Schmidt FS-422 Series User manual

Edition FSR-422 01.E
Instruction Manual
Valid as of: 01.09.2017 • Please keep the manual for future reference!
Tension Meter
Series: FS-422
Model: FSR-422
Software
»Tension Inspect 3«
Version: TI3
TI3-4
TI3-8
TI3-12
TI3-16
TI3-20
TI3-24
S C H M I D T
c o n t r o l i n s t r u m e n t s

2
Contents
1 Warranty and liability ............................................................................................... 3
1.1 Notices within the instruction manual..................................................................... 3
1.2 Responsibilities of the operating company............................................................. 3
1.3 Responsibilities of the Personnel ........................................................................... 3
1.4 Informal safety measures....................................................................................... 4
1.5 Training of the personnel ....................................................................................... 4
1.6 Intended use .......................................................................................................... 4
1.7 Dangers in handling the device.............................................................................. 4
1.8 Copyright................................................................................................................ 4
1.9 Declaration of conformity, RoHs II and WEEE registration .................................... 4
2 Available models ...................................................................................................... 5
2.1 General information................................................................................................ 5
2.1.1 Available models with RS-422 interface........................................................... 5
2.2 Specifications of the FS-422 series........................................................................ 6
2.3 Pin assignment of the RJ45 connector .................................................................. 6
2.3.1 Connecting the tension meter........................................................................... 6
2.4 Optional accessories.............................................................................................. 6
2.5 Delivery includes .................................................................................................... 7
2.6 Unpacking .............................................................................................................. 7
3 Initial setup and operating procedure .................................................................... 7
3.1 Notes before starting measurement....................................................................... 7
3.2 Mounting possibilities ............................................................................................. 7
3.3 Setting the sensor addresses................................................................................. 7
3.4 Connecting the sensors ......................................................................................... 8
3.5 Determining the tension range ............................................................................. 10
3.6 Internal adjustment of the sensors ....................................................................... 11
3.6.1 Zero adjustment.............................................................................................. 11
3.6.2 Gain adjustment ............................................................................................. 12
4 Service and maintenance....................................................................................... 13
4.1 Rollers .................................................................................................................. 13
5 Cleaning................................................................................................................... 13
6 Verification interval ................................................................................................ 13
6.1 Verification of calibration and determination of repair costs................................. 14
7 Correspondence ..................................................................................................... 15
8 Repairs..................................................................................................................... 15

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1.3 Responsibilities of the personnel
All persons who work with the device agree to perform the following duties before starting
work:
- to observe the basic regulations on industrial safety and accident prevention.
- to read the chapter on safety and the warning notices in these instruction manual and
to confirm with their signatures that they have understood them.
1 Warranty and liability
In principle, the supply of the device is subject to our “General Conditions of Sale and
Delivery.” These have been provided to the operating company on conclusion of the
contract, at the latest.
Warranty:
- SCHMIDT tension meters are warranted for 12 months.
Parts subject to wear, electronic components and measuring springs are not covered by
the warranty. No warranty or liability will be accepted for bodily injury or property damage
resulting from one or several of the following causes:
- Misuse or abuse of the device.
- Improper mounting, commissioning, operation and maintenance of the device
(e.g. verification interval).
- Operation of the device if any safeguards are defective or if any safety and protection
precautions are not properly installed or not operative.
- Failure to comply with the notices in the instruction manual regarding transport,
storage, mounting, commissioning, operation, maintenance and setup of the device.
- Any unauthorized structural alteration of the device.
- Insufficient inspection of device components that are subject to wear.
- Opening the device or improper repair work.
- Disasters caused by the effects of foreign objects or by force majeure.
1.1 Notices within the instruction manual
The fundamental prerequisite for the safe handling of this device and its troublefree opera-
tion is the knowledge of the basic safety notices and safety instructions.
These instruction manual contains the most important notices for the safe operation of the
device.
These instruction manual, in particular the safety notices, must be observed by any person
who works with the device. In addition, the applicable local rules and regulations for the
prevention of accidents must be complied with.
The representations within the instruction manual are not true to scale.
The dimensions given are not binding.
General indications of direction, such as FRONT, REAR, RIGHT, LEFT apply when view-
ing the front of the device.
1.2 Responsibilities of the operating company
In compliance with the EC Directive 89/655/EEC, the operating company agrees to only
permit persons to work with the device who:
- are familiar with the basic regulations on industrial safety and accident prevention and
who have been trained in handling the device.
- have read and understood the chapter on safety and the warning notices in these
instruction manual and have confirmed this with their signatures.
- are examined regularly on their safe and conscientious working method.

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1.7 Dangers in handling the device
The device has been designed according to the state of the art and the approved safety
standards. Nevertheless, its use may cause serious or fatal injury to the user or third
persons, and/or an impairment of the device or of other material assets.
The device may only be applied:
- For its intended use in a faultless condition with regard to the safety requirements.
- Malfunctions that could impair safety must be remedied immediately.
- Personal protective equipment must be used according to the EC Directive 89/686/EEC.
1.4 Informal safety measures
The instruction manual must always be kept on hand where the device is operated.
Apart from the instruction manual, the applicable general and local regulations on
accident prevention and environmental protection must be provided and complied with.
1.6 Intended use
The device is intended exclusively to be used as a tension meter.
Any other use or any use exceeding this intention will be regarded as misuse.
Under no circumstances shall Hans Schmidt & Co GmbH be held liable for damage result-
ing from misuse.
The intended use also includes:
- Complying with all notices included in the instruction manual and observing all
inspection and maintenance works.
1.8 Copyright
The copyright on these instruction manual remains with the company
Hans Schmidt & Co GmbH.
These instruction manual is intended for the operating company and its personnel only.
They contain instructions and notices that may only be reproduced on the prior written
permission of
Hans Schmidt & Co GmbH
and under indication of the complete reference data.
Violations will be prosecuted.
1.5 Training of the personnel
Only trained and instructed personnel is permitted to work with the device. The responsi-
bilities of the personnel must be clearly defined for mounting, commissioning, operation,
setup, maintenance, and repair. Trainees may only work with the device under the super-
vision of experienced personnel.
The device must not be operated in potential explosive areas and must not
come into contact with aggressive substances.
1.9 Declaration of conformity, RoHs II and WEEE registration
In compliance with the EU Directives 2014/30/EU and 2011/65/EU
Hans Schmidt & Co GmbH is registered in compliance with
the German Electrical and Electronic Equipment Act (ElektroG)
under WEEE Reg. No. DE 48092317.

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2 Available models
2.1 General information
These instruction manual refer to the FSR-422 model of the FS series;
The individual models of the FS series are also available with the following modifications
(customized versions):
- Special tension ranges
- Customized roller dimensions and materials
- Special calibration using customer supplied material
Model numbers:
Model with tension range
Code for guide rollers
(if not standard)
Complete
Order No.
FSR-10N-422 + FB = FSR-10N-FB-422
2.1.1 Available models with RS-422 interface
Model Tension Ranges N
FSR-10N-422 0 - 10
FSR-20N-422 0 - 20
FSR-50N-422 0 - 50
FSR-100N-422 0 - 100
FSR-200N-422 0 - 200
FSR-500N-422 0 - 500
Guide rollers:
V-Groove Line Speed
m/min ... max.
Groove Ø
in mm Roller Material
Standard 4000 29.5 Hadened steel
Code R1 4000 29.5 Hard chrome-plated steel
(radius R5)
Code F4000 70 Hard-coated aluminium
Code FB 4000 70 Tempered steel
flat
Code B6 2000 29.5 Hardened steel, width 6 mm
Code B10 2000 29.5 Hardened steel, width 10 mm

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2.2 Specifications of the FS-422 series
Calibration: According to SCHMIDT factory procedure
Accuracy: ± 1% full scale and ± 1 digit or better
Other calibration material: ± 3 % full scale or better
Overload protection: 100% of range
Measuring principle: Strain gauge bridge
Meas. roller deflection: 0.5 mm, max.
Natural frequency
of measuring spring: Approx. 500 Hz, depending on tension range
Signal processing: Digital 12-bit A/D converter, sampling rate approx. 4800/sec
Internal averaging up to 4 sec
Communication
Frequency: Approx. 200 readings/sec
Output signal: RS-422 (57600 baud, 8 bits, no parity, 1 stop bit)
ASCII communication, max. cable length 400 m
Temperature coefficient: Zero point: less than ± 0.05% full scale/°C
Temperature range: 10 - 45 °C
Air humidity: 85% RH, max.
Power supply: 15 to 24 V DC, 50 mA (regulated)
Housing: Aluminium
2.3 Pin assignment of the RJ45 connector
Pin
No. Signal Description
1 VCC Supply voltage
2 GND Ground (GND)
3 TX+ (Y) Transmitted data +
4 RX- (B) Received data +
5 RX+ (A) Received data -
6 TX- (Z) Transmitted data -
7 Not assigned
8 Not assigned
2.4 Optional accessories
SW-TI3: »Tension Inspect 3« software for PC evaluation of readings
SW-TI3-XX: »Tension Inspect 3« software for PC evaluation of readings from up
to 24 sensors
EBG800: RS-422/RS-232 converter
EK0715: Open-ended connection cable (length 3 m) for connection to the
RS-422/RS-232 converter
EK0711: Sensor-to-sensor connection cable, length 3 m
EK0712: Sensor-to-sensor connection cable, length 1.5 m
The requirements of the CE specification are only complied with if the ten-
sion sensor is equipped and operated with display units and connecting
cables supplied by Hans Schmidt & Co GmbH. Certification to the CE
specification does not extend to, and shall be invalid for any other combina-
tion. Under no circumstances shall Hans Schmidt & Co GmbH be held liable
for any damage resulting from the use of non-SCHMIDT sensors or cables.
2.3.1 Connecting the tension meter
RJ45 connectors
1 2 3 4 5 6 7 8

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2.6 Unpacking
Unpack the instrument and inspect it for any shipping damage. Notices of defect must be
announced immediately, in writing, at the latest within 7 days on receipt of the goods.
2.5 Delivery includes
Sensor
Instruction manual
3 Initial setup and operating procedure
3.1 Notes before starting measurement
Tensions that exceed the tension range of the instrument by more than 100%
may cause permanent damage to the measuring spring and must be avoided
under any circumstances.
Hans Schmidt & Co GmbH provides no warranty or liability for self-made
cables.
The model number, the serial number, the calibration label (option) and the
SCHMIDT Quality Seal are provided on the cylindrical portion of the sensor.
3.2 Mounting possibilities
Sensors of FS-422 series can be mounted in different ways:
- Mounting by using the frontplate on a cylindrical hole (panel cut out: longhole R19
Length 54 mm)
- Mounting on a flat platform
3.3 Setting the sensor addresses
You can connect up to 24 sensor units by cable to the RS-422/RS-232 converter and
on to a PC, by using the factory-provided assignment of the channel numbers.
The sensor models of the FSR-422 series are supplied as complete units, which
have been customized for the specific application. The sensor addresses have
been factory preset in this case and usually do not need to be changed.
M4
fig. 3.2
M4

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3.4 Connecting the sensors
- If the sensor is delivered with the standard roller, it is already mounted in the factory.
If the device is supplied with a roller code F, FB, R1, B6 or B10, it must be installed.
Tight the cap nut with 1 Nm.
- Install the sensor at the desired measuring location using the 4 provided mounting holes
(fig. 3.2b).
To avoide damage of the load cell, the transmission of force has to occure in direction of
the arrow. The direction of force ist the angle bisector (fig.3.2a).
- Connect the sensor(s), the RS-422/RS-232 converter, and the PC.
- If the material path is other than vertical or if the process material deviates significantly
from the SCHMIDT calibration material, you need to carry out zero adjustment and gain
adjustment as described in Chapters 3.6.1 and 3.6.2 before starting measurement.
- Allow approx. 10 minutes for thermal stabilization of the sensor.
- Thread the process material through the measuring roller, following the arrow on the
front of the sensor.
fig. 3.4a
Mounting holes
front plate
RJ45 connectors
LED
Mounting holes
Housing
fig. 3.4b

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3.4 Connecting the sensors (cont.)
The cable length between the last sensor and the converter may be
max. 1000 m.
The cable length between the converter and the PC may be max. 10 m
Online sensor 01
Online sensor 02
Other online sensors
1 2 3 4 5 6 7 8
RJ45 connectors
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
fig. 3.4c
RS-422/RS-232 converter
PC
Pin
No. Signal Description Colors
8 Not assigned
7 Not assigned
6 TX- (Z) Transmitted data - Blue/White
5 RX+ (A) Received data + Green
4 RX- (B) Received data - Green/ White
3 TX+ (Y) Transmitted data + Blue
2 GND Ground (GND) Brown / White
1 VCC (+VS) Supply voltage Brown
Input

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3.5 Determining the tension range
The tension range can be calculated for every wrapping angle with this formula:
material path
α
Wrap angle
30°
60°
90°
180°
Resultant
dorce multiplier
0.5 x (FZLine Tension)
1.0 x (FZLine Tension)
1.4 x (FZLine Tension)
2.0 x (FZLine Tension)
Wrap
angle
Recommended wrapping angle 40 - 180°
FN= Multiplier x FZ
FNFZ
α
Guide
Roll
Line
tension
FN= Nominal load (multiplicator x FZ)
FZ= Line tension
α= Wrapping angle at the guide roll
FN = 2 ∙ FZ ∙ sin α
2
When selecting the nominal measurement force it is necessary to take into
account the weight of the guide roll and raise the nominal load respectively,
particularly when working with small nominal forces.

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3.6.1 Zero adjustment
- Install the sensor in the desired position at the measuring location using the provided
mounting holes.
- Allow approx. 10 minutes for thermal stabilization of the sensor.
fig. 3.4.1b
Force direction
Measuring
roller
3.6 Internal adjustment of the sensors
General information:
All tension meters are calibrated with standard materials - such as polyamide monofila-
ment (PA) - according to the SCHMIDT factory procedure; therfore the wraping angle is
180°.
In any case you need to carry out static zero and gain
adjustment as described in Chapters 3.6.1 and 3.6.2.
Do not insert the screwdriver at an
angle as this may damage the potentiometer.
Since zero and gain adjustments are always performed
statically, the readings may differ under dynamic load.
- Start the measuring in the software
- Adjust the potentiometer, which you can reach through the zero hole in the housing,
with a screwdriver (with a point width of max. 1.9 mm) until the software displays the
value of 0 N,
Zero
Gain
fig. 3.6.1a

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Do not insert the screwdriver at an angle as this may damage the
potentiometer.
Gain adjustment of sensors with output signal Code A10 has to be realized
with display unit.
3.6.2 Gain adjustment
Requirement: Zero adjustment carried out.
Thread the process material in the measuring roller
fig. 3.4.2b
Measuring
roller
Weight
Force
direction
- Hang a weight that corresponds to e.g. 100 % of the tension range from the process
material.
- Start the measuring in the software
- Adjust the potentiometer, which you can reach through the GAIN hole in the housing,
with a screwdriver (with a point width of max. 1.9 mm) until the software displays the
value of 100 %,
Zero
Gain
fig. 3.6.2a

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4 Service and maintenance
The instrument is easy to maintain. Depending on operating time and load, the instru-
ment should be checked according to the applicable local regulations and conditions (as
described in Chapter 3.6). The use of other test methods than the procedure described in
Chapter 3.6 may cause deviating measuring results.
4.1 Rollers
You should regularly inspect the rollers to assure that they are running easily and
smoothly. You can replace the rollers yourself, as necessary. Please indicate the tension
meter model and the serial number in your spare-parts order.
5 Cleaning
For cleaning the instrument, do not use any
AGGRESSIVE SOLVENTS
such as trichloroethylene or similar chemicals.
NO WARRANTY OR LIABILITY
shall be accepted for damage resulting from improper cleaning.
6 Verification interval
The question of finding the right frequency of calibration accuracy verification depends on
several different factors:
Operating time and load of the SCHMIDT tension meter
Tolerance band defined by the customer
Changes to the tolerance band compared to previous calibrations
Therefore, the interval between verifications of calibration must be determined by the
user’s Quality Assurance Department, based on the user’s experience.
Assuming normal operating time and load as well as careful handling of the tension meter,
we recommend a verification interval of one year.

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6.1 Verification of calibration and determination of repair costs
Flow chart for verifying the calibration of used tension meters, incoming and outgoing
verification with Inspection Certificate 3.1 according to DIN EN 10204
Delivery
Unit can be
calibrated
(functional)
Repair costs
exceed 40 % of as
new value
Costs approved
by customer
No
Yes
No
Yes
No
Yes
Vertification of the
calibration
Visual inspection
and functional test
Values within
specification
Prepare certification
for
incoming calibration
Determination
of costs
Make of
cost estimate
Repair and
adjustment
Verification of the
calibration
Calibration label
on the instrument
No
Invoice scrapping
and disposal
Invoice repair and
calibration services
and dispatch
Invoice
calibration services
and dispatch
Prepare certificate
for outgoing
calibration
Yes
Calibration label
on the instrument

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7 Correspondence
Should you have any questions regarding the instrument or instruction manual, or their use,
please indicate above all the following details which are given on the ID plate:
1.) Model
2.) Serial number
8 Repairs
Shipping instructions:
We kindly ask for return free of charge for us, if possible by airmail parcel. All occurring
charges, if any (such as freight, customs clearance, duty etc.), will be billed to customer.
For return from foreign countries, we ask you to include a proforma invoice with a low value
for customs clearance only, e.g. 50 Euro, each and to advise the shipment in advance by
fax or eMail.
To avoid unnecessary follow-up questions, and the resulting loss of time or
possible misunderstandings, please return the instrument with a detailed fault
description to our service department. Please indicate in your order whether you
require an Inspection Certificate 3.1 according to DIN EN 10204.
Service address: Hans Schmidt & Co GmbH
Schichtstr. 16
84478 Waldkraiburg
Germany

Mailing address:
P. O. B. 11 54
84464 Waldkraiburg Germany
Shipping address:
Schichtstr. 16
84478 Waldkraiburg Germany
Hans Schmidt & Co GmbH
Phone:
int. + 49 / (0)8638 / 9410-0
Fax:
int. + 49 / (0)8638 / 4825
int. + 49 / (0)8638 / 67898
More than 75 years - Worldwide -
e-mail:
[email protected]
Internet:
http://www.hans-schmidt.com
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