double sheet detector r1000-series e20 with integrated fieldbus interface · 2019-05-10 · manual...

DOUBLE SHEET CONTROL E20

Double Sheet Detector R1000-series E20

with integrated fieldbus interface Pos: 1 /D oppelbl ech/Geräte/E20/Deckbl att/D eckbl att @ 0\mod_1173195768953_501.doc @ 3188

Electro magnetic principles – microcontroller based

Single – sided contact double sheet control of ferrous materials

No force after measurement

4 exchangeable sensors for double sheet control of 0.1 – 12 mm (.004 - .472 inch) sheet thickness

Optional version 4P allows connection of up to four identical sensors

Programmable for 255 different sheet thicknesses and materials

Calibration without sheet samples

Digital display of sheet thickness and operational parameters

Monitoring of over-gauge and under-gauge limit

Monitoring of operating voltage and sensor gap

Galvanically isolated 3-bit input interface and 5-bit output interface

Integrated fieldbus interface with process and parameter interface

− Profibus DP − ControlNet − DeviceNet − Interbus-S − CanOpen − ProfiNet IO − CC-Link − EtherNet/IP − EtherCAT

Copyright

© 2015 ROLAND ELECTRONIC GmbH Otto-Maurer-Str. 17 DE 75210 Keltern

All rights on this document are at Roland Electronic GmbH. Reproduction (also partly), electronical coverage, translation, transmission to third parties,

only with our prior permission.

Subject to change without further notice.

===== Ende der Stückliste =====

Manual

Double Sheet Detector R1000 series E20

with integrated fieldbus interface B0046191 / Rev. 1.12 Inhaltsverzeichnis

ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33 3

Declaration of conformity according to EC directives ..................................................................................... 5

1 Safety advice .......................................................................................................................................... 7

1.1 Safety instructions and warnings for user .......................................................................................... 7

1.2 Declaration of icons ............................................................................................................................ 7

1.3 Intended use ....................................................................................................................................... 8

1.4 Fieldbus terminology .......................................................................................................................... 8

2 Technical data ........................................................................................................................................ 9

2.1 Technical data control unit E20 .......................................................................................................... 9

2.2 Versions of the control unit E20........................................................................................................ 11

2.3 Sensors ............................................................................................................................................. 12

2.4 Sensor performance data (Measuring time) ..................................................................................... 16

2.5 Sensor cables ................................................................................................................................... 22

2.6 Connectors of the P-sensors and the sensor cable ......................................................................... 22

2.7 Scope of Delivery ............................................................................................................................. 26

3 System description .............................................................................................................................. 27

3.1 Measurement principle ..................................................................................................................... 27

3.2 General hints for process security .................................................................................................... 27

3.3 Control unit ....................................................................................................................................... 28

3.4 Parameters of the control unit .......................................................................................................... 28

3.5 Application samples .......................................................................................................................... 33

4 Mounting ............................................................................................................................................... 39

4.1 General mounting instructions .......................................................................................................... 39

4.2 Dimensions of the system ................................................................................................................ 40

4.3 Mounting of sensors ......................................................................................................................... 44

5 Electrical installation ........................................................................................................................... 59

5.1 General instructions .......................................................................................................................... 59

5.2 Configuration of connectors .............................................................................................................. 60

5.3 Connecting diagram - examples ....................................................................................................... 70

6 Communication with the PLC ............................................................................................................. 73

6.1 Fieldbus specific messages .............................................................................................................. 73

6.2 Data transmission communication.................................................................................................... 74

6.3 Process channel ............................................................................................................................... 75

6.4 Parameter channel ........................................................................................................................... 89

6.5 External I/O control ........................................................................................................................... 97

6.6 Fieldbus configuration file ............................................................................................................... 102

7 Start-up ................................................................................................................................................ 107

7.1 Initially applying power to the system ............................................................................................. 107

7.2 Operation ........................................................................................................................................ 107

7.3 Configuration menu ........................................................................................................................ 108

7.4 General information regarding the configuration ............................................................................ 110

7.5 Changing, setting-up or checking the configuration ....................................................................... 110

7.6 Program parameters ....................................................................................................................... 111

Manual


with integrated fieldbus interface Inhaltsverzeichnis B0046191 / Rev. 1.12

4 ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33

7.7 System parameters ........................................................................................................................ 115

7.8 Data storage via serial RS232-interface ........................................................................................ 122

7.9 Firmware update ............................................................................................................................ 123

8 Operation ............................................................................................................................................ 125

8.1 Abbreviated operating instructions ................................................................................................ 125

8.2 Entering a measurement program ................................................................................................. 126

8.3 Zero adjust ..................................................................................................................................... 126

8.4 Teach-In ......................................................................................................................................... 127

9 Fault messages, causes and remedies ........................................................................................... 129

9.1 Faults concerning Memory ............................................................................................................ 130

9.2 Faults concerning Zero adjust ....................................................................................................... 130

9.3 Faults concerning Teach-In ........................................................................................................... 130

9.4 Faults concerning RS232 Transmission ........................................................................................ 131

9.5 Faults concerning Measuring operation ......................................................................................... 131

9.6 Faults concerning Keyboard .......................................................................................................... 131

9.7 Faults concerning Supply voltage .................................................................................................. 132

9.8 Faults concerning PLC parallel inputs ........................................................................................... 132

9.9 Faults concerning Fieldbus interface ............................................................................................. 132

9.10 Other faults .................................................................................................................................... 133

10 Maintenance ....................................................................................................................................... 135

10.1 Replacement of sensors ................................................................................................................ 135

10.2 Exchange of control unit ................................................................................................................ 136

10.3 Replacement of fuses .................................................................................................................... 137

10.4 Data backup via the fieldbus interface or serial interface .............................................................. 137

10.5 Firmware update via RS232 interface ........................................................................................... 137

10.6 Short description RPP-XP software ............................................................................................... 138

10.7 Spare parts .................................................................................................................................... 138

11 Technical records .............................................................................................................................. 139

11.1 Exchange of equipment ................................................................................................................. 139

11.2 Fieldbus configuration files ............................................................................................................ 140

11.3 Parameter channel commands ...................................................................................................... 141

12 Order data .......................................................................................................................................... 147

12.1 Versions of control unit E20 ........................................................................................................... 147

12.2 Sensors and accessories ............................................................................................................... 149

12.3 Cables ............................................................................................................................................ 150

12.4 Cable plugs and cable sockets ...................................................................................................... 150

12.5 Other accessories .......................................................................................................................... 150

13 Appendix ............................................................................................................................................ 151

13.1 Sensor data (Measuring time) of older hardware versions 1…4 ................................................... 151

13.2 System configuration form ............................................................................................................. 155

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Manual

Double Sheet Detector R1000 series E20 with integrated fieldbus interface

B0046191 / Rev. 1.12 Safety advice


Declaration of conformity according to EC directives

Manufacturer: Roland Electronic GmbH

Otto-Maurer-Str. 17

DE 75210 Keltern

Product name: E20

Product type: Double Sheet Detector R1000 series

Roland Electronic GmbH declares that the product listed above complies with the requirements of the EMC directives listed below.

Applied Directives:

2006/95/EG Low Voltage Directive

EN61010-1: 2010

2004/108/EG: EMC Directive

EN61000-6-2: 2005-08 EN61000-6-4: 2007-01

Date of mark’s apposition: 09.12..2015

Keltern, 09.12..2015 Managing Director

Place, Date Signature Function of the signer

The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a particular purpose especially as it may relate to product liability.

The safety instructions and warnings must be observed.

ISO 9001 : 2008

Reg.-no. 5152 QM08


Manual


with integrated fieldbus interface Safety advice B0046191 / Rev. 1.12


Blank page

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Manual


B0046191 / Rev. 1.12 Safety advice


1 Safety advice Pos: 5 /Komponenten allgemein/Sicherheitshinweise @ 2\mod_1316526033469_501.docx @ 10093 @ 2 @ 1

1.1 Safety instructions and warnings for user

This manual contains all information required for the correct operation of the Roland equipment.

It has been written for technically qualified personnel.

Unauthorized tampering with the unit, especially ignoring the warnings in the manual can cause malfunction and damage to the unit. Only authorized personnel should be allowed to make changes to the unit and perform cable connections especially the power supply.

Should it be necessary, e.g. in case of service or repair, to make measurements within the unit, then all customary accidents prevention procedures should be observed. Only professional electrical tools should be used.

Note The factory pre-settings – especially the upper / lower limit values – have been chosen such that an optimal machine protection is ensured.

Diverging settings can impair the machine protection.

Safety advice for persons with cardiac pacemakers!

Persons with cardiac pacemakers are to stay away from the sensors!

The strong magnetic / electromagnetic fields of the sensors can cause malfunction of cardiac pacemakers and other such apparatus!

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1.2 Declaration of icons

Warning - general dangers!

Reference to imminent hazards, which can result in severe bodily harm or death.

Warning - dangers by high voltage!

Reference to imminent hazards due to electricity, which can result in severe bodily harm or death.

Attention - Damage of construction units!

Reference to a potential imminent situation, which can result in damage to the product or environs.

Note

Useful reference to an application or deepening information.

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Manual


with integrated fieldbus interface Safety advice B0046191 / Rev. 1.12


1.3 Intended use

Flexible Manufacturing Systems in the sheet processing industry require reliable Double Sheet Control systems in order to protect presses and other sheet processing machines against damage caused by feeding multiple sheets.

The Double Sheet Detector R1000 E20 was specifically developed for this technical environment. Depending on the application (type of material, thickness, sensor gap) the E20 can be used with up to four sensors. The reliable function of the Double Sheet Detector depends therefore markedly on the selection of the correct sensors and the mounting of the sensors.

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1.4 Fieldbus terminology

Within this manual the following Fieldbus specific expressions are used:

Term used in the manual Fieldbus specific expression

Master Scanner

Slave Node

Baud rate Data rate

Bus address Mac ID / node address

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Manual


B0046191 / Rev. 1.12 Technical data


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2.1 Technical data control unit E20

Operating voltage: 24 VDC, +6 V / -2 V Power consumption: Hardware Version 1…7 (till July 2007): P42AGS: 120 W; other sensors 45W, in idle: <10 W Hardware Version 8 (since July 2007): P42AGS: 80 W; other sensors 45W, in idle: <10 W Hardware Version A: P128: 120 W, in idle: < 10 W

Switch on current: 10 Amps for 1 ms External fuse: 5 Amps medium time lag Weight: approx. 2.3 kg (5.07 lbs) Wall mount enclosure approx. 1.8 kg (3.96 lbs) Front panel enclosure Ambient temperature: 0 - 50 °C (30 - 122° F)

Wall mount enclosure:

Protection category: IP65

E20-xx (without connected plugs): approx. 225 x 240 x 80 mm (L x W x H) approx. 8.85 x 9.45 x 3.15 inch (L x W x H)

E20 (with connected plugs): approx. 225 x 360 x 80 mm (L x W x H) approx. 8.85 x 14.2 x 3.15 inch (L x W x H)

Front panel enclosure:

Protection category: IP40 (inside) IP65 (front cover)

E20-xx-x-FP: approx. 240 x 240 x 120 mm (L x W x H) approx. 9.45 x 9.45 x 4.7 inch (L x W x H)

Additional characteristics:

• 255 parameter sets memory

• Programming via push keys or fieldbus

• Three galvanically isolated optocoupler inputs 24 VDC with joint common

Specification: - min. switching voltage HIGH: 20 VDC - max. switching voltage HIGH: 30 VDC - min. switching voltage LOW: 0 VDC - max. switching voltage LOW: 8 VDC

• Five galvanically isolated optocoupler outputs with positive external supply

Specification: - max. switching voltage: 50 VDC - max. switching current: 100 mA (current limitation) - max. switching power: 2,4 W (resistive load)

Attention: In case of inductive load a coil protection diode should be used. Otherwise the signal output could be destroyed by the excess voltage generated by switching the inductive load off.

Manual


with integrated fieldbus interface Technical data B0046191 / Rev. 1.12


• RS232 interface

Specification:

Baud rate: 4800 - 19200 baud

Data Bits: 8

Parity-Bit: None

Stop-Bit: 1

Hardware Handshake: None

The selection of the interface parameters with the exception of the baud rate is made via the software and cannot be changed by user.

• Fieldbus interface

Profibus-DP interface according to EN 50170, protocol version 1.10, max. baud rate 12 Mbit/s

ControlNet communication adapter (profile number 12) according to int. ControlNet specification

DeviceNet communication adapter (profile number 12) according to ODVA specification (group two only server)

Interbus-S - interface, certification protocol no. 440, 500 kbit/s, RS422

CanOpen - interface, according to DS301 v4.02 compliant

ProfiNet IO – interface

CC-Link V1

EtherNet/IP

EtherCAT

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Manual




2.2 Versions of the control unit E20

The control unit article key is coded as follows:

1. Control unit E20 for connection of one sensor:

A = Control unit

B = Type of fieldbus: PR = Profibus-DP CN = ControlNet DN = DeviceNet (B-coded) DNT = DeviceNet (A-coded) IN = Interbus-S CP = CanOpen PN = ProfiNet IO CC = CC-Link EN = EtherNet/IP ET = EtherCAT

C = pluggable connections at control unit

D = Control unit in front panel enclosure

2. Control unit E20 for connection of up to four sensors, all sensors connected directly at the control unit.

A = Control unit

B = Connection of up to 4 sensors

B = Type of fieldbus:

PR = Profibus-DP CN = ControlNet DN = DeviceNet (B-coded) DNT = DeviceNet (A-coded) IN = Interbus-S CP = CanOpen PN = ProfiNet IO CC = CC-Link EN = EtherNet/IP ET = EtherCAT

C = pluggable connections at control unit

D = Control unit in front panel enclosure

Basing on the article key shown above the following versions are available:

• E20-xx-S: Control unit for wall mounting with data backup via fieldbus or serial interface

• E20-xx-S-FP: Control unit for front panel mounting with data backup via fieldbus or serial interface

• E20-4P-xx-S: Control unit for connection of up to four sensors in wall mount enclosure with data backup via fieldbus or serial interface

• E20-4P-xx-S-FP: Control unit for connection of up to four sensors in front panel enclosure with data backup via fieldbus or serial interface

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E20-xx-S-FPA B C D

E20-4P-xx-S-FPA B C D E

Manual




2.3 Sensors

The sensor description has the following code:

A = Electro magnet B = Diameter C = Model* D = Thread E = Quick disconnect *Model: V: extended thickness measuring range A: stands for a larger air gap

Fig. 1: Designation of sensors Pos: 13 /Doppelblech/Sensoren/P-Sensoren/P30/P30GS Techn. Daten @ 1\mod_1304686037382_501.docx @ 9169 @ 3 @ 1

2.3.1 Sensor P30GS

P30GS P30GS P30GS

with straight cable plug with 90° angled cable plug

All dimensions are in mm. Length tolerance ± 0.8 mm, all other dimensions ± 0.2 mm

Fig. 2: Sensor P30GS

Technical data

Measuring range 1): 0.1 – 2.5 mm .004 – .1 inch

Ambient temperature: 0 – 60 °C 30 – 140 °F

Class of protection: IP65

Weight: approx. 0.21 kg 0.46 lbs

Sensor cable: pluggable

Measurable ohmic resistances 2):

Pin 1-2: Approx.15 Ω

Pin 4-3:

Pin 1-4: 0 Ω

Pin 2-3:

1) Related to single sheet thickness 2) Pins are not connected to the sensor housing

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P42AGSA B C D E

1)

1)

Manual




2.3.2 Sensor P42AGS

P42AGS P42AGS P42AGS

with straight cable plug with 90° angled cable plug

All dimensions are in mm. Length tolerance ± 0.8 mm, all other dimensions ± 0.2 mm

Fig. 3: Sensor P42AGS

Technical data

Measuring range 2): 0.2 – 4.0 mm .01 - .16 inch






Pin 1-2: Approx. 20 Ω

Pin 4-3:

Pin 1-4: 0 Ω

Pin 2-3:

1) Related to single sheet thickness 2) Pins are not connected to the sensor housing

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1)

1)

Manual




2.3.3 Sensor P75VGS

Fig. 4: Sensor P75VGS

Technical data

Measuring range 1): 0.2 – 6.5 mm (.004 - .25 inch) 0.2 – 8.0 mm (.008 - .31) 2)






Pin 5-6: Approx.15 Ω

1) Related to single sheet thickness 2) with restriction 3) Pins are not connected to the sensor housing

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Manual




2.3.4 Sensor P128GPPS

Fig. 5: Sensor P128GPPS

Technical data

Measuring range 1): 1.0 – 12.0 mm .04 - .47 inch




Sensor cable: pluggable 1) Related to single sheet thickness

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Manual




2.4 Sensor performance data (Measuring time)

In the following diagram the response time of the control unit for measurement is shown depending in sensor type and number of sensors activated by the program. In addition the response time depends on the selected system parameter “measure”, the actual sheet thickness, the nominal sheet thickness and the upper limit (up).

System parameter „measure“

• „fast“ The actual response time depends on the measured sheet thickness, the nominal thickness and the upper limit (up). The maximum response time is limited by the nominal thickness and the upper limit (see diagram and example). Advantage: maximum response time is low. Disadvantage: In case of measuring results larger than the double sheet threshold, the text “2-sheet” is issued instead of the actual measurement value.

• „normal“ The actual response time depends on the measured sheet thickness. The maximum response time corresponds to the maximum sheet thickness.

Example 1:

• System parameter “Measure: fast” • P75VGS sensor • Measurement with one sensor • Nominal thickness 1.0 mm = 100% • upper limit (UP) 120% (=1.2 mm)

Actual sheet thickness = 1 mm actual response time = 120 ms

Actual sheet thickness = 2 x 1 mm actual response time = 130 ms

Actual sheet thickness = 7 x 1 mm (sensor on stack) actual response time = 130 ms

The maximum response time is 130 ms (with “up“ = 120%). This means that after the signal "measurement start" was issued (max. 5 ms), it will take 130 ms until the result of the measurement is available as output signal (with “up“ =120%).

Example 2:

• System parameter “Measure: normal” • P75VGS sensor • Measurement with one sensor • Nominal thickness 1.0 mm = 100% • upper limit (UP) 120% (=1.2 mm)

Actual sheet thickness = 1 mm actual response time = 120 ms

Actual sheet thickness = 2 x 1 mm actual response time = 160 ms

Actual sheet thickness = 7 x 1 mm (sensor on stack) actual response time = 400 ms

The maximum response time is 400 ms (with “up“ = 120%). This means that after the signal "measurement start" was issued (max. 5 ms), it will take 400 ms until the result of the measurement is available as output signal (with “up“ =120%).

Note The advantage in measuring time is significant, if the thickness of material is considerably lower than the measuring range of the sensor.

Manual




Note The sensor diagrams shown here are valid for systems with Hardware Version 5 and higher (from system no. 103237, from date 27.02.2006).

Having the “old” sensor diagrams (before HW version 5) available could be useful, e.g. for exchanging control units with “old” / “new” Hardware versions).

For this reason the “old” sensor diagrams are shown in the appendix

Measuring time P30GS (Device-Hardware-Version 5 and higher)

Fig. 6: System reaction time P30GS

1,0 1,5 2,0 2,5

4 sensors

3 sensors

2 sensors

1 sensor

P30GS

150 %120 %

0

Sys

tem

re

acti

on

tim

e [m

s]

Standard working range

Single sheet thickness (Nominal thickness) [mm]

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

0

Manual




Measuring time P42AGS (Device-Hardware-Version 5 and higher)

Fig. 7: System reaction time P42AGS

1,0 1,5 2,0 2,50 3,0 3,5 4,0

P42AGS

150 %120 %

4 sensors

3 sensors

2 sensors

1 sensor

Sy

ste

m r

eac

tion

tim

e [m

s]



40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

310

320

330

340

350

360

370

380

Manual




Measuring time P75VGS (Device-Hardware-Version 5 and higher)

Fig. 8: System reaction time P75VGS

50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

1,0 2,00

950

1000

1050

1100

1150

1200

1250

1300

1350

1400

1450

1500

1550

1600

1650

3,0 4,0

P75VGS

150 %120 %

5,0 6,0 7,0 8,0

with restriction

4 sensors

3 sensors

2 sensors

1 sensor



Sys

tem

rea

ctio

n t

ime

[ms]

Manual




Measuring time P128GPPS

Fig. 9: System reaction time P128GPPS

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

3200

3300

3400

3500

3600

3700

3800

3900

4000

4100

4200

4300

4400

4500

4600

4700

1,0 2,00


3,0 4,0 Single sheet thickness(Nominal thickness) [mm]

5,0 6,0 7,0 8,0

with restriction

9,0 10,0 11,0 12,0

P128GPPS

0

100

200

300

400

4800

4900

5000

150 %120 %

1 sensor

3 sensors

4 sensors

2 sensors

Sys

tem

rea

cti

on

tim

e [

mm

]

Manual




Double Sheet thresholds above 120% reduce the performance of the system with regard to air gaps between the sheets and increase the systems reaction time according to the diagram.

Air gaps influence the performance negatively because air has - in contrast to steel - a high resistance to the magnetic flux. Therefore, air gaps reduce the performance of the system considerably (see chapter “3.1 Measuring principle“).

For reliable double sheet monitoring there should be no air gap between sheet and sensor and also between the sheets. The most reliable double sheet recognition results, if no air gap exists. These aspects should be specifically observed when mounting the sensors.

The influence of air gaps are described in the following diagrams.

Attention The performance data of both diagrams cannot be combined.

Max. air gap between sensor and first sheet (1st air gap)

Max. air gap between first and second sheet (2nd air gap)

The data apply for a set upper limit of 120%.

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2 3 4 5 6 7 8 9 10 11 12

0,20,40,60,81,01,21,41,61,82,02,22,42,62,83,0

Sheet thickness[mm]

1st a

ir g

ap [m

m]

P128GPPS

P75VGS

P42AGS

P30GS

1.

23456789

1011

1 2 3 4 5 6 7 8 9 10 11 12 Sheet thickness[mm]

2nd

air

gap

[mm

]

P128GPPSP75VGS

P42AGS

P30GS

2.

Manual




2.5 Sensor cables

Suitable cable types:

• Oilflex FD810CY 2 x 1mm²

• Unitronic FDCP (TP) plus 1 x 2 x 1mm² (UL / CSA)

ROLAND ELECTRONIC uses according to standard the Oilflex FD810CY 2 x 1mm2 cable.

• Both cables are oil-proof and suitable for drag chains

- Bending radius fix use 31 mm

- Bending radius flexible use 58 mm

Cable marking:

• for P30GS and P42AGS - SM12CPM12S-GG (straight receptacle at the sensor) - SM12CPM12S-GW (right angle receptacle at the sensor)

• for P36GS / P42GS / P75GS / P75VGS - SM12CPS-GG (straight receptacle at the sensor) - SM12CPS-GW (right angle receptacle at the sensor)

• for P128GPPS - SM12CPPPS-GG (straight receptacle at the sensor) - SM12CPPPS-GW (right angle receptacle at the sensor)

The cables are equipped with quick disconnect plug at the sensor side and with bootlace ferrules at the control unit side.

Note The sensor cable is an active component of the sensor technology. The

technical data of the sensors is valid only if the cable specification is met. A shielded 2 x 1 mm² cable must be used. The cable length can be to up to 50 m. Following the rule "the shorter the better" generally leads to better measuring results.

2.6 Connectors of the P-sensors and the sensor cable

For the connection of the P-sensors can be used as in the following picture.

Note The sensor cable is an active part of the sensor. The performance data is therefore based on the compliance with cable specification.

Manual




2.6.1 Cable SM12CPM12S for sensors P30GS, P42AGS and sensor cable extension

Fig. 10: Sensor cable SM12CPM12S

Cable socket at sensor side Cable plug at unit side

Sensor Control unit

A

B

C

black (1) [white]

black (2) [brown]

blank (Shield)

Cable types for sensors P30GS,P42AGS and the sensor cable extension (order data):

• SM12CPM12S-GG (straight receptacle at the sensor) • SM12CPM12S-GW (right angle receptacle at the sensor)

The standard length is 5 meter. Cable length up to 50 meter made to order, longer cables please enquire.

Note In particular with larger lengths the sensor cable should not be placed

directly adjacent to cables with large noise potential.

The cable is drag cable suitable and oil resistant. Cable type: • Oilflex FD810CY 2 x 1mm2

• Unitronic FDCP (TP) plus 1 x 2 x 1mm2 (UL / CSA)

Ø 20

55

Ø 20

62

Cable socket

to sensor / to cable extensionCable plug

to cable extension / to control unit

Plug contacts 3)

3) View plug side

1 black (1) [white]2 black (2) [brown]3 N.C.4 N.C.5 blank (Shield)


Ø 20

5431

33OILFLEX FD810CY 2 x 1 mm²[Unitronic FDCP (TP) plus 1 x 2 x 1 mm² (UL / CSA)]

Right angle cable socket (optional)

Receptable contacts1)

1) View contact side *

*

*The maximum allowed fastening torque is 0.6 NM

- It is not allowed to fasten the locking screw with pliers, pipe wrenches or similar! - We request to tighten the locking screw by hand or to use a fastening tool with torque control e.g. Binder Tool 713-825, Binder Order no. 07 0079 000 http://www.binder-connector.de/de/zubehoer/82149

2) Cable

2)

*

234

P30GS

P42AGS

12345 5

12345

12345C

Manual




2.6.2 Sensor cable SM12CPS for sensors P36GS, P42GS, P75GS and P75VGS

Fig. 11: Sensor cable SM12CPS

Cable types for the P36GS, P42GS, P75GS and P75VGS sensor (order data):

• SM12CPS-GG (straight receptacle at the sensor) • SM12CPS-GW (right angle receptacle at the sensor)






78

51

2 3

6

4

Cable plug

Plug contacts 1)

1)View plug side

1 black (1) [white]2 black (2) [brown]

5 blank (Shield)

Cable socket

to sensor


black (1) [white]black (2) [brown]

blank (shield)

56

1) View contact side

Receptacle contact 1)

N.C.1 - 4

3 - 4 N.C.

OILFLEX FD810CY 2 x 1 mm²[Unitronic FDCP (TP) plus 1 x 2 x 1 mm² (UL / CSA)]

Ø 30

75

53




Ø 20

62

*

to control unit / to cable extension


Sensor Control unit

A

B

C

black (1) [white]

black (2) [brown]

blank (Shield) 2

3

45

P36GS

P42GS

6P75GS

P75VGS

12

3

45

6

1

23

45

1

23

4

5C

Manual




2.6.3 Sensor cable SM12CPPPS for sensors P128GPPS

Fig. 12: Sensor cable CPS

Cable types for the P128GPPS sensor (order data):

• SM12CPPPS-GG (straight receptacle at the sensor) • SM12CPPPS-GW (right angle receptacle at the sensor)






Cable plugto control unit / to cable extension

Plug contacts1)

1) View plug side


Cable socket

to sensor


N.C.

black (1) [white]black (2) [brown]

blank (shield)

1234

1) View contact side

Receptacle contact 1)

Ø 19

60

1

2 3

4


Ø 20

43

60


Ø 20

62

*




Sensor Control unit

A

B

C

black (1) [white]

black (2) [brown]

blank (Shield) P128GPPS

1

234

5

123

45

123

4

1

234

Manual




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2.7 Scope of Delivery

Included in the delivery of each E20 / I20 / UDK20 / L20 is the following accessorial material:

• 1 plug for power supply + inputs *

• 1 plug for output signals *

• 1 plug for fieldbus output *

• 1 plug for fieldbus input *

• 1 cable for communication (RS232 or USB) *

All this material is packed in a plastic bag as shown below.

Fig. 13: Typical accessorial material

Note * Connectors are only included, if the ordered version is equipped with the corresponding connector.

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Manual


B0046191 / Rev. 1.12 System description


3 System description Pos: 21 /Doppelblech/Geräte/E20 Bus/3 Systembeschreibung/Systembeschreibung - allgemein @ 0\mod_1173874512921_501.docx @ 3884 @ @ 1

Flexible production systems in the sheet processing industry require automated, reliable double sheet detection in order to protect presses and other processing machinery from damage by multiple sheets. The E20 was specifically developed for this technical environment.

The E20 is based on the product platform R1000 and consists in the standard version of three components:

• Control unit

• One sensor for ferrous materials

• Sensor cable

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3.1 Measurement principle

The double sheet detector is based on the electromagnetic principle. It monitors ferromagnetic sheets with single sided sensors and exerts forces during the monitoring process only. A change of the sheet thickness results in a change of induction. The system calculates the sheet thickness from this change. Corresponding to the pre-set limits 0-sheet, 1-sheet or 2-sheets signals are generated.

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3.2 General hints for process security

The process security of the system is influenced by the following factors:

• the stability of the measuring values

• the setting of under-gauge threshold and over-gauge threshold

• the evaluation of the status signals

Stable measuring conditions will result in stable measuring results. For measuring procedures with single-sided contacting sensors the air gap between sensor and material surface is a decisive criterion.

Air gaps varying from measurement to measurement will cause varying mesuring results. Basically, such situations are bad, since in such cases the user is inclined to decrease the under-gauge threshold and to increase the over-gauge threshold. On doing so, the user puts up with the drastically increasing risk of not detecting a double sheet.

The following external factors decisively influence the stability of measuring results and need to be considered for operation of a double sheet detector:

• the air gap between sensor and material surface

• the magnetical characteristics of the material

• the tolerance in material thickness

From this some simple rules derive, which enable a large degree of process security when abided by:

• Always care for good contact of the sensor with the material!

• Use separate programs to measure different sheet thickness (and alloy)!

• Adjust the switching thresholds as tight as possible!

Manual


with integrated fieldbus interface System description B0046191 / Rev. 1.12


Furthermore it is necessary that the control checks all status signals of the E20, also the 0-sheet signal. While measuring, only the 1-sheet signal may occur. If 0-sheet or 2-sheet occurs, the measured sheet may not be transported on. In such cases, the sheet will usually be deposited, re-picked and measured again. • The control needs to evaluate all status signals!

Checking-up through the 0-sheet signal is to assure that a sheet really is in front of the sensor during measuring. If 0-sheet occurs while measuring, the measurement is not correct. For example, a defective sensor holder might prevent the sensor from contacting the sheet. Monitoring the sheet thickness would then only be performed apparently.

In case of double sheet fatal consequences could then result.

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3.3 Control unit

The E20 is based on the product platform R1000.

Major features of the control unit:

• Programmable for 255 different sheet thicknesses

• Fieldbus interface for the control, operation and data exchange with the PLC

• Calibration by a teach-in procedure (see “3.3 Calibration“)

• Digital display of sheet thickness and operating parameters

• Monitoring of over gauge and under gauge limits

• Monitoring of operating voltage and sensor gap

• Optocoupler for direct I/O control via the PLC for fast measurement operations

• Software firmware update

• Data backup via fieldbus interface or serial interface

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3.4 Parameters of the control unit

The E20 provides for extensive configuration. So, different customer requirements can be served. Configuration is performed by setting system parameters and program parameters.

System parameters are set only once on commissioning, and will then remain unchanged. Program parameters contain items which are material and job depending, and enable individual adaptation to the measuring task.

Manual




3.4.1 System parameters

“Language“

System languages available for operating the unit via display and keyboard:

• German • English • Spanish • Italian • French

“Dimension“

Switches the indication of the thickness values on the display between mm inch.

“Bus readout“

Switches the out feeding of the thickness values via Field bus between mm inch.

“Bus address“

Sets the bus address, as far as a participant address is required for Field bus. Value range 1…125

“Baud rate Field bus“

Sets the Baud rate of the Field bus (as far as required for the Field bus).

In case off EtherNet/IP: DHCP/IP/SUBNET/GATEWAY

“CLR parameter (Clear Program Parameter)“

Deletes all program parameters. For doing so, the parameter needs to be set to “yes“. Executing the command requires several minutes, since the program memory will completely cleared. All program parameters will be reset to the default values and existing teach-in data will be deleted. Using this function only makes sense if a unit is to be newly used for another machine.

“Measurement fast/normal”

For time-critical applications the measuring time can be slightly shortened for measuring FE material. If “fast“ is selected and double sheet occurs, the measuring is terminated on reaching the upper switch limit, and the information “2-sheet“ is released. If “normal“ is selected, the measuring will be executed to the end and the measured thickness will be displayed.

“Password yes/no“

Switches the password request on/off. If the password request is set “on“, the system / program parameters can only be changed after the password has been entered.

“Sensor type“

At the time of editing the sensor types P30, P36, P42, P42A, P75, P75V and P128 are available. For this sensor a characteristically curve for linearization purposes exists.

“Number of sensors“

Defines the number of connected sensors. Those sensors are then available for measuring (only for 4P-Version).

Manual




“Sensor selection” Selection of the sensor by program or via the inputs A and B.

“Measurement operation“

Sets how the measuring is to be triggered. The following modes are available:

• Demo This mode of operation is intended for equipment demonstrations, but not for normal process operation. The system executes measurements continuously. The repetition rate of the measurement depends on the type of sensor: 1 second for P42, P30, P42A, P75V; 2 seconds for P36; 4 seconds for P75; 15 seconds for P128.

• Ext. Single (default setting) The Here a single measuring is performed. For doing so, the signal “Measuring start“ must be externally fed. Another measuring requires a new flank of the “Measuring start“ signal.

• Ext. Permanently The system executes measurements, as long as the “Measurement start“ signal is applied via the external PLC input. The repetition rate of the measurement depends on the type of sensor: 0.5 seconds for P42, P30, P42A, P75V; 1 second for P36; 2 seconds for P75; 7 seconds for P128.

“2-sheet hold“

Currently only “no“ is possible.

“External Measurement start“

The signal “Measurement start“ can be linked via 3 opto coupler inputs (Measuring start input 1,2,3). Possible configurations:

• IN0 (default setting)

• IN0 and IN1

• IN0 and IN1 and IN2

“Output level“

Sets the logics voltage for outputs 0-,1-,2-sheet and "Warning". Default setting is 0 V DC.

“External Adjust“

Sets whether an external teach-in / zero adjust is to be possible. If “yes“ is set, the PLC can trigger the procedure via the inputs “Teach-In 0-, 1-sheet“. Default setting is “no“.

• The external adjust may only be performed under supervision of an operator.

“Diagnosis factor“

Diagnosis of the factors located during the Teach-In. No default setting.

“E20-PR-S-(1)“ “SV:xx HV:xx“

Unit identification. Needs to be at hand for telephone support.

“Bus diagnosis“

Viewing of the process data. Helpful for commissioning on Field bus connected.

Manual




3.4.2 Program parameters

The sensor is operated with an electro magnetical method – called “P“ measurement. For the P measurement a compensation curve for linearization exists. The compensation curve fits to ST37 steel. Other steel alloys resp. magnetical materials deviate from this curve. This causes measuring results which can deviate for more than 5% from the real sheet thickness. In such cases it is useful to calibrate the unit (later merely called “Teach-In“).

In order to avoid frequent Teach-In procedures for different materials and thicknesses, the unit provides for 255 program memories. Every such memory consists of a data set with the following parameters.

“Sensor number“

Entry of the selected sensor (/sensor sequence) for multi-channel systems (e.g. E20-4P…).

“Nominal measure“

Changes the nominal measure. It can be shown in mm or inch. Default setting either 0,03mm or 0,001 inch.

“TO“ and “TU“

Changes the limit values for the lower and upper switching threshold. The values can be entered either in % or in mm/inch. On these thresholds the status signals depend. In a window comparator the three signals will be generated from the measuring signal.

The signal “0-sheet“ is generated when the measuring signal falls short of the lower switching threshold. The lower switching threshold TU can be set from 1...99%. The signal “2-sheet“ is generated when the upper switching threshold is exceeded. The upper switching threshold TO can be set from 100...150%. If the measuring value is within both limits, the signal “1-sheet“ is generated.

a

b

c

TO

TU

Signal range for 0-sheet



switching threshold for upper limit

switching threshold for lower limit

Fig. 14: Visualization of switching thresholds

The preset values (TO=120% resp. TU=80%) should only be changed under the following aspects:

1. the 1-sheet range becomes restricted, since the measuring values are very stable. Thus the process security increases. The restriction can be done by decreasing the TO value, by increasing the TU value, or both.

2. the 1-sheet range becomes extended for a time. Thus the process security decreases. Such an action should only be performed in exceptional cases, the user has to decide about that. Extending the 1-sheet range is commonly considered due to mechanical problems (air gap, uneven sheets). This measure prevents the machine from standstill, until the mechanical problem is solved.

210

Signal

Obere SchaltschwelleUpper switching threshold

Untere SchaltschwelleLower switching threshold

a

b

c

TO

TU

Manual




“Zero adjust“

Before commissioning a new system, after having exchanged a sensor or a sensor cable or a control unit, a zero adjust must be performed. This zero adjust eliminates the variation of the sensors. The sensors can be zero adjusted “separately“ or “all in one stroke“.

• The zero adjustment is valid for all programs.

“Teach-In“

Because of the linearization of the sensor it is possible to measure with factory calibration in many applications. However, the prerequisite for such measurement are:

• Use of the preset thresholds „low“ (lower limit = 80%) and „up“ (upper limit = 120%) • Correctly executed zero adjustment

It is, however, possible that the measurement is not satisfactory: Then the measured thickness values under normal operating conditions deviate sufficiently to generate nuisance trips. If, for example among the measured value is too low or too high, the control unit generates an under gauge signal (0-sheet) or an over gauge signal (2-sheet). As a consequence the transportation of the sheet is stopped by the PLC - even though no obvious fault has occurred.

Such a deviation of the measured value can have different causes, for example:

a) the measured sheet actually has an under gauge or over gauge thickness

b) there is air gap present between the sensor and the sheet surface

c) the measured material differs in its magnetic properties from the reference material ST37 (regular low carbon steel), the linearization curve does not fit the material

In the cases of a) and b):

The causes have to be eliminated, otherwise the measurement will not be satisfactory.

In the case of c):

Here the teach-in calibration has to be executed with the material to be processed. After the teach-in procedure the measurements will be more precise with the processed material. The calibration applies only to the selected program.

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Manual




3.5 Application samples

The following are two typical application examples for the usage of the E20.

If more than one sensor is required, then the E20-4P is a good choice. Four sensors of the same type can be connected to this control unit.

These sensors cannot be operated simultaneously, but only sequentially. The switching (sequencing) can be made as follows:

a) by program switching b) by external sensor selection A/B c) with the so-called sequencer mode

Manual




Method a)

Meaningful, if the sheets to be monitored by the various sensors have different sheet thicknesses. Also suitable if the nominal thickness changes from cycle to cycle.

For this procedure the respective parameter set (program) must contain nominal thickness and sensor number. The selection of the program is then performed by the PLC.

Disadvantage: Relative long time required for switching the program via the parallel interface.

Note Sensor selection via "program" must be selected in the system configuration.

0.7 mm(.028 in.)

0.5 mm(.020 in.)

0.8 mm(.032 in.)

2 3 4 1

Start

PLC1. Select program 1

2. Measuring program 1

3. Analysis result of program 1

4. Select program 2



7. Select program 3



10. Select program 4



Program Thickness Sensor

1 1.0 mm 1

2 0.7 mm 2

3 0.5 mm 3

4 0.8 mm 4

Manual




Method b)

Advantageous when measuring the same sheet thickness with each sensor. Each measurement sensor is addressed via the inputs A/B of the control unit. In addition, the result of each measurement is available as output.

Note Advantage: Substantial time saving compared to program switching.

Note Sensor selection via "external (inputs A and B)" must be selected in the system configuration.

0.9 mm(.035 in.)

0.9 mm(.035 in.)

0.9 mm(.035 in.)

0.9 mm(.035 in.)

2 3 4 1

Start


1 0.9 mm - *

* If sensor selection A/B configured, the sensor number cannot selected in the program.

PLC

01. Select sensor 1 via A/B

02. Measure program. 1

03. Evaluate result of program 1










Manual




Method c)

Advantageous when measuring the same sheet thickness with each sensor. In contrast to the method b) addressing of each sensor is done automatically by the E20. The sequence of the sensors is predetermined in the program.

Note Advantage: Very fast measurements are possible, smaller software effort on the PLC side.

Only one output is generated for connected sensors. The summary output is formed with the following priorities: 2-sheet before 0-sheet, 0-sheet before 1-sheet.

The measurement results are simultaneously available via Fieldbus (Byte 12-23).

Note To activate this method sensor selection has to be done via "program" in the system configuration. A separate selection of the "sequencer mode" is not required.

The sequence of addressing the sensors is done in the program parameters section under "sensor number".

3 4 1

StartStart


1 1.5 mm 1, 2, 3, 4

PLC



1.5 mm(.06 in.)

1.5 mm(.06 in.)

1.5 mm(.06 in.)

1.5 mm(.06 in.)

Manual




In addition to the selection by sensor number (see “11.3 System Configuration - number of sensors"), the following sequences for the selection are available:

Sequence

Sensor 1 + sensor 2 Sensor 1 + sensor 3 Sensor 2 + sensor 3 Sensor 1 + sensor 2 + sensor 3 Sensor 1 + sensor 4 Sensor 2 + sensor 4 Sensor 3 + sensor 4 Sensor 1 + sensor 2 + sensor 4 Sensor 1 + sensor 3 + sensor 4 Sensor 2 + sensor 3 + sensor 4 Sensor 1 + sensor 2 + sensor 3 + sensor 4

Note If all four sensors are activated, each possible sequence with only 2 or 3 sensors can be selected. On the other hand the sequences for example for the sensor number 4 cannot be selected, if only 3 sensors are activated.

The following rule applies: The highest sensor number in the sequence determines the minimum number of activated sensors.

Note The sequence is a program parameter, therefore methods a) and c) can form a practical combination, for example, two stacks of sheet for instance left and right blanks with different thicknesses can thus be checked for double sheet.

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1.8 mm(.07 in.)

2 3 4 1

StartStart

1.0 mm(.04 in.)

1.8 mm(.07 in.)


1 1.0 mm 1, 2

2 1.8 mm 3, 4

PLC

1. Select program 1



4. Select program 2



Manual




Blank page

Manual


B0046191 / Rev. 1.12 Mounting


4 Mounting Pos: 28 /Doppelblech/Geräte/E20 Bus/4 Montage/Montage - Allgemeine Hinweise @ 0\mod_1173695080093_501.docx @ 3424 @ 2 @ 1

The mounting of the Double Sheet Detector R1000 E20 determines the measurement accuracy and the reliability of operation.

The system was designed for operating in rough industrial environments. However, the following mounting instructions should be observed in order to minimize mechanical, thermal, and electromagnetic influences on the operation.

4.1 General mounting instructions

The enclosure for wall mounting meets IP65 and is designed for mounting the enclosure close to the sensor location. This results in the use of shorter sensor cables with a corresponding lower exposure to electromagnetic noise and could therefore result in better measurements.

The control unit should be installed in locations where no vibration exists and no additional heat is transferred into the system (even better reduce the heat in the control unit). In addition the control unit should be installed in such a fashion that it can be easily opened for service purposes. During the operation the control unit and the sensors should be under visual control of the operating personnel.

Attention Strong vibrations and additional heat can damage the control unit.

In case of panel or operator consoles the front panel version should be used.

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Manual


with integrated fieldbus interface Mounting B0046191 / Rev. 1.12


4.2 Dimensions of the system

4.2.1 Unit in industrial enclosure

Version E20 for one sensor

Fig. 15: Dimensions of the wall mount enclosure - connection view

Version E20-4P for up to four sensors

All dimensions are in mm. Tolerance: ±0.4 mm

Fig. 16: Dimensions of the wall mount enclosure - connection view

Manual




Front view

Note For the connection of the plugs a minimum additional space of 120 mm below the control unit is necessary.


Fig. 17: Dimensions of the wall mount enclosure - front view

Manual




4.2.2 Front panel enclosure

Note A minimum depth of 120 mm is required for connecting the plugs.


Fig. 18: Dimensions of the front panel enclosure -front view

4 x Ø 4,2 for Philips head screw M4 DIN 74

240

220

240

220

23

23

Manual





Fig. 19: Dimensions of the front panel enclosure -front view

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240

100

150

Mo

untin

g S

pace

: 120

(4

.73

in.)

50

Manual




4.3 Mounting of sensors

The reliable function of the Double Sheet Detector depends to a great degree on the correct mounting of the sensors. The following mounting rules should be followed:

• The sensor must be mounted perpendicular to the sheet and fully contact the sheet surface. Foreign matter should not obstruct the contact.

• Tilting or air gaps between the sensor and the sheet surface can result in faulty measurements.

• It is possible to cover the sensor surface with thin Teflon in order to avoid damage to the sheet metal surface. However, this will reduce the performance and is, therefore, not recommended.

• Mounting in steel / distance to magnets

• It is important to set the under gauge threshold of the control unit and analyze the under gauge signal at the 0-sheet output.

• It is important to set the upper gauge threshold of the control unit and analyze the upper gauge signal at the 2-sheet output.

• A spring loaded mounting bracket or the installation directly into the vacuum cup is recommended (see the following sections).

Attention Air gaps can result in faulty measured values. This applies also to tilting or partial gaps or bowed sheets. Ignoring these factors can result in unreliable operations.

The E20 can detect unintentional air gaps. The lower limit (“low“) should be used for this purpose. The lower limit should be adjusted to more than 80%. An air gap causes a decrease of the measured value. As soon as the measured value falls below the under gauge threshold, then under gauge is signalled at the 0-sheet output. It is absolutely necessary that the control unit stops the current operation and issue is a fault signal. Only if this fault condition is eliminated should sheet processing be allowed to continue.

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5 mm

5 m

m

X X

X Y

kein Stahlno steel

keine Magneteno magnets

X = Sensordurchmesser Sensor diameter

y = Sensordurchmesser½½ Sensor diameter

Manual




4.3.1 Checklist for Mounting of contacting Sensors

In the interest of longest lifetime and operational security the following items should be observed when mounting contacting sensors and checked in regular intervals.

Point of attention Possible influences Checked

Cable type 1 Use only the recommended cable with highest flexibility and durability.

Cable routing

2 Avoid any tension of the cable. Route the cable with enough clearance.

3 Special care has to be taken to the route of cable in front of sensor plug, if a flexible sensor bracket is used. The cable should never have a bend close to the plug. Also the meander of the cable has to be symmetrically to the axis of the plug, see enclosed sketch.

Plug 4 Correctly tighten the arresting ring of the plug. This avoids too strong wear of contacts. If possible choose a sensor with fixed cable instead.

Sensor mounting in the destacking tool

5 Use a sensor bracket which is flexible enough to let the sensor align also to tilted sheets. This avoids unnecessary wear of sensor contact surface.

6 Properly adjust sensor edge so that it aligns with the rubber burls of the suction cup. Do not allow excess end. See enclosed sketch. This avoids unnecessary wear of sensor contact surface.

7 Properly adjust sensor mounting in regard to the lifting suction cups of tooling. Do not allow sensor suction cup to excess lifting suction cups. This avoids unnecessary wear of sensor contact surface.

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4.3.2 Spring loaded sensor brackets

P-sensors should always be fitted into spring mounted sensor bracket rather than rigid mounting arrangements.

A substantial advantage is in the fact that the sensor present itself perpendicular to the sheet metal surface even though sensor bracket and sheet surface may not be completely aligned at a right angle.

It is important to observe that lateral cable pull does not tilt the sensor. In addition it must be ensured that the springs do not get stuck. If the springs get stuck tilting of the sensor may result or stuck springs can actually provoke tilting. Ideally the spring mounted bracket should be pre-loaded in order to ensure that the sensor is presented perpendicular to the sheet even under dynamic conditions.

NoppenBurlsSensorkante

Sensor edge

SaugerSuction cup

Sensor

Manual




Fig. 20: Overview Sensor bracket

Type SH42GS SHS42GS SHS42G-FB SHX42 SHX42-DL

Description Spring loaded sensorbracket

Spring loaded sensorbracket with

Spring loaded sensorbracket with

bellow suction cup

Spring loaded sensor bracket with

and lateral clearance

Fits to P42GS P42AGS PW42GS PW42AGS

Sensor mounting Thread M42 x 1.5 Thread M42 x 1.5 Thread M42 x 1.5 Thread M42 x 1.5 Thread M42 x 1.5

Total height* 69 mm plussensor excess length

114 mm 128 mm 120 mm 120 mm

Spring travel approx. 26 mm approx. 26 mm approx. 37 mm approx. 70 mm approx. 70 mm

Weight approx.0.7 kg (1.54 lbs) approx. 1.2 kg (2.64 lbs) approx. 1.2 kg (2.64 lbs)

approx. 0.75 kg (1.65 lbs)(SHS42G-FB80)

approx. 0.85 kg (1.87 lbs) approx.0.85 kg (1.87 lbs)

Pressure force at 1/2spring travel

approx. 48 N approx. 48 N approx. 60 N approx. 25 N approx. 25 N

Suction cup diameter n.a. 110 mm

85 mm(SHS42GS-85**)

100 mm

80 mm(SHS42G-FB80)

110 mm 110 mm

Vacuum feed n.a. Hose 8 mm OD Hose 8 mm OD Hose 8 mm OD Hose 8 mm OD

Spare parts Spring Kit2395117

Spring Kit2395117

Rubber lips (black)2395110

2395168**Rubber pressure pad

2395109

Bellows suction cup100 mm (red)

2395045

Bellows suction cup80 mm (red)

2395100(SHS42G-FB80)

Strap setSHX42-STRAP-80

Rubber lips (black)2395110

Rubber pressure pad2395109

Strap setSHX42-STRAP-80

Bellows suction cup110 mm (yellow)

2395218

Accessories SHKBracket clamp for mounting of sensor brackets

to destacking tools

SHX-AZ2-25Shank / Adaptor for 25 mmClamp collar / swivel arm

Application properties

For vertical destackers + + + + +For Robot-Loaderand high-speed lineardestackers

- - - + + +

For inclined sheetstacks

- o + + + +

Suction delay time*** none 0.1 s 0.5 s 0.1 s 0.1 s

Notes For narrow sheets andapplications where

weight is critical

Strong hold on evensheets due to suction

cup.

Suited for utmost sen-sor contact on inclined

or ondulated sheetstacks.

Rigid during approach.For high lateral acceleration (up to 2g),

minimal wear.

* total height unloaded

*** heavily dependent on vaccuum strength, tube resistance, contact angle and contact pressure to sheet

Never use sensor bracket as a lifting suction cup ! (except sheet is smaller than area of 3 suction cups)NOTE: The colors of the suction cup points to different hardnesses: Red – Shore 45; Yellow – Shore 55; Black – Shore 60

Manual




4.3.2.1 Spring loaded sensor bracket SH42GS

Fig. 21: Spring loaded sensor bracket SH42GS

66

"A"

57

Hub

max

.65

min

.25

98

10Ø

View in direction "A"without sensor

ø20.5

30O

50

110

8045°

120°

75°

40

90Sensor

movable

fixed

All Dimensions are in mm. Tolerance: ±0.4 mm.

Manual




4.3.2.2 Spring loaded sensor bracket SH75GS

Fig. 22: Spring loaded sensor bracket SH75GS

Pos: 33 /Doppelblech/Sensoren/Sensorhalterungen/Gefederte Sensorhalterung SHS42GS + SHS75GS mit Flachsauger @ 1\mod_1215005515656_501.docx @ 6417 @ 344 @ 1

Sensor

66

"A"

54H

ubm

ax.6

5m

in.2

5

98

View in direction "A"without sensor

152.5

152.

5

20,575°

44.

5x

45°

19x

45°

R = 66.7

R=

42.5

120°10.5

45°

movable

10Ø

fixed

All Dimensions are in mm. Tolerance: ±0.4 mm.

Manual




4.3.3 Spring loaded sensor bracket with flat suction cup

Destacking of blanks is done mostly with the vacuum suction cups. For the measurement of the sheet thickness the sensors should rest vertically and flat on the sheet. The best contact to the sheet surface is made by mounting the sensor into a vacuum suction cup.

That suction cups present the sensor vertically to the sheet surface and function fast because of the low volume of air required. Deviations from the right angle have to be compensated by the spring-loaded Sensor brackets, otherwise no vacuum can be generated. Bellow style vacuum suction cups can themselves compensate deviations from the right angle but they can also pull an inclined sensor to the sheet surface or in inclined sheet to the sensor leading to instability of measurement. The forces acting in this process can lead to wear and tear to the bracket and lips of the suction cups. Generating and releasing vacuum requires considerably longer time.

The suction cups are not designed to lift and carry the sheet. In order to prevent inadvertently the sensor losing touch to the sheet it is necessary to maintain a certain degree of spring load between sensor and sheet. Sensor cable and vacuum hoses should be mounted in such a fashion that low angular forces act on the sensor bracket. If necessary the sensor thread can be sealed with a permanently elastic sealant (Hylomar, Loctite) or a narrow Teflon web.

The spring-loaded sensor bracket contains fixing holes to attach the bracket to the carrying tooling. In special cases (on request) is an operation without the vacuum cup or the lifting/carrying of the sheet with the sensor bracket possible.

4.3.3.1 Spring travel of SHS42GS and SHS75GS

Fig. 23: Spring travel for SHS42GS and SHS75GS

674

6

ausgefedert (Zug)extracted (pull)

54

46

unbelastetunstressed

26

46

eingefedert (Druck)retracted (pressure)

Manual




4.3.3.2 Spring loaded sensor bracket SHS42GS with flat suction cup

The spring loaded sensor bracket SHS42GS with flat suction cup is intended for accommodating the sensors. It is well suitable for use in feeder destacking applications (only vertical motions, no turning motions). For usage with robotic destackers the sensor bracket SHS42G-FB (with bellow suction cup) is to be preferred.

All dimensions are in mm. The dimensional tolerance is ± 0.4 mm

Fig. 24: Spring loaded sensor bracket SHS42GS with flat suction cup

View in direction "A" without clamping bracket

Hose8 mm

ø20,5

30O

50

110

8045°

120°

75°

409

0

Sensor

Clamping bracket SHK

Rubber nipples

Sensor edge

Sensor

Suction cup

"A"Spring loaded sensor bracket


98

288

66

X40

2,51,5

25Ø

40 25

011or

cus

tom

er r

equ

est

see fig.“Spring travel”

appr

ox.

approx.

Manual




4.3.3.3 Spring loaded sensor bracket SHS75GS with flat suction cup

The spring loaded sensor bracket SHS75GS with flat suction cup is intended for accommodating the sensors. It is well suitable for use in feeder destacking applications (only vertical motions, no turning motions).


Fig. 25: Spring loaded sensor bracket SHS75GS with flat suction cup

Pos: 34 /Doppelblech/Sensoren/Sensorhalterungen/Gefederte Sensorhalterung SHX42 @ 1\mod_1215005516500_501.docx @ 6422 @ 34 @ 1

Clamping bracket SHK

160

Spring loaded sensor bracket Sensor

66

ø25

25

94

M8

Rubber nipples

Sensor edge

Sensor

Suction cup

"A"

40

300

orcu

stom

mad

e

98

28

Connection 1/4"

View in direction "A"without clamping bracket

152.5

152.

5

20.575°

44.5

x45

°

19x

45°

R = 66.7

R=

42.5

120°10.5

45°

see fig.“Spring travel”

Manual




4.3.4 Spring mounted sensor bracket SHX42

Features:

• Very stiff in extended condition, for lateral acceleration up to 2g. Thus precise putting on the sheet without canting, also on splayed sheets or bevelled TWB stacks.

• Very elastic in pressed condition and movable into all directions. Lateral motions of the sheet being transported can thereby also be compensated up to approx. ±1 centimetre.

• No appearance of lateral forces, thus only minimal wear.

• Fast suction and releasing of the sheets due to small air volume under the suction hood, compared to bellows suction cups.

• Same sealing gasket and burled plate as used with the Roland SHS42GS.

• Good access to the sensor from above, no counter-nut required.

• Fixing of sensor by lateral headless screw with plastic pressure pad.

Fig. 26: Sensor bracket SHX42

Fig. 27: Base plate for sensor bracket SHX42

150

110 Ø

max

. 12

0

Manual




Mounting of the sensor bracket

The mounting plate has a total of 10 M8 tap holes at distances of 50 and 100 mm. At least 2 of them must be used for mounting. An adapter with 25 mm shank for swivel arm is available. Other adapters may be ordered by request. Item 1 - 4 describes the mounting of the sensor into the sensor bracket and item 5 - 8 describes the mounting of the sensor bracket.

Fig. 28: Mounting of the sensor bracket SHX42

Manual




Replacing the gasket

Pull the rubber disc over the lower edge. Pay attention for undamaged sealing lips at the inner and outer edge as well as for uniform projection of the sealing edge. The gasket can be bilaterally used.

Pos: 35 /Doppelblech/Sensoren/Sensorhalterungen/Gefederte Sensorhalterung SHX42-DL @ 3\mod_1449659030495_501.docx @ 23798 @ 34 @ 1

4.3.5 Spring mounted sensor bracket SHX42-DL

Features:

• Very stiff in extended condition, for lateral acceleration up to 2g. Thus precise putting on the sheet without canting, also on splayed sheets or bevelled TWB stacks.

• Very elastic in pressed condition and movable into all directions. Lateral motions of the sheet being transported can thereby also be compensated up to approx. ±1 centimetre.

• No appearance of lateral forces, thus only minimal wear.

• Fast suction and releasing of the sheets due to small air volume under the suction hood, compared to bellows suction cups.

• Bellows suction cup with a shore grade of 55

• Good access to the sensor from above, no counter-nut required.

• Fixing of sensor by lateral headless screw with plastic pressure pad.

Fig. 29: Sensor bracket SHX42-DL

Fig. 30: Base plate for sensor bracket SHX42-DL

Pos: 36 /Doppelblech/Sensoren/Sensorhalterungen/Gefederte Sensorhalterung SHS42G-FB mit Faltenbalgsauger @ 1\mod_1215005514906_501.docx @ 6410 @ 3 @ 1

150

110 Ø

max

. 12

0

Manual




4.3.6 Spring loaded sensor bracket SHS42G-FB (with bellow suction cup)

The spring loaded sensor bracket SHS42G-FB with bellow suction cup is intended for the installation of the P sensor. It is well suitable for use in robotic destackers, since transversal forces (appearing on fast turning motions) are well compensated.

The suction vacuum and the integrated nap ring assure a full-area pressure contact of sensor and sheet.

The suction cup has a Shore hardness of 45 (red), harder suction cups with a Shore hardness of 60 (black) are available (see chapter 12 „Order data - sensors and accessories).

On installing, attention must be paid that the sensor is thoroughly sealed (e.g. with Teflon tape) in the thread seating.

Considerations:

• The sensor face must align with the naps.

• The vacuum must adequately effect.

• The suction facility must be kept free from loading, i.e. the springs may only be low pre-tensioned.

• The suction facility must not be used as load-lifting device.

Fig. 31: Sensor bracket SHS42G-FB

: unloaded 128 ± 1

: unloaded 90 ± 1

: Spring travel: appr. 37

enclosed:swingable angular connectionfor hoseinner Ø6mm, outerØ8 mm

1

2

3

39,5

33

15,0°

60,5

69

,5

M42x1,5Ø84,5

Ø21 ISO

10642 - M8x80-8

.8

A-A ( 1 : 2 )

20

Ø99

110

130

7050

10x45,0°

Ø1

02

Ø85

38

65,5

G½

-

M42x1,5

Manual




4.3.6.1 Clamping bracket SHX-AZ2-25

For fixing the sensor bracket SHX42 to swivel arms with 25 mm clamp collar.

Fig. 32: Clamping bracket SHX-AZ2-25

Pos: 37 /Doppelblech/Sensoren/Sensorhalterungen/Klemmvorrichtung SHK @ 1\mod_1215005517687_501.docx @ 6429 @ 3 @ 1

Manual




4.3.7 Clamping bracket SHK

The clamping bracket SHK can be used for the mounting of the spring loaded sensor brackets SHS...GS or SH...GS.

All Dimensions are in mm. Tolerance: ± 0.2 mm.

Fig. 33: Clamping bracket SHK

4.3.8 Electromagnetic interference

Electromagnetic interference can affect the measuring accuracy of the sensor. Therefore the sensors should not be installed close to devices which cause electromagnetic interference. Such devices are e.g. frequency converters, servo motors or proximity switches on inductive basis. In case of switching magnets a minimum distance of 20 mm should be observed in order to avoid feedback.

The sensor cables should not be placed directly adjacent to cables with large interference potential, e.g. power supply cable. This applies especially to longer cable lengths.

Pos: 38 /Doppelblech/Geräte/E20 Bus/4 Montage/Fehlerhafter Einbau der P-Sensoren @ 0\mod_1173692370656_501.docx @ 3394 @ 3 @ 1

25

94

M20

M8

21

40

95

3

95

orcu

stom

mad

e

.

.

5

5

Manual




4.3.9 Incorrect mounting of the P sensors

The following illustration shows examples of incorrect installations of P-sensors.

Faulty!

The sensor does not touch the sheet.

Faulty!

The sensor does not sit perpendicular on the sheet, the sensor bracket is apparently not suitable.

Faulty!

An air gap exists between the first and the second sheet. The sensor is mounted in an unfavourable position.

Faulty!

An air gap exists between the first and the second sheet. The second sheet clings to the first sheet, perhaps by stamping residuals.

Faulty!

Fault prone control in a bucket. An air gap exists between bended sheets.

Fig. 34: Incorrect mounting of the p sensors

Pos: 39 /Doppelblech/Geräte/E20 Bus/4 Montage/Elektromagnetische Störungen @ 0\mod_1173692244625_501.docx @ 3389 @ 3 @ 1


Manual


B0046191 / Rev. 1.12 Electrical installation


5 Electrical installation Pos: 42 /Doppelblech/Geräte/E20 Bus/5 Elektrische Installation/Elektrische Installation - allgemein @ 0\mod_1173691545546_501.docx @ 3384 @ 23 @ 1

5.1 General instructions

The sensor cables should be kept as short as possible in order to minimize the influence of electromagnetic noise. Cable shields must be connected according to the connection diagrams only and should not have any additional connections.

Attention Damaged cable installations can result in additional electrical connections. This can disturb the measured values.

5.1.1 Mounting instruction for M12 connectors with arresting ring

These connectors have a positioning key at the plug and a positioning slot at the receptacle. These items are designed to prevent incorrect connecting positions.

For this reason if plug and receptacle are connected together then these positioning features should fit to each other.

Only then it is possible to connect plug and receptacle without force and with proper pin configuration.

A Positioning slot at female connector

B Positioning nose at male connector

C Threaded arresting ring

D Connector assembly ring. Never turn this ring when arresting the plug with the arresting ring C.

Fig. 35: Positioning facility and arresting ring

When the connection is established correctly as described, plug and socket can be arrested with the arresting ring.

Important

1) Turn only the threaded arresting ring C ! If the whole plug becomes turned, the locking facility and the contact pins will break and the connector will become useless.

2) Never mis-use parts of a connector as holder for mounting the counterpart.

Pos: 43 /Doppelblech/Geräte/E20 Bus/5 Elektrische Installation/Steckerbelegung @ 0\mod_1173450978484_501.docx @ 3379 @ 2333334444444444333 @ 1

Ø 20

55

Ø 20

62

Cable socket

to sensorCable plug

to cable extension

Plug contacts 3)

3) View plug side



Ø 20

5431

33OILFLEX FD810CY 2 x 1 mm²[Unitronic FDCP (TP) plus 1 x 2 x 1 mm² (UL / CSA)]


Receptable contacts1)

1) View contact side *

*



2) Cable

2)

*

A B

C

D

Manual


with integrated fieldbus interface Electrical installation B0046191 / Rev. 1.12


5.2 Configuration of connectors

5.2.1 Configuration of connectors at the R1000 E20

(Connection for one sensor)

System in industrial enclosure

System as front plate mount

A Connector for RS232

B1 RSI interface

B2 Optocoupler output

C1 Fieldbus1) output

C2 Fieldbus1) input

D Connector for sensor

E Connector for system grounding

G Power supply connector / optocoupler input

Fig. 36: Connections at E20

1) the fieldbus connections are specific to each type of fieldbus, see section “5.2.5 Fieldbus connection”

Manual




5.2.2 Configuration of connectors at the R1000 E20-4P

(Connection for up to 4 sensors)

System in industrial enclosure

System as front plate mount

A Connector for RS232

B1 RSI interface

B2 Optocoupler output

C1 Fieldbus1) output

C2 Fieldbus1) input

D1 Connector for sensor 1




E Connector for system grounding

G Power supply connector / optocoupler input

Fig. 37: Connections at E20-4P

1) the fieldbus connections are specific to each type of fieldbus, see section “5.2.5 Fieldbus connection”

Manual




5.2.3 Connection for RS232 (pos. A)

Connections at control unit Manufacturer / types / notes

RS232 M8, 3-pin, female connector at control unit

Binder type 768 and others

View: plug side

pin 1 GND

pin 2 RXD

pin 3 TXD

Shield / ground Internal at enclosure (common)

The interface cable SM8KRS232D9S belongs to the scope of supply.

Cable SM8KRS232D9S:

X = grounding connection at cable socket

Fig. 38: Cable SM8KRS232D9S

3

RXD - 2

TXD - 3

5

3

2

1

2

3

4

5

6

7

8

9

Kabellänge 3 mCable length 3m

X

3

Manual




5.2.4 Connection of Optocoupler outputs and RSI interface (pos. B1 and B2)

Note The Optocoupler inputs are placed at the supply voltage connection (pos. G)

The RSI enables the operation of future ROLAND sensors which have not only the signal output but also the RSI interface.

On the following pages the pin configuration of the optocoupler outputs and the RSI (ROLAND serial interface) are described.

Connector at control unit Manufacturer / types / notes

Optocoupler output M8, 8-pin, A-coded, female

connector at control unit Binder type 713 and others

View: plug side

pin 1 +24VDC External supply 24V DC

pin 2 OUT0 1st optocoupler output

pin 3 OUT1 2nd optocoupler output

pin 4 OUT2 3rd optocoupler output

pin 5 OUT3 4th optocoupler output

pin 6 OUT4 5th optocoupler output

pin 7 -

pin 8 Shield / ground Internal at enclosure (common)

RSI M12, 5-pin, A-coded, female

connector at control unit Binder type 713 and others

View: plug side

pin 1 Shield / ground Internal at enclosure (common)

pin 2 -

pin 3 GND

pin 4 RSI- High

pin 5 RSI- High

Table: Pin configuration of optocoupler output and RSI interface

Optocoupler outputs for fast switching operation

For reasons of velocity and for diagnostic purposes it could be useful to issue the relevant switching signal 0-sheet, 1-sheet, 2-sheet via a real-time interface. Latency periods and cycle times of fieldbus communications are eliminated.

Signal Meaning Notes

OUT0 0-sheet 1st optocoupler output

OUT1 1-sheet 2nd optocoupler output

OUT2 2-sheet 3rd optocoupler output

OUT3 Enable 4th optocoupler output

OUT4 Warning 5th optocoupler output

21

65

4

37 8

1 25

4 3

Manual




5.2.5 Fieldbus connection (pos. C1 and C2)

5.2.5.1 Profibus-DP

According to the Profibus-DP Organization (PNO) for the protection class IP67 a round connector M12 with inverse coding should be used. A “T-Connector“ is not necessary, because the control unit is equipped with input and output connectors.

The corresponding cable plugs are part of the standard scope of supply.

Note If the E20 is the last participant in the bus, then an external terminating resistor should be placed into the open connector. The resistor is not included in the scope of supply.

Allocation of Profibus connection (Profibus-DP Slave)

Input (Pos. C2) Output (Pos. C1)

M12, 5-pin, B-coded, male connector at control unit M12, 5-pin, B-coded, female connector at control unit

View: plug side

Pin 1 +5V

View: plug side

Pin 2 Line A

Pin 3 GND

Pin 4 Line B

Pin 5 Shield/Earth

Suppliers / types / notes: Binder, type 715 (B-coded) and others

5.2.5.2 ControlNet

The control unit has two coaxial fieldbus connections “A“ and “B“ for ControlNet. For normal applications one connection can be used, for redundant applications both connections must be used.

The corresponding cable plugs are not within the scope of supply.

1 Connector C1 (ControlNet output)

2 Connector C2 (ControlNet input)

Allocation of ControlNet connector

Fieldbus type Connector C1 "A" Connector C2 "B"

ControlNet BNC BNC

2

5

1

3 4

5

21

34

Manual




5.2.5.3 DeviceNet (B-coded)

An M12 plug with inverse coding is used for the DeviceNet connection. A T-connector is not necessary, because the control unit is equipped with input and output.


Note If the E20 is the last participant in the bus, then an external termination resistor should be placed into the open connector. The resistor is not included in the scope of supply.

Allocation of DeviceNet connection

Input (Pos. B) Output (Pos. C)


View:

plug side

Pin 1 shield

View:

plug side

Pin 2 V +

Pin 3 V -

Pin 4 CAN High

Pin 5 CAN Low


5.2.5.4 DeviceNet (A-coded)

An M12 plug with inverse coding is used for the DeviceNet connection. A T-connector is not necessary, because the control unit is equipped with input and output.


Note If the E20 is the last participant in the bus, then an external termination resistor should be placed into the open connector. The resistor is not included in the scope of supply.

Allocation of DeviceNet connection


M12, 5-pin, A-coded, male connector at control unit M12, 5-pin, A-coded, female connector at control unit

View:

plug side

Pin 1 Shield

View:

plug side

Pin 2 V +

Pin 3 V -

Pin 4 CAN High

Pin 5 CAN Low

Suppliers / types / notes: Binder, type 715 (A-coded) and others

2

5

1

3 4

5

21

34

125

43

1 25

4 3

Manual




5.2.5.5 CanOpen

An M12 plug with inverse coding is used for the CanOpen connection. A T-connector is not necessary, because the control unit is equipped with input and output.


Note If the E20 is the last participant in the bus, then an external termination

resistor should be placed into the open connector. The resistor is not included in the scope of supply.

Allocation of CanOpen connection



View:

plug side

Pin 1 shield

View:

plug side

Pin 2 n. a.

Pin 3 GND

Pin 4 CAN_H

Pin 5 CAN_H


5.2.5.6 Interbus-S The corresponding cable plugs are part of the standard scope of supply.

Allocation of Interbus-S connection

Input (Pos. C2, male connectors) Output (C1, female connectors)

M12, 5-pin, B-coded, Male contacts at the control unit (male socket)

M12, 5-pin, B-coded Female contacts at the control unit (female socket)

View:

plug side

pin 1 DO

View:

plug side

pin 1 DO

pin 2 /DO pin 2 /DO

pin 3 DI pin 3 DI

pin 4 /DI pin 4 /DI

pin 5 GND pin 5 GND

Plug enclosure shield Plug enclosure shield

The module supports 500 kbit/s operation. The corresponding cable plugs are part of the standard scope of supply.

5.2.5.7 ProfiNet IO

The ProfiNet IO connection is implemented as 1-Port.

Allocation of ProfiNet IO connection

Round-shape connector, M12, 4-pin., D-coded, socket contact at control unit (Pos. C2)

View:

Plug side

Pin 1 TD +

Pin 2 RD +

Pin 3 TD –

Pin 4 RD –

Plug enclosure Shield


2

5

1

3 4

5

21

34

2

5

1

3 4

5

1 2

4 3

1

2

3

4

Manual




5.2.5.8 CC-Link

The unit supports the protocol version 1 of CC-Link.

An M12 plug with A-coding is used for the CC-Link connection. A T-connector is not necessary, because the control unit is equipped with input and output.


5.2.5.9 EtherNet/IP

The EthernetI/P connection is implemented as 1-Port.

Round-shape connector, M12, 4-pin., D-coded, socket contact at control unit (Pos. C2)

View:

Plug side

Pin 1 TD +

Pin 2 RD +

Pin 3 TD –

Pin 4 RD –



1

2

3

4

Note If the E20 is the last participant in the bus, then an external termination resistor should be placed into the open connector. The resistor is not included in the scope of supply. A resistor between DA und DB 110 Ohm or 130 Ohm ½ Watt can be used.

Allocation of CC-Link connection


M12, 4-pin, A-coded, male connector at control unit M12, 5-pin, A-coded, female connector at control unit

2 1 3 4

View:plug side

Pin 1 SLD

View:plug side

Pin 2 DB

Pin 3 DG

Pin 4 DA

Pin 5 ---

Suppliers / types / notes: Binder, type 715 (A-coded) and others

1 25

4 3

Manual




5.2.5.10 EtherCAT

Round-shape connector, M12, 4-pin., D-coded, socket contact at control unit

IN (Pos. C2) OUT (Pos. C1)

View: Plug side

Pin 1 TD +

Pin 2 RD +

Pin 3 TD –

Pin 4 RD –



5.2.6 Sensor connection (pos. D)

The sensor connection at the control unit is a quick disconnect type. The following cables are to be used:

• SM12CPS-GG and SM12CPS-GW for P36GS, P42GS, P75GS and P75VGS • SM12CPM12S-GG and SM12CPM12S-GW for P30GS and P42AGS • SM12CPPPS-GG and SM12CPPPS-GW for P128GPPS

Connector at control unit (pos. D) Manufacturer / types / notes

P30GS P42AGS P75VGS

P128GPPS

M12, 5-pin Female connector at control unit

Binder, series 713

View: Plug side

pin 1 Sensor signal 1

pin 2 Sensor signal 2

pin 3 -

pin 4 -

pin 5 Shield

5.2.7 Connection of earth ground (pos. E)

The enclosure of the R1000 has an M6 threaded screw for earth ground connection. This screw must be connected to the earth ground of the equipment with a copper wire gauge of 1.5 mm² cross section.

Attention The earth ground/central machine ground must not be connected to + 24 VDC.

1

2

3

4

1

2

3

4

1 25

4 3

Manual




5.2.8 Supply voltage connection and Optocoupler inputs (pos. G)

For the sensor voltage supply a small HAN 3A metal (metric thread) with an 8 pin insert is used. In addition to the voltage supply the opto coupler inputs are used with this connection.

Connector at control unit Input (pos. G) Output Manufacturer / types / notes

Voltage supply Enclosure HAN 3A

EMI-type, metrical 7-pin insert and PE

Pin contact at control unit

none Harting and others

view onto contacts

pin 1 +24VDC 24 VDC, +6 V / -2 V / 5 A

pin 2 GND

pin 3 IN0 + Input of 1st optocoupler +

pin 4 IN1 + Input of 2nd optocoupler +

pin 5 IN2 + Input of 3rd optocoupler +

pin 6 IN – Optocoupler 1,2,3 –

pin 7 -

pin 8 Shield / ground Internal at enclosure (ground)

A corresponding cable plug is part of the standard scope of supply.

Note The connecting cable for the power supply should be kept short.

Up to 20 m length use a 2 x 1 mm ² cable. For longer cables, the cross section must be increased accordingly (see power consumption data in chapter "2.1 Technical data").

Attention The earth ground/central machine ground must not be connected to + 24 VDC.

Optocoupler inputs for fast measurements

For real-time measurements it is possible to start measurement with external optocoupler inputs. The optocoupler function with a control voltage of 20 to 28 VDC. For connections see table on page 40 "Pin configuration of voltage supply connection".

Signal Meaning Note

IN0 External measurement start 1 1st optocoupler input

IN1 External measurement start 2 2nd optocoupler input

IN2 External measurement start 3 3rd optocoupler input

The combination of measurement start 1, 2 and 3 can be adjusted in the system configuration menu.

Note Measurement start signal can be issued either via the process channel or

via an optocoupler. Simultaneous measurement start signals result in fault messages.

Pos: 44 /Doppelblech/Geräte/E20 Bus/5 Elektrische Installation/Anschlusspläne @ 0\mod_1173449767000_501.docx @ 3369 @ 2333 @ 1

12

3 4

5

67

8

Manual




5.3 Connecting diagram - examples

5.3.1 Connecting diagram E20 with one sensor

for P30GS and P42AGS for P36GS, P42GS, P75GS and P75VGS

for P128GPPS

1 Cable 2 Cable 3 Cable

Order no.: SM12CPM12S-GG Order no.: SM12CPM12S-GW (90° angle socket at sensor)

Order no.: SM12CPS-GG Order no.: SM12CPS-GW (90° angle socket at sensor)

Order no.: SM12CPPPS-GG Order no.: SM12CPPPS-GW (90° angle socket at sensor)

FD810CY 2 x 1mm² or Unitronic FDCP (TP) plus 1 x 2 x 1 mm² (UL / CSA)

1a Cable plug (5 contacts) 2a Cable plug (5 contacts) 3a Cable plug (5 contacts)

Order no.: 2277704 Order no.: 2277704 Order no.: 2277704

Pin 1 black (1) [white] Pin 2 black (2) [brown] Pin 3 N.C. Pin 4 N.C. Pin 5 blank (shield)



1b Cable socket (5 contacts) 2b Cable socket (7 contacts) 3b Cable socket (4 contacts)

Order no.: 2276116 (straight) 2276117 (90° angle)




Pin 1 N.C. Pin 2 N.C. Pin 3 N.C. Pin 4 N.C. Pin 5 black (1) [white] Pin 6 black (2) [brown] Pin blank (shield)

Pin 1 black (1) [white] Pin 2 black (2) [brown] Pin 3 N.C. Pin 4 blank (shield)

Fig. 39: E20 with one sensor

1

1b

2a

2b

3a

3b

Manual




5.3.2 Connecting diagram E20 with one sensor and cable extension

1 Cable




for P128GPPS


















Fig. 40: E20 with one sensor and cable extension

32 4

1a

1b

4a 3a 2a

2b

3b4b

Manual




5.3.3 Connecting diagram E20-4P with 4 sensors


for P128GPPS


















Fig. 41: E20 with 4 sensors Pos: 45 /Kapitelübersicht/05. Kommunikation mit der SPS @ 0\mod_1121421968312_501.docx @ 510 @ 1 @ 1

1b

1a

2b

2a

3b

3a

Manual


B0046191 / Rev. 1.12 Communication with the PLC


6 Communication with the PLC Pos: 46 /Doppelblech/Geräte/E20 Bus/6 Kommunikation mit der SPS/Kommunikation mit der SPS - allgemein @ 0\mod_1173449388937_501.docx @ 3364 @ @ 1

The fieldbus interface contained in the R1000 enables the communication with a fieldbus master. The well defined data structure of the R1000 enables the use of the cyclical communication data transmission mode.

The R1000 has a four line display. The additional 2 lines, as compared to the previous regular version, are used for fieldbus specific messages.

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6.1 Fieldbus specific messages

After applying power the start message is displayed. It consist of the message of the bus system, the status message and the slave address.

1 Bus system message (here: Profibus DP)

2 Status message

3 Parameter channel message

4 Bus (slave) address (only if Fieldbus with node bus address)

5 Fieldbus baud rate (only if Fieldbus with baud rate) or MAC ID

Fig. 42: Fieldbus specific message from the R1000 after the start

Overview regarding the messages:

Status message

• Init: Display after start-up of the R1000. This message is displayed until the initializing processes is internally completed.

• Online: The fieldbus interface is in operation

• Offline: The fieldbus interface is not in operation or displays a fault

Parameter channel messages

• Closed: The parameter channel is closed

• Open: The parameter channel is open

• Conflict: A collision occurred when opening the parameter channel

• Collis.: A collision occurred during parameter transmission

Bus (slave) addresses

• 1... : Possible Slave addresses, which can be adjusted via software depending on the fieldbus type.

Note The messages are regularly updated and enhanced. It is therefore

possible that there are deviations to the messages described here.

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Manual


with integrated fieldbus interface Communication with the PLC B0046191 / Rev. 1.12


6.2 Data transmission communication

Currently the R1000 uses an I/O configuration for the cyclical data exchange with the master. This means that for each transmission direction 1 parameter channel (8 Byte) as well as one process channel has been provided. In contrast to the E10 (4 Byte) with the E20 16 byte for the process channel are used.

The following table shows the layout of the communication facility:

Mas

ter

Data direction Input Data direction

R10

00

–> Byte E0

Par

amet

er

chan

nel

–> –> Byte E1 –> –> Byte E2 –> –> Byte E3 –> –> Byte E4 –> –> Byte E5 –> –> Byte E6 –> –> Byte E7 –> –> Byte E8

Pro

cess

cha

nnel

–> –> Byte E9 –> –> Byte E10 –> –> Byte E11 –> –> Byte E12 –> –> Byte E13 –> –> Byte E14 –> –> Byte E15 –> –> Byte E16 –> –> Byte E17 –> –> Byte E18 –> –> Byte E19 –> –> Byte E20 –> –> Byte E21 –> –> Byte E22 –> –> Byte E23 –>

Data direction Output Data direction <– Byte S0

Par

amet

er

chan

nel

<– <– Byte S1 <– <– Byte S2 <– <– Byte S3 <– <– Byte S4 <– <– Byte S5 <– <– Byte S6 <– <– Byte S7 <– <– Byte S8

Pro

cess

cha

nnel

<– <– Byte S9 <– <– Byte S10 <– <– Byte S11 <– <– Byte S12 <– <– Byte S13 <– <– Byte S14 <– <– Byte S15 <– <– Byte S16 <– <– Byte S17 <– <– Byte S18 <– <– Byte S19 <– <– Byte S20 <– <– Byte S21 <– <– Byte S22 <– <– Byte S23 <–

The R1000 is controlled by the process channel and via the parameter channel all systems and program data are accessible.

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Manual




6.3 Process channel

The process channel functions with the bytes I/O8 through I/O23. The parallel interface used in the regular R1000 is simulated via are the process channel which makes the direct program selection possible.

As a new function the inputs read by the R1000 for program selection are mirrored onto the available outputs of the process channel. It is therefore possible to check the function of the R1000 via the PLC.

Layout of the process channel:

Inputs Byte Description

I8 Control

I9 Program selection 1 - 255

I10 Program selection; block 1...4 (reserved). Sensor selection (only for systems E10 / E20)

I11 free

I12 Control sensor 1

I13 free

I14 free


I16 free

I17 free


I19 free

I20 free


I22 free

I23 free

Outputs Byte Description

O8 Control signals (0-sheet, 1-sheet, 2-sheet)

O9 Mirroring E9

O10 Mirroring E10 and measuring value, thickness S1

O11 Measuring value, thickness S1

O12 Control signal sensor 1

O13 Measuring value, thickness sensor 1











Manual




6.3.1 Process channel – functions and signals

Bytes 8 - 11: Byte.Bit PLC –> R1000 (BIN) R1000 –> PLC (BOUT)

8.0 System test Function result

8.1 Measurement start Current measuring program: Teach-In performed

8.2 Teach-In 0-sheet / zero adjust Function fault

8.3 Teach-In 1-sheet Ready1)

8.4 --- Warning2)

8.5 Clear 2-sheet / clear 0-1-2 outputs + warning 0-sheet2) (summary output)

8.6 Program switching 1-sheet2) (summary output)

8.7 Reset function fault 2-sheet2) (summary output)

9.0 Bit 0 measuring program Bit 0 current measuring program








10.0 ---

High byte thickness value4) (sensor 1)

10.1 ---

10.2 ---

10.3 ---

10.4 ---

10.5 ---

10.6 Sensor selection A3) Current sensor selection A

10.7 Sensor selection B 3) Current sensor selection B

11.0 ---

Low byte thickness value4) (sensor 1)

11.1 ---

11.2 ---

11.3 ---

11.4 ---

11.5 ---

11.6 ---

11.7 ---

1), 2), 3), 4)

Footnotes see Table “Bytes 21 to 23”

Explanation of the summary output function in case of 0-sheet, 1-sheet, 2-sheet:

If the equipment is operated in the sequencer mode (program with several sensors, e.g. 1+3+4), then the measurement results are issued as “summary output“. The following priorities are assigned:

• If one or several of the sensors issue the double sheet signal (2-sheet), then the “summary output“ is 2-sheet

• If only the 1-sheet is present, then the “summary output“ is 1-sheet

• Otherwise the “summary output“ is 0-sheet

If the results of individual sensors are required, then interrogate bytes 12-23.

Manual




Bytes 12 - 14: Byte.Bit PLC –> R1000 (BIN) R1000 –> PLC (BOUT)

12.0 --- Type of material at sensor 1 (here always 1)

12.1 --- Current measuring program S1: Teach-In performed

12.2 Zero adjust (sensor 1) ---

12.3 Teach-In 1-sheet (sensor 1) ---

12.4 --- Warning 2)

12.5 --- 0-sheet 2) sensor 1

12.6 --- 1-sheet 2) sensor 1

12.7 --- 2-sheet 2) sensor 1

13.0 --- High byte thickness value 4) (sensor 1)

13.1 ---

13.2 ---

13.3 ---

13.4 ---

13.5 ---

13.6 --- ---

13.7 --- ---

14.0 --- Low byte thickness value 4) (sensor 1)

14.1 ---

14.2 ---

14.3 ---

14.4 ---

14.5 ---

14.6 ---

14.7 ---

2), 4)


Manual




Bytes 15 - 17: Byte.Bit PLC -> R1000 (BIN) R1000 -> PLC (BOUT)





15.4 --- Warning 2)

15.5 --- 0-sheet 2) sensor 2

15.6 --- 1-sheet 2) sensor 2

15.7 --- 2-sheet 2) sensor 2


16.1 ---

16.2 ---

16.3 ---

16.4 ---

16.5 ---

16.6 --- ---

16.7 --- ---


17.1 ---

17.2 ---

17.3 ---

17.4 ---

17.5 ---

17.6 ---

17.7 ---

1), 2), 3), 4) Footnotes see Table “Bytes 21 to 23”

Manual




Bytes 18 - 20: Byte.Bit PLC -> R1000 (BIN) R1000 -> PLC (BOUT)





18.4 --- Warning 2)

18.5 --- 0-sheet 2) sensor 3

18.6 --- 1-sheet 2) sensor 3

18.7 --- 2-sheet 2) sensor 3


19.1 ---

19.2 ---

19.3 ---

19.4 ---

19.5 ---

19.6 --- ---

19.7 --- ---


20.1 ---

20.2 ---

20.3 ---

20.4 ---

20.5 ---

20.6 ---

20.7 ---

2), 4)


Manual




Bytes 21 - 23: Octet.bit PLC -> R1000 (BIN) R1000 -> PLC (BOUT)





21.4 --- Warning 2)

21.5 --- 0-sheet 2) sensor 4

21.6 --- 1-sheet 2) sensor 4

21.7 --- 2-sheet 2) sensor 4


22.1 ---

22.2 ---

22.3 ---

22.4 ---

22.5 ---

22.6 --- ---

22.7 --- ---


23.1 ---

23.2 ---

23.3 ---

23.4 ---

23.5 ---

23.6 ---

23.7 ---

1)

Ready / ENABLE (via I/O): If 0/0V, then control unit fault. Operator action necessary at the control unit, e.g. memory fault, voltage missing or too low. 2)

The control unit configuration can be selected 0V active or 24V active for these outputs. This applies also to I/O outputs. 3)

Sensor selection with E20 via process channel or program data. 4)

The measuring value is spent as follows:

HIGH BYTE (Byte 10 resp. 13, 16, 19, 22 without Bit 6, 7) Low Byte (Byte 11 resp. 14, 17, 20, 23)

1. Micrometer = 0…16000µm

2. 1 - 10000 inch = 0…6300 x 10-5 inch

3. 1/10% = 0…9999 1/10%

Manual




Binary scheme for the sensor selection:

Sensor selection B Sensor selection A Sensor

0 0 1

0 1 2

1 0 3

1 1 4

The sensor selection A/B is active only if it is the version 4P and in the system configuration "Sensor selection external" has been selected.

Attention The sensor selection A/B must take place, when no measurement is active. The selection is taken over with the next measurement. This also applies to the general zero adjust and Teach-In 1-sheet.

Note In the following timing diagrams all outputs and inputs via the bus are designated as BOUT and BIN, in contrast, the opto coupler interface uses OUT or IN.

Manual




6.3.2 Start single measurement via process channel

Fig. 43: Start single measurement via process channel

ts: System reaction time = Measuring time ( see chapter 2.4)

1) In case of “Function fault“ = 1 “Function result“ will sometimes remain at 0.

Set “Measurement start“ to HIGH

Waiting for “Function fault“ or Waiting for “Function result“

In case of “Function fault“:

- Pause 100 ms

- Set “Measurement start” to LOW

- Reset “Function fault“

In case of “Function result":

- Analyse

- Set “Measurement start” to LOW

Measurement start

BIN 10.6 to 10.7Sensor selection A/B


BOUT 8.0Function result 1)

BOUT 8.2Function fault

BOUT 8.3Ready

OUT 0 to OUT 2 + OUT 4(Warning, 0-sheet, 1-sheet, 2-sheet)

BOUT 8.4 to 8.7(Warning, 0-sheet, 1-sheet, 2-sheet)

“1” in case of fault


„0“ active

„0“ active

< 5ms ts < 10ms

Manual




Explanation:

• If a fault occurs when initiating the function (for instance a previous function is still active) then only the “Function fault“ is displayed. The “Function result“ will not be displayed. The other outputs remain in their current status.

• If the fault occurs during execution, the “Function fault“ is displayed. The “Function result“ will not be displayed (if the fault is connected to the function). The outputs remain in their current status.

• If the fault occurs after the result, for instance, by a faulty operation then this has no influence on the “Function result“.

• If the “Measurement start“ cycle is shorter than the duration of the function then the “Function result“ will not be displayed. However, the function is nevertheless executed ! For safety reason the control should not be executed in this fashion !

• If the “Measurement start“ cycle is longer than the duration of the function then the “Function result“ will be displayed as shown in the timing diagram.

Note Faults which are not critical can be deleted via the process channel with the “Reset function fault“ command.

Note The measured timing periods were determined with 12 Mbit- Profibus. These timing periods can vary with different transmission rates and bus systems. The cycle time of the PLC has not been taken into account.

Note If several measurements are executed consecutively, the measuring

operation time should not exceed 10 seconds. It is advisable to keep a recovery time of at least twice the measuring operation time. Example: 10 measurements within 1 second, then 2 seconds of recovering time. If the recovery time is less than twice the measuring time, the sensor will warm up and the measuring value will drift.

Manual




6.3.3 Start continuous measurement via process channel

Fig. 44: Timing diagram for start continuous measurement via process channel

Note The output “Function result“ is set with the appearance of the first measurement value and then remains set.



tp: additional break times:

• P30, P42, P42A, P75V 0.5 seconds

• P36 1.0 second

• P75 2.0 seconds

• P128 7.0 seconds


ts < 10msts pt+ ts pt+ ts pt+ ts pt+

„1” if fault

„0” if fault

„0“ active

„0“ active

BIN 8.1Measurement start





BOUT 8.3Ready


OUT 0 to OUT 2 + OUT 4(Warning, 0-sheet, 1-sheet, 2-sheet)

Manual




6.3.4 Program switching

Fig. 45: Timing diagram for program switching



Program no. Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

1 0 0 0 0 0 0 0 0

2 0 0 0 0 0 0 0 1

… … … … … … … … …

255 1 1 1 1 1 1 1 0

not used 1 1 1 1 1 1 1 1

< 10ms

„1” if fault

0V if fault

BIN 8.6Program switching

BIN Binary value9.0 to 9.7Measurement program

BOUT Binary value9.0 to 9.7Current measurment program


BOUT8.2Function fau lt

BOUT 8.3Read y

Manual




6.3.5 System test

The system test should be performed before each measuring cycle.

Fig. 46: Timing diagram for system test



< 10ms

BIN 8.0System test


BOUT 10.6 bis 10.7Sensor selection A/B



BOUT 8.3Ready

OUT 0 to OUT 3 + OUT 4( 0-sheet, 1-sheet, 2-sheet)Warning,


OUT 3ENABLE

„1” if fault

0V if fault

Manual




6.3.6 Clear 2-sheet / Clear 0-, 1- , 2-sheet outputs

Fig. 47: Timing diagram for clear sheet outputs


6.3.7 Teach-In 0-sheet / Zero adjust

Fig. 48: Timing diagram for Teach-In / zero adjust


Note According to the setting in the configuration menu, item 12 "Sensor selection" the Zero adjust causes following: - external: the selected sensor in "selection A/B" is nulled. - Program: the selected sensors in the active program are nulled.


< 10ms< 10ms < 10ms



BOUT 8.3Ready

OUT( 0-sheet, 1-sheet, 2-sheet)Warning,


BIN 8.5( 0-sheet, 1-sheet, 2-sheet) CLR 2-sheet,

„0“ active

„0“ active

„1” if fault

0V if fault

< 10ms

„1” if fault

0V if fault


BOUT 10.6 to 10.7Sensor selection A/B



BOUT 8.3Ready

BIN 8.2Teach-In 0-sheet,Zero adjust

Manual




6.3.8 Teach-In 1-sheet

Fig. 49: Timing diagram for Teach-In 1-sheet

Note The uncorrected thickness (thickness taken from the curve) is issued via the process channel. Should the thickness deviate more then 10 percent (exceptions 20 percent) from the nominal thickness then the cause for this deviation must be investigated. This could be: wrong sheet, wrong thickness, bowed sheet, air gap between sensor and sheet.


Note According to the setting in the configuration menu, item 12

"Sensor selection" the Teach-In causes following: - external: the selected sensor in "selection A/B" is teached. - Program: the selected sensors in the active program are teached.


< 10ms

„1” if fault

0V if fault


BOUT 10.6 to 10.7Sensor selection A/B



BOUT 8.3Ready

BIN 8.3Teach-In 1-sheet

Manual




6.3.9 Reset Function fault

Fig. 50: Timing diagram for reset function fault

OUT ENABLE is not reset if a critical systems fault is present. Examples are memory fault, power failure, or voltage too low. Critical faults cannot be reset via the process channel. It is necessary to eliminate the cause of the fault.



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6.4 Parameter channel

The parameter channel is designed to exchange systems and parameter data of the R1000 with the master. Primary purpose is the central data backup on the master. In addition, certain measurement and operating parameters can be extracted from the R1000 and analysed by the master.

Note The configuration of the data format has to be compatible with the

PLC for consistent data transmission !

The data transmission via the parameter channel must be initiated with the service “Open parameter channel“. The end of data transmission mission via the parameter channel must be completed with the service “Close parameter channel“.

If the parameter channel is open then it is not possible to issue control commands via the process channel or via inputs on the keyboard.

< 10ms

„1” if fault

0V if fault



BOUT 8.3READY

BIN 8.7Reset function fault

Manual




6.4.1 Structure of the parameter channel

Structure of the parameter channel

Meaning I/O Byte Notes

Byte 0 1 2 3 4 5 6 7

Management x Data access control (reading, writing, handshake)

Program index x Selection of the tooling program

Parameter index x Selection of the parameter

Application data byte 0 x MSB (most significant byte) LSB (least significant byte)

Application data byte 1 x



Checksum x Checksum of the transferred bytes 1 - 6

Data access control

Services are initiated exclusively by the master. The R1000 as slave cannot initiate data transmissions.

The management byte (E0) is used by the master to select the service (for example writing or reading) and to confirm the access. The R1000 confirms via the management myte (A0) the execution of the command. If an access is not allowed and therefore, the service cannot be executed, then the R1000 declares this action a collision.

Structure of management byte

Management byte (I0/O0) Bit

7 6 5 4 3 2 1 0

Collision 0 = access correct, 1 = access not correct." "1"" is set by the R1000 only if a service is inadmissible or cannot be executed. In this case the master has to take the service back, in order to reset the error condition. See section "reset faulty access" in this chapter.

x

Handshake This condition is changed with each new command. Only the master controls, if a new order from the R1000 has to be executed. The R1000 mirrors that handshake as soon as the order has been processed. If the order could be executed, the collision bit remains set to 0. If the order could not be executed, then the collision bit is set to 1 by the R1000. Additional orders can be executed only by cancelling the incorrect service.

x

Application data length always set to 11 (11 = 4 byte) x x

Service selection 0000 = Empty service 0001 = Read parameter 0010 = Write parameter 0100 = Open parameter channel 1000 = Close parameter channel 00000000 = Reset parameter channel

x x x x

Manual




Program index

Program index enables the access to one of the 255 programs. The access to the systems parameters is made via the program index 255.

Program index

Meaning Program index byte Notes

Bit 0 1 2 3 4 5 6 7

Program no. x x x x x x x x 0 = program 1, 255 = system parameter

Parameter index

The parameter index enables the access to the parameters of each program.

Parameter index

Meaning Parameter index byte Notes

Bit 0 1 2 3 4 5 6 7

Parameter no. x x x x x x x x 0 ...18 at program parameter 1 ... 24 at system parameter see section "12.5 Parameter channel commands"

Application data bytes

The application data bytes 0 to 3 contain the data which can be transmitted.

Application data bytes

Meaning Application data byte 0 - 3 Notes

Bit 0 1 2 3 4 5 6 7

Application data x x x x x x x x The 4 bytes include the application data

Checksum

The checksum is formed of the bytes 1 – 6.

Checksum

Meaning Checksum byte Notes

Bit 0 1 2 3 4 5 6 7

Checksum x x x x x x x x Checksum of data communication bytes 1 - 6

The checksum of bytes 1 - 6 is calculated and the least significant byte of the result is inserted into byte 7.

Manual




6.4.2 Service "Open parameter channel"

The service open parameter channel is initiated by the master with the selection of the service. The content of the index bytes E1, E2 and the application data bytes 0 through 3 are not relevant. The checksum of bytes 1 through 6 is calculated and inserted in byte 7. To initiate the service the master changes the handshake bit.

To avoid data fault the following sequence is compulsory:

1. Service selection, program index, parameter index 2. Switch handshake

In addition consistent data transmission from master is necessary.

Note For the service “Open parameter channel“ the index bytes E1,E2 and the application data bytes E3... E6 are not relevant.

The R1000 checks the data with the checksum and mirrors the application data, the service selection and the index selection into A1, A2.The R1000 sets the handshake bit in A0.0 only in the last step and signals thereby that the data is valid. This sequence is observed by the R1000 in order to avoid data faults.

The slave should ensure a consistent data transmission.

Attention If reading cannot be executed the collision bit is set. The fault number is transmitted instead of application data, see section “6.4.8 Reset faulty access“. The collision bit can be deleted with one of the following services: Close parameter channel, Empty service or Reset parameter channel.

Manual




6.4.3 Service "Close parameter channel"

The service “Close parameter channel“ is initiated by the master by selecting the service. The content of the index bytes E1, E2 and the application data bytes 0 through 3 is not relevant. The checksum of bytes 1 through 6 is calculated and inserted in byte 7. To initiate the service the master changes the handshake bit.

To avoid data fault the following sequence is compulsory:

1. Service selection, program index, parameter index 2. Switch handshake


Note For the service “Open parameter channel“ the index bytes E1,E2 and the application data bytes E3... E6 are irrelevant.

The R1000 checks the data with the checksum and mirrors the application data bytes, the service selection and the index selection in A1, A2. The R1000 sets the handshake bit in A0.0 only in the last step and signals thereby that the data is valid. This sequence is observed by the R1000 in order to avoid data faults.


Attention If the checksum is correct then the closing of the parameter channel is always executed. A set collision bit is thereby deleted.

6.4.4 Service "Read parameters"

The master initiates the service “Read parameter“ by selecting the service, and index bytes E1 and E2. The content of the application data bytes 0 to 3 is not relevant. The checksum of byte 1 through 6 is calculated and inserted in byte 7. To initiate the service the master changes the handshake bit.

In order to avoid data faults the following sequence is compulsory:

1. Service selection, program index, parameter index

2. Switch handshake


Note The application data bytes E3 - E6 of the service “Read parameter“ are not relevant.

The R1000 checks the data with the checksum and makes the content of the respective parameters available in the application data bytes of parameter channel A3... A6. In addition the R1000 mirrors the service “Read parameter“ and the index adjustment in A1, A2. Only in the last step sets the R1000 the handshake bit into A0.0 and indicates thereby that the data is valid.

This sequence is observed by the R1000 in order to avoid data faults.


Attention A collision bit is set if reading cannot be executed. Instead of application data the default number is transmitted, see “6.4.8 Reset faulty access“.

Manual




6.4.5 Service "Write parameters"

Initiate the master with the setting of the service selection, the index bytes E1 and E2. The content of the application data bytes 0 to 3 are also stored. The checksum of byte 1 through 6 is calculated and inserted in byte 7. To initiate the service the master changes the handshake bit.


1. Service selection, program index, parameter index, application data byte 0 to 3 2. Switch handshake

In addition consistent data communication from the master is necessary.

The R1000 checks the data with the checksum and transfers the content of the application data bytes of the parameter channel E3… E6 into its own parameter memory. Afterwards the R1000 mirrors the index adjustment in A1, A2 and the application data in A3..A6. Only in the last step inserts the R1000 the handshake bit in A0.0 and indicates thereby that the data has been completely accepted. The same sequence applies here also, in order to avoid data faults.


Attention If writing cannot be executed, the collision bit is set. In place of the application data a fault number is transmitted, see section “6.4.8 Reset faulty access“.

6.4.6 Service "Empty service"

The master initiates the service “Empty service“ with the setting of the service selection. The content of the index bytes E1, E2 and the application data bytes 0 to 3 are not relevant. The checksum of byte 1 through 6 is calculated and inserted in byte 7. To initiate the service the master switches the handshake bit.


1. Service selection, program index, parameter index, application data byte 0 to 3

2. Switch handshake

In addition consistent data communication from the master is necessary.

The R1000 checks the data with the checksum and mirrors the index adjustment in A1, A2 and the application data in A3..A6. A possibly set collision bit is set back. Only in the last step inserts the R1000 the handshake bit in A0.0 and indicates thereby that the data has been completely accepted. The same sequence applies here also, in order to avoid data faults.


Attention If the service “Empty service“ cannot be executed, the collision bit is set (remains set). In place of the application data a fault code is transmitted, see section “6.4.8 Reset faulty access“.

6.4.7 Service "Reset parameter channel"

The service “Rest parameter channel“ initiates the master by transferring a zero string. The service was added for safety reasons during the start up of the system or in case a fault occurs in the bus.

The R1000 closes the parameters channel and mirrors "parameters channel closed" (38 00 00 00 00 00 00 00 Hex). The handshake bit remains set to 0. The collision bit is also set to 0.

Attention If the fieldbus is off-line the service “Reset parameter channel“ is automatically executed.

Manual




6.4.8 Reset faulty access

For the following reasons a service cannot be executed:

• The current operating conditions do not allow the execution of the selected service.

• The collision bit in the management byte has not been reset.

• The index register address invalid parameters.

• The service cannot be applied to this parameter.

• The application data contains inadmissible values.

• The service is unknown.

The reasons above can prevent the service execution during reading or writing. The R1000 indicates this problem by the collision bit. In order to prevent an additional uncontrolled access procedure, the R1000 expects the reset of the called service by the master. In addition the master executes an “Empty service“ with the confirmation of a handshake. After receipt of this empty order, the R1000 puts the collision bit back and confirms the service with a handshake. Thus the fault condition can be reset and the R1000 is available for further orders.

Note If necessary the collision bit can be reset by the service “Close parameter channel“ and by the service “Reset parameter channel“. However the parameter channel is thereby closed.

6.4.9 Listing of parameter channel commands

A list with all parameter channel commands is specified in chapter “11.3

Manual




6.4.10 Example: Remote control with parameter adjustment for the E20

H is the handshake bit and switched by the master and with each data transmission via the parameter channel (see section of “6.4.1 Layout of the parameters channel - data access control“)

1. Terminate current activities via I/O or process channel

2. Open parameter channel with service “Open parameter channel“ - Transfer: 0H110100b 00h 00h 00h 00h 00h 00h 00h - Wait for answer: 0H110100b 00h 00h 00h 00h 00h 00h 00h - In case of a collision: Undo the collision with the service “Empty service“, remove the cause of the collision and open again. If necessary evaluate fault number in application data bytes.

3. Set sensor number to the desired program index (e.g. program number 7, sensor number 1)

- Transfer: 0H110010b 06h 01h 00h 00h 00h 01h 08h - Wait for answer: 0H110010b 06h 01h 00h 00h 00h 01h 08h - In case of a collision: Undo the collision with the service “Empty service“, remove the cause of the collision and open again. If necessary evaluate fault number in application data byte

4. Set nominal thickness to the desired program index (e.g. program number 7, 1.00 mm) - Transfer: 0H110010b 06h 02h 00h 00h 03h E8h F3h - Wait for answer: 0H110010b 06h 02h 00h 00h 03h E8h F3h - In case of a collision: Undo the collision with the service “Empty service“, remove the cause of the collision and open again. If necessary evaluate fault number in application data byte

5. Set the lower limit to the desired program index (e.g. program number 7, 80%) - Transfer: 0H110010b 06h 04h 00h 00h 03h 20h 2Dh - Wait for answer: 0H110010b 06h 04h 00h 00h 03h 20h 2Dh - In case of a collision: Undo the collision with the service “Empty service“, remove the cause of the collision and open again. If necessary evaluate fault number in application data byte

6. Set the upper limit to the desired program index (e.g. program number 7, 120%) - Transfer: 0H110010b 06h 05h 00h 00h 04h B0h BFh - Wait for answer: 0H110010b 06h 05h 00h 00h 04h B0h BFh - In case of a collision: Undo the collision with the service “Empty service“, remove the cause of the collision and open again. If necessary evaluate fault number in application data byte

7. Close Parameter channel - Transfer: 0H111000b 00h 00h 00h 00h 00h 00h 00h - Wait for answer: 0H111000b 00h 00h 00h 00h 00h 00h 00h - In case of collision: Undo the collision with service “Empty service“, remove the cause of the collision (normally only wrong content or checksum are possible) and close. If necessary evaluate fault number in application data bytes.

8. Switch program number via the process channel (e.g. switch to program number 7) - Transfers: byte 9: 06h, byte 8: 40h - Answer: byte 8: 01h, byte 9: 06h - Transfer: byte 8: 00h - Answer: byte 8: 00h - In case of malfunctioning the “Function fault“ is returned (see also section “6.3 Process channel“)

9. Execute zero adjust via the process channel (without sheet in front of the sensor) - Transfer: byte 8: 04h - Answer: byte 8: 01h - Transfer: byte 8: 00h - Answer: byte 8: 00h - In case of malfunctioning the “Function fault“ is returned (see also section “6.3 Process channel“)

10. Execute teach-in via the process channel (attach sheet with nominal thickness to the sensor) - Transfer: byte 8: 08h - Answer: byte 8: 01h - The thickness from the curve is sent to byte 10 and 11. If the issued thickness deviates more than 10% (exceptions 20%) of the nominal thickness, then it is necessary to search for the cause. This could be: wrong sheet, wrong thickness, warped sheets, air gap between sensor and sheet. - In case of malfunctioning the “Function fault“ is returned (see also section “6.3 Process channel“)

11. Open, if necessary, the parameters channel again and read the internal program parameter (1-13) of the selected programs and store the data backup in the PLC. Then close the parameters channel again.

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Manual




6.5 External I/O control

The system is normally controlled via the process channel. The exception is the signal "Measurement start", which, for fast procedures, can also be controlled via the optocoupler inputs (IN). A mixed operation is also possible. The control cannot, however, be made simultaneously by both signal sources.

The “Measurement start“ signals can be initiated via the process channel or the opto couplers. Simultaneous initiation is not possible. That means that the initiation of measurement start is not accepted by opto couplers, if measurement start of the process channel is active or not processed. The same applies to the other way.

optocoupler inputs


IN0 Measurement start input 1 Optocoupler input 1 24 V active



The “Measurement start“ inputs are linked in different combinations via AND. The following configuration can be selected in the control unit:

• IN0

• IN0 and IN1

• IN0 and IN1 and IN2

In addition the signals 0-, 1-, 2-sheet, ENABLE and warning are available for further processing via optocoupler (OUT).

optocoupler ouputs


OUT0 Output 0-sheet 1st Optocoupler output standard 0 V active (selection in the control unit configuration)

OUT1 Output 1-sheet 2nd Optocoupler output standard 0 V active (selection in the control unit configuration)

OUT2 Output 2-sheet 3rd Optocoupler output standard 0 V active (selection in the control unit configuration)

OUT3 Output ENABLE 4th Optocoupler output standard 24 V active (cannot be selected for safety reasons)

OUT4 Warning 5th Optocoupler output standard 0 V active (cannot be selected for safety reasons)

Manual




6.5.1 Explanation of summary output 0-sheet, 1-sheet and 2-sheet:

If the unit is used in sequencer-mode (more than 1 sensor in a program e.g. 1+3+4), the measurement result is formed as summary output. The priorities are:

2-sheet is issued if at least one sensor detects 2-sheet.

1-sheet is issued if all sensors detect 1-sheet.

0-sheet is issued if no 2-sheet is detected but at least one sensor detects 0-sheet.

Truth table for summary output

Sensor 1 Sensor 2 Sensor 3 Sensor 4

2-sheet is issued if:

2-sheet any condition

any condition 2-sheet any condition

any condition 2-sheet any condition

any condition 2-sheet


1-sheet 1-sheet 1-sheet 1-sheet


0-sheet 0-sheet / 1-sheet

0-sheet / 1-sheet 0-sheet 0-sheet / 1-sheet

0-sheet / 1-sheet 0-sheet 0-sheet / 1-sheet

0-sheet / 1-sheet 0-sheet

The results of the separate sensors are available in the bytes 12-23 and can be used as required.

6.5.2 Signal "Enable"

The signal “ENABLE“ corresponds with the two process channel signals BOUT “Ready“ and BOUT “Function fault“ according to the following Boolean logic.

Fig. 51: Boolean function “ENABLE”

If the signal BOUT “Ready“ is reset, then a fault has occurred, which requires a user intervention at the control unit. Possible causes: memory faults, missing or too low voltages.

Note The timing diagrams in the sections “6.5.4“ and “6.5.5“ do not contain an

explicit chart of the signal “ENABLE“.

&BOUTReady

BOUTFunction fault

ENABLE

ENABLE = BOUT Ready BOUT Function fault

Manual




6.5.3 Signal "Warning"

The “Warning“ signal is an additional output signal with fixed evaluation thresholds.

The signal becomes activated if the measurement result is below 80% or above 120% of the preset nominal value.

Application:

If the "Warning" is active in the measurement, though only one sheet in front of the sensor, measurement problems may have occurred:

• Air gap between sensor and sheet

• Wrong type of sheet

• Sensor coverage not sufficient

Note If these requirements are met, but a warning signal is issued, then the

Teach-in must be repeated. The requirements from section “4.3 Sensor mounting“ should be observed.

Note The signal will also be activated if measurements without a sheet

(measurement value <80%) and measurements with double sheet / two sheets (measurement value >120%).

Manual




6.5.4 Start single measurement via external input

Fig. 52: Timing diagram for Start single measuring via external inputs

ts: System reaction time = Measuring time ( see chapter 2.4) 1)

In case of “Function fault“ = 1 “Function result“ will sometimes remain at 0.

Note The operation of the individual measurement, which is initiated via the

external input, can be controlled via the process channel, see section “6.3.2 Start single measurement via process channel“. If no control is done via the process channel, then the measurement operation must be controlled by the signal “ENABLE“, see section “6.5.2 Signal ENABLE“.

Note If several measurements are executed consecutively, the measuring

operation time should not exceed 10 seconds. It is advisable to keep a recovery time of at least twice the measuring operation time. Example: 10 measurements within 1 second, then 2 seconds of recovering time. If the recovery time is less than twice the measuring time, the sensor will warm up and the measuring value will drift.

IN / BINMeasurement start

BINSensor selection A/B

BOUTSensor selection A/B

BOUTFunction result)1)

BOUTFunction fault

BOUTReady

OUT(0-sheet, 1-sheet, 2-sheet)

BOUT(0-sheet, 1-sheet, 2-sheet)



„0“ active

„0“ active

< 5ms ts < 10ms

Manual




6.5.5 Start continuous measurement via external input

Fig. 53: Timing diagram for start continuous measurement via external inputs

Note The output function result is set with the arrival of the first measured

value and remains set.


tp: additional break times:

• P30, P42, P42A, P75V 0,5 seconds

• P36 1,0 second

• P75 2,0 seconds

• P128 7,0 seconds

1)

In case of “Function fault“ = 1 “Function result“ will sometimes remain at 0.

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< 5ms t s < 10msts pt+ ts pt+ ts pt+ ts pt+

IN / BINMeasurement start

BINSensor selection A/B

BOUTSensor selection A/B

BOUTFunction result)1)

BOUTFunction fault

BOUTReady

BOUTBus(0-sheet, 1-sheet, 2-sheet)

OUT(0-sheet, 1-sheet, 2-sheet)

„1” if fault

„0” if fault

„0“ active

„0“ active

Manual




6.6 Fieldbus configuration file

6.6.1 GSD file for Profibus-DP

The GSD file contains the specific configuration data of the slave. The data must be known to the Profibus master.

The manufacturers of the Profibus master supply the tools for the integration of the GSD file into the Profibus network. Suitable are for example the Siemens step 7 tools. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the master.

The GSD file is supplied on a CD or can be downloaded from the Roland homepage.

Note 24 Bytes I/O must be set.

6.6.2 EDS file for ControlNet

The EDS file contains the specific configuration data of the ControlNet adapter. The data must be known to the scanner.

The manufacturers of the scanner supply the tools for the integration of the EDS file into the ControlNet network. Suitable are for example Rockwell RSNetworx configuration tools. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the scanner.

The EDS file is supplied on a CD or can be downloaded from the Roland homepage.

Note: 24 Bytes I/O must be set.

6.6.3 EDS file for DeviceNet

The EDS file contains the specific configuration data of the slaves. The data must be known to the DeviceNet master.

The manufacturers of the DeviceNet master supply the tools for the integration of the EDS file into the DeviceNet network. Suitable are for example the Allen-Bradley DeviceNet manager. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the master.



Manual




6.6.4 EDS file for CanOpen

The EDS file contains the specific configuration data of the slaves. The data must be known to the master.

The manufacturers of the master supply the tools for the integration of the EDS file into the network. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the master.


Note 3 PDOs with 8 Bytes each are set.

6.6.5 GSD file for ProfiNet IO

The GSD file contains the specific configuration data of the device. The data must be known to the controller.

The manufacturers of the controller supply the tools for the integration of the GSD file into the Profibus network. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the controller.

The GSD file is supplied on a CD or can be downloaded from the Roland homepage.


Manual




6.6.6 CPS file for CC-Link

The CSP file contains the specific configuration data of the device. The data must be known to the controller.

The manufacturers of the controller supply the tools for the integration of the CSP file into the network. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the controller.

The CSP file is supplied on a CD or can be downloaded from the Roland homepage.

Three „occupied Stations“ with 36 Byte are used. 12 Byte are Bit Data Area and 24 Byte Word Data Area.

Link Input (Roland R1000 => PLC)

W0 W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17

Bit Data area word 0 to 4 (Byte 0-9)

System area word 5

Word Data area word 0 to 3


not used Bit 3 = Remote Ready *1)

Roland I20 Parameter channel (see Chapter 6.2)

Roland I20 Process channel (see Chapter 6.2)

Link Output (PLC => Roland R1000)

W0 W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17

Bit Data area word 0 to 4 (Byte 0-9)

System area word 5



not used not used Roland I20 Parameter channel (see Chapter 6.2)

Roland I20 Process channel (see Chapter 6.2)

*1) Remote Ready: after Roland R1000 is ready for Data exchange the signal Remote READY is set. If Remote READY is off the Data are not valid.

Manual




6.6.7 EDS file for EtherNet/IP

The EDS file contains the specific configuration data of the device. The data must be known to the controller.

The manufacturers of the controller supply the tools for the integration of the EDS file into the network. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the controller.



6.6.8 Device Description file for EtherCAT

The Device Description file contains the specific configuration data of the device. The data must be known to the controller.

The manufacturers of the controller supply the tools for the integration of the Device Description file into the network. Roland Electronic does not supply such tools, because they have to be compatible with the interface design of the controller.

The Device Description file is supplied on a CD or can be downloaded from the Roland homepage.


n is output as a collective message 0-sheet Are the results or individual sensors are needed, these can be retrieved in the bytes 12 – 23.

Manual




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B0046191 / Rev. 1.12 Start-up


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7.1 Initially applying power to the system

The R1000 E20 is designed for an operating voltage of 24 VDC (+6 V / -2 V). This voltage is to be checked before applying power. The control unit is automatically switched on by applying the power. After applying power, the type of system, the version number and the bus system message are briefly displayed. Then the system switches into that measurement menu, which was active before the unit was switched off.

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7.2 Operation

Note Units with CanOpen bus module require approx. 30 s to reach the

operational status after applying power to the system.

Note The system is factory adjusted for “single measurement“. Therefore the system functions only if the signal “measurement start“ is activated via the fieldbus. The modification of the configuration is described in the following sections.

After applying power to the system, the version number and the bus system message are briefly displayed. Afterwards the system switches into that measurement menu which was active before the unit was switched off.

1 LED functions 2 Pushbutton functions 3 Program number 4 Selected sensor 5 Type of material 6 Nominal thickness 7 Measurement status 8 Bus address 9 Upper limit value 10 Sensor number with measured value 11 Fieldbus status 12 Bus type 13 Lower limit value 14 Bus baud rate or MAC-ID

Fig. 54: Frontal view of the R1000 with enlarged display detail

LED functions (symbols above the keys)

< ON, if the measured value reaches (or falls short of) the lower limit value.

Norm ON, if the measured value is within the lower and upper limit values.

> ON, if the measured value reaches (or exceeds) the upper limit value.

Enable - blinks, if a fault is present - ON, if the equipment is in measurement mode - OFF, during parameter programming with the keyboard

Key functions (symbols below the keys)

Changes the parameters (forward)

Changes the parameters (backwards)

Enter Selects a parameter for changing and confirming the change

Menu Activates the menu level, for deleting a fault message and exiting the menu level. Pos: 56 /Doppelblech/Geräte/E20 Bus/7 Inbetriebnahme/Konfigurationsmenü @ 0\mod_1173267697421_501.docx @ 3214 @ 2333 @ 1

Manual


with integrated fieldbus interface Start-up B0046191 / Rev. 1.12


7.3 Configuration menu

7.3.1 Main menu structure

Fig. 55: Main structure of configuration menu

7.3.2 Sub structure “Program parameters”

Fig. 56: Sub structure „Program parameters“

ButtonMENU

Config.

Review change(password)

System Parameter 7.7 General system configuration

Program Parameter 7.6 Parameter of the respective measurement programs

Data backup 7.8 Backup of the data stored in the systemvia RS232-Interface

Firmware-Update 7.9 Firmware-Update

up% (100-150%) and absolute

1 / 2 / 3 / 4 / 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4 / 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

Sensor number

low% (0 - 99%) and absolute

P30: Nominal thicknessP36:P42:P42A:P75:P75V:

Zero adjust offon separate (only the sensors selected in the menu)

Sensor 1 on / offSensor 2 on / offSensor 3 on / offSensor 4 on / off

Teach-Inon separate (only the sensors selected in the menu)

Sensor 1 on / offSensor 2 on / offSensor 3 on / offSensor 4 on / off

off

Program Parameter

0,03 - 2,5 mm (.001 - .098 inch)0,03 - 2,5 mm (.001 - .098 inch)0,03 - 4,0 mm (.001 - .16 inch)0,03 - 4,0 mm (.001 - .16 inch)0,03 - 6,0 mm (.001 - .24 inch)0,03 - 6,0 mm (.001 - .24 inch)

on common (only the sensors selected in the menu)

P128: 1 - 12 mm (.040 - .47 inch)

Manual


B0046191 / Rev. 1.12 Start-up


7.3.3 Sub structure “System parameters”

Fig. 57: Sub structure „System parameters“

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System parameters

German / English / Italian / French / SpanishLanguage

mm / inchDisplay in(%mm / %inch) only for Version 1P

Bus address

external single measurementMeasuring modeexternal continuous measurementdemo mode

Hold 2-sheet

yesPasswordno

0 V activeOutput 0-1-2 24 V active

external adjust yesno

1 / 2 / 3 / 4 ( only for Version 4P)Number of sensors

programSensor selection external

normalMeasurementfast

yesCLR Parameterno

(Clear Program Parameter)

mm / inchBus-readout(%mm / %inch) only for Version 1P

not available (reserved)

P30 / P36 / P42 / P42A / P75 / P75V / P128Sensor type

according to Bus type

according to Bus typeBaud rate

according to Bus typeDHCP/IP/SUBNET/GATEWAY



no (fixed)yes (planned)

0+1+2external measuring modeIN0+1IN0

Diagnostic factors FactorThickness range


V: xx HV: xxE20 Fieldbus type

Bus diagnostic IN Process dataOUT Process data

Manual




7.4 General information regarding the configuration

Note The correct configuration depends on the communication with the PLC,

on the measurement task and the connected components.

The following rules apply to the operation in the configuration mode:

• The configuration mode is activated (while in measurement mode) by pressing the MENU key.

• The configuration mode is terminated or cancelled by pressing the MENU key.

• The selected / set parameters can be changed when the items are blinking in the display.

• The selected / set parameters are activated by pressing the ENTER key.

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7.5 Changing, setting-up or checking the configuration

In order to select, set-up or check the system / program parameters, press the MENU key.

The following menu is shown (here: Profibus):

Fig. 58: Indication after calling-up the menu

This menu option permits either reviewing or changing the configuration.

• Configuration review: The system / program parameters cannot be changed. The measurement mode is not interrupted.

• Configuration change: All system / program parameters can be changed after entering the password. The following menu option is shown.

Fig. 59: Password request

Each blinking digit can be changed with the arrow keys and confirmed with ENTER. After having entered the correct password, the following menu appears for the adjustment of the configuration mode.

If the entered password is incorrect then the cursor returns to the first digit of the password and the input must be repeated. The input of the password can be aborted by pressing the MENU button.

Note: A fault is generated if PLC commands are executed while entering the

password or changing parameters.

configuration review Profibus DP ONLINE / Closed 1

password 4711

configuration program parameters

Manual


B0046191 / Rev. 1.12 Start-up


Fig. 60: Selecting the configuration mode

Available configuration modes:

• Configuration system parameter

• Configuration program parameter

• Data backup

• Firmware update

System parameters are general adjustments (e.g. language). Program parameters are application specific adjustments (e.g. input of nominal sheet thickness).

Note After exiting the configuration mode the password remains active for five

minutes. Thus other configuration adjustments can be made, without re-entering the password. If no key is pressed (while in the menu level), then the program changes to the measurement mode

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7.6 Program parameters

The program parameters contain the information required for the various measurement programs. For accessing the program parameters, select the mode “configuration program parameter“ and confirm with ENTER.

Program parameter 1: Selecting the measuring program to be configured.

Fig. 61: Selecting the program to be configured

Here the measuring program (1-255) to be configured is selected. All following adjustments apply to the selected program (here: program no. 1).

Program parameter 2: Selecting the sensor to be used for measurement (only for 4P version).

Fig. 62: Selecting the sensor

Here the sensor (1 - 4) must be selected, which is to be used for measurement (4P version only). For this purpose the item "program" must be selected under “sensor selection“ in the system configuration (system parameter 12). If the sensor selection is made via "program" the sequence measurements are also available. Thus the following combinations are available:

• 1 / 2 / 3 / 4 / 1+2 / 1+3 / 1+4 / 2+3 / 2+4 / 3+4 / 1+2+3 / 1+2+4 / 1+3+4 / 2+3+4 / 1+2+3+4

Note A change of the sensor deletes the values determined during

Teach-In. A new Teach-In is required.

program param. 1 program number: 1

program param. 2 sensor no.: 1

Manual




Program parameter 3: Specifying the nominal thickness of the sheet to be measured.

Fig. 63: Adjusting the nominal thickness

Here the nominal thickness of the sheet to be measured is specified. Normally, the nominal thickness is the sheet thickness used for teach-in.

Note A change of the nominal thickness deletes the values determined

during teach-in. A new teach-In is required.

Program parameter 4: Setting the percentage threshold of the upper limit value.

Fig. 64: Adjusting the upper limit

Value range: between 100% and 150%, with simultaneously displaying the absolute limit value.

The maximal settable absolute limit depends on the sensor:

• P42, P42A: 5 mm (.197 in.)

• P30, P36: 3 mm (.118 in.)

• P75: 6,8 mm (.268 in.)

• P75V: 9,2 mm (.362 in.)

• P128: 14 mm (0.551 in.)

Program parameter 5: Setting the percentage threshold of the lower limit value.

Fig. 65: Adjusting the lower limit

Value range: between 0% and 99%, with simultaneously displaying the absolute limit value.

program param. 3 nom. thick.: 0.90mm

program param. 4 up 150% 1.350 mm

program param. 5 low: 50% 0.450 mm

Manual


B0046191 / Rev. 1.12 Start-up


Program parameter 6: Zero adjust

The Zero adjust procedure must be performed at commissioning and after having exchanged a sensor.

Attention Before performing a Zero adjust procedure, verify in any case that no sheet is in front of the sensor (the sensors).

Fig. 66: Status of Zero adjust

Possible choices (only for 4P versions):

• off: no Zero adjust to be performed.

• on: perform Zero adjust.

• separate: All connected sensors must be zero adjusted individually (each sensor is addressed individually for “on“ or “off“).

• common: All sensors are zero adjusted at the same time.

Note The choices “separate“ and “common“ are available only for 4P versions with more than one sensor connected. The choice “on“ is available only for 4P versions with one sensor connected and for 1P versions.

During the zero adjust the following message is shown:

Fig. 67: Display during zero adjust

Note Fault messages are described in the chapter 9 Fault messages“.

When the zero adjust is completed, the following message appears:

Fig. 68: Zero adjust successfully completed

The zero adjust is now completed.

program param. 6 zero adjust: off

program param. 6 zero adjust: active

program param. 6 zero adjust: off

Manual




Program parameter 7: Teach-in

Fig. 69: Status of Teach-in

Possible choices:

• off: A teach-in has not been executed

• on: A teach-in will now be performed

For performing a teach-in, select “on“ and press the ENTER key (if no teach-in was done or if a teach-in has to be repeated).

Then the operator is requested to attach a sheet with the nominal thickness:

Fig. 70: Request for attaching a sheet

After having attached a sheet press the ENTER key.

Attention A sheet without air gap must be attached to the sensor. The position of the sheet during teach-in must be the same as for normal operation. Otherwise the measurement result could be faulty.

During the teach-in procedure the Teach-in value is displayed:

Fig. 71: Teach-in measurement value

This measured value can be accepted or changed, e.g. to calibrate the control unit.

The Teach-in procedure is now completed.

Attention For a 4P system with sequential measurement the entire teach-in procedure for all sensors is performed in the selected sequence. For sensor selection A/B the teach-in for the selected sensor is then competed. However, if all sensors should be taught, then the teach-in of the other sensors must be repeated separately.

program param. 7 attach sheet !!

program param. 7 TI value: 0.97 mm

program param. 7 teach-in: on

Manual


B0046191 / Rev. 1.12 Start-up


Description of the Teach-in procedure:

Locally at the control unit With PLC (parallel or fieldbus)

With system parameter 3:

mm or inch %mm or inch mm or inch %mm or inch

Step 1: attach sheet to sensor and initiate teach-in

measured value is displayed

measured value is displayed

– – – –

Step 2: Calibration

change displayed value to actual value (e.g. as measured with a micrometer)

Max possible correction see I.

displayed value is transferred as nominal thickness (100%) to the program

Max possible correction see II.

measured thickness is changed to nominal thickness

Max possible correction see III.

measured thickness is transferred as nominal thickness (100%) to the program

Max possible correction see II.

I. Maximum possible correction is twice the displayed value, however, not more than 133% of the nominal thickness and not more than the max. measurable thickness (depends on sensor size), under-gauge correction is max. 75% of the displayed value, however not less than 50% of the nominal dimension

II. Unlimited, displayed value must be larger than 0.05 mm and smaller than the max. measurable thickness (depends on sensor size)

III. +100% / -25% related to the measured thickness. If this correction range is not sufficient, in order to reach the nominal dimension, an error message is generated

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7.7 System parameters

Note The selected system configuration should be documented in the form

“System configuration“ in the chapter “13.2. This information is required in case a system needs to be exchanged.

The general adjustments are specified in the system parameters.

For accessing, select the “system parameter configuration“ mode and confirm with ENTER.

System parameter 1: Setting the dialogue language.

Fig. 72: Selecting the dialogue language

Possible choices:

• English • German • Italian • French • Spanish

System parameter 2: Selecting the dimensions for the display (mm / inch).

Fig. 73: Selecting the dimension for the display

When changing the measurement dimensions, then the sheet metal thicknesses of the stored program parameters are also converted into the new dimension. In addition, %mm and %inch are also available (not for 4P version).

system parameter 1 language: english

system parameter 2 display in: mm

Manual




System parameter 3: Selecting the dimensions for output via fieldbus (mm / inch).

Fig. 74: Selecting the dimensions for the fieldbus output

When changing the measurement dimensions, then the sheet metal thicknesses of the stored program parameters are also converted into the new dimension. As in the previous parameter, %mm and %inch are also available.

System parameter 4: not available (reserve).

Fig. 75: Reserved system parameter

System parameter 5: Setting the bus address.

Abb. 76: Setting the fieldbus address

• Profibus: 1 - 125 • ControlNet: 0 - 99 • DeviceNet: 0 - 63 • CanOpen: 1 - 127 • ProfiNet IO: – – • CC-Link: 1 – 62 • EtherNet/IP – – • EtherCAT – –

Note for Profibus: If this adjustment is to be made in the hardware, then the bus

address can be set with the rotary switches inside the enclosure (1 to 99). If this adjustment is to be made via software, then the rotary switches must be turned to address 0.

This system parameter is only for EtherNET/IP

If DHCP is switched on, the IP-setting will done via DHCP. If DHCP switched off, must the IP-adress, SubNET and Gateway be selected.

Fig. 77: Setting DHCP

Here is the IP-address selected.

Fig. 78: Setting IP-address

system parameter 3 bus readout: mm

system parameter 4 not available

system parameter 5 bus address: 1

system parameter 5 EthernetIP DHCP: no

system parameter 5b IP: 192.168. 0. 10

Manual


B0046191 / Rev. 1.12 Start-up


Here is the SubNet selected.

Fig. 79: Setting SubNet

Here is the Gateway selected.

Fig. 80: Setting Gateway

Fig. 81: Setting bus baud rate

Depending on the fieldbus type, the bus baud rate can be set:

Profibus: up to 12Mbps/s; selection at master

ControlNet: -----

DeviceNet: 125/250/500/kBit

CanOpen: 10/20/50/125/250/500/800/1000 kbps

ProfiNet IO: ----

CC-Link: 125/625kbps 2,5/5/10Mbps

EtherNet/IP: – –

EtherCAT: – –

Interbus: 500 kbits/s

System parameter 6: Deleting all measuring programs.

Fig. 82: Deleting of measuring programs

Possible choices:

• yes • no

Attention The deletion cannot be undone.



system parameter 5c Snet:255.255.255. 0

system parameter 5d GWay: 0. 0. 0. 0

system parameter 5b bus baud rate: 500kb

system parameter 6 CLR param.: no


Manual




System parameter 8: Switching the password function on / off.

Fig. 84: Switching the password on / off

Attention If no password is activated, then all parameters can be accessed at any time. We recommend this only during starting-up the system. For daily operation the password function should be activated.

System parameter 9: Selecting the speed of measurement.

Fig. 85: Selecting the speed of measurement

Possible choices:

• normal: Here the system reaction time depends on the measured sheet thickness. The maximum can be inferred from the diagrams in chapter "2.4 Sensor data.

• fast: Here the system is enabled to detect double sheets before the "normal" end of the measurement. The system reaction time is shorter and depending on the adjusted nominal thickness as well as the upper limit value. Disadvantage: In case of measuring results larger than the double sheet threshold, a double sheet signal is issued but not the actual measurement values.

System parameter 10: Specifying the type of sensor.

Fig. 86: Specifying the type of sensor

Possible choices:

• P30 • P36 • P42 • P42A • P75 • P75V • P128

Attention Changing the current configuration will delete all stored program parameters. Then for all sheet types the nominal thickness values must be re-entered and the Teach-In must be performed again.

system parameter 8 password: yes

system parameter 9 measurement: fast

system parameter 10 sensor type: P42

Manual


B0046191 / Rev. 1.12 Start-up


System parameter 11: Specifying the number of connected sensors (only for 4P unit).

Fig. 87: Specifying the number of sensors

Possible choices:

• 1 sensor • 2 sensors • 3 sensors • 4 sensors

Attention Changing the current configuration will delete all stored program parameters. Then for all sheet types the nominal thickness values must be re-entered and the Teach-In must be performed again.

System parameter 12: Specifying the type of actuating the sensors (only for 4P control unit).

Fig. 88: Sensor selection

Possible choices:

• External: Switching of sensor is accomplished via the external PLC lines „Sensor selection“ A and B. Advantage: faster sensor switching procedure.

• Program: Switching of sensor is accomplished via program selection. A sensor (sensor sequence) is assigned to each program. Advantage: less programming effort.



system parameter 11 number of sensors: 1

system parameter 12 sel. sensor: ext.


Manual




System parameter 14: Adjusting the measuring mode.

Fig. 90: Adjusting the measuring mode

Possible measurement modes:

• External continuous measurement: The system executes measurements, as long as the “Measurement start“ signal is applied via the external PLC input. The repetition rate of the measurement depends on the type of sensor: 0.5 seconds for P42, P30, P42A, P75V; 1 second for P36; 2 seconds for P75; 7 seconds for P128.

• External single measuring: The system measures once if the “Measurement start“ signal is applied via the external PLC input. Each measurement must initiated separately. The hints in chapter 6.3.2. „timing diagram single measurement“ must be abided by.

• Demo mode: This mode of operation is intended for equipment demonstrations, but not for normal process operation. The system executes measurements continuously. The repetition rate of the measurement depends on the type of sensor: 1 second for P42, P30, P42A, P75V; 2 seconds for P36; 4 seconds for P75; 15 seconds for P128.

System parameter 15: Specifying the system reaction when 2-sheet is detected.

Fig. 91: Adjusting the 2-sheet reaction

Possible choice:

• No: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of sheets between the sensors. The equipment does not block operation if double sheet is encountered.

• Yes: (Currently under preparation) The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of sheets between the sensors. If double sheet is detected, the output “2-sheet“ is activated and the equipment is blocked until the 2- sheet condition is cleared.

system parameter 14 mode: ext.continuous

system parameter 15 hold if 2sheets: no

Manual


B0046191 / Rev. 1.12 Start-up


System parameter 16: Programming the “Measurement start“ inputs under external control.

Abb. 92: Adjusting the measurement start inputs

Possible operating conditions:

• IN0: If 24 VDC is applied to IN0, then the measurement is executed. If 0 VDC is applied to this input then the measurement is stopped.

• IN0 + IN1: The measurement is performed only, if 24 VDC is applied simultaneously to IN0 and IN1.

• IN0 + IN1 + IN2: The measurement takes place only, if 24 VDC is applied simultaneously to IN0 and IN1 and IN2.

System parameter 17: Setting the output logic (0-sheet, 1-sheet, 2-sheet outputs).

Fig. 93: Setting the output logic

Possible choices:

• 0 V: As shown in the timing diagrams.

• +24 V: The outputs 0-sheet, 1-sheet and 2-sheet are inverted, i.e. the respective signals in the timing diagrams must be seen inverted.

Note The outputs “Enable“ and “Warning“ are not affected thereby.

System parameter 18: Deactivating / activating the external calibration via fieldbus.

Fig. 94: Deactivating / activating the external calibration

Here the external calibration, which is possible via fieldbus with the signals “teach-in“ and “zero adjust“, can be deactivated / activated.

System parameter 19: Diagnostic factors.

This system parameter is used for the equipment diagnostics and should not be changed by the user.

Fig. 95: Diagnostic factors (fixed)

system parameter 16 ext. meas.start: IN0

system parameter 17 output 0-1-2: 0V

system parameter 18 ext. adjust: no

system parameter 19 diagnostic factors

Manual






System parameter 21: Bus diagnostics and interrogating the fieldbus process data.

Fig. 97: Interrogating the field bus process data

Parameter channel

Input I: 00 00 00 00 00 00 00 00

Byte 0 1 2 3 4 5 6 7

Output 0: 00 00 00 00 00 00 00 00

Byte 0 1 2 3 4 5 6 7

Process channel

Input (Low/High) IL: 00 00 00 00 00 00 00 00

Byte 0 1 2 3 4 5 6 7

Output (Low/High) 0L: 00 00 00 00 00 00 00 00

Byte 0 1 2 3 4 5 6 7

IH: 00 00 00 00 00 00 00 00 Byte 0 1 2 3 4 5 6 7

0H: 00 00 00 00 00 00 00 00 Byte 0 1 2 3 4 5 6 7

Fig. 98: Explanation of the parameter channel and the system channel

O“ stands for the outgoing data to the fieldbus and “I“ for the incoming data of the fieldbus.

The bytes are displayed in hexadecimal format.

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7.8 Data storage via serial RS232-interface

For better prevention from loss of data, a data backup procedure is available for the system configuration and the parameter sets. This is made via the RS232-interface (not in B- versions). The secured data can be transferred to spare units in case of exchange after a failure.

The data backup is accomplished with the RPP software available from ROLAND.

The data backup procedure can be selected in the menu configuration. The following menu is displayed during the data backup.

Fig. 99: Status of data backup

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system parameter 21 IN/OUT Bus proc.data

system parameter 21

I: 0000000000000000

Parameter backup active

Manual


B0046191 / Rev. 1.12 Start-up


7.9 Firmware update

Roland systems are constantly enhanced. In order to use new functions, firmware update is required.

For performing such an update, the Double Sheet Detector must be connected to the RS232-interface of the computer via the supplied cable. In the configuration mode the firmware update must be selected, then the following messages are alternatingly displayed:

Fig. 100: Messages for activating firmware update

The firmware update is activated by simultaneously pressing the keys arrow and ENTER for 5 seconds:

Fig. 101: Start firmware update

The update will then be executed via the “Phytec“ Flash Tool. This tool can be found on the enclosed CD.

Firmware update arrow key UP + ENTER

FIRMWARE UPDATE start pressing key

ROLAND R1000 BUS - FIRMWARE UPDATE - CONNECT RS232 - PRESS ENTER TO EXIT

Manual




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Manual


B0046191 / Rev. 1.12 Operation


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8.1 Abbreviated operating instructions

After applying power to the system, the version number and the bus system message are briefly displayed. Afterwards the system switches into that measurement menu which was active before the unit was switched off.

Note Units with CanOpen bus module require appr. 30 seconds to reach the

operational status after applying power to the system.

Note The system is factory adjusted for “single measurement“. Therefore the system functions only if the signal “measurement start“ is activated via the fieldbus. The modification of the configuration is described in chapter 7 “Start-up”.

1 LED functions 2 Pushbutton functions 3 Program number 4 Selected sensor 5 Type of material 6 Nominal thickness 7 Measurement status 8 Bus address 9 Upper limit value 10 Sensor number with measured value 11 Fieldbus status 12 Bus type 13 Lower limit value 14 Bus baud rate or MAC-ID

Fig. 102: Frontal view of the R1000 with enlarged display detail

LED functions (symbols above the keys)

< ON, if the measured value reaches (or falls short of) the lower limit value.

Norm ON, if the measured value is within the lower and upper limit values.

> ON, if the measured value reaches (or exceeds) the upper limit value.

Enable - blinks, if a fault is present - ON, if the equipment is in measurement mode - OFF, during parameter programming with the keyboard

Key functions (symbols below the keys)

Changes the parameters (forward)

Changes the parameters (backwards)

Enter Selects a parameter for changing and confirming the change

Menu Activates the menu level, for deleting a fault message and exiting the menu level.

Manual


with integrated fieldbus interface Operation B0046191 / Rev. 1.12


In the measuring mode the measured value can be read in the display. The control unit automatically compares the measured value with the adjusted thresholds. The result is transmitted via the interface to the PLC and also to the front panel LED's.

During the normal measurement process no further actions on the control units are necessary with the following few exceptions. The following situations require action directly at the control unit or an action via the field bus interface:

• Clear fault and error messages (see to chapter “9. Error messages, causes and remedies“)

• Teaching of new types of metal and sheet metal thicknesses (see section “7.7 Configuration of the program parameters“)

• Clearing a 2-sheet condition (in preparation)

The following notes for the measuring operations should be observed:

Note If the measured value fluctuates and deviates substantially from nominal

value during normal operation then an air gap between sensor and sheet surface is the most likely cause. A renewed Teach in cannot overcome this problem.

Note Do not adjust the upper limit (“up“) above 120 %.

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8.2 Entering a measurement program

1 Push the MENU key, switch to "change" with the keys and confirm with ENTER key

2 Enter the password

3 Switch to "program parameter" and confirm with ENTER key

4 Select the desired program number at the control unit

5 In of case of a 4P control unit is, select the appropriate sensor

6 Enter the nominal dimension (nominal thickness of the sheet to be processed)

7 Adjust lower limit (“low“) to 80% (default setting)

8 Adjust upper limit (“up“) to 120% (default setting)

9 Return into the measurement mode with the MENU key

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8.3 Zero adjust

1 Push the MENU key, switch to "change" with the key and confirm with the ENTER key




5 Switch to zero adjust (parameter 6)

6 Select "zero adjust" and confirm with ENTER key

7 The message "remove sheet" appears, then confirm with ENTER key

8 After the message "zero adjust active" the message "zero adjust completed" is shown. Then confirm with ENTER key

9 Return into the measurement mode with the MENU key

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Manual


B0046191 / Rev. 1.12 Operation


8.4 Teach-In

1 Push the MENU key, switch to "change" with the key and confirm with the ENTER key




5 Switch to Teach-In (parameter 7)

6 Select "teach-in" and confirm with ENTER key

7 The message "attach sheet" appears, then confirm with ENTER key

8 After "teach-in active" the message "Teach-In value: x.xx" is shown – the value can be corrected with the keys (the adjustment is not possible if "%mm" or "%inch" were selected in the configuration menu option 2)

9 Return to the measurement mode with the MENU key

Attention The actual measured value cannot deviate too far from the nominal dimension, otherwise the fault message "teach-in fault" appears. (this restriction is not valid if in the configuration option 2 "%mm" or "%inch" were selected).

The exact teach-in procedure is described in the chapter “7.6 Program parameter 7: teach-in".

Note High-alloy steels (e.g. TRIP steel) generate a significantly lower measurement signal than normal steel. Deviations of up to 30% are possible. To prevent this, the nominal thickness should be set to a smaller value if necessary. This can be necessary for thin sheets less than 0.5 mm thickness.

Example: Nominal thickness 2.00 mm – manual Teach-In

• The micrometer measures actual value to be: 1.92 mm.

• The teaching shows a value of: 1.89 mm.

• The display value is now corrected to 1.92 mm.


Manual


with integrated fieldbus interface Operation B0046191 / Rev. 1.12


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Manual


B0046191 / Rev. 1.12 Fault messages, causes and remedies


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In case of malfunction a message containing the fault number and the associated error text is displayed

Fig. 103: Example of a fault message

The fault number indicates the fault and the probable cause. The fault description and the suitable measures to remedy the fault condition are found in the following tables. The cause of malfunction must be eliminated before the equipment can continue operation.

The fault can be cleared by pressing the MENU key on the control unit.

Note As long as the cause of the fault is not eliminated, the fault cannot be

cleared.

The fault messages are summarized into the following classes:

• Memory faults

• Teach-In faults

• Transmission faults (RS232)

• Measuring operating faults

• Keyboard faults

• Operating voltage faults

• PLC input faults

• Fieldbus operation faults

• Other faults

Error code: 60 power

Manual


with integrated fieldbus interface Fault messages, causes and remedies B0046191 / Rev. 1.12


9.1 Faults concerning Memory

No. Reason Remedy

2 Error while writing to the EEPROM. No storage in memory possible.

The EEPROM is defective

3 System parameter “Program Number” is out of range > 255.

The storage faults no. 3 to 19 (excluded fault no. 12) can be redressed as follows:

• Select the faulty system parameter in system config.

• Press ENTER key; the corresponding entry then blinks.

• Change the value with the arrow keys.

• Store the value by pressing the ENTER key again.

• Recycle power in order to check the new value.

4 System parameter “Measuring time” is not realistic.

5 System parameter “Dimensions in” is neither mm nor inch.

6 System parameter “Measuring mode” is neither single measurement nor continuous measurement resp. keyboard nor PLC.

7 System parameter “Output Bus” neither mm nor inch.

8 System parameter “Language” is not realistic.

9 System parameter “Number of sensors” is not realistic.

10 System parameter “2-sheet hold” is not realistic.

11 System parameter “Measurement start” is not realistic.

12 see below

13 System parameter “Sensor selection” is not realistic.

16 System parameter “Sensor type” is not defined.

17 System parameter “Output Level 0-1-2” is not realistic.

18 System parameter “External adjustment” is not realistic.

19 System parameter “Bus address” is not realistic.

20 Memory error XX. The program no. XX is not realistic.

The program has been deleted. Create a new program and store it. Recycle power.If error code appears again, change EEPROM.

21 Same as above, but several programs have been deleted. The numbers of the deleted programs cannot be indicated. Check all programs. Recycle power. If error code appears again, change EEPROM.

12 Parameter for zero adjust is not realistic. Repeat zero adjust.

9.2 Faults concerning Zero adjust

No. Cause Remedy

25 The zero adjust value is not realistic Perform new zero adjust. Perhaps there was material in front of the sensor.

9.3 Faults concerning Teach-In

No. Cause Remedy

30 The sheet cannot be taught because there is no sheet in front of the sensor or the sheet thickness is wrong.

Check sheet for correct thickness. Repeat teach-in. If fault appears again, the sensor might be defective.

Manual




9.4 Faults concerning RS232 Transmission

No. Cause Remedy

40 Checksum does not correspond to transmitted information Check program and data transmission connection

41 Dimension is incorrect (mm instead of in. or in. instead of mm) or no numerical character at the position expected (e.g. --.00MM instead of 00.001MM)

Compare transmitted dimension and dimension in the parameter set at E20. Numerical characters in the data format require a number. (e.g. 00.011MM or 01.0000MM)

45 The transmitted value is out of the defined range (e.g. Program no. > 255)

Repeat data transmission with correct values.

47 The serial commands are following too fast. Include a small pause between the individual serial values.

49 The command is not known or not permitted. Check command or reconfigure the control unit.

9.5 Faults concerning Measuring operation

No. Cause Remedy

51 The current between sensor and unit was interrupted during measurement.

S1 = Sensor 1, S2 = Sensor 2 S3 = Sensor 3, S4 = Sensor 4

Check cable and connectors, exchange sensor

52 a) Measuring time is not realistic (too short)

b) Wrong sensor selected

c) The zero adjust was done with sheet

a) Exchange sensor.

b) Set sensor on sheet >2.5 mm and select correct sensor.

c) Perform zero adjust without sheet

53 Internal DC/DC converter is defective. Exchange hardware

54 The current between sensor and unit was interrupted during measurement.

S1 = Sensor 1, S2 = Sensor 2 S3 = Sensor 3, S4 = Sensor 4

Check cable and connectors, exchange sensor

For Demo mode only: If the faults 51 to 54 appear due to wrongly set values for sensor type / number of sensors / sensor sequence, then the correct configuration can only be established by directly entering the configuration menu (by simultaneously pressing all 4 operation keys) and setting the correct values. Only then the fault condition will be redressed.

9.6 Faults concerning Keyboard

No. Cause Remedy

55 The change of system or program parameter is not possible because a serial fieldbus function is active (e.g. Teach-in or Measurement start).

Await completion of fieldbus function or stop it.

56 The change of system or program parameter is not possible because a parallel function is active (e.g. Teach-In or Measurement start).

Await completion of parallel function or stop it.

57 The change of system or program parameter is not possible because a parameter channel is open.

Close parameter channel.

Manual




9.7 Faults concerning Supply voltage

No. Cause Remedy

60 Operating voltage was below 20 VDC. Check power supply.

62 Sensor voltage too low. Check external power supply (insufficient power ?). Contact Roland Electronic Service Department.

9.8 Faults concerning PLC parallel inputs

No. Cause Remedy

71 The parallel function is not possible, because the system was configured for the “demo mode”.

Configure system parameter Measurement operation to “external continuous measurement” or “single measurement”.

72 The parallel function is not possible, because the system is operated via the keyboard.

Finish the operation via keyboard and return the system to neutral operation by pressing the menu key.

73 The parallel function cannot be performed because a fieldbus function is active, e.g. “teach-in” via the fieldbus and “measurement start” via parallel inputs.

Wait for the completion of the fieldbus function or finish it and repeat parallel function.

74 The parallel function is not possible, because a parameter channel is open.

Close parameter channel.

9.9 Faults concerning Fieldbus interface

No. Cause Remedy

80 The inserted fieldbus coupler is defective. Recycle power, if the fault reappears then the equipment has to be returned.

81 The commands come too fast via the parameter channel. Always wait for the results of the parameter channel transmission before transferring new data.

82 The fieldbus function is not possible to perform, because a parallel PLC function is active , for instance, “Measurement start” via the parallel PLC inputs and in addition “Measurement start” via the fieldbus.

Avoid simultaneous operation.

83 The fieldbus function is not possible to perform, because another field bus function is active at the same time, e.g. “Measurement start” and “Program switching”.

Implement only one function.

84 The fieldbus function is not possible, because the measuring mode is set to ”demo mode”.

Configure the parameter “measurement operation” to “external continuous measurement” or “external single measurement”.

85 The fieldbus function is not possible, because the menu (keyboard operation) is operational.

Terminate the operation via the keyboard and return the unit with the menu key to its basic mode.

86 The activated fieldbus function is not possible or disabled in the system.

If the function is required, then it should be selected under systems configuration.

87 The fieldbus function cannot be executed, because the equipment detected double sheet (with configuration ”double sheet hold”).

Clear double sheet condition via fieldbus or via keyboard.

88 The program number activated in the menu program selection is > 255.

Select valid program number.

90 The selected sensor at the inputs sensor selection A and B is not valid. Example: Sensor no. 4 is selected but only two senors are configured.

Select the correct sensor.

91 The field bus function cannot be executed, because the parameter channel is active.

Close Parameter channel.

Manual




9.10 Other faults

No. Cause Remedy

>91 An error has occurred which cannot be unequivocally identified to one of the above error codes.

Contact Roland Electronic Service Department.


Manual




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Manual


B0046191 / Rev. 1.12 Maintenance


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Generally the Double Sheet Detector R1000 E20 requires no special or regular maintenance.

If new types of sheet metal and dimensions are to be processed, then a new teach-in for new programs to be stored is necessary, see also section “7.6 Program parameter 7: Teach-in“.

In the following cases a new teach-in for all programs becomes required:

• If a sensor exchange was not done according to the instructions in the following section “10.1 Sensor exchange“

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10.1 Replacement of sensors

In order to further use the taught programs, the following must be observed:

• Before the sensor is removed, its installation position must be exactly documented. This applies especially to the installation position with regard to the measuring axis.

• The original installation position in all directions has to be restored. This applies especially to the gaps between the sheets.

Note If the original sensor positions cannot be restored, then the teach-in has to be repeated for all programs.

After having exchanged a sensor, the zero adjust must be performed again.

Proceed as follows:

For an E20 or E20-4P control unit with one sensor:

1 Ensure that no sheet is in front of the sensor

2 Press the MENU key, select “change“ and confirm with the ENTER key


4 Change to “program parameter“ and confirm with the ENTER key

5 Ensure that no sheet is in front of the sensor

6 Change to “zero adjust“, select “on“ and confirm with the ENTER key

7 The unit shows “Remove sheet”, perform and confirm with the ENTER key

8 Control unit shows “zero adjust: active“, then “zero adjust: off“

9 Exit the programming with the MENU key

Manual


with integrated fieldbus interface Maintenance B0046191 / Rev. 1.12


For a 4P control unit with 2-4 sensors:

1 Verify that no sheet is in front of the sensor resp. the sensors

2 Press the MENU key, switch to “change“ and confirm with the ENTER key


4 Switch to “program parameter“ and confirm with the ENTER key

5 Verify that no sheet is in front of the sensor resp. the sensors

6 Switch to “zero adjust“ and confirm with the ENTER key

7 Select “zero adjust: separate“ or “zero adjust: common“

7.1 If “zero adjust: separate“, then confirm with the ENTER key

7.1.1 The display shows: “zero adjust S1: on“ or “zero adjust S1: off“

If zero adjust is desired, then select „on“ and confirm with the ENTER key.

if zero adjust is not desired (or sensor is not used in program), then select “off“ and confirm with the ENTER key.

7.1.2 The display shows: “zero adjust S2: on“ or “zero adjust S2: off“

If zero adjust is desired, then select „on“ and confirm with the ENTER key.

if zero adjust is not desired (or sensor is not used in program), then select “off“ and confirm with the ENTER key.

Step 7.1.2 repeats for sensor 3 (S3) and sensor 4 (S4) if they were selected.

7.2 If “zero adjust: common“, then confirm with the ENTER key, all connected sensors will become zero adjusted.

8 The display will show “zero adjust: active“, and then “zero adjust: off“

9 Exit the programming with the MENU key.

10.2 Exchange of control unit

Note When exchanging the control unit, pay attention to the Hardware versions

of the systems!

From Hardware version 5 (from system no. 103227, from 27.02.2006) different measurement times apply. Please see section 3.2 „Sensor data“ and chapter 13 „Sensor data“.

Exchange with RPP software

The E20 permits backup of the equipment parameters with the provided RPP-software via the RS232 interface.

Exchange without RPP software

The original system configuration must be restored after an equipment exchange. In this conjunction the documentation form “11.3 System configuration“ in the chapter “11. Technical data“, should be used during the new start-up. If this form is not available, the information must be retrieved from the equipment documentation.

Manual


B0046191 / Rev. 1.12 Maintenance


10.3 Replacement of fuses

Attention The fuse should be checked only by trained personnel, since it is necessary to open the control unit.

The power supply fuse is 5 x 20 mm, 5 Amp slow blow. A spare fuse is accommodated in the control unit. The position of the spare fuse is shown in the picture below.

Note The picture shows a control unit for front panel mounting. The position of the fuse is identical in the wall mount enclosure.

1 Fuse

2 Spare fuse

Fig. 104: Position of fuses in the R1000

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10.4 Data backup via the fieldbus interface or serial interface

The R1000 offers the possibility of data exchange with a master. The system and program parameter can be stored in the PLC via the fieldbus. In addition, stored or modified data can be written back again into the control unit. The data backup via the RS232 interface is also possible.

10.5 Firmware update via RS232 interface

The enhanced main board now contains a more efficient µC, larger SRAM memory as well as a flash memory. Thus for the first-time a ROLAND firmware update is possible without exchanging EPROMs. The R1000 has therefore now a RS232-interface as a standard.

For the firmware update the Phytec Company Flashtool should to be used, which runs as application under Windows and is part of the scope of supply.

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Manual


with integrated fieldbus interface Maintenance B0046191 / Rev. 1.12


10.6 Short description RPP-XP software

The RPP-XP software serves the purpose of creating a data backup onto an external PC and rewriting it back onto a ROLAND system.

In case of a defective control unit this backup can be transferred to another control unit.

The instructions of the programs can be accessed via the help function after installation (pdf).

Hardware requirements

• C-version of a ROLAND unit series R1000, such as E10, E20, I10, UDK10, UDK20 or Fieldbus units

• PC with Windows® 95 / 98 / 2000 / NT / XP / Vista / 7 installed and a free serial interface or USB, set at COM1 ... COM10

• null modem cable for the serial interface, or USB-serial adapter

• Your installation directory must have write permissions for later users.

• Switch the device to backup mode (For details refer to chapter 7.8).

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10.7 Spare parts

ROLAND ELECTRONIC recommends to inventory the following spare parts (minimum):

• One sensor

• A set of cables

Whether a spare control unit should be kept in inventory has to be decided on individual basis.

Pos: 78 /Kapitelübersicht/11. Technische Unterlagen @ 0\mod_1121422102859_501.docx @ 515 @ 1 @ 1

Manual


B0046191 / Rev. 1.12 Technical records


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11.1 Exchange of equipment

11.1.1 Exchange of a standard R1000 against one with integrated fieldbus equipment

The following information is important for the direct exchange of older R1000 control units respectively their continued use:

Control units Notes Relevant for

All Types

The enclosure dimension is length x width x height (LxWxH) of the fieldbus version is 200x200x70mm.

The older control units have the following dimensions 180x140x70mm or 140x140x70mm (dimensions without plug connectors).

The connectors remain at the bottom of the enclosure.

Below the enclosure should be sufficient space (approximately 120 mm) because all Fieldbus versions are equipped with connectors.

Mechanical design (MD)

All Types The fieldbus control units are all fully downward compatible except for the following points.

Electrical design (ED)

All Types The Profibus connection uses M12 circular connectors (Reverse Coding), due to of IP65 requirements.

ED

All Types

The data backup via the serial interface is not available for the fieldbus B-version.

The data backup via the parameter channel of the fieldbus interface is possible with all versions.

ED

UDK10

The heavy multipin industrial plug connector for the connection of the PLC interface and the supply voltage has been replaced by the smaller Harting HAN 3 plug.

All other plug connectors remain the same.

ED

I10

All PG gland connectors have been replaced by plug connectors.

For the connection of the sensor cables to the Control Unit M18 circular connector are being used, the same as for the connection of the sensor. Thus new sensor cables are necessary for the connection of the sensor. These new sensor cables are necessary for the connection to the Control Unit.

For the voltage supply the Harting 3 plug has been selected.

The connection of the Sensor Switch Box with PG gland connections has been replaced by a flange receptacle connector. The corresponding sensor cable has connectors on both ends.

ED

I10 with Sensor Switch Box

The cables for the connection of the sensors to the Sensor Switch Box remain the same.

ED

I10 with MS sensors

For the connection of the MS42GS, MS42AGS and/or MS54S to the appropriate Sensor Connection Box there is no change in the type of cable (i.e. on the sensor side the circular connector M18 and on the SCB side terminal connection).

ED

E10 and E10-4P E20 and E20-4P

All PG gland connections are replaced by plug connectors.

For the sensor connections common shielded M12 circular connector are used.

For voltage supply the Harting HAN 3 connector has been selected.

ED

Manual


with integrated fieldbus interface Technical records B0046191 / Rev. 1.12


11.1.2 Exchange of a E10 fieldbus control unit against a E20 fieldbus system

A R1000 E10 fieldbus control unit can be completely replaced by a R1000 E20 fieldbus system. The following must thereby be considered.

1. Enclosure The enclosure with the connections and mounting fixtures is fully compatible.

2. Power consumption The power consumption of the E20 fieldbus can go up to 100W. The E10 has only the power consumption of 10W. Therefore, the cross-section of the power supply cable should be selected accordingly.

3. Fieldbus interface The process channel has been extended from 4 bytes to 16 bytes (i.e. altogether 24 bytes for the E20 fieldbus as compared to 12 bytes the E10 fieldbus control unit). The control via the fieldbus interface is compatible, however extended accordingly. The equipment supplies now also the individual results of measurement with the additional bytes and offers additional operational features.

4. External I/O control The external I/O control of the E20 fieldbus control unit corresponds to that of the E10 fieldbus system.

5. Measurement functions The E20 fieldbus has a shorter measuring time. With that new so-called sequencer mode several sensors can be more efficiently interrogated.

6. Sensors All presently available sensors can be connected to the E20 fieldbus equipment. However, using the new sensor P4AGS (not for E10) is recommended instead of the P42GS.

7. Sensor cable The sensor cables are fully compatible.

8. Modes of operation The dimensions %mm and %inch are not available for E20-4P control unit (if used with separated sensors).

9. Sensor selection When “sensor selection A/B” is set, the selection will be taken over only when a new signal “measurement start” is applied. In the demo mode the selection will not be performed.

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11.2 Fieldbus configuration files

The configuration files for the respective fieldbus systems can be found on the enclosed CD.

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Manual




11.3 Parameter channel commands

Read internal program parameters Version 1.2 27.02.03

Management Program index Parameter

index Application

data 0 Application

data 1 Application

data 2 Application

data 3 Checksum Value range Note

Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 E20 E20

Open param. channel 0H110100 00000000 00000000 00000000 00000000 00000000 00000000 checksum

Close param. channel 0H111000 00000000 00000000 00000000 00000000 00000000 00000000 checksum

Empty service 0H110000 00000000 00000000 00000000 00000000 00000000 00000000 checksum

Reset param. channel 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000

Read sensor no. 0H110001

Program number binary coded

00000001 00000000 00000000 00000000 00000000 checksum

Read nominal dimension in µm

0H110001 00000010 00000000 00000000 00000000 00000000 checksum

Read nominal dimension in 1/10000 inch

0H110001 00000011 00000000 00000000 00000000 00000000 checksum

Read TU% in 1/10%

0H110001 00000100 00000000 00000000 00000000 00000000 checksum

Read TO% in 1/10%

0H110001 00000101 00000000 00000000 00000000 00000000 checksum

Read internal progr. param. 1

0H110001

example:

00000000 = 1 11111110 = 255

11111111 is reserved

for system parameter

data

00000110 00000000 00000000 00000000 00000000 checksum


0H110001 00000111 00000000 00000000 00000000 00000000 checksum


0H110001 00001000 00000000 00000000 00000000 00000000 checksum


0H110001 00001001 00000000 00000000 00000000 00000000 checksum


0H110001 00001010 00000000 00000000 00000000 00000000 checksum


0H110001 00001011 00000000 00000000 00000000 00000000 checksum


0H110001 00001100 00000000 00000000 00000000 00000000 checksum


0H110001 00001101 00000000 00000000 00000000 00000000 checksum


0H110001 00001110 00000000 00000000 00000000 00000000 checksum


0H110001 00001111 00000000 00000000 00000000 00000000 checksum


0H110001 00010000 00000000 00000000 00000000 00000000 checksum


0H110001 00010001 00000000 00000000 00000000 00000000 checksum


0H110001 00010010 00000000 00000000 00000000 00000000 checksum

Manual




Answer internal program parameters Version 1.2 27.02.03


index Utilizable byte

0 Utilizable byte

1 Utilizable byte 2

Utilizable byte 3

checksum Value range Note


Answer sensor no.

0H110001

Program number binary coded

00000001 00000000 00000000 00000000 value 8 bit checksum 1 - 15 yes with 4P

Answer nominal dimension in µm

0H110001 00000010 00000000 00000000 value high byte low byte 16 bit checksum 30 - 1500 /

8000 depending on sensor

Answer nominal dimension in 1/10000 inch

0H110001 00000011 00000000 00000000 value high byte low byte 16 bit checksum 10 - 590 /

3150 depending on sensor

Answer TU% in 1/10 %

0H110001 00000100 00000000 00000000 value high byte low byte 16 bit checksum 0 - 1000

Answer TO% in 1/10 %

0H110001 00000101 00000000 00000000 value high byte low byte 16 bit checksum 1000 - 1500

Answer internal progr. param. 1

0H110001

example:

00000000 = 1 11111110=255

11111111 is reserved

for system parameter

data

00000110 internal value internal value internal value internal value checksum float

0.75 - 2.0 teach multi S1


0H110001 00000111 internal value internal value internal value internal value checksum float









0H110001 00001010 internal value internal value internal value internal value checksum 0

















Manual




Write internal program parameters Version 1.2 27.02.03


index Utilizable

byte 0 Utilizable

byte 1 Utilizable

byte 2 Utilizable

byte 3 checksum

Value range

Note


Write sensor no. 0H110010 Program 00000001 00000000 00000000 00000000 value 8 Bit checksum 1 - 15 yes with 4P

Write nominal dimension in µm 0H110010 number 00000010 00000000 00000000 value high

byte low byte 16

bit checksum

30 - 1500 / 8000

depending on sensor

Write nominal dimension in 1/10000 inch

0H110010 binary 00000011 00000000 00000000 value high

byte low byte 16

bit checksum

10 - 590 / 3150

depending on sensor

Write TU% in 1/10 % 0H110010 coded 00000100 00000000 00000000 value high

byte low byte 16

bit checksum 0 - 1000

Write TO% in 1/10 % 0H110010 00000101 00000000 00000000 value high

byte low byte 16

bit checksum

1000 - 1500

(<max. sensor thickness)

Write internal progr. param. 1 0H110010 example: 00000110 internal value

internal value

internal value

internal value

checksum float


Write internal progr. param. 2 0H110010 00000000 = 1 00000111 internal value

internal value

internal value

internal value

checksum float


Write internal progr. param. 3 0H110010 11111110=255 00001000 internal value

internal value

internal value

internal value

checksum float


Write internal progr. param. 4 0H110010 00001001 internal value

internal value

internal value

internal value

checksum float


Write internal progr. param. 5 0H110010 11111111 is 00001010 internal value

internal value

internal value

internal value

checksum 0

Write internal progr. param. 6 0H110010 reserved 00001011 internal value

internal value

internal value

internal value

checksum 0

Write internal progr. param. 7 0H110010 for system 00001100 internal value

internal value

internal value

internal value

checksum 0

Write internal progr. param. 8 0H110010 parameter 00001101 internal value

internal value

internal value

internal value

checksum 0

Write internal progr. param. 9 0H110010 data 00001110 internal value

internal value

internal value

internal value

checksum 0


internal value

internal value

internal value

checksum 0


internal value

internal value

internal value

checksum 0


internal value

internal value

internal value

checksum 0


internal value

internal value

internal value

checksum 0

Manual




Read system parameters Version 1.2 27.02.03

Management

Program index

Parameter index

Utilizable byte 0

Utilizable byte 1

Utilizable byte 2 Utilizable byte 3 Checksum Value range Note


Read sys. param. 1

0H110001 11111111 00000001 00000000 00000000 00000000 00000000 checksum

Read sys. param. 2

0H110001 11111111 00000010 00000000 00000000 00000000 00000000 checksum

Read sys. param. 3

0H110001 11111111 00000011 00000000 00000000 00000000 00000000 checksum

Read sys. param. 4

0H110001 11111111 00000100 00000000 00000000 00000000 00000000 checksum

Read sys. param. 5

0H110001 11111111 00000101 00000000 00000000 00000000 00000000 checksum

Read sys. param. 6

0H110001 11111111 00000110 00000000 00000000 00000000 00000000 checksum

Read sys. param. 7

0H110001 11111111 00000111 00000000 00000000 00000000 00000000 checksum

Read sys. param. 8

0H110001 11111111 00001000 00000000 00000000 00000000 00000000 checksum

Read sys. param. 9

0H110001 11111111 00001001 00000000 00000000 00000000 00000000 checksum

Read sys. param. 10

0H110001 11111111 00001010 00000000 00000000 00000000 00000000 checksum

Read sys. param. 11

0H110001 11111111 00001011 00000000 00000000 00000000 00000000 checksum

Read sys. param. 12

0H110001 11111111 00001100 00000000 00000000 00000000 00000000 checksum

Read sys. param. 13

0H110001 11111111 00001101 00000000 00000000 00000000 00000000 checksum

Read sys. param. 14

0H110001 11111111 00001110 00000000 00000000 00000000 00000000 checksum

Read sys. param. 15

0H110001 11111111 00001111 00000000 00000000 00000000 00000000 checksum

Read sys. param. 16

0H110001 11111111 00010000 00000000 00000000 00000000 00000000 checksum

Read sys. param. 17

0H110001 11111111 00010001 00000000 00000000 00000000 00000000 checksum

Read sys. param. 18

0H110001 11111111 00010010 00000000 00000000 00000000 00000000 checksum

Read sys. param. 19

0H110001 11111111 00010011 00000000 00000000 00000000 00000000 checksum

Read sys. param. 20

0H110001 11111111 00010100 00000000 00000000 00000000 00000000 checksum

Read sys. param. 21

0H110001 11111111 00010101 00000000 00000000 00000000 00000000 checksum

Read sys. param. 22

0H110001 11111111 00010110 00000000 00000000 00000000 00000000 checksum

Read sys. param. 23

0H110001 11111111 00010111 00000000 00000000 00000000 00000000 checksum

Read sys. param. 24

0H110001 11111111 00011000 00000000 00000000 00000000 00000000 checksum

Manual




Answer system parameters Version 1.2 27.02.03 Management Program index

Parameter index

Utilizable byte 0 Utilizable byte 1

Utilizable byte 2 Utilizable byte 3 Checksum Value range Note


Answer sys. param. 1 0H110001 11111111 00000001 00000000 00000000 00000000 value 8 bit checksum 0 - 4 Language

Answer sys. param. 2 0H110001 11111111 00000010 00000000 00000000 00000000 value 8 bit checksum 0 - 3 Dimension

Answer sys. param. 3 0H110001 11111111 00000011 00000000 00000000 00000000 value 8 bit checksum 0 - 3 Output bus

Answer sys. param. 4 0H110001 11111111 00000100 00000000 00000000 00000000 value 8 bit checksum 0 (Display time)

Answer sys. param. 5 0H110001 11111111 00000101 00000000 00000000

value high byte low byte 16 bit checksum

depending on fieldbus Bus address

Answer sys. param. 6 0H110001 11111111 00000110 00000000 00000000 00000000 value 8 bit checksum 0 Bus baudrate

Answer sys. param. 7 0H110001 11111111 00000111 00000000 00000000 00000000 value 8 bit checksum 0, 1 Password

Answer sys. param. 8 0H110001 11111111 00001000 00000000 00000000 00000000 value 8 bit checksum 1 - 6 Sensor type

Answer sys. param. 9 0H110001 11111111 00001001 00000000 00000000 00000000 value 8 bit checksum 1 - 4 No. of sensors

Answer sys. param. 10 0H110001 11111111 00001010 00000000 00000000 00000000 value 8 bit checksum 0, 1 Sensor selection

Answer sys. param. 11 0H110001 11111111 00001011 00000000 00000000 00000000 value 8 bit checksum 0

(magnetic conveyor)

Answer sys. param. 12 0H110001 11111111 00001100 00000000 00000000 00000000 value 8 bit checksum 0 - 2 Meas. Mode

Answer sys. param. 13 0H110001 11111111 00001101 00000000 00000000 00000000 value 8 bit checksum 0 (Hold 2-sheet)

Answer sys. param. 14 0H110001 11111111 00001110 00000000 00000000 00000000 value 8 bit checksum 1, 2, 3 1-2-3 Meas. start

Answer sys. param. 15 0H110001 11111111 00001111 00000000 00000000 00000000 value 8 bit checksum 0, 1 Level 0-1-2

Answer sys. param. 16 0H110001 11111111 00010000 00000000 00000000 00000000 value 8 bit checksum 0, 1 Ext. Adjustment


value high byte low byte 16 bit checksum 0 (reserve)









Answer sys. param. 22 0H110001 11111111 00010110 1 sign 1 sign 1 sign 1 sign checksum clear text System series

Answer sys. param. 23 0H110001 11111111 00010111 1 sign 1 sign 1 sign 1 sign checksum clear text System type


value high byte low byte 16 bit checksum 1 -... Software version

Manual




Write system parameters Version 1.2 27.02.03

Management Program

index Parameter

index Utilizable

byte 0 Utilizable

byte 1 Utilizable

byte 2 Utilizable

byte 3 Checksum Value range Note


Write sys. param. 1

0H110010 11111111 00000001 00000000 00000000 00000000 value 8 Bit checksum 0 - 4 Language

Write sys. param. 2

0H110010 11111111 00000010 00000000 00000000 00000000 value 8 Bit checksum 0 - 3 Dimension

Write sys. param. 3

0H110010 11111111 00000011 00000000 00000000 00000000 value 8 Bit checksum 0 - 3 Output bus

Write sys. param. 4

0H110010 11111111 00000100 00000000 00000000 00000000 value 8 Bit checksum 0 (Display time)

Write sys. param. 5

0H110010 11111111 00000101 00000000 00000000 value high

byte value low

byte checksum

depending on fieldbus

Bus address

Write sys. param. 6

0H110010 11111111 00000110 00000000 00000000 00000000 value 8 Bit checksum 0 Bus Baudrate

Write sys. param. 7

0H110010 11111111 00000111 00000000 00000000 00000000 value 8 Bit checksum 0, 1 Password

Write sys. param. 8

0H110010 11111111 00001000 00000000 00000000 00000000 value 8 Bit checksum 1 - 6 Sensor type

Write sys. param. 9

0H110010 11111111 00001001 00000000 00000000 00000000 value 8 Bit checksum 1 - 4 No. of sensors

Write sys. param. 10

0H110010 11111111 00001010 00000000 00000000 00000000 value 8 Bit checksum 0, 1 Sensor selection


0H110010 11111111 00001011 00000000 00000000 00000000 value 8 Bit checksum 0 (Magnetic conveyor)


0H110010 11111111 00001100 00000000 00000000 00000000 value 8 Bit checksum 0 - 2 Meas. Mode


0H110010 11111111 00001101 00000000 00000000 00000000 value 8 Bit checksum 0 (Hold 2-sheet)


0H110010 11111111 00001110 00000000 00000000 00000000 value 8 Bit checksum 1, 2, 3 1-2-3 Meas. start


0H110010 11111111 00001111 00000000 00000000 00000000 value 8 Bit checksum 0, 1 Level 0-1-2


0H110010 11111111 00010000 00000000 00000000 00000000 value 8 Bit checksum 0, 1 Ext. Adjustment


0H110010 11111111 00010001 00000000 00000000 value high

byte value low

byte checksum 0 (reserve)


0H110010 11111111 00010010 00000000 00000000 value high

byte value low



0H110010 11111111 00010011 00000000 00000000 value high

byte value low



0H110010 11111111 00010100 00000000 00000000 value high

byte value low



0H110010 11111111 00010101 00000000 00000000 value high

byte value low



0H110010 11111111 00010110 00000000 00000000 00000000 00000000 checksum clear text System series


0H110010 11111111 00010111 00000000 00000000 00000000 00000000 checksum clear text System type


0H110010 11111111 00011000 00000000 00000000 00000000 00000000 checksum 1 -... Software version

*for DeviceNet: 00000000 Bus address: 0 -63

Bus baud rate: 00 = 125 kB 01 = 250 kB 10 = 500 kB 11 = not used


Pos: 83 /Kapitelübersicht/12. Bestelldaten @ 0\mod_1121422152468_501.docx @ 516 @ 1 @ 1

Manual


B0046191 / Rev. 1.12 Order data


12 Order data Pos: 84 /Doppelblech/Geräte/E20 Bus/12 Bestelldaten/Gerätevarianten @ 0\mod_1173364635750_501.docx @ 3304 @ 22 @ 1

12.1 Versions of control unit E20

Fieldbus note The control sided plugs are within the scope of delivery.

Profibus-DP

E20-PR-S Connection of 1 sensor in wall-mount enclosure, data backup via Profibus-DP or serial interface E20-4P-PR-S Connection of max. 4 equal sensors

E20-PR-S-FP Connection of 1 sensor in front panel enclosure, data backup via Profibus-DP or serial interface E20-4P-PR-S-FP Connection of max. 4 equal sensors

ControlNet

E20-CN-S Connection of 1 sensor in wall-mount enclosure, data backup via ControlNet or serial interface E20-4P-CN-S Connection of max. 4 equal sensors

E20-CN-S-FP Connection of 1 sensor in front panel enclosure, data backup via ControlNet or serial interface E20-4P-CN-S-FP Connection of max. 4 equal sensors

DeviceNet (B-coded)

E20-DN-S Connection of 1 sensor in wall-mount enclosure, data backup via DeviceNet or serial interface E20-4P-DN-S Connection of max. 4 equal sensors

E20-DN-S-FP Connection of 1 sensor in front panel enclosure, data backup via DeviceNet or serial interface E20-4P-DN-S-FP Connection of max. 4 equal sensors

DeviceNet (A-coded)

E20-DNT-S Connection of 1 sensor in wall-mount enclosure, data backup via DeviceNet or serial interface E20-4P-DNT-S Connection of max. 4 equal sensors

E20-DNT-S-FP Connection of 1 sensor in front panel enclosure, data backup via DeviceNet or serial interface E20-4P-DNT-S-FP Connection of max. 4 equal sensors

Interbus-S

E20-IN-S Connection of 1 sensor in wall-mount enclosure, data backup via Interbus-S or serial interface E20-4P-IN-S Connection of max. 4 equal sensors

E20-IN-S-FP Connection of 1 sensor in front panel enclosure, data backup via Interbus-S or serial interface E20-4P-IN-S-FP Connection of max. 4 equal sensors

CanOpen

E20-CP-S Connection of 1 sensor in wall-mount enclosure, data backup via CanOpen or serial interface E20-4P-CP-S Connection of max. 4 equal sensors

E20-CP-S-FP Connection of 1 sensor in front panel enclosure, data backup via CanOpen or serial interface E20-4P-CP-S-FP Connection of max. 4 equal sensors

ProfiNet IO

E20-PN-S Connection of 1 sensor in wall-mount enclosure, data backup via ProfiNet or serial interface E20-4P-PN-S Connection of max. 4 equal sensors

E20-PN-S-FP Connection of 1 sensor in front panel enclosure, data backup via ProfiNet or serial interface E20-4P-PN-S-FP Connection of max. 4 equal sensors

Manual


with integrated fieldbus interface Order data B0046191 / Rev. 1.12


CC-Link

E20-CC-S Connection of 1 sensor in wall-mount enclosure, data backup via CC-Link or serial interface E20-4P-CC-S Connection of max. 4 equal sensors

E20-CC-S-FP Connection of 1 sensor in front panel enclosure, data backup via CC-Link or serial interface E20-4P-CC-S-FP Connection of max. 4 equal sensors

EtherNet/IP

E20-EN-S Connection of 1 sensor in wall-mount enclosure, data backup via EtherNet/IP or serial interface E20-4P-EN-S Connection of max. 4 equal sensors

E20-EN-S-FP Connection of 1 sensor in front panel enclosure, data backup via EtherNet/IP or serial interface E20-4P-EN-S-FP Connection of max. 4 equal sensors

EtherCAT

E20-ET-S Connection of 1 sensor in wall-mount enclosure, data backup via EtherCAT or serial interface E20-4P-ET-S Connection of max. 4 equal sensors

E20-ET-S-FP Connection of 1 sensor in front panel enclosure, data backup via EtherCAT or serial interface E20-4P-ET-S-FP Connection of max. 4 equal sensors

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Manual


B0046191 / Rev. 1.12 Order data


12.2 Sensors and accessories

Order information Description

P30GS Sensor 30 mm Ø, without cable, with M12 sensor plug for sensor cable connection, sensor with threaded body M30 x 1.5 mm, 2 flat nuts

P42AGS Sensor 42 mm Ø, without cable, but with sensor plug for sensor cable connection, sensor with threaded body M42 x 1.5 mm, 2 flat nuts

P75VGS Sensor 75 mm Ø, without cable, but with sensor plug for sensor cable connection, sensor with threaded body M75 x 1.5 mm, 2 flat nuts

P128GPPS Sensor 128 mm Ø, without cable, but with sensor plug for sensor cable connection, sensor with threaded body M128 x 1.5 mm, 2 flat nuts

SH42GS Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm

SH75GS Spring loaded sensor bracket, for direct installation of sensors with threaded body M75 x 1.5 mm

SHS42G-FB Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm with bellow-shaped vacuum cup, without clamping bracket, suction cup diameter 100 mm

SHS42G-FB80 Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm with bellow-shaped vacuum cup, without clamping bracket, suction cup diameter 80 mm

SHS42GS Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm, with vacuum cup, without clamping bracket, suction cup diameter 110 mm

SHS42GS85 Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm, with vacuum cup, without clamping bracket, suction cup diameter 85 mm

SHS75GS Spring loaded sensor bracket, for direct installation of sensors with threaded body M75 x 1.5 mm, with vacuum cup, without clamping bracket, suction cup diameter 110 mm

SHX42 Spring loaded sensor bracket, for direct installation of sensors with threaded body M42 x 1.5 mm, with vacuum cup, suction cup diameter 110 mm SHX42-DL

SHX42-STRAP-80 Set of belt strap for SHX42, for spring travel 70 mm

SP42GS Suction cup, for direct installation of sensors with threaded body M42 x 1.5 mm.

SP75GS Suction cup, for direct installation of sensors with threaded body M75 x 1.5 mm

SHK Clamping bracket, for SHS42GS, SH42GS, SHS75GS, SH75GS, for mounting the sensor brackets to the customer specific destacking systems

SK90/42 Vacuum cup, with ball joint; P.N. S0002373

SK90/42-1 Ball joint, with mounting plates - for SK90/42 and SHF90/42 P.N. S0002531

SK90/42-2 Suction cup, with connecting part - for SK90/42 and SHF90/42 P.N. S0002532

2395037 Spare rubber lips, for sensor bracket SHF90/42 or SK90/42

2395038 Gasket, made of rubber, for suction cup SP75GS and for sensor bracket SHS75GS

2395039 Spare rubber pad, for suction cup SP75GS and for sensor bracket SHS75GS

2395045 Spare rubber pad, red, for sensor bracket SHS42G-FB

2395046 Spare rubber pad, black, for sensor bracket SHS42G-FB

2395109 Spare rubber pad, for suction cup SP42GS and for sensor bracket SHS42GS

2395110 Spare rubber lips, for sensor bracket SHS42 or suction cup SP42

2395168 Spare rubber lips, for sensor bracket SHS42GS-85

2395218 Bellows suction cup for sensor bracket SHX42-DL

Manual


with integrated fieldbus interface Order data B0046191 / Rev. 1.12


12.3 Cables

The standard cable length is 5 meters. Customized lengths up to 50 meters can be ordered; larger lengths upon request.

Order information Specification Description

SM12CPM12S-GG OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P30GS or P42AGS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and straight receptacle for connection of the sensor. This cable is suitable for cable additions for the other three cable types (in-line connections).

SM12CPM12S-GW OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P30GS or P42AGS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and right angle receptacle for connection of the sensor.

SM12CPS-GG OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P75VGS / P75GS / P36GS / P42GS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and straight receptacle for connection of the sensor.

SM12CPS-GW OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P75VGS / P75GS / P36GS / P42GS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and right angle receptacle for connection of the sensor.

SM12CPPPS-GG OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P128GPPS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and straight receptacle for connection of the sensor.

SM12CPPPS-GW OILFLEX FD 810 CY 2 x 1 mm² Cable for connection of sensor P128GPPS to E20 fieldbus, both cable ends with quick disconnect plug, straight cable plug for connection of the control unit and right angle receptacle for connection of the sensor.

12.4 Cable plugs and cable sockets


2276036 Cable receptacle, 4 pin, Push-Pull, ODU series K, for P128GPPS

2276042 Right angle cable receptacle, 4 pin, Push-Pull, ODU series K, for P128GPPS

2276116 Cable receptacle, 5 pin, M12, Binder series 713, for P30GS and P42AGS

2276117 Right angle cable receptacle, 5 pin, M12, Binder series 713, for P30GS and P42AGS

2276539 Cable receptacle for the incoming bus, 5 pin, M12, Binder series 715

2276637 Cable receptacle, 7 pin, Touchel-Amphenol C164-637M-7S for P75VGS

2277017 Cable plug for ProfiNet IO, EtherNet/IP and EtherCAT, M12, 4-pin, D-coded, M12

2277639 Right angle cable receptacle, 7 pin, Touchel-Amphenol C164-639F-7S, for P75VGS

2277703 Cable plug for RS232 connection, 3 pin, M8, Binder series 768

2277704 Cable plug (to control unit), 5 pin, M12, Binder series 713

2277705 Cable plug (to control unit) for outputs, 8 pin, M12, Binder series 713

2277708 Cable plug for the outgoing bus , 5 pin, M12, Binder series 715

S0002750 Cable receptacle (complete) for power supply and inputs,8 pin, HAN8U

12.5 Other accessories


RPP Software for data backup

SM8KRS232D9S Cable for RS232 connection to the PC, 3 m length Pos: 86 /Kapitelübersicht/13. Anhang @ 1\mod_1216365152421_501.docx @ 6533 @ 1 @ 1

Manual


B0046191 / Rev. 1.12 Appendix


13 Appendix Pos: 87 /Doppelblech/Geräte/E20 Bus/13 Anhang/Sensordaten HW 1…4 @ 1\mod_1216365850125_501.docx @ 6551 @ 2 @ 1

13.1 Sensor data (Measuring time) of older hardware versions 1…4

With introducing the Hardware version 5 (from system no. 103227, from date 27.02.2006) the measurement times have been remarkably reduced. The current sensor diagrams are shown under section 2.4 “Sensor data”.

Anyhow, having the “old” sensor diagrams available could be useful (e.g. for exchanging control units with “old” / “new” Hardware version).

For this reason the “old” sensor diagrams are shown here.

Measuring time P30GS (of old Device-Hardware-Versions 1 – 4)

Fig. 105: System reaction time P30GS

0 0,5 1,0 1,5 2,0 2,5


Single sheet thickness(Nominal thickness) [mm]

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

4 sensors

3 sensors

2 sensors

1 sensor

150%

120%

P30GS

Sys

tem

re

actio

n tim

e [m

s]

Manual


with integrated fieldbus interface Appendix B0046191 / Rev. 1.12


Measuring time P42AGS (of old Device-Hardware-Versions 1 – 4)

Fig. 106: System reaction time P42AGS

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

310

320

330

340

350

360

370

380

390

4,0 Single sheet thickness(Nominal thickness) [mm]


3,53,02,52,01,51,00,50

150%

120%

P42AGS

4 sensors

3 sensors

2 sensors

1 sensor

Sys

tem

rea

ctio

n ti

me

[ms]

Manual




Measuring time P75VGS (of old Device-Hardware-Versions 1 – 4)

Fig. 107: System reaction time P75VGS

100

150

200

250

300

350

400

450

500

550

600

650

700

750

800

850

900

950

1000

1050

1100

1150

1200

1250

1300

1350

1400

1450

15001550

16001650

1700

0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0

150%

120%

P75VGS

4 sensors

3 sensors

2 sensors

1 sensor

with restriction

Sys

tem

rea

ctio

n tim

e [m

s]


Single sheet thickness(Nominal thickness) [mm]

Manual




Blank page

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Manual




13.2 System configuration form

Language: ( ) D ( ) E ( ) I ( ) S ( ) F

Dimensions: ( ) mm ( ) inch not with 4P: ( ) %mm ( ) %inch

Output Bus: ( ) mm ( ) inch not with 4P: ( ) %mm ( ) %inch

Bus address: ( ) 1 ( ) other ( ) Hardware

Bus baud rate: ( ) ______________

MAC ID : ( ) ______________

DHCP: _____________ IP: ______________ SubNet: _____________ Gateway: _____________

Password: ( ) yes ( ) no

Measurement: ( ) fast ( ) normal

Sensor type: ( ) P30 ( ) P42 ( ) P75V ( ) P128

Number of sensors: 4P only: ( ) 1 ( ) 2 ( ) 3 ( ) 4

Sensor selection: not with 4P ( ) program - fixed

4P only: ( ) program ( ) external

Meas. mode: ( ) ext. continuous meas. ( ) ext. single meas. ( ) demo mode

Hold 2-sheet: ( ) no

Meas. start: ( ) IN0 ( ) IN0+IN1 ( ) IN0+IN1+IN2

Level: ( ) 0 VDC ( ) +24 VDC

External adjust: ( ) yes ( ) no

Unit version: ( ) __________________

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Manual




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double sheet detector r1000-series e20 with integrated fieldbus interface · 2019-05-10 · manual...

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