Vishay G4 User manual

G4 Multi Channel
Weighing Instrument
Program versions 1.8.0.0, 1.9.0.0, and 1.10.0.0
Technical Manual
RM type
GB

G4 Multi Channel Weighing Instrument
1. Introduction
General .............................................1-1
Functions ..........................................1-2
Maintenance .....................................1-4
Safety information ............................1-4
Technical data ..................................1-5
Ordering information ......................1-12
2. Installation
Mechanical installation .....................2-1
Electrical installation .........................2-2
CPU unit............................................2-3
VIEWPAN module ............................2-5
WF IN, WF IN2 and HS WF2 ...........2-6
AOUT1 and AOUT4 .........................2-9
DIO8 ...............................................2-10
Profibus-DP Fieldbus Adaptor.........2-11
DeviceNet Fieldbus Adaptor ..........2-13
3. Set-up
General .............................................3-1
Operators interface ...........................3-3
Menu structure .................................3-8
Parameters .....................................3-11
Program options .............................3-48
4. Calibration
General .............................................4-1
Common parameters .......................4-2
Data sheet calibration ......................4-4
Table calibration ...............................4-5
Deadweight calibration .....................4-5
5. Operation
General .............................................5-1
Power supply ....................................5-1
Power-up sequence .........................5-1
Weight display ..................................5-2
Security locks ...................................5-3
Taring ...............................................5-4
Gross/Net operation .........................5-5
Zero setting ......................................5-5
Zero-track./Auto. zero setting ...........5-6
Motion ...............................................5-6
Weight printing .................................5-7
Batch report printing .........................5-8
Main menu ........................................5-8
Level supervision ...........................5-10
Setpoint function ............................5-11
Use of inputs and outputs ..............5-12
Filter function .................................5-12
Flow rate ........................................5-14
6. Communication
General ............................................6-1
Serial interface..................................6-1
Modbus RTU Slave ..........................6-1
Modbus TCP Slave ..........................6-2
External I/O.......................................6-3
EtherNet/IP ......................................6-4
Ftp Server.........................................6-9
Modbus protocol ..............................6-9
Fieldbus interface ...........................6-38
Fieldbus and EtherNet/IP Data Def.6-39
Weight printing................................6-52
7. Remote Access
General ............................................7-1
Browser requirements.......................7-1
Using the Remote Access ...............7-2
Security.............................................7-2
Remote Access Login and Logout....7-3
Remote / Local Access.....................7-5
Remote Set-up..................................7-6
Remote Access Maintenance.........7-10
Instrument Restart..........................7-19
8. Maintenance
General ............................................8-1
Diagnostics .......................................8-1
File handling ....................................8-5
Create Backup .................................8-6
Restore Backup ...............................8-6
Set Default........................................8-6
Program Upgrade .............................8-7
Instrument Restart............................8-7
9. Troubleshooting
General.............................................9-1
Error codes ......................................9-1
Appendix
Declaration of Conformity.............App.1
Contents

Technical Manual
PRECAUTIONS
READ this manual BEFORE operating or servicing this instrument. FOLLOW these
instructions carefully. SAVE this manual for future reference.
!
USE IN HAZARDOUS LOCATIONS
See FM and cFM approvals.
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B,
C and D HAZARDOUS LOCATIONS or NON-HAZARDOUS LOCATIONS.
WARNING- EXPLOSION HAZARD.
NONINCENDIVE FIELD WIRING CONNECTIONS TO CLASS I, II, III, DIV 2,
GROUPS A, B, C, D, E, F, G WHEN INSTALLED PER DWG 401709.
DO NOT REMOVE OR REPLACE CONNECTORS OR DISCONNECT EQUIPMENT
WHEN A FLAMMABLE OR COMBUSTIBLE ATMOSPHERE IS PRESENT.
INDOOR USE ONLY.
USB CONNECTION NOT ALLOWED TO BE USED IN HAZARDOUS LOCATIONS.
ATTENTION-DANGER D'EXPLOSION.
RACCORDEMENT POUR ATMOSPHERE NON EXPLOSIVE POUR CLASS I, II, III,
DIV 2, GROUP A, B, C, D, E, F, G INSTALLE SUIVANT PLAN 401709.
NE PAS DECONNECTER OU REMPLACER LES CONNECTEURS OU
DEBRANCHER L'EQUIPEMENT EN PRESENCE D'ATMOSPHERE IMFLAMMABLE
OU EXPLOSIVE.
UTILISATION INTERIEURE UNIQUEMENT.
CONNEXION USB NON AUTORISEE EN ZONE DANGEREUSE.
INTENDED USE
The G4 Instrument family are multi-channel measuring and control devices intended for
industrial systems. Its basic function is to convert the signals from transducers to useful
information. Transducer excitation is included as well as parameter controlled signal
processing, indication of output levels, error supervision and operation of optional
external equipment.
The instrument supports several types of communication interfaces. The instruments
are modular and can be equipped with different types of I/O units. There are transducer
interface modules, digital and analog input/output modules.
WARNING
Only permit qualified personnel to install and service this instrument.
Exercise care when making checks, tests and adjustments that must be
made with power on. Failing to observe these precautions can result in
bodily harm.
DO NOT allow untrained personnel to operate, clean, inspect, maintain,
service, or tamper with this instrument.

G4 Multi Channel Weighing Instrument
1-1
1. Introduction
General
The G4 Instrument is a high performance multi channel weight indicator intended for
industrial systems.
Its basic function is to convert the signals from strain gauge transducers to useful
weight information. Transducer excitation is included as well as parameter controlled
signal processing, indication of output levels, error supervision and operation of
optional external equipment. The instrument can be equipped with up to 6
synchronized weighing channels.
The instrument is modular and can be equipped with different types of I/O units to
match the demands in the specific applications. There are strain gauge transducer
interface modules, a digital input/output module, analog output modules and a
service panel with integrated 24 V DC power supply.
Internal solid-state outputs in the instrument can be used for output functions from level
supervision, setpoints, etc. or ‘In process’ indication, reporting the operating status of
the G4 Instrument.
The CPU unit in the instrument has several communication interfaces. It has two serial
communication ports, an Ethernet port, an USB port and a fieldbus slot.
Several G4 Instruments can be controlled from a master computer or PLC.
Serial communication interfaces are RS-485 and RS-232 for communication with a
computer/PLC (using Modbus RTU protocol) or for transmitting print out data to a
connected printer. The Ethernet interface is using Modbus TCP and the optional
fieldbus interface uses Profibus or DeviceNet.
It is possible to access the instrument, set-up and maintenance functions, remotely
over the Ethernet connection using a Web Browser on a connected PC.
In the Weighing program there are two program options available, one is the Flow Rate
program option and the other is the Scale Batching program option. By entering its
option code a program option is enabled. The option code can be purchased from your
supplier.
It is possible to load new software into the instrument using the USB port.
All functions in the G4 Instrument are controlled by set-up parameters. Setting of
parameter values can be performed via a service panel with display and 4 keys
(VIEWPAN module). The Rail mount instrument type is powered with 24 V DC. All input
and output signals are galvanically isolated from the power supply by operational
insulation.
CPU
unit
I/O
unit
1
I/O
unit
2
I/O
unit
3
Service panel with
Power supply unit
Backplane
DIN rail mount version
Enclosure & mounting accessories
Block structure of a G4 Instrument

Technical Manual
1-2
Functions
Measurement with strain gauge transducers.
Both excitation voltage and output signal are measured at the transducer to avoid
influence from voltage drop in the connection cable. Excitation to the transducer, from
the G4 Instrument is provided over separate wires.
A shielded 6-wire cable must be used to connect a distant transducer to the instrument.
A/D conversion.
The analog signals from the transducer are converted to digital form and filtered
to give an internal transducer signal with high resolution.
Calculation.
The transducer excitation and signal values are combined to form an internal
transducer signal, representing the load on the transducer. Influenced by calibration
data, this signal is converted to a digital measurement value, the weight value, which
can be presented at the local display window and at external equipment.
Error supervision.
As long as the error supervision detects no error, the signal ‘In process’ is present
but if an error is detected, ‘In process’ will be off and a specific error message will be
displayed. ‘In process’ can be set to control any digital output. Note that there are
weighing channel specific and instrument specific error detection.
Levels.
32 level comparators in the instrument can be set to switch at defined signal levels with
any selected hystereses added, meaning that the switch level can be different for
increasing and decreasing signal. Output signals from these comparators are available
on the serial communication. The level comparator outputs can also be set to control
digital outputs from the instrument.
Communication.
The G4 Instrument utilizes the serial interface, Ethernet and a fieldbus interface for
communication with control computer. The serial interface consists of a RS-232
(COM1) connection and a RS-485/RS-422 (COM2) connection. COM2 can be used
with 2- or 4-wire connection.
Weight values, level status, error status etc. can be collected and commands given
through the communication interfaces. Modbus RTU protocol is used for the serial
interfaces, Modbus TCP and EtherNet/IP for the Ethernet connection. For the optional
fieldbus interface Profibus or DeviceNet can be used.
The serial interfaces can also be used to connect a printer for printing of weight and/or
flow rate values etc. If the Scale Batching Program Option is enabled it is possible to
print batching reports.

G4 Multi Channel Weighing Instrument
1-3
Instrument modes.
In normal operation mode the G4 Instrument is presenting the measurement values on
the front panel (VIEWPAN) alpha numerical display. Only one weight value at a time
can be shown.
During parameter set-up the instrument will continue normal operation. However if
hardware set-up parameters have been changed the instrument will be restarted.
The operator will always be notified before the instrument is restarted.
Parameter setting.
In the instrument all operating functions are controlled by set-up parameters with
numerical values, string values, or pre-selected values from a list of alternatives.
Parameter set-up is performed by the keys at the service panel (VIEWPAN).
Presentation.
The instrument can present measured or calculated values, parameter settings etc.
at the front panel. An extensive system of menus gives the possibility to present various
information about the instrument. The VIEWPAN module can present one value at a time.
Measured or calculated values, status of levels and so on, can be transferred to
external equipment via the different communication interfaces (some are optional).
Scale Batching program option.
There is a batching function within the instrument, which is enabled with an option
code, which can be bought from the instrument supplier. The batching option gives the
possibility to perform individual batching with each scale. See the separate ‘Scale
Batching Program Option’ ‘Technical Manual Supplement’ available for the batching
option.
Flow Rate program option.
With the Flow Rate program option enabled the instrument can calculate the flow rate
based on the weight. The flow rate is calculated and set-up individually for each scale.
Flow rate can be shown on the display, sent to (optional) analog outputs and read
through any of the available communication alternatives in the instrument. An option
code is required to enable this program option. See the description of the flow rate
calculation in this manual.
Remote Access.
It is possible to access the instrument through the Ethernet connection. Using a Web
Browser on the connected PC most set-up and maintenance functions are available on
the PC. This possibility simplify commissioning and service. It makes it possible to
access instruments from outside the local network (internet) providing the network
allow this.

Technical Manual
1-4
Maintenance
The G4 instrument needs no maintenance performed by the end-user. Any service
or repair work must be performed by qualified personnel.
Contact your supplier.
Cleaning
Before cleaning the G4, break the power connection to the instrument.
Use a soft cloth to clean the exterior of the instrument.
Safety information
Utilization.
Before connecting power to the instrument, check that all fixation screws
at the modules are tightened so that the instruments functional grounding
by the housing is maintained.
The instrument may only be utilized for the measurement and control functions,
described in this Technical Manual. It is especially important to adhere to the load limits
of the input/output connectors. We accept no responsibility for any damage arising from
improper operation.
Any changes to the instrument, which causes any function changes, may only be
carried out by the manufacturer, or after discussion with and permission by the
manufacturer.
Meaning of symbols, used in this manual
Direct current.
!
Caution, risk of danger. Documentation needs to be consulted.

G4 Multi Channel Weighing Instrument
1-5
Technical data
Enclosure type RM – Rail Mount enclosure
Dimensions
Enclosure design Aluminium housing with plastic frames
Rail mount DIN 46 277/3 and DIN EN 50022 (w=35 mm, h=7.5 mm)
Display, keyboard See VIEWPAN module
Environmental
Temperature range
Rated performance: -10 to +50 °C
Storage: -25 to +85 °C
Relative humidity Max. 85% up to 40 °C, decreasing linear to 50% at 50 °C
Rated pollution Pollution degree 2
Protection IP20. For indoor use.
Altitude Up to 2000 m
EMC, RF CE (Industrial), OIML

Technical Manual
1-6
VIEWPAN
Module type Display/keypad interface with integrated power supply for
the complete instrument.
Input voltage 24 V ±15% including fluctuations, 40W
Impulse withstand (overvoltage)
category I of IEC 60364-4-443
Output voltage 24 V output 0.1 A
The same voltage as input voltage
Display
2 x 16 character LCD with backlight
Keyboard 4 keys
CPU
Module type CPU module
RTC backup battery Manufacturer Type
Lithium battery Panasonic-BSG CR2032
CR2032 3V GP Batteries CR2032
Varta CR2032 (V)
COM1 (RS232) and
COM2 (RS485) For process data and control or printout data to a connected
printer. Isolated by operational insulation
Protocol Modbus RTU
Baud rate Up to 115 kbaud
Fieldbus For process data and control (optional)
Types Profibus or DeviceNet.
USB Version 1
Keyboard USB keyboard for PC
USB Memory USB type for PC
For backup and restore of set-up parameters.
For change to a new program version
Ethernet 10/100BASE-T. For process data, control, file transfer and
remote access.
Protocol Modbus TCP, EtherNet/IP, ftp, http.
RJ45 Indications Green LED: Transmitting. Yellow LED: Receiving.

G4 Multi Channel Weighing Instrument
1-7
WF IN / WF IN2
Module type Weight/Force input module
Max. # of transducers 8 (350 ohm) per channel
Maximum 48 transducers per instrument
Excitation voltage: 5 VDC
A/D conversion: 3.9 kHz, 16 000000 units (24 bits)
Input range +/- 7 mV/V
Update rate: 2.3 −300 readings per second
No. of channels: WF IN has 1 Weight/Force channel
WF IN2 has 2 Weight/Force channels
Sensitivity: 0.1 µV
Zero drift: <10 nV/V/K
Span drift: <2 ppm/K
Digital I/O 4 inputs, 24 V ±15%, 5 mA from external power supply,
isolated by operational insulation and
with common return
2 outputs, 24 V ±15%, max 100 mA from external power
supply, isolated by operational insulation and
with common return

Technical Manual
1-8
HS WF2
Module type High Speed Weight/Force input module
Max. # of transducers 4 (350 ohm) per channel
Excitation voltage: 10 VDC
A/D conversion: 20 kHz, 16 000000 units (24 bits)
Input range +/- 4.5 mV/V
Update rate: 12.5 −800 readings per second
No. of channels: HS WF2 has 2 Weight/Force channels,
separately isolated by operational insulation
Sensitivity: 0.1 µV
Zero drift: <10 nV/V/K
Span drift: <2 ppm/K
Digital I/O 4 inputs, 24 V ±15%, 5 mA from external power supply,
isolated by operational insulation and
with common return
2 outputs, 24 V ±15%, max 100 mA from external power
supply, isolated by operational insulation and
with common return

G4 Multi Channel Weighing Instrument
1-9
DIO8
Module type Digital input/output module
Separate I/O module 2 units can be used
Digital I/O 8 inputs, 24 V ±15%, 5 mA from external power supply,
isolated by operational insulation and
with common return
8 outputs, 24 V ±15%, max 100 mA from external power
supply, isolated by operational insulation and
with common return
AOUT1 / AOUT4
Module type Analog output module
Number of channels 1 or 4 channels,
separately isolated by operational insulation
Resolution 65000 units, 16 bits
Voltage output 0 – 10 V, -10 – 10 V, > 1 kohm load
Current output 4 – 20 mA, 0 – 20 mA, -12 – 20 mA, -20 – 20 mA,
< 500 ohm load
Update rate Scale update rate, adjustable smoothing filter.

Technical Manual
1-10
Profibus-DP
Module type Profibus-DP fieldbus adaptor
Connector Profibus 9-pin, female D-sub (DB9F)
Baudrate Auto setting 9.6 kbps – 12 Mbps
Address 1 – 125, set by parameter
Fieldbus data 16 bytes from fieldbus to instrument.
32 – 244 bytes from instrument to fieldbus
(may be limited by the master).
See chapter ‘Communication’ section
‘Fieldbus communication interface’ for details on fieldbus
data mapping.
Mounting The fieldbus adaptor is mounted through the front of
the CPU module with LED’s and connector accessible
through the CPU front panel.
Remove the plastic cover from the fieldbus slot in the CPU
module front panel. Insert the adaptor very carefully and
make absolutely sure that the adaptor slides correctly into
the guides in the connector on the CPU PCB. Tighten
the two fastening screws at the adaptor front and check
that the two securing hooks locks into the CPU PCB.
Settings All fieldbus settings are done with setup parameters in the
instrument. No settings are done on the module itself.

G4 Multi Channel Weighing Instrument
1-11
DeviceNet
Module type DeviceNet fieldbus adaptor
Connector 5 pin male connector.
Baudrate 125, 250, 500 kbps or Auto. Set by parameter.
Address 0 – 63, set by parameter
Fieldbus data 16 bytes from fieldbus to instrument.
32 – 244 bytes from instrument to fieldbus
(may be limited by the master).
See chapter ‘Communication’ section
‘Fieldbus communication interface’ for details on fieldbus
data mapping.
Mounting The fieldbus adaptor is mounted through the front of
the CPU module with LED’s and connector accessible
through the CPU front panel.
Remove the plastic cover from the fieldbus slot in the CPU
module front panel. Insert the adaptor very carefully and
make absolutely sure that the adaptor slides correctly into
the guides in the connector on the CPU PCB. Tighten
the two fastening screws at the adaptor front and check
that the two securing hooks locks into the CPU PCB.
Settings All fieldbus settings are done with setup parameters in the
instrument. No settings are done on the module itself.
Bus Supply Voltage According to the DeviceNet (Node) Specification:
nominal 24 VDC, range 11 – 25 VDC.

Technical Manual
1-12
Ordering information
For Rail mount (RM) instruments
G4-RM-FB-S1-S2-S3-V-SW
Instrument type
RM Enclosure type RM Rail mount
FB Fieldbus interface 0
P
D
None
Profibus
DeviceNet
Si Slot 1 to 3 type 0
2
3
4
6
7
8
Blank
HS WF2 High speed weight/force input module, 2 ch
WF IN Weight/force input module, 1 channel
WF IN2 Weight/force input module, 2 channels
AOUT1 Analog Output module, 1 channel
AOUT4 Analog Output module, 4 channels
DIO8 Digital Input and output module
V User interface and
power V VIEWPAN, 24VDC
SW Software (note 1)
W
F
S
(No code specified) Standard Weighing Program
Standard Weighing Program
Standard Force Program
Special Program (note 2)
Example: G4-RM-0-4-8-0-V-W
•G4 instrument (G4)
•Rail mount (RM)
•No field bus (0)
•Slot 1 = WF IN2 (4)
•Slot 2 = DIO8 (8)
•Slot 3 = Blank (0)
•Power =VIEWPAN unit (V)
•Software = Weighing program (W)
Note 1: The Software (SW) code specifies the program function that should be installed
in the instrument. If no code is specified the standard Weighing program will be
supplied.
Note 2: If a special program option is desired, the designation of the special program
must be specified when ordering.

G4 Multi Channel Weighing Instrument
1-13
Separate modules
Spec.no Module type Module name
110 544 CPU CPU unit
110 546 HS WF2 High speed dual Weight/Force input module
110 547 WF IN Single Weight/Force input module
110 548 WF IN2 Dual Weight/Force input module
110 549 AOUT1 Single channel analog output module
110 550 AOUT4 Four channel analog output module
110 551 DIO8 Digital input/output module
110 552 BLANK Blank panel
110 554 VIEWPAN Rail mount service panel
110 559 PROFIBUS-DP Profibus DP fieldbus adaptor
110 560 DEVICENET DeviceNet fieldbus adaptor
Module selection rules
Every system needs 1 VIEWPAN module and 1 CPU module (can be equipped with
one fieldbus adaptor).
Limitations on number of I/O modules that can be used in one instrument:
•Maximum 3 modules (not counting the VIEWPAN module).
•Maximum 3 WF IN / WF IN2 or 2 HS WF2 modules.
•HS WF2 and WF IN(2) cannot be mixed in the same system
•Maximum 1 AOUT1 or 1 AOUT4 module.
•Maximum 2 DIO8 modules.

Technical Manual
1-14

G4 Multi Channel Weighing Instrument
2-1
2. Installation
Mechanical installation
See chapter ‘Introduction – Technical data’ for references to RM mechanical measures.
G4, RM type, should be used in a dry, clean environment or it must be mounted
in a cabinet, protecting from water, dust etc. The instrument is prepared for
mounting on a flat surface by DIN rail according to Technical data.
The instrument needs minimum 200 mm space above this surface.
To remove the instrument from the rail, the black lever at the lower bottom side of
the instrument must be engaged.
Each instrument should have a free space of minimum 30 mm to the left
and to right, 100 mm above and below the instrument.
Cable ducts may be mounted in this free space.
All electrical connections to the instrument modules are made to terminals
at the front side so enough room for these terminals should be arranged.
CABLE DUCT
LOCK LEVER
TERMINALS
100
100
200
RM instrument.
Recommended free space at the instrument.

Technical Manual
2-2
Electrical installation
The field wiring of the instrument shall be suitable to the environment
(e.g. chemically) in the end-user application.
Field wiring installation shall comply with any national regulations, hereunder National
Electrical Code (NEC) for US and/or Canadian Electrical Code for Canada.
•A switch or circuit-breaker shall be included in the building installation.
•The switch shall be in close proximity to the equipment and
within easy reach of the operator.
•The switch shall be marked as the disconnecting device for the equipment.
•The equipment switch or circuit-breaker employed as disconnecting device shall
comply with relevant requirements of IEC 60947-1 and IEC 60947-3.
For electrical installation with an external dc supply, see page 2-5.
WARNING
Make sure that that the power to the instrument is turned off before:
-any modules are removed from or inserted in the instrument.
-any connections are connected to or disconnected from the instrument.
All modules should be regarded as ESD sensitive. Make sure that an ESD safe
environment is maintained when inserting modules, removing modules and when
handling modules separately from the instrument. Modules must be kept in
metallised ESD bag when not mounted in the instrument.
!