Vishay G4 User manual

GB
G4 Multi Channel
Weighing Instrument
Program version 1.2.0.0
Operating instructions,
Quick installation
PM/DT/HE types

Operating instructions, Quick installation

G4 Multi Channel Weighing Instrument
Contents
Introduction
General ............................................................. 1
Power supply ..................................................... 1
Start-up ............................................................. 1
Maintenance ..................................................... 2
Safety information ............................................. 2
Front panel
General ..............................................................3
Display alternatives ............................................4
Operation
Zero indication and zero adjustment ..................5
Gross weight ......................................................5
Net weight ..........................................................6
Taring .................................................................6
Editing Preset Tare ............................................7
Level supervision ...............................................8
Flow display .......................................................9
Installation
Mechanical installation .....................................11
Electrical installation ........................................11
DC supply, AC supply ......................................12
CPU unit ...........................................................13
WF IN, WF IN2 and HS WF2 ...........................14
Basic set-up
General ............................................................17
Hardware configuration ....................................17
Security lock .....................................................17
Common parameters .......................................18
Clock set-up .....................................................20
Scale calibration ...............................................21
Data sheet calibration ......................................24
Deadweight calibration .....................................27
Zeroing of gross weight ....................................30
Appendix 1
Common set-up values
Appendix 2
Scale set-up values

Operating instructions, Quick installation
PRECAUTIONS
READ this manual BEFORE operating or servicing this instrument.
FOLLOW these instructions carefully.
SAVE this manual for future reference.
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
Introduction
General
G4 is a high performance multi channel weighing instrument intended for industrial
systems. Its basic function is to convert the signals from strain gauge transducers to
useful weight information. Several types of communication interfaces are supported
by G4, which makes it easy to integrate the instrument into industrial processes.
The front panel of G4, types PM/DT/HE, is flat, dustproof, and waterproof. It has
a back lighted graphical colour LCD display with touch sensitive screen for weight
information, set-up information and error messages.
It also has function keys and a numeric keypad for entry of digits.
The basic configuration of the instrument performs weighing and flow rate
calculation. All functions are controlled by set-up parameters.
‘Operating instructions, Quick installation’ for G4, types PM/DT/HE, includes basic
installation and set-up information, required for correct measuring with the instrument.
This description deals with the following points:
•Weighing with G4, types PM/DT/HE.
•Flow rate measurement.
•Quick installation.
•Data sheet calibration.
•Deadweight calibration in two points.
Additional installation and set-up of more instrument functions, not covered by this
description, can also be performed, for example:
•Complete installation.
•Complete set-up.
•Setting of communication parameters.
•Table calibration.
•Level supervision.
For a complete instrument description, refer to:
G4 Multi Channel Weighing Instrument
Technical Manual PM/DT/HE types
Power supply
Power supply to the weight indicator should not be turned off during weekends and
over-night. Continuous power supply to electronics and transducers prevents moisture
condensation in the units.
Start-up
As soon as power is connected to the instrument, a start-up period begins.
The text ‘Start up Please wait!’ and a WAIT symbol (hour-glass) will be displayed
after some seconds.
Then G4 automatically switches to normal measuring operation.
If the instrument is set for operator start-up, the text
‘Press ENTER to start operation!’ will be shown.
If a warm up time has been set, the text ‘Warming up Please wait!’ will be displayed
before the instrument switches to measuring operation.
If any error is detected, the start-up stops and an error message will be displayed.
1

Operating instructions, Quick installation
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 the Technical Manual for G4 Multi Channel Weighing Instrument, PM/DT/HE types.
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.
Front panel of instrument G4, types PM, DT, and HE.
2

G4 Multi Channel Weighing Instrument
Front panel
General
G4 has a flat, dustproof, and waterproof front panel with a back lighted and touch
sensitive graphic colour LCD display and all necessary keys to perform weighing,
batching, and set-up operations.
Display
G4 normally displays either gross weight or net weight digitally, and in some cases
also gives a graphic representation of the gross weight.
Actual status information for the weight value and date and time will also be shown
at the display.
The Level status (max 4 levels) for the scale and other configurable information may
also be displayed in some cases.
If an error occurs this will be indicated by an error code at the display.
Info key
The Info key at the upper right corner of the panel is used to enter G4 menu system.
Function keys
Just below the display there are five function keys, marked F1 to F5.
Actual key functions, if any, are indicated at the lower line of the display.
To the right of the display, four arrow keys are provided. These keys control
the position of the cursor, the indicated area at the display.
The Enter key ( ) is situated between the arrow keys. It is used to accept
the selection indicated by the cursor, to finish the entry of a value etc.
A set of keys for entry of digits is also provided.
Pressing function keys or the Enter key can be replaced by tapping at corresponding
areas in the display.
Symbol keys
Six keys, marked with weighing symbols, are provided at the lower border of the panel.
Three of them control the zero setting function, the tare function, and the gross/net
function. The remaining three keys have no function in these instrument versions.
Key Name Function
ZERO
0ZERO Setting the gross weight value to zero (provided the value
is in the zeroing range: –1 % to +3 % of the capacity) and
setting the auto tare value to zero.
TARE
T
TARE Taring, i.e. entry of the gross weight as auto tare value and
display of net weight zero. Depending on actual setting
taring may be prevented if ‘Motion’ is displayed.
B/N
GROSS/NET Toggling between display of gross weight and net weight.
Net weight can be displayed only if a tare value other than
zero has been entered.
3

Operating instructions, Quick installation
Display alternatives
It is possible to configure G4 to display one, two or four scales at a time, or a
combination of the mentioned views. If a combination of views is used, the arrow keys
'right' and 'left' are used to select a display alternative. Only configured scales will be
shown.
Arrow keys 'up' and 'down' are used to select one of the configured scales. When
several scales are displayed, the selected scale is indicated yellow. The function keys
will influence only the selected scale.
If display of only one scale is selected, detailed information of weight and other selected
information can be presented.
If display of two or four scales is selected, the weight values will be shown, but less other
information.
2006-09-24 19:07
------ ------ ------P.Tare Levels
Scale: 1 Gross
103.2 kg
Levels 4: 5: 6: 7:
Preset Tare: 33.0kg
Water
2006-09-24 19:07
------ ------ ------P.Tare Levels
Scale: 1
Gross 102.8 kg
Scale: 2
Net Zero 000.0 kg
Scale: 3
Net Zero 000.0 kg
Scale: 4
Gross 004.9 kg
2006-09-24 19:07
------ ------ ------P.Tare Levels
Scale: 2 Net Motion
3.4 kg
Scale: 1 Gross
103.2 kg
‘Level status’
Status of the level supervision is presented in four boxes below the weight value
presentation. The boxes have fixed positions. When a digit is shown at a box,
the corresponding Level is in use. For each scale the four lowest level numbers
that are in use will be shown. A Level box will be marked green when the level
of the supervised weight signal is above the set value for that Level.
‘Information lines’
By set-up parameters it is possible to configure the instrument to display selected
information on two information lines below the Level status boxes.
2006-09-24 19:07
Scale: 1 Gross
103.2 kg
Levels 4: 5: 6: 7:
Preset Tare: 33.0kg
Water
------ ------ P.Tare Levels ------
Example:
Levels 4, 5, 6, and 7 are in use; the weight signal is above Level 4.
Preset Tare (33.0 kg for Scale 1) on Info line 1.
Scale Name (Water for Scale 1) on Info line 2.
4

G4 Multi Channel Weighing Instrument
Operation
Zero indication and zero adjustment
A basic zero setting of the gross weight for unloaded scale is performed at installation
as a part of the calibration. When a ‘good zero’ is displayed, the text ‘Zero’ is shown
to the right in the display.
Minor correction of the zero value may be needed and can rapidly be performed.
Zero adjustment
If, for unloaded scale, the text ‘Zero’ is not shown, but the gross weight is
close to zero, a rapid zero adjustment can be performed.
The gross weight must be stable (text ‘Motion’ not shown) and the key ZERO
must be enabled.
2006-09-24 19:07
Scale: 1 Gross
000.2 kg
Levels 4: 5: 6: 7:
Preset Tare: -----
Water
------ ------ P.Tare Levels ------
ZERO
0
2006-09-24 19:07
Scale: 1 Gross Zero
000.0 kg
Levels 4: 5: 6: 7:
Preset Tare: -----
Water
------ ------ P.Tare Levels ------
Zero adjustment can only be performed if the accumulated deviation from the basic zero
setting in the last calibration is within -1 % to +3 % of the ‘Capacity’.
In other cases a new basic zero setting must be performed.
Gross weight
The gross weight is the total weight loaded on the scale after zero setting.
Gross weight is displayed when the text ‘Gross’ is shown in the display.
When net weight is displayed, the GROSS/NET key can be pressed to change
to display of gross weight, provided that the GROSS/NET key is enabled.
2006-09-24 19:07
Scale: 1 Net
103.2 kg
Levels 4: 5: 6: 7:
Preset Tare: -----
Water
------ ------ P.Tare Levels ------
GROSS/NET
B/N
2006-09-24 19:07
Scale: 1 Gross
143.4 kg
Levels 4: 5: 6: 7:
Preset Tare: ------
Water
------ ------ P.Tare Levels ------
In some cases, gross weight is shown as a graphic bar at the display.
Maximum length of the bar corresponds to ‘Capacity’ of the scale.
5

Operating instructions, Quick installation
Net weight
The net weight is the difference between the gross weight and a tare value.
If the tare value is zero, net weight can not be displayed.
Net weight is displayed when the text ‘Net’ is shown in the display.
When gross weight is displayed, the GROSS/NET key can be pressed to change
to display of net weight, provided that the GROSS/NET key is enabled.
2006-09-24 19:07
Scale: 1 Gross
143.4 kg
Levels 4: 5: 6: 7:
Preset Tare: ------
Water
------ ------ P.Tare Levels ------
GROSS/NET
B/N
2006-09-24 19:07
Scale: 1
Levels
Preset Tare:
Water
Net
103.2 kg
4: 5: 6: 7:
-----
------ ------ P.Tare Levels ------
Taring
Taring means storing of a tare value for the scale. Net weight will be calculated as
the difference between the gross weight and this tare value. If the tare value is zero,
net weight will not be displayed.
At default setting, taring can always be performed, provided the key TARE is enabled.
But the scale can also be set to allow taring only at stable weight (when the text
‘Motion’ is not shown).
In G4 two tare values can be used: Auto tare and Preset tare.
Auto tare
By taring, the actual gross weight is stored as Auto tare value, and the scale will switch
to display of net weight ‘zero’.
2006-09-24 19:07
Scale: 1 Gross
014.5 kg
Levels 4: 5: 6: 7:
Preset Tare: ------
Water
------ ------ P.Tare Levels ------
TARE
T
2006-09-24 19:07
Scale: 1
Levels
Preset Tare:
Water
Net Zero
000.0 kg
4: 5: 6: 7:
-----
------ ------ P.Tare Levels ------
6

G4 Multi Channel Weighing Instrument
Editing Preset tare
In this example Scale 1 is set for taring with
‘Preset tare’, and for displaying the value
of the ‘Preset Tare’ at Info Line 1
(and Scale Name at Info Line 2).
The example shows editing the Preset tare
value, using the numeric keypad.
Press 'P.Tare'.
2006-09-24 19:07
Scale: 1 Gross
034.5 kg
Levels 4: 5: 6: 7:
Preset Tare: 0.00 kg
Water
------ ------ P.Tare Levels ------
Press 'Edit' to edit the value.
If Operator Lock is activated,
the Operator Code will be needed.
Preset tare, Scale 1
Preset Tare 1 0.0 kg
Edit Escape
The actual value of 'Preset tare' is displayed.
Use the numeric keypad to write the new value.
Finish by 'Enter'.
Edit: Preset tare 1
Enter Escape
Value: kg
Maximum value: 999999 kg
Minimum value: 0 kg
33.0
Menu 'Preset tare, Scale 1' will be shown
with the new value.
Press 'Escape' to return to display of
normal weighing operation.
Preset tare, Scale 1
Preset Tare 1 33.0 kg
Edit Escape
7

Operating instructions, Quick installation
Level supervision
With G4 it is possible to supervise different weighing signals at defined levels.
The instrument contains 32 supervising units, Level 1 to Level 32, which can be
connected to the scales by the parameter set-up. For each scale up to 4 connected
Levels are indicated at the display in normal operation. All Levels connected to a scale
are shown if 'Levels' or function key F4 is pressed.
Edit Levels
The supervision levels are easily edited from
the G4 front panel during normal operation.
In this example Scale 1 has five levels of
supervision.
Level number 6 should be edited.
Press 'Levels'.
Select Level 6 by using arrow keys up and
down to position the indicator.
(Or tap at Level 6 to edit.)
Press 'Edit'.
If Operator Lock is activated, the Operator Code
will be needed.
The actual value of Level 6 is displayed.
Use the numeric keypad to write the new value.
Finish by 'Enter'.
Menu 'Levels, Scale 1' will be shown
with the new value for Level 6.
Press Escape' to return to display of
normal weighing operation.
2006-09-24 19:07
------ ------ ------P.Tare Levels
Scale: 1 Gross
034.5 kg
Levels 4: 5: 6: 7:
Preset Tare: 33.0 kg
Water
Levels, Scale 1
Edit Escape
Level 4 20.0 kg
Level 5 40.0 kg
Level 6 55.0 kg
Level 7 85.0 kg
Level 9 120.0 kg
Edit: Level 6
Enter Escape
Value: kg60.0
Maximum value: 999999 kg
Minimum value: -999999 kg
Levels, Scale 1
Edit Escape
Level 4 20.0 kg
Level 5 40.0 kg
Level 6 60.0 kg
Level 7 85.0 kg
Level 9 120.0 kg
8

G4 Multi Channel Weighing Instrument
Flow display
When option Flow display is activated for a scale, function key F5 will show
the text 'W/F'. Pressing function key F5, or tapping at 'W/F', will switch the scale
between display of weight value (indicated by 'Gross' or 'Net') and display of
flow value (indicated by 'Flow').
2006-09-24 19:07
Scale: 1 Gross
123.4 kg
Levels 4: 5: 6: 7:
Preset Tare: 33.0 kg
Water
------ ------ P.Tare Levels W/F W/F
2006-09-24 19:07
Scale: 1
Levels
Preset Tare:
Water
Flow
0.00 kg/s
4: 5: 6: 7:
33.0 kg
------ ------ P.Tare Levels W/F
9

Operating instructions, Quick installation
10

G4 Multi Channel Weighing Instrument
Installation
Mechanical installation
The instrument G4 has a flat plastic front panel and can be ordered with three
different housings: aluminium housing for panel mounting or stand-alone use,
or stainless steel housing for stand-alone use in harsh environment.
Instruments for panel mounting have an integrated gasket that gives sealed
attachment to mounting panels. Stand-alone instruments have sealed housings.
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.
For cable diameters, see specification in the Technical Manual.
These instruments have plugged cable entry holes. Replace a suitable number of plugs
by the strain reliefs delivered with the instrument.
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 made via an external dc supply unit
or an internal ac/dc supply unit.
All electrical connections to G4, including connection to ground, are made via
plug-in terminal blocks. Shielded cables are needed, exept for the power input,
and the cables should be routed so that electromagnetic interference from power
cables is avoided.
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.
11

Operating instructions, Quick installation
DC SUPPLY 24 V
!The output of the external dc supply must be rated 24 V , ±15%
including fluctuations, min. 40 W. The supply must provide Double Insulation
between Mains parts and 24 V SELV or SELV-E circuit, and a limited-energy
circuit (max. available current 8 A). For the US market this energy limit
can be achieved with an ANSI/UL 248-14 fuse rated 5 A.
For other markets an IEC 60127 T type fuse rated 4 A may also be used.
24 V In
+24 V In
Terminals 1, 2, and 3.
Connect power to terminal 1 (positive) and 0 V
Ground
terminal 2 (0 V). To achieve functional
grounding, terminal 3 should be connected
to ground. +24 V Out
0 V
24 V Out
Terminals 4 (positive) and 5 can be used
to supply max. 100 mA to logics, like
outputs and inputs.
AC SUPPLY 110-240 V
!Mains supply cable shall be separated and routed away
from SELV or SELV-E field wiring.
Remove power before removing the module from the instrument.
Make sure the fixation screws are well tightened during operation.
110-240 V In
Terminals 1, 2, and 3. 110-240 V~
Connect power to terminal 1 and 2. Protective earth
To achieve functional grounding, terminal 3
should be connected to protective earth.
+24 V Out
0 V
24 V Out
Terminals 4 (positive) and 5 can be used
to supply max. 100 mA to logics, like
outputs and inputs.
1
DC SUPPLY
0 V
Shield
0 V
Shield
+24 VDC In
+24 VDC Out
2
3
4
5
6
1
AC SUPPLY
Shield
0 V
Shield
110-240 VAC
+24 VDC Out
2
3
4
5
6
12

G4 Multi Channel Weighing Instrument
CPU unit
External computing devices connected to the CPU communication interfaces
of the instrument have to comply with the standard, UL 60950.
The internal battery in the CPU module is to be used only in the equipment
where servicing of the battery circuit and replacement of the lithium battery
will be done by a trained technician.
COM1
RS-232 Serial communication.
This is a SELV/SELV-E circuit.
COM 1 can be used for serial communication
(DTE)
RS-
9p
232
25p
!
with computer/PLC (Modbus RTU).
Point to point communication, only one
G4 unit connected to the computer/PLC.
Connections are made to terminals
7 to 9. Shielded cable must be used.
Connect the shield to terminal 10.
COM2
RS-485 Serial communication for
2-wire or 4-wire with common 0 V.
This is a SELV/SELV-E circuit.
Communication port COM2 can be
used for serial communication with
computer/PLC (Modbus RTU).
Connections are made to terminals
1 to 5. Shielded cable must be used.
Connect the shield to terminal 6.
The communication line must be
terminated at both ends.
If G4 is connected at the end of
the communication line, the switches
T2 and R2 must be set according to
the table below.
2-wire termination:
Both T2 switches ON,
both R2 switches OFF.
4-wire termination:
Both T2 switches ON
both R2 switches ON.
2 3
3 2
5 7
TX
RX
0V
Shield
COM1 RS-232
10
9
8
7
RS485 2-wire COM2
+5
0
+5
0
T2 +5
T2 0
R2 +5
R2 0
1 T-
T+
R-
R+
0 V
Shield
6
2
3
4
5
T2
T2
R2
R2
RS485 4-wire COM2
1 T-
T+
R-
R+
0 V
Shield
6
2
3
4
5
13

Operating instructions, Quick installation
WF IN, WF IN2 and HS WF2
!The voltage levels on connectors of I/O modules shall not exceed
hazardous voltage levels of 30 Vrms, 42.4 Vpeak or 60 Vdc under normal
conditions. In wet locations these voltage levels shall not exceed 16 Vrms,
22.6 Vpeak or 35 Vdc.
Transducer inputs
Terminals 17 – 23 (channel 1), 10 – 16 (channel 2). See next page.
Transducer connection should be handled with great care to achieve good
measuring data. Transducer integrated cables may not be shortened.
NOTE!
Transducer cables must be routed at least 200 mm away from 230/380 V, 50/60 Hz
power cables. By cables with other frequencies or high power, an even wider distance
is preferable.
4-wire connection should be used if the transducer integrated cable is long enough to
be connected directly to a transducer input. At 4-wire connection, some terminals must
be interconnected as shown in the figure on next page.
6-wire connection should be used if the integrated cable must be lengthened
or if several transducers should be connected to one transducer input.
The channel 1 cable shield must be connected to terminal 21 and
the channel 2 cable shield must be connected to terminal 14.
In WF IN and WF IN2 the shield terminals are internally connected to the G4 housing,
which is internally connected to earth via the power supply connector terminal 3 (Shield).
The shield shall not be connected at any other point.
In HS WF2 the transducer input channels are separately insulated by operational
insulation and the shields can be connected to the most convenient ground/earth point.
This can be the junction box when using multiple transducers or at the barrier ground
when using Ex zener barriers.
In the junction box SL-4 from Nobel Weighing Systems, see figure, all necessary
terminals are provided.
14

G4 Multi Channel Weighing Instrument
10
15
13
12
11
14
16
Exc.-
Exc.+
Sign.+
Sign.-
4-wire connection
Transducer
Transducer input, ch. 2
Exc+
Sense+
Exc-
Sense-
Sign+
Sign-
Shield
Junction box 6-wire connection Transducer input, ch. 1
17
22
20
19
18
21
23
Exc.-
Exc.+
Sign.+
Sign.-
Transducer
Transducer
Exc.-
Exc.+
Sign.+
Sign.-
Exc+
Sense+
Exc-
Sense-
Sign+
Sign-
Shield
A transducer may be connected directly to terminals at the transducer input.
For several transducers or long distances,
a junction box and lengthening cable is needed.
For a HS WF2 channel, the shield can be connected to
ground/earth at any point.
15

Operating instructions, Quick installation
16