Vishay G4-PM User manual

G4 Multi Channel
Force Instrument
Program version 101.1.0.0
Technical Manual
PM/DT/HE types
GB

G4 Multi Channel Force Instrument
1. Introduction
Manual updates .....................................1-1
General ..................................................1-1
Functions ...............................................1-2
Maintenance...........................................1-3
Safety information ..................................1-3
Technical data .......................................1-4
Ordering information ..............................1-12
2. Installation
Mechanical installation ...........................2-1
Electrical installation ..............................2-2
CPU unit.................................................2-3
DC SUPPLY ..........................................2-5
AC SUPPLY ..........................................2-6
WF IN, WF IN2 and HS WF2 .................2-7
AOUT1 and AOUT4 ...............................2-10
DIO8 ......................................................2-11
Profibus-DP Fieldbus Adaptor ................2-12
DeviceNet Fieldbus Adaptor ..................2-14
Front panel ............................................2-16
3. Instrument Functionality
General...................................................3-1
Function Block........................................3-1
4. Set-up
General ..................................................4-1
Graphical touch display .........................4-2
Menu structure .......................................4-6
Parameters ............................................4-8
5. Calibration
General ..................................................5-1
Common parameters .............................5-2
Calibration using datasheet ...................5-3
Using parameters values from
a previous calibration .............................5-4
Calibration with known forces.................5-5
6. Operation
General ..................................................6-1
Power supply .........................................6-1
Power-up sequence ...............................6-1
Display alt. by normal operation .............6-2
Security locks ........................................6-4
Zero setting ............................................6-4
Main menu .............................................6-5
Level supervision ...................................6-6
Use of inputs and outputs ......................6-7
Filter function .........................................6-8
7. Communication
General ..................................................7-1
Serial interface........................................7-1
Modbus RTU Slave ................................7-1
Modbus TCP Slave ................................7-2
Modbus protocol ....................................7-3
Fieldbus interface....................................7-28
8. Remote Access
General ..................................................8-1
Browser requirements.............................8-1
Using the Remote Access ......................8-2
Security...................................................8-2
Remote Access Login and Logout ..........8-3
Remote / Local Access ...........................8-6
Remote Set-up........................................8-7
Remote Access Maintenance .................8-10
9. Maintenance
General ..................................................9-1
Diagnostics .............................................9-1
File handling ...........................................9-4
Create Backup .......................................9-4
Restore Backup .....................................9-4
Set Default..............................................9-4
Program Upgrade ...................................9-5
Instrument Restart ..................................9-5
10. Troubleshooting
General...................................................10-1
Error codes ............................................10-1
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.
!
DO NOT allow untrained personnel to operate,
clean, inspect, maintain, service, or tamper with
this instrument.
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.

G4 Multi Channel Force Instrument
1-1
1. Introduction
Manual updates
This manual is updated for the 101.1.0.0 program version. In this program is a web
server added which enables for the user to access the instrument using a PC running a
web browser. This manual can also be used for the previous program version
(101.0.0.0) where the only differences are the ‘Network Configuration’ menu, the
Instrument restart functionality and the remote access part.
General
The G4 Instrument is a high performance multi-channel force indicator intended for
industrial systems.
Its basic function is to convert the signals from strain gauge transducers to useful force
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 8 synchronized force
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.
Internal solid-state outputs in the instrument can be used for output functions from level
supervision 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 using Modbus RTU protocol.
The Ethernet interface is using Modbus TCP and the optional fieldbus interface uses
Profibus or DeviceNet.
Block structure of a G4 Instrument

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1-2
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.
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 with keys and/or graphical touch display on
the front panel.
24 V DC or 110/230 V AC powers the G4 Instrument. All input and output signals
are galvanically isolated from the power supply by operational insulation.
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 force 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
force 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 hysteresis added, meaning that the switch level can be different for
increasing and decreasing signal. It’s possible to set level switching delays. 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.
Force values, web tension 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 and Modbus TCP for the Ethernet connection. For the optional
fieldbus interface Profibus or DeviceNet can be used.

G4 Multi Channel Force Instrument
1-3
Instrument modes.
In normal operation mode the G4 Instrument is presenting the measurement values on
the front panel graphical display. One or more Function Blocks can be shown
simultaneously. The user can configure the display via set-up parameters.
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 front panel of the instrument and/or
by using the buttons displayed on the touch display.
Presentation.
The instrument can present measured or calculated values, status of levels, parameter
settings etc. at the front panel. An extensive system of menus gives the possibility to
present various information about the instrument.
Measured or calculated values, status of levels and so on, can be transferred to
external equipment via the different communication interfaces (some are optional).
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 will simplify commissioning and service. It will make it possible
to access instruments from outside the local network (internet) providing the network
allow this.

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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. For cleaning
the instrument front panel a soft, damp cloth may be used.
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.
Alternating current.
!
Caution, risk of danger. Documentation needs to be consulted.

G4 Multi Channel Force Instrument
1-5
Technical data
Enclosure
types PM - Panel mount DT –Desktop HE – Harsh Environment
Enclosure
design Aluminum housing, plastic panel Aluminum housing, plastic panel Stainless steel housing, plastic panel
Dimensions See figure
Panel thickness:
2 – 25 mm
See figure See figure
Strain relief — 6 pcs. for cable dia.
4.3 to 11.4 mm 6 pcs. for cable dia. 4.3 to 11.4 mm
Display Color TFT LCD screen with backlighting, 5.7” 320x240 pixels
Keyboard Touch screen and 34 membrane keys
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 Pollution degree 3 Pollution degree 3
Protection IP65 (panel), indoor use IP65, indoor use.
Rated for wet locations IP65, indoor use. Rated for wet locations
Altitude Up to 2000 m
EMC, RF CE (Industrial)

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PM -Panel mount enclosure outlines and panel cutout.
DT -Desktop enclosure outlines
HE - Harsh environment enclosure outlines

G4 Multi Channel Force Instrument
1-7
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
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 and control
Protocols Modbus TCP, ftp, http
RJ45 Indications Green LED: Transmitting. Yellow LED: Receiving.
DC SUPPLY
Module type Power supply module
Input 24 V ±15% including fluctuations, 40W
Impulse withstand (overvoltage)
category I of IEC 60364-4-443
Output 24 V output 0.1 A
The same voltage as input voltage

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1-8
AC SUPPLY
Module type Power supply module
Input voltage 110-240 V~ +10% -15% including fluctuations, 50/60 Hz, 40W
Output voltage 24 V output 0.1 A
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: 9.3 −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

G4 Multi Channel Force Instrument
1-9
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: 25 −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
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

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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 Function Block update rate, adjustable smoothing filter
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 ‘7 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.

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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 ‘7 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.

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Ordering information
For Panel mount (PM), Desktop (DT) and Harsh environment
(HE) instruments
G4-PM-FB-S1-S2-S3-S4-S5-S6-P-SW
Instrument type
PM Enclosure type PM
DT
HE
Panel mount
Desktop
Harsh environment
FB Fieldbus interface 0
P
D
None
Profibus
DeviceNet
Si Slot 1 to 6 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
P Power supply D
A DC power supply AC power supply
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-PM-0-4-8-0-0-0-0-D-F
•G4 instrument (G4)
•Panel mount (PM)
•No fieldbus (0)
•Slot 1 = WF IN2 (4)
•Slot 2 = DIO8 (8)
•Slot 3 = Blank (0)
•Slot 4 = Blank (0)
•Slot 5 = Blank (0)
•Slot 6 = Blank (0)
•Power = DC supply (D)
•Software = Force program (F)
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 number of the special program must
be specified when ordering.

G4 Multi Channel Force 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
110 553 DC SUPPLY DC supply unit
110 559 PROFIBUS-DP Profibus DP fieldbus adaptor
110 560 DEVICENET DeviceNet fieldbus adaptor
Module selection rules
Every system needs 1 Power supply 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 6 modules.
•Maximum 4 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.

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G4 Multi Channel Force Instrument
2-1
2. Installation
Mechanical installation
See chapter ‘1. Introduction – Technical data’ for references to PM, DT and HE
mechanical measures: outer extents, body extents and panel cutout (PM).
PM type instrument:
Make sure the panel thickness meets the specification and that there is room enough
behind the panel for the instrument and the connected cables (minimum 200 mm).
Cut a panel opening according to the specification on page 1-5.
Insert the instrument through the opening. Hold it in place while attaching brackets
and wing-headed bolts to the four nuts, sliding in grooves of the housing.
Tighten the bolts and make sure the integrated gasket of the instrument is
compressed against the mounting panel, giving a sealed attachment.
DT and HE type instrument:
Arrange enough space for cables and strain reliefs behind or below the instrument.
DT instrument housings have 6 plugged openings facing downwards, intended for
the cable strain reliefs. As an alternative, knock-out openings in the back panel can be
knocked open for strain reliefs facing backwards.
HE instrument housings have 12 plugged openings for the cable strain reliefs, facing
downwards and backwards.
Enclosed with each instrument is a set of 6 strain reliefs. For each cable one strain
relief should be mounted with a sealing washer on the exterior and a locknut inside
the housing.
Mounting legs are fitted to the instrument housings by knob-headed bolts and threaded
holes or nuts. Use the enclosed fixing brackets to attach the legs to the table or a wall.
295
278
150
108
Dia. 4.4
Dia. 4.4

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Electrical installation
The field wiring of the instrument shall be suitable to the environment
(e.g. chemically) in the end-user application.
Mains cables shall be separated and routed away from SELV or
SELV-E field wiring.
For DT and HE instruments UL Listed and KAM cord type flexible cables shall be used.
The cable diameters must be selected in accordance with the strain relief specification.
See Technical Data.
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.
The power supply for the instruments can be
an external DC source and an internal DC SUPPLY unit
or external AC mains and an internal AC SUPPLY unit.
For electrical installation with an internal DC SUPPLY unit, see page 2-5.
For electrical installation with an internal AC SUPPLY unit, see page 2-6.
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
metallized ESD bag when not mounted in the instrument.