Page 1 G4 Multi Channel Force Instrument Program version 101.1.0.0 Technical Manual RM type...
Page 3: Table Of Contents
G4 Multi Channel Force Instrument Contents Filter function ......... 6-7 1. Introduction 7. Communication Manual updates ........1-1 General ..........1-1 General ..........7-1 Functions ..........1-2 Serial interface ........7-1 Maintenance .......... 1-4 Modbus RTU Slave ........ 7-1 Safety information ........1-4 Modbus TCP Slave ........
Page 4 Technical Manual 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.
Page 5: Introduction Manual Updates
(101.0.0.0) where the only differences are the ‘Network Config.’ 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.
Page 6: Functions
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).
Page 7 G4 Multi Channel Force Instrument Instrument modes. In normal operation mode the G4 Instrument is presenting the measurement values on the front panel (VIEWPAN) alphanumerical display. Values for one Function Block at a time can be shown. During parameter set-up the instrument will continue normal operation.
Page 8: Maintenance
Technical Manual 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.
Page 9: Technical Data
G4 Multi Channel Force Instrument 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 Rated performance: -10 to +50 °C...
Page 10 Technical Manual 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...
Page 11 G4 Multi Channel Force Instrument 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)
Page 12 Technical Manual 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 25 − 800 readings per second Update rate: No.
Page 13 G4 Multi Channel Force Instrument 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,...
Page 14 Technical Manual 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).
Page 15 G4 Multi Channel Force Instrument 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.
Page 16: Ordering Information
Software (note 1) (No code specified) Standard Weighing Program Standard Weighing Program Standard Force Program Special Program (note 2) Example: G4-RM-0-4-8-0-V-F • G4 instrument (G4) • Rail mount (RM) • No field bus (0) • Slot 1 = WF IN2 (4) •...
Page 17 G4 Multi Channel Force Instrument Separate modules Spec.no Module type Module name 110 544 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...
Page 18 Technical Manual 1-14...
Page 19: Installation Mechanical Installation
See section ‘1. 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.
Page 20: Electrical Installation
Technical Manual 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. •...
Page 21: Cpu Unit
Connect shield to terminal 6. The communication lines must be terminated in Shield both ends. If G4 is connected at the end of the communication line switches must be set as: 2-wire termination: Both T2 ON, both R2 OFF. 4-wire termination: Both T2 ON, both R2 ON.
Page 22 Technical Manual Field Bus Slot for optional Fieldbus interface. Profibus DP-V1 and DeviceNet are available. See section Profibus-DP Fieldbus Adaptor or DeviceNet Fieldbus Adaptor later in this chapter for details. Connector for USB device(s). This port has no operational insulation and should be considered as a SELV/SELV-E circuit.
Page 23: Viewpan Module
The integrated power supply is used to supply the complete instrument. 24 V input Terminals 1, 2 and 3. The G4 instrument should be powered by 24 V connected according to the diagram below. To achieve functional grounding, terminal 3 should be connected to ground.
Page 24: Wf In, Wf In2 And Hs Wf2
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 pin 3 (shield). The shield shall not be connected at any other point.
Page 25 G4 Multi Channel Force Instrument 4-wire connection Transducer input, ch. 2 Exc.+ Exc+ Exc.- Sign.+ Sense+ Sign.- Transducer Exc- Sense- Sign+ Sign- Shield Junction box 6-wire connection Transducer input, ch. 1 Exc.+ Exc+ Exc.- Sign.+ Sense+ Sign.- Transducer Exc- Sense- Exc.+...
Page 26 Digital inputs Terminals 6 – 9 and terminal 5 (ICom) as a common connection. Four digital inputs are provided, with functions that can be set in the G4 set-up. External sourcing (24 V ) from the instrument power supply (max. 100 mA) or from a separate DC supply must be used.
Page 27: Aout1 And Aout4
G4 Multi Channel Force Instrument AOUT1 and AOUT4 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.
Page 28: Dio8
Digital inputs Terminals 11 – 18 and terminal 19 (ICom) as a common connection. Eight digital inputs are provided, with functions that can be set in the G4 set-up. External sourcing (24 V ) from the instrument power supply (max. 100 mA) or from a separate DC supply must be used.
Page 29: Profibus-Dp Fieldbus Adaptor
G4 Multi Channel Force Instrument Profibus-DP Fieldbus Adaptor Profibus module front view (1) Operation mode LED. (2) Status LED. (3) Profibus connector. PROFIBUS DP-V1 Operation mode LED State Indication Not online / No power Green On-line, data exchange Flashing Green...
Page 30 For reliable fieldbus function, line termination must be arranged in both ends of the transmission line. For a G4 instrument, at the end of the cable, a connector with line termination should be used. For all other G4 Instruments connection without line termination should be used.
Page 31: Devicenet Fieldbus Adaptor
G4 Multi Channel Force Instrument DeviceNet Fieldbus Adaptor DeviceNet module front view (1) Network Status LED. (2) Module Status LED. (3) DeviceNet connector. DeviceNet (Pin 1) Network Status LED State Indication Not online / No power Green On-line, one or more connections are established...
Page 32 For reliable fieldbus function, line termination must be arranged in both ends of the transmission line. For a G4 instrument placed at the end of the line, terminate line by placing a 121-ohm resistor between CAN L (pin 2) and CAN H (pin 4).
Page 33: Instrument Functionality General
G4 Multi Channel Force Instrument 3. Instrument Functionality General This chapter describes the functionality of the different parts of the force instrument. Function Block All measuring functions in the instrument are based on configurable function blocks. A Function Block is used to calculate the force or web tension of one to four inputs and the sums and differences if more than one input is used.
Page 34 Technical Manual output. Also the input forces are available for monitoring etc, see ‘Common values’ later in this chapter. Force Mode The following table and figures explains the function and the values from a Function Block in force mode (set-up parameter ‘X:Web T. Mode’ = Off). A ‘(F)’...
Page 35 G4 Multi Channel Force Instrument Web Tension Mode A Function Block can be configured for web tension measuring by setting set-up parameter ‘X:Web T. Mode’ to On. In this case some of the force values will be recalculated to a web tension value using the ‘X:Web T. Factor’ as shown below.
Page 36 Technical Manual Input A Output 3 Output 7 Output 1 1 / WTF Output 4 Input B Difference Input C Output 5 Output 2 1 / WTF Output 8 Input D Output 6 WTF = Web Tension Factor Four Channel Function block, Web Tension mode Common values The following table explains the available input values to a Function Block.
Page 37: Set-Up General
Warning: Changes done during editing of set-up parameters will affect the behavior of the instrument immediately. The user must take all necessary precautions to prevent any undesired effects in the process monitored or controlled by the G4 instrument or a connected control system.
Page 38: Operators Interface
Technical Manual configured here. There are parameters for hystereses setting and level switching delays. Inputs: The use of the instruments digital inputs is set in this menu. Note that the inputs are numbered 11 to 38. Inputs 11 to 18 corresponds to inputs on slot 1 I/O module, 21 to 28 correspond to inputs on slot 2 I/O and so on.
Page 39 G4 Multi Channel Force Instrument From any of the operating display views, displaying the main menu is done by pressing ‘+’ and ‘↑’ keys simultaneously for 1 second. The ViewPan ‘+’ and ‘−’ keys are used to scroll the available menu items and the ‘↵’...
Page 40 Technical Manual Parameter Set-up menu To enter a Parameter Set-up sub menu the desired one is selected by scrolling with ‘+’ or ‘−’ Main Menu keys until it’s shown. Then the sub menu is Param. Set-up entered by pressing ‘↵’. Returning to ‘Main Menu’...
Page 41 G4 Multi Channel Force Instrument Parameter editing procedure Parameter set-up This example shows the ‘General’ General parameter menu but editing is done similar throughout the menu system. The desired menu is selected by scrolling Language Edit with ‘+’ or ‘−’ keys until it is shown. Then the...
Page 42: Menu Structure
Technical Manual Menu structure Main Menu *sub menu *Levels *Clock Set-up *Param. Set-up *System Info. *Maintenance *Network Config (Cont. on next page) Levels Clock Set-up Param. Set-up *General Level values for *Hardware Config. Date and time set-up configured levels *Calibration *Communication *Level Superv.
Page 43 G4 Multi Channel Force Instrument (from previous page) System Info. Maintenance Network Config *Diagnostics Information on serial *IP Config. *File Handling numbers, program *Server Config. *Create Backup versions, network *Restore Backup status and installed *Set Default I/O modules. *Program Upgrade...
Page 44: Parameters
Technical Manual Parameters On the following pages a survey of all parameters is presented. The parameters are divided in groups following the menu they belong to. For choice parameters the available choices are given. For numerical parameters, a value range is given. At the end of the table, the default value is given in <...
Page 45 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Time Format 12 h Defines the time format. 24 h 12 h: 12 hour time format. <24h> 24 h: 24 hour time format. Zero Key Disables/enables the Zero function from the front panel.
Page 46 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menu ‘Hardware Config.’ Fieldbus Not In Use This parameter defines what type of fieldbus that will be used in Profibus the CPU. DeviceNet Not In Use: The fieldbus is not used regardless of any installed <Not In Use>...
Page 47 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. F.Block 1 Inp.A Not In Use This parameter defines which measuring channel (slot and Slot 1, Ch 1 channel) that should be use as input A to Function Block 1.
Page 48 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Func.Block2 Type Not In Use This parameter defines if Function Block 2 is used and, if used, 1 Channel the no of inputs it should use. 2 Channel Not In Use: The Function Block is not used. 4 Channel 1 Channel: 1 channel type.
Page 49 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Func.Block3 Type Not In Use This parameter defines if Function Block 3 is used and, if used, 1 Channel the no of inputs it should use. 2 Channel Not In Use: The Function Block is not used.
Page 50 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menus ‘Function Block 1’ – ‘Function Block 8’ The Calibration menu contains up to 6 sub menus, one for each used Function Block. The parameters are the same for all 6 menus. Here only Function Block 1 parameters are shown.
Page 51 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. 1:Resolution 0.001 Defines the decimal point position and resolution format for the 0.002 displayed force value. All set-up parameters using the 0.005 measurement unit will be written with the decimal point position 0.01...
Page 52 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. 1:HSWF Update R. 25 Hz Defines the update rate for the measuring channel belonging to 50 Hz Function Block 1 if the force conversion module is of HS WF 2 100 Hz type.
Page 53 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. 1:A ValueCal.P1 Range: +/–999999 This parameter defines, for Input A, the load in the lowest Unit: calibration point, normally 0. Measurement Unit The live force will be displayed when the enter button is pressed.
Page 54 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. 1:B ValueCal.P1 Range: +/–999999 This parameter defines, for Input B, the load in the lowest Unit: calibration point, normally 0. Measurement Unit The live force will be displayed when the enter button is pressed. <0>...
Page 55 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. 1:C ValueCal.P1 Range: +/–999999 This parameter defines, for Input C, the load in the lowest Unit: calibration point, normally 0. Measurement Unit The live force will be displayed when the enter button is pressed.
Page 56 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. 1:D ValueCal.P1 Range: +/–999999 This parameter defines, for Input D, the load in the lowest Unit: calibration point, normally 0. Measurement Unit The live force will be displayed when the enter button is pressed. <0>...
Page 57 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. 1:A Force: This help display of live force value for Function Block 1, Input A, gives the possibility to check the force at any moment. This value is only shown if the input is used.
Page 58 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menu ‘Serial Com.’ Modbus Address Range: 1 to 247 Defines the instrument Modbus address. <1> COM1:Mode Not in use Defines use of serial port Com 1. Modbus Slave Not in use: The port is not used. <Not in use>...
Page 59 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. COM1:Float Form. Modicon Float Sets how the Modbus slave should handle floating point values. Float Modicon Float: Modicon floating point format. < Modicon Float > Float: IEEE 32 bit floating point format See chapter 7 ‘Communication’...
Page 60 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. COM2:Float Form. Modicon Float Sets how the Modbus Slave should handle floating point values. Float Modicon Float: Modicon floating point format. < Modicon Float > Float: IEEE 32 bit floating point format. See chapter 7 ‘Communication’...
Page 61 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Menu ‘Fieldbus’ Note: The Fieldbus menu is not shown if parameter ‘Fieldbus‘ (in Hardware Config menu) is set to ‘Not In Use’. See chapter 7 ‘Communication − Fieldbus interface’ for more details on fieldbus configuration and usage.
Page 62 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Block 1 Type Not In Use Sets the data source for Data Block 1. Selections Sum/Difference Sum/difference, Output 1-2, Output 3-4, Output 5-6, Output 7-8, Output 1-2 Input A-B Force, Input C-D Force, Input A-B Signal and Output 3-4 Input C-D Signal are values from the selected Function Block, Output 5-6...
Page 63 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Block 1 Format Floating Point Sets the Data Block 1 Format. Integer Floating Point: The Data Block data format is floating point. < Floating Point > Integer: The Data Block format is integer.
Page 64 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menus ‘Level 1’ – ‘Level 32’ NOTE: There are 32 levels each with the following parameters described below. Level 1 Source ( - Level 32 Source) Not in use Defines the signal to be supervised by the Level Supervisor. See detailed description of Function Block in chapter 3 for a detailed Difference explanation of the different signals.
Page 65 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Level 1 F.Block ( - Level 32 F.Block) Defines which Function Block that will be supervised by the level. 1: The level is supervising Function Block number 1.
Page 66 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menus ‘Inputs Slot 1’ - ‘Inputs Slot 3’ NOTE: There are three possible sub menus, one for each slot. In each slot sub menu there are up to 8 possible inputs named 11 to 18 for slot 1, 21 to 28 for slot 2 and so on.
Page 67 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. Menus ‘Outputs Slot 1’ - ‘Outputs Slot 3’ NOTE: There are three possible sub menus, one for each slot. In each slot sub menu there are up to 8 possible outputs named 11 to 18 for slot 1, 21 to 28 for slot 2 and so on.
Page 68 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. Menu ‘Analog Outputs’ NOTE: There are 4 possible analog outputs each with the parameters described below. If the selected analog output module is AOUT4 there will be parameters for four analog outputs displayed, if the AOUT1 is selected only the parameters for the first analog output (shown below) will be shown.
Page 69 G4 Multi Channel Force Instrument Range/Alternatives Explanation and <default value> result of alternatives. AOUT1 F.Block (- AOUT4 F.Block) 1: Function Block number 1 uses this analog output. 2: Function Block number 2 uses this analog output. …. 8: Function Block number 8 uses this analog output.
Page 70 Technical Manual Range/Alternatives Explanation and <default value> result of alternatives. AOUT1 Bandwidth (- AOUT4 Bandwidth) 1.6 Hz Sets the analog output bandwidth. 3 Hz Note: This parameter is not shown if parameter ‘AOUT 1 Source’ 6 Hz is set to ‘Not in use’. 12 Hz 25 Hz 50 Hz...
Page 71: Calibration General
G4 Multi Channel Force Instrument 5. Calibration General When measuring with the G4 Instrument, the transducer output signal, corresponding to the transducer load, is converted to a force value. The conversion is controlled by several parameters with values defined during calibration of the individual Function Blocks.
Page 72: Common Parameters
Technical Manual If the G4 Instrument must be replaced, a table calibration of the replacement unit can be performed, with recorded values from an earlier calibration. To get the best accuracy, a ‘Known Force’ calibration with known force to at least 2/3 of the used range, should be performed.
Page 73: Calibration Using Datasheet
G4 Multi Channel Force Instrument Calibrating using datasheet When calibrating with data given in the transducer data sheet the ‘Table calibration’ method should be used. Note that there are two different ways that the transducer characteristics may be described in a data sheet. Choose the appropriate method below.
Page 74: Using Parameters Values From A Previous Calibration
Technical Manual X:A Zero Offset This parameter is used for entry of the recorded zero offset value from a previous calibration. If a zeroing has been performed with parameter ‘Set zero’ above, the value of parameter ‘Zero offset’ need not be changed. Repeat the calibration for all inputs used in the current Function Block.
Page 75: Calibration With Known Forces
G4 Multi Channel Force Instrument The front panel Zero function and the communication Zero function will zero all inputs of the Function Block. The Set Zero parameter only zero the corresponding input and the user must repeat zeroing for all configured inputs of the Function Block.
Page 76 Technical Manual...
Page 77: Operation General
G4 Multi Channel Force Instrument 6. Operation General This version of G4 instrument with strain gauge transducers is designed mainly for force and web tension purposes. The measurement values are displayed at the front panel, and can also be transmitted to a master computer/PLC.
Page 78: Operating Display
Technical Manual Operating display In the operating display it is possible to display force/web tension information from one function block at a time. The upper display row shows the function block number followed by the sum value (force or web tension) and the unit. If the selected function block is a two or four channel function block then the second row will display the difference value.
Page 79: Security Locks
G4 Multi Channel Force Instrument Security locks In the G4 instrument two security locks are included to prevent unauthorised access to the instrument via the panel keys. The locks can be activated by parameters in menu ‘Main menu/Parameter set-up/General’. The following requires a login password if the corresponding lock is on.
Page 80: Main Menu
Clock Set-up: Used to set the instrument clock and date. Time and Date formats are set-up with parameters trough ‘Parameter set-up’ menu. Param. Set-up: Access to the G4 instrument parameter set-up menu system. See chapter ‘Set-up’ for more details on setup.
Page 81: Level Supervision
G4 Multi Channel Force Instrument Level supervision The G4 instrument contains 32 supervision Levels that can be used to supervise defined signals in the instrument. Digital outputs can be connected as outputs for the Levels. The properties for each Level are configured by set-up parameters.
Page 82: Use Of Inputs And Outputs
Levels. Use of inputs and outputs Internal I/O’s are included on some of the I/O-modules that the G4 instrument can be equipped with. Different module types have different number of inputs and outputs. A DIO8 module have 8 inputs and 8 outputs while the force conversion modules HS WF2, WF IN and WF IN2 each have 4 inputs and 2 outputs.
Page 83: Filter Function
G4 Multi Channel Force Instrument Filter function In the instrument the measured values are filtered according to the settings chosen by the user during set-up. The filter settings can be selected from a wide range. This means that the instrument can be configured from very stable indication to more fast response but with less stable readings depending on the demands from the actual application.
Page 84 Technical Manual HS WF2 module filter Update rate - 3 dB damping Damping at -40° phase shift frequencies ≥ fs / 2 (fs) frequency frequency ≥ 20 dB 800 Hz ++ 87 Hz 21 Hz ≥ 90 dB 800 Hz 48 Hz 10 Hz ≥...
Page 85: Communication General
Modbus RTU Slave General All the G4 units connected to the network can listen to what is transmitted in the network, but only one unit at a time may transmit. A time-sharing principle is needed to allow communication in both directions (half duplex).
Page 86: Modbus Tcp Slave
• The instrument will as default be given the address 1. If more than one instrument is used in a network, each G4 instrument must be given a unique address in parameter ‘Modbus address’ (in ‘Param. Set-up’, menu ‘Communication’, sub menu ‘Serial Com.’).
Page 87: Modbus Protocol
G4 Multi Channel Force Instrument Modbus protocol For communication with a master computer (PLC) the Modbus protocol is used in the instrument. The Modbus protocol is a standard protocol, used for master/slave communication in the industry. Information is transmitted in blocks of data to minimise polling and response time delays.
Page 88 Technical Manual General registers The G4 instrument has a number of Modicon 'Holding Registers' (registers 4XXXX ... ). The Modbus function 03 'Read Holding Registers' should be used to read these registers and the Modbus function 05 'Preset Single Register' or 16 'Preset Multiple Registers' should be used to write to the registers.
Page 89 G4 Multi Channel Force Instrument Data type: Data type: float Explanation Integer (2 reg./value) 40062 (1 reg) 44062 Function Block 3: Error code 40063 (1 reg) 44064 Function Block 3: Status 40064 (3 reg) 44066 Function Block 3: Sum 40067 (3 reg)
Page 90 Technical Manual Data type: Data type: float Explanation Integer (2 reg./value) 40132 (1 reg) 44122 Function Block 8: Error code 40133 (1 reg) 44124 Function Block 8: Status 40134 (3 reg) 44126 Function Block 8: Sum 40137 (3 reg) 44128 Function Block 8: Difference 40140 (3 reg) 44130...
Page 91 G4 Multi Channel Force Instrument Data type: Data type: float Explanation Integer (2 reg./value) 40217 (3 reg) 44200 Function Block 2: Output 2 40220 (3 reg) 44202 Function Block 2: Output 3 40223 (3 reg) 44204 Function Block 2: Output 4...
Page 92 Technical Manual Data type: Data type: float Explanation Integer (2 reg./value) 40312 (3 reg) 44266 Function Block 3: Input C Signal (mV/V) 40315 (3 reg) 44268 Function Block 3: Input D Signal (mV/V) 40318 (1 reg) 44270 Function Block 4: Error code 40319 (1 reg) 44272 Function Block 4: Status...
Page 93 G4 Multi Channel Force Instrument Data type: Data type: float Explanation Integer (2 reg./value) 40400 (3 reg) 44330 Function Block 5: Output 7 40403 (3 reg) 44332 Function Block 5: Output 8 40406 (3 reg) 44334 Function Block 5: Input A Force...
Page 94 Technical Manual Data type: Data type: float Explanation Integer (2 reg./value) 40488 (3 reg) 44394 Function Block 7: Sum 40491 (3 reg) 44396 Function Block 7: Difference 40494 (3 reg) 44398 Function Block 7: Output 1 40497 (3 reg) 44400 Function Block 7: Output 2 40500 (3 reg) 44402...
Page 95 G4 Multi Channel Force Instrument Data type: Data type: float Explanation Integer (2 reg./value) 40583 (3 reg) 44460 Function Block 8: Input D Force 40586 (3 reg) 44462 Function Block 8: Input A Signal (mV/V) 40589 (3 reg) 44464 Function Block 8: Input B Signal (mV/V)
Page 96 Technical Manual Data type: Data type: float Explanation Integer (2 reg./value) 42022 (3 reg) 46018 Level 5 value 42025 (3 reg) 46020 Level 6 value 42028 (3 reg) 46022 Level 7 value 42031 (3 reg) 46024 Level 8 value 42034 (3 reg) 46026 Level 9 value 42037 (3 reg)
Page 97: Serial Number
G4 Multi Channel Force Instrument Instrument type This register holds the type of the instrument. For a G4 Multi Channel Force Instrument this value is 4002. Standard program major and minor version This registers holds the major and minor version for a standard program.
Page 98 Technical Manual Instrument error This register holds the overall error code for the instrument. Normally this register should contain ‘00’ which means no error. Instrument status This register holds the overall status for the instrument Bits set to 1 in this register have the following meaning: Bit no Function Comment Remote operation...
Page 99 G4 Multi Channel Force Instrument Function Block X: Error code This register holds the first error code for a Function Block. Normally this register should contain ‘000’ which means no error. Error codes 000 to 255 and 000 to X255 are valid in this register, where X (1-4) indicates which input channel (A-D) the three digit error code belongs to.
Page 100 Technical Manual Function Block X: Sum This register holds the sum value for a Function Block. The actual use of the sum value varies with type of Function Block. The value should not be read alone because the status and error codes are stored in other registers.
Page 101 G4 Multi Channel Force Instrument Function Block X: Input B signal – Input D signal (mV/V) See ‘Function Block X: Input A signal (mV/V)’. Analog output value 1, 2, 3, 4 These registers holds the values sent to the analog outputs. The registers can be used for fault finding in the system.
Page 102 Technical Manual Status of inputs 31-38, 41-48 Bits set to 1 in this register have the following meaning: Bit no Function Bit no Function Digital input 31 activated. Digital input 41 activated. Digital input 32 activated. Digital input 42 activated. Digital input 33 activated.
Page 103 G4 Multi Channel Force Instrument Status of outputs 11-18, 21-28 Bits set to 1 in this register have the following meaning: Bit no Function Bit no Function Digital output 11 activated. Digital output 21 activated. Digital output 12 activated. Digital output 22 activated.
Page 104 Technical Manual Status of outputs 51-58, 61-68 Bits set to 1 in this register have the following meaning: Bit no Function Bit no Function Digital output 51 activated. Digital output 61 activated. Digital output 52 activated. Digital output 62 activated. Digital output 53 activated.
Page 105 G4 Multi Channel Force Instrument Level status 17-32 Bits set to 1 in this register have the following meaning: Bit no Function Comment Above level 17 The supervised signal is above Level 17. Above level 18 The supervised signal is above Level 18.
Page 106 Technical Manual Command register As this register is read, the answer will always contain only zero's. There are a number of actions that can be activated in the instrument. The value of this register (when different from zero) will activate one of these actions, as described in below.
Page 107 G4 Multi Channel Force Instrument Level X value These registers are used to read and write levels that are supervised by the instrument. I/O bits (Coils) The instrument has a number of I/O bits that the master can write to using Modbus function 05 or 15.
Page 108 Technical Manual Data representation Data sent to and from the instrument uses 16 bit holding registers (40XXX) and can use different formats for flexibility. Integer Unsigned integer (1 modbus register) Values stored in one modbus register as an unsigned integer (16 bit number without decimals).
Page 109 G4 Multi Channel Force Instrument Float values The type of float values used in the communication is selected in the set-up for the different communication interfaces. Values stored as standard IEEE 32 bit float values. Each value has two registers assigned to it.
Page 110: Exception Responses
Technical Manual Exception responses When the master sends a query to a slave it expects a normal response (as described earlier). One of the following three events occur after a query from the master. 1. Normal response. The slave has received the query without communication error and can handle the query normally.
Page 111 G4 Multi Channel Force Instrument Supported Modbus functions Function Description Reads the state of discrete outputs (0X references, coils). Only implemented because some 'masters' use this function to initiate Read Coil Status communication. Coil range: 1 – 16 (Max number of points to read: 16).
Page 112: Fieldbus Interface
Technical Manual Fieldbus interface The optional fieldbus interface is based on a network communication module from HMS Industrial Networks. Available fieldbusses are Profibus and DeviceNet. With setup parameters the fieldbus interface is configured for the specific needs of an installation. It is possible to setup address, baud rate (if applicable to the actual fieldbus type) and mapping of the memory area in the fieldbus module that is available to the network.
Page 113 G4 Multi Channel Force Instrument Data from the fieldbus (Outputs in the master) General This 16 bytes block is mandatory, i.e. it is always mapped to the fieldbus in the instrument. Byte Contents Command Number of registers to write Start address, Read/Write...
Page 114 Technical Manual Byte 1: Used to define the number of registers to write. Bytes 2 and 3: Define from which register number to read or write. Bytes 4 to 15: Contains the data when writing to the instrument. Data to the fieldbus (Inputs in the master) General Data to the fieldbus are divided into two categories, one is the mandatory “base block”...
Page 115 G4 Multi Channel Force Instrument The first 32 bytes of data from the instrument to the fieldbus are mandatory. Bytes 0 and 1: Contains the actual instrument error information (the value 0 means no error). See ‘7. Communication – Modbus protocol – Instrument error’.
Page 116 Technical Manual Configurable data blocks Data Blocks is used to transfer data from the Byte Contents instrument to the master. Up to 12 data Start of data block 1 blocks can be used. Each block consists of 16 bytes. The data blocks have fixed Start of data block 2 positions in memory, see list below.
Page 117 G4 Multi Channel Force Instrument Function Block sum and difference values data block Byte Contents (Floating-point format) Contents (Integer format) Offset + 0 Function Block x: Error code Function Block x: Error code Offset + 1 Function Block x: Error code...
Page 118 Technical Manual Function Block Output 1 and Output 2 values data block Byte Contents (Floating-point format) Contents (Integer format) Offset + 0 Function Block x: Error code Function Block x: Error code Offset + 1 Function Block x: Error code Function Block x: Error code Offset + 2 Function Block x: Error code...
Page 119 G4 Multi Channel Force Instrument Function Block Input A Force and Input B Force values data block Byte Contents (Floating-point format) Contents (Integer format) Offset + 0 Function Block x: Error code Function Block x: Error code Offset + 1...
Page 120 Technical Manual Function Block Input A Signal and Input B Signal values data block Byte Contents (Floating-point format) Contents (Integer format) Offset + 0 Function Block x: Error code Function Block x: Error code Offset + 1 Function Block x: Error code Function Block x: Error code Offset + 2 Function Block x: Error code...
Page 121 G4 Multi Channel Force Instrument Level status Byte Contents (Floating-point format) Contents (Integer format) Offset + 0 Level status 1 – 16 Level status 1 – 16 Offset + 1 Level status 1 – 16 Level status 1 – 16 Offset + 2 Level status 1 –...
Page 122 Technical Manual Input Status (Floating-point format) Byte Content Offset + 0 Status of inputs 11 – 18, 21 – 28 Offset + 1 Status of inputs 11 – 18, 21 – 28 Offset + 2 Status of inputs 11 – 18, 21 – 28 Offset + 3 Status of inputs 11 –...
Page 123 G4 Multi Channel Force Instrument Output Status (Floating-point format) Byte Content Offset + 0 Status of outputs 11 – 18, 21 – 28 Offset + 1 Status of outputs 11 – 18, 21 – 28 Offset + 2 Status of outputs 11 – 18, 21 – 28 Offset + 3 Status of outputs 11 –...
Page 124 Technical Manual Inp./Outp Status (Integer format) Byte Content Offset + 0 Status of inputs 11 – 18, 21 – 28 Offset + 1 Status of inputs 11 – 18, 21 – 28 Offset + 2 Status of inputs 31 – 38, 41 – 48 Offset + 3 Status of inputs 31 –...
Page 125 G4 Multi Channel Force Instrument AOUT1-4 Value (Floating-point format) Byte Content Offset + 0 Analogue output value 1 Offset + 1 Analogue output value 1 Offset + 2 Analogue output value 1 Offset + 3 Analogue output value 1 Offset + 4...
Page 126 Technical Manual AOUT1-2 Value (Integer format) Byte Content Offset + 0 Analogue output value 1, int Offset + 1 Analogue output value 1, int Offset + 2 Analogue output value 1, int Offset + 3 Analogue output value 1, int Offset + 4 Analogue output value 1, dec Offset + 5...
Page 127 G4 Multi Channel Force Instrument AOUT3-4 Value (Integer format) Byte Content Offset + 0 Analogue output value 3, int Offset + 1 Analogue output value 3, int Offset + 2 Analogue output value 3, int Offset + 3 Analogue output value 3, int...
Page 128 Technical Manual Examples Example 1: Setting ‘Level 1 Value’ to 123.5 (Writing to float value register). 1. Make sure that the previous command was not 251. Set command byte (00) to 0 if previous command was 251. 2. Set number of registers (2) to write in byte 01. 3.
Page 129 G4 Multi Channel Force Instrument Example 3: Set read window to read floating point data from Function Block 2 (registers 44050 to 44061). Note that the number of registers read is always 12. 1. Make sure that the previous command was not 250. Set command byte (00) to 0 if previous command was 250.
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Page 131: Remote Access General
Configuration’ menu is the ‘Server Config’ menu found where the Web Server can be enabled (default) or disabled. Also the password can be set here. The remote access interface of the G4 instrument is intended to facilitate the set-up and maintenance work with the instrument. During e.g. commissioning it will make it possible to have the PC close to the equipment when the instrument is placed away from the equipment.
Page 132: Using The Remote Access
Technical Manual Using the Remote Access To navigate in the menu system a mouse, touch pad, pointing stick etc. must be used. The keyboard cannot be used for navigation. Hovering with the mouse pointer over a selection in a menu will highlight the item and clicking will open the next menu level or allow for a parameter to be edited.
Page 133: Remote Access Login And Logout
G4 Multi Channel Force Instrument Remote Access Login and Logout Entering the IP Address of the desired instrument in the address field of the browser will have the instrument Web Server presenting the login form, see the picture below. Login form The user ID is always ‘G4User’...
Page 134 Technical Manual When the correct login credentials are entered the entry screen will be displayed. This picture will show the Instrument Name (if set) or possible start up errors (serious or fatal errors). Any errors shown here must normally be corrected from the instrument and not through remote access.
Page 135 G4 Multi Channel Force Instrument Live screen Logged out screen Clicking the ‘Close the Window’ text will close the browser (if allowed by the browser). Note that the browser may save the login credentials which then are proposed as default next time the user tries to login to the same unit.
Page 136: Remote / Local Access
Technical Manual The overriding user will continue at the same position in the menu system as the old user was. The override function is intended to give a new user a warning not to interfere with another Remote Access user unconscious. Note that if a user has been idle for 30 min he will be logged out automatically.
Page 137: Remote Set-Up
Warning: Changes done during editing of set-up parameters will affect the behavior of the instrument immediately. The user must take all necessary precautions to prevent any undesired effects in the process monitored or controlled by the G4 instrument or a connected control system.
Page 138 Technical Manual Main Menu To reach the main menu the user first has to connect to the instrument by entering the IP Address and then (if required) entering the login user ID (G4User) and the password (default 1937, possible to change). This will display the Entry Screen and by clicking the ‘Menu’...
Page 139 G4 Multi Channel Force Instrument Parameter editing This example shows the ‘General’ parameter menu but editing is done similar throughout the menu system. To edit a parameter, simply click on it. If all items in the menu don’t fit on the screen, it is possible to scroll through the list of parameters using the scroll bar at the right of the screen.
Page 140: Remote Access Maintenance
Technical Manual When editing a numerical parameter e.g. a level hystereses setting as in the figure, the new value should be typed with the keyboard numerical keys. To confirm the new value click the ‘Enter’ button on the screen. To abort editing and keep the previous setting, click the ‘Escape’ button. Editing a value parameter Remote Access Maintenance General...
Page 141 G4 Multi Channel Force Instrument Function Blocks Shows information about all used function blocks, one at the time. Values with the unit ‘--‘ are not used in the current configuration of the function block and in case of error the five lines in the middle (‘Sum:’ to ‘Outp. 4’) will be replaced by an error message.
Page 142 Technical Manual Communication Shows status for the two serial ports, the External I/O and the Modbus TCP Slave. The serial ports COM1 and COM2 can be ‘Not In Use’, ‘Modbus RTU Slave’ or ‘Printer. In the example below ‘COM1:’ is not used and ‘COM2:’ is in Modbus RTU Slave mode with address 1, 115200 baud, 8 data bits, no parity and 1 stop bit.
Page 143 G4 Multi Channel Force Instrument Fieldbus Shows the fieldbus type, address and status of the optional Fieldbus interface. It also gives the possibility to study the contents in selected parts of the instrument memory (data to and from the fieldbus master). The function is very useful for advanced fault finding in case of problems with the fieldbus communication.
Page 144 Technical Manual Digital Inputs Shows the status of digital inputs. Digital inputs are numbered 11 – 68. Each row corresponds to a slot. Only the currently available inputs in each slot are shown. The first field on each line is the input numbers for the line and the following digits indicates status of the inputs.
Page 145 G4 Multi Channel Force Instrument Digital Outputs Shows the status of digital outputs. It is also possible to change the status of the digital outputs. The digital outputs are numbered 11 – 68. Each row corresponds to a slot. Only the currently available outputs in each slot are shown.
Page 146 Technical Manual Analog Outputs Shows the output value or a possible error message for installed analog outputs. It is also possible to override the normal operation and set the output value for each analog output. To change an output value click the button marked with the output number and enter wanted value.
Page 147 G4 Multi Channel Force Instrument File Handling menu The file handling has access to the ‘user tree’ directory structure in the instrument. The default folders are ‘InstrBackup’, ‘LogFiles’, ‘Misc’ and ‘Recipes’. The folder ‘InstrBackup’ is used as default when creating or restoring backup and the folder ‘LogFiles’...
Page 148 Technical Manual Restore Backup Restoring a previously stored parameter backup to the instrument. Any additional information in the backup file is displayed before a backup file is restored. Backup files are fetched from the PC. Using the Restore Backup requires either a Set-up Code or an Operator Code if a lock is activated.
Page 149 G4 Multi Channel Force Instrument Instrument Restart With the instrument restart function it is possible to force the instrument to make complete restart (corresponding to a power down – power up cycle). This must be used with great caution especially if done from a remote position. The user must make sure that no hazardous situation will occur.
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Page 151: Maintenance General
G4 Multi Channel Force Instrument 9. Maintenance General The Maintenance menu includes a number functions used for diagnostics, maintenance and program upgrade purposes. The Maintenance menu is found under the Main menu. From any of the operating views, displaying the main menu is done by pressing ‘+’ and ‘↑’...
Page 152 Technical Manual Communication COM1: Shows status for the two serial ports and the Modbus TCP Not In Use Slave. Each used serial port uses two displays to show the information. First display shows the use of the serial port and the second display shows the settings. COM2: When a correct message is received on an interface the Modbus RTU Slave...
Page 153: Digital Outputs
G4 Multi Channel Force Instrument Digital Inputs Shows the status of installed digital inputs. Inputs: 11-14 The upper row shows the input numbers for the selected 0 0 1 0 card slot in the instrument and the digits on the lower row indicates the current available inputs in the slot.
Page 154: File Handling
Technical Manual File Handling File handling is used for copying, moving (renaming) and deleting files. Files can be copied and moved between folders in the instrument and between a USB memory and the instrument (both to and from the USB memory). A file can be renamed while copying or moving.
Page 155: Create Backup
G4 Multi Channel Force Instrument Create Backup Parameter values are stored in a file that can be used to restore to the same or other instruments of the same type. The user can select to save the back-up file, either in the instrument or on a connected USB memory.
Page 156: Instrument Restart
Technical Manual Instrument Restart With the Instrument Restart function it is possible to force the instrument to make complete restart (corresponding to a power down – power up cycle). This must be used with great caution. The user must make sure that no hazardous situation will occur. To use the Instrument Restart function requires either a Set-up Code or an Operator Code if a lock is activated.
Page 157: Troubleshooting General
G4 Multi Channel Force Instrument 10. Troubleshooting General During installation and maintenance of the G4 Instrument, the sub menus ‘System Info.’ and ‘Maintenance / Diagnostics’ can be useful for solving possible problems related to I/O modules, Ethernet, Serial Communication etc.
Page 158 Technical Manual Force errors The indication is either temporary or stays on until the cause is cured. Error Explanation code No error. The instrument is in ‘normal state’ and no error is detected. x003 Instrument not in normal state. Force/Web Tension values are not valid. x005 Over range Over range means that the input signal from the transducer exceeds...
Page 159 G4 Multi Channel Force Instrument Start-up errors These error codes can only appear during start-up. Error Explanation code Set-up data error Indicates faulty set-up. Enter set-up mode, perform the necessary editing and save the new parameter settings or use the “Set Default values”...
Page 160 Fieldbus command error. Command error response on fieldbus connection. Indicates that the command sent to the G4 instrument via the fieldbus could not be executed. Internal Timeout A internal timeout occurred. If this error occurs when a command is sent to the instrument, try the command again.
Page 161 G4 Multi Channel Force Instrument Set-up errors These errors occur only during instrument set-up from the front panel. Certain errors depend on more than one set-up parameter and it is the operator’s responsibility to locate and correct all faulty set-up parameters.
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Page 163: Appendix 1
G4 Multi Channel Force Instrument Appendix 1.
Page 164 Technical Manual...
Page 166 Document no. 35149 Article no. 600 896 R3 © Vishay Nobel AB, 2011-09-30 Subject to changes without notice. Vishay Nobel AB Box 423, SE-691 27 Karlskoga, Sweden Edgewater Drive, Norwood, MA 02726, USA Phone +46 586 63000 · Fax +46 586 63099...

Vishay G4 Technical Manual

1 Introduction Manual Updates

2 Installation Mechanical Installation

3 Instrument Functionality General

4 Set-Up General

5 Calibration General

6 Operation General

7 Communication General

8 Remote Access General

9 Maintenance General

10 Troubleshooting General

Appendix 1

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