
21 Technical Data.........................................................................................67

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1Safety Instructions
1.1 Warnings
a) High danger of health injury or loss of life
Danger
This symbol refers to high risk for persons to get health injury or loss life. Instructions
have to be followed strictly.
b) Risk of damage of machines
Caution
This symbol refers to information, that, if ignored, could cause heavy mecanical damage.
This warning has to be followed absolutely.
c) Note for proper function
Note
This symbol refers to important information about proper use of the devise. If not
followed, malfunction can be the result.
1.2 List of Safety Instructions
The functionality of the Tension Measuring Amplifier is only guaranteed, if the
components and their application are used as recommended by FMS. Arrangements
other than the one recommended here can cause heavy malfunction. The installation
instructions on the following pages must strictly be followed.
Local installation regulations are to preserve safety of electric equipment. They are not
taken into consideration by this operating manual. However, they have to be strictly
followed.
Improper handling may damage the fragile electronic equipment! Don’t use rough
tools such as screwdrivers or pliers! Operators handling the processor board must
wear a well earthed bracelet in order to discharge static electricity.
Bad earth ground 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 ground connection is
done.

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2Definitions
CAN (Controller Area Network): CAN is an asynchronous, serial bus system. It was
designed to reduce wires in cable harnesses. The CAN bus system works according the
Carrier Sense Multiple Access / Collision Avoidance System. It’s a very reliable system that
is used in large numbers in the automotive industry since 1989.
Offset: Correction value for compensation of the roller or pulley weight. The offset
adjustment ensured that a force of 0N will generate a signal of 0V exactly.
Gain: Amplification factor for the measuring signal. The proper value will set the
measuring range of the sensor to the corresponding output range of the signal.
3System Components
An EMGZ480/EMGZ480.M16 system consist of the following components (refer to Fig. 1
and Fig. 2):
Force sensors
•For mechanical/electrical conversion of the tension force
•Force measuring bearing
•Force measuring roller
•Force measuring journal
Electronic unit EMGZ480
•Supplying 1 or 2 force sensors
•With integrated CAN-BUS interface for operation and parametrisation
•Operates as CAN Open CiA-DS 301 Slave
•One analogue output
•Wall mounting version
Electronic unit EMGZ480.M16
•Optimised for rotating applications (M16 connector)
•Supplying 1 or 2 force sensors
•With integrated CAN-BUS interface for operation and parametrisation
•Operates as CAN Open CiA-DS 301 Slave
•Wall mounting version
CAN-BUS master computer
•For operation of the electronic unit EMGZ480 / EMGZ480.M16
•Operates as CAN Open CiA-DS 301 Master
•Any master computer or PLC suitable
(Italic text indicates a variant or option)

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4System Description
Fig. 1: Basic application of the EMGZ480 Tension Measuring Amplifier E480001e
Fig. 2: Basic application of the EMGZ480.M16 Tension Measuring E480015e
Amplifier with wireless data transmission
4.1 Functional Description
The force measuring sensor gathers the tension force in the material and transmits the
value as a mV signal to the electronic unit. There the mV signal is amplified and
conditioned depending on the chosen configuration. The resulting feedback value can be
read by the CAN-BUS master. The application dependent calculations are done by the
CAN-BUS master.

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4.2 Force Sensor
The force measuring sensors base on the flexion or dual flexion beam principle. The
flexion in the sensor body is measured by strain gauges as a mV signal. In order to
minimize the power supply influence to the strain gauges Wheatstone Bridge and achieve
a clean and accurate amplification, the force sensors are supplied with a very stable,
controlled supply voltage.
4.3 Electronic Unit EMGZ480, EMGZ480.M16
General Information
A microprocessor in the electronic unit handles all calculation and communication tasks.
The electronic unit contains a signal amplifier with a highly accurate sensor power supply
section. The integrated CAN-BUS interface block handles the CAN-Bus protocol.
EMGZ480 and EMGZ480.M16 can process the signals of two force sensors (sum signal).
Strain Gauge Amplifier
The strain gauge amplifier section provides the highly accurate 5V DC supply voltage for
one or two force measuring sensors. A highly accurate, fixed difference amplifier raises
the mV signal to the Volt-range (up to10V). This signal is fed to 14-Bit A/D converter.
The microprocessor conditions the signal and calculates all application specific
parameters like Offset, Gain, Filter and Limit values. The digitalised signal can then be
read by the CAN-BUS master.
CAN-BUS Interface
The EMGZ480 and EMGZ480.M16 operate the CAN Open / CiA-DS 301 interface. The
interface is galvanically isolated.
Operation
The entire parameter setting is done over the CAN-BUS. Parameters and settings are
stored in a none-volatile memory, completely fail-save
Fig. 3: Block Diagram EMGZ480 E480005e

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5Quick Installation Guide
•Collect and check all your requirements such as: Configuration of the CAN-BUS
interface (address number, data format, Baudrate, PDO cycle time, termination, etc),
calibration mode (ref. to „8. Calibrating the measuring amplifier“).
•Draw your final wiring diagram according to FMS recommendations (refer to „7.
Installation and wiring“)
•Install and wire all your components (refer to „7. 4Installation and wiring“)
•Set your parameters in the CAN-BUS master computer (ref. to „10. Specification of
the CAN-BUS interface“)
•Put EMGZ480 measuring amplifier into operation and calibrate it by means of CA-
BUS (refer to „8. Calibrating the measuring amplifier“)
•Turn system on and proceed with a test run with low speed
•If required, activate additional application-specific functions of the CAN-BUS master
computer (DP master)
Note
If a real-time control loop is implemented with the CAN-BUS, you must ensure that the
application-specific CAN-BUS protocol is time wise short enough to provide sufficient
control dynamics.

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6Dimensions
6.1 Dimensions EMGZ480
Fig. 4: Outline drawing EMGZ480 C480017e

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6.2 Dimensions EMGZ480.M16
Fig. 5: Outline drawing EMGZ480.M16 C480018e
EMGZ480 and EMGZ480.M16 come in robust and resilient aluminium housing. They
were designed to work under the most stringent environmental conditions. The sealed
housing is rated for a protection class of IP68.

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7Installation and Wiring
7.1 Mounting the Force Sensors
For mounting the force measuring sensors please consult the respective installation
manual. The manual is always delivered together with the sensor. In rotating applications
it is recommended mounting the Force Measuring Sensors as close as possible to the
rotation axis.
Note
In rotating applications the force measuring sensors are mounted such that centrifugal
forces are compensated. Using FMS RMGZ sensors this can be achieved by turning the
Red Point parallel to the rotation axis and in direction of the positive force component
(refer to Fig. 6).
Caution
It is of paramount importance to compensate the centrifugal forces caused by the rotating
base plate of the strander. The measuring results will be wrong, if this rule is broken
Fig. 6: RMGZ Red Point alignment in strander applications RTM00014e
Wire
Red Point
RMGZ Sensor
Resultin
g
force com
p
onen
t
Rotation Axis
of Base Plate
Rotating
Base Plate

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7.2 Mounting the Measuring Amplifier
We recommend mounting the Measuring Amplifier EMGZ480/480.M16 as close as
possible to the Force Measuring Sensor
Caution
Improper handling may damage the fragile electronic equipment! Don’t use rough tools
such as screwdrivers or pliers! Operators handling the processor board must wear a well
earthed bracelet in order to discharge static electricity.
7.3 Connector Configuration and Setting Elements
Fig. 7: Connector configuration, setting (jumpers) EMGZ480 EMGZ480016e

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Fig. 8: Connector configuration, settings (jumpers) EMGZ480.M16 EMGZ480018
Note
The CAN-BUS network must be terminated properly. Otherwise the installation cannot
be set into operation. It has to be ensured that only the last device of the CAN-BUS chain
is terminated.

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7.4 Wiring Diagrams
Fig. 9: Wring Diagram EMGZ480 E480011e
Fig. 10: Wring Diagram EMGZ480.M16 E480011e

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Note
The connection of the shield must be done as indicated in our wiring diagram. The shield
should be connected only to the measuring amplifier side. At the force sensor side, the
shield should stay open. Other arrangements may cause ground/earth loops which may
interfere with the measuring signal.
Wiring of the CAN-BUS cables
CAN-BUS devises must be connected with
standardised cables of the type (1x2x0.34
mm2) [AWG 22] or 2x2x0.25mm2[AWG
23] shielded 2 twisted pairs cables.
EMGZ480: The cables are assembled as
shown in Fig. 11 and connected to the
terminals on the amplifier board. Special
attention must be paid to the shield and its
connection.
EMGZ480.M16: The cables are delivered by FMS already with M16 connectors on both
sides for easy assembly. For the EMGZ480.M16 amplifier version cables of the type
2x2x0.25 mm2[AWG 23] shielded 2 twisted pairs are used.
Caution
The functionality of the Tension Measuring Amplifier is only guaranteed, if the
components and their application are used as recommended by FMS. Arrangements other
than the one recommended here can cause heavy malfunction. The installation
instructions on the following pages must strictly be followed.
Caution
Local installation regulations are to preserve safety of electric equipment. They are not taken
into consideration by this operating manual. However, they have to be strictly followed.
Caution
Bad earth ground 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 ground
connection is done.
Fig. 11: Assembly of CAN-BUS cables
E470009e

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8Calibrating the Measuring Amplifier
To get correct measuring values, offset and gain have to be set before putting the device
into operation. There are several methods to do this:
8.1 Simulating Method, Calibration with the PLC or PC
The following instructions are referring to a
setup and calibration inside the machine.
The material tension will be simulated by a
weight (Fig. 12). Offset and Gain
calibration is done in the PLC or the master
computer.
Checking the Force Measuring Sensor
•Connect Force Measuring Sensor to the
EMGZ480 amplifier (ref. to 7.4 “Wiring
Diagram”).
•Check whether a load in the processing
direction results in a positive signal. If
the output is negative, change the wires
+signal and –signal in the amplifier.
•If a second Force Measuring Sensor is
required, repeat previous point.
Offset Compensation
•Align Force Measuring Sensor in the intended operation direction (red point).
•Insert material or a rope loosely to the machine.
•Find with CAN-BUS object 2051h the offset value. The measuring amplifier calculates
automatically the offset value.
•The found value is stored in the object 2001h Offset in [Digit].
Gain Determination
•Load material or rope with a defined weight (Fig. 12). The roller configuration must
correspond to the real configuration in the machine (wrap angle, distance of the
rollers etc.)
•Enter the force in [N] or [lbs] corresponding to the used weight in the CAN-BUS
object 2052h. This will initiate the calibration process.
•The calculated Gain value is stored in the parameter CAN-BUS object 2002h Gain.
Fig. 12: Calibrating the measuring
amplifier C431011e

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8.2 Mathematical Method
If the material tension cannot be simulated with weights as described in paragraph 8.1,
the calibration has to be done by calculation. This way of calibrating is less accurate
because the exact angles are often unknown. The actual mounting conditions, which
usually deviate from the ideal world, can also not be taken into account.
Mathematical base for calculating the Gain factor:
fig. 13: 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
GainFactor ⋅⋅ =2/sinsin
1
γδ

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Example:
•Please do the offset adjustment as described in „8.1. Simulating Method, Calibration
with PLC or PC“.
•Calculate the Gain factor using the formula above.
•Enter the calculated Gain value in the parameter CAN-BUS object 2002h Gain.
•Offset and Gain are now fail safe stored in the measuring amplifier.
8.3 Scaling of Analogue Output
The analogue output in the EMGZ480 (see schematics in Fig.9) can be scaled to any
nominal force. E.g. 500N must correspond to 10V the maximal output signal of the
amplifier.
•Calibrate sensor and amplifier as shown in “8.1. Simulating Method, Calibration with
the PLC or PC”.
•Enter the nominal force that should correspond to the maximum output of the
amplifier in CAN-BUS object 2040h.
•The value has 4 digits. The decimal point depends on the CAN-BUS Object 2003h
“Force of sensor”.
•The scaling factor is now fail safe stored in the measuring amplifier.
8.4 Configuring the Lowpass Filter
The lowpass filter in the EMGZ480/480.M16 suppresses faulty signal variations that may
be caused by unbalanced rollers, vibrations of the machine, or similar instances. Signal
variations that are faster than the cut-off frequency of the filter are suppressed. The
lowpass filter is configured by setting the cut-off frequency and its filter order. The table
below shows the value that has to be sent to CAN-BUS object 2005h.
Lowpass filter
cut-off frequency Setting value for filter of 1st order Setting value for filter of 2nd order
(Filter OFF) 00h 00h
1 Hz 43h C3h
2 Hz 44h C4h
5 Hz 45h C5h
10 Hz 46h C6h
20 Hz 47h C7h
50 Hz 48h C8h
100 Hz 49h C9h
Note
If the cut-off frequency is set too low, the output signal will become sluggish. In such a
case it could happen that the feedback value is no longer suitable for control loop
applications. The best trade off for the cut-off frequency must be found by considering
the control loop limitations.

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9Parameter Setting
9.1 List of System Parameters
Parameter Unit Min Max Default
Language German, English -
Unit-System Metric or US standard Metric
Baud-rate kBit 50, 100, 125, 250 250
Cycle time PDO [ms] 50, 100, 200, 500 100
9.2 List of Parameter EMGZ 480 / 480.M16
Parameter Unit Min Max Default
Offset [Digit] –8000 8000 0
Gain [-] 0.100 32.000 1.000
Force of Sensor [N, kN, cN] 1 9999 1000
Unit of Sensor [N, cN, kN] or [lb, clb, klb] N
Lowpass output [Hz] 0.1 200.0 50.0
Limit Value 1 min or max Min, Max Min
Limit Value 1 1) 2) 0
Limit Value 2 min or max Min, Max Max
Limit Value 2 1) 2) 0
Scaling Analogue Output 1) 2) 0
1) If unit-system Metric = [N, cN, kN] / If unit-system US standard = [lb, clb, klb]
2) A force value can be entered. The value must contain 4 digits. The decimal point depends from
the parameter Nom. Force of Sensor
Note
Wong parameter settings can cause malfunctions during operation. Prior to
commissioning the configuration of the system (parameter setting) must be done
conscientiously.

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9.3 Description of the System Parameters
The system parameters can be read or written with the CAN-BUS Objects
Language
Use: This parameter determines the display language on the CAN-Master
(e.g. PC or PLC)
Range: English, German Default: English
CAN Object: 2080h
Measuring system
Use: This parameter indicates the measuring system that will be displayed. If
it is set to metric, all force values are shown in [N, cN, kN]. If it is set
to US standard, all force values are shown in [lb, clb, klb].
Range: Metric, US standard Default: Metric
CAN Object: 2081h
Baudrate
Use: This parameter sets the speed of the CAN-BUS interface. If this
parameter is changed the electronic unit must be reset (power off – on).
Range: 50, 100, 125, 250 Default: 250
CAN Object: 2082h Unit: [kBit]
Cycle time PDO
Use: The parameter determines the cycle time (frequency) of the PDO
transmission in the CAN-BUS interface. If this parameter is changed
the electronic unit must be reset (power off – on).
Range: 50, 100, 200, 500 Default: 100
CAN Object: 2083h Unit: [ms]