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Proton InteliSENS DG1030 Instruction Manual

Single axis laser scanning diameter gauge
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Instruction Manual
InteliSENS DG1030 Single Axis Laser Scanning
Diameter Gauge
Issue 1a
31 July 2019
Proton Products Co. Ltd.
10 Aylesbury End
Beaconsfield
Buckinghamshire HP9 1LW
England
www.protonproducts.com
Page 1 of 66
Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

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  • Page 1 InteliSENS DG1030 Single Axis Laser Scanning Diameter Gauge Issue 1a 31 July 2019 Proton Products Co. Ltd. 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Page 1 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 2: Table Of Contents

    ACCESS LEVELS ..........................35 ..........36 TANDARD OMMUNICATIONS NTERFACES CAN- ....................... 36 BUS COMMUNICATIONS CAN-bus interface ............................36 CAN-bus LED indicator ..........................36 RS-232 C ......................... 37 OMMUNICATIONS Page 2 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 3 Reading a block of output parameters ......................55 Reading a continuous stream of a single output parameter ............... 55 Reading a continuous stream of a block of output parameters ..............56 Page 3 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 4 ONTACT DETAILS FOR ENQUIRIES SALES AND SERVICE ............................66 EB SITE ......................... 66 NQUIRIES AND SALES ..........................66 ERVICE ENQUIRIES ............66 ANUAL FEEDBACK AND COPYRIGHT Page 4 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 5: Declaration Of Conformity (Ce)

    (CE) ECLARATION OF ONFORMITY Proton Products International Limited declares that the equipment listed below fulfils the requirements of directive EMC: 2014/30/EU and Low Voltage: 2014/35/EU. The following standards were applied: Radio -⁠ ETSI EN 300 328 V2.1.1 (2016-⁠ 1 1)

  • Page 6: Introduction

    When fitted with the optional CDI4 interface display unit, the InteliSENS DG1030 diameter gauge can operate as a standalone unit. RS-232, RS-422, RS-485 and Ethernet communication interfaces are installed as standard for straightforward connection to computers or PLCs.

  • Page 7: Specifications

    RS-232*, RS-422, RS-485, CAN-bus**, Ethernet *An optional RS-232-to-USB converter cable is available for connection to USB equipped computers. **CAN-bus protocol is proprietary and reserved for connection to other Proton Products equipment such as a CDI4 interface display unit. Page 7 of 66...

  • Page 8: Ptional Interfaces

    (requires PI feedback controller option) Fast Fourier Transform analysis for amplitude and frequency of periodic diameter variations SMFD Single Measurement Flaw Detection (Lump and Neck detection) Page 8 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 9: Dimensional Drawings

    IMENSIONAL RAWINGS Page 9 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 10: Annotated Drawings

    PI feedback controller I/O Air wipe air inlet 6mm push-fit Air wipe air inlet for optical windows Mounting holes M5 x 10 mm Securely mount the gauge before operation. Page 10 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 11: Optional Accessories

    DB9 industrial bus port. • Comes as a pair for connecting to either type A or type B terminated network cables. Proton part number 00041MC048 Page 11 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 12: Electrical Interfaces

    Requires the PI feedback controller interface option (00047MC061) to be installed. Proton part number 00054SW011 Single Measurement Flaw Detection (SMFD) • High-speed lump and neck flaw detection. Proton part number 00054SW014 Page 12 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 13 Displays all measurements. • Provides menu-based setting of all parameters. • Provides data logging, presets and alarms. • Connection via RS-232, Ethernet or EtherNet/IP. Proton part number 00054SW015 Page 13 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 14: Interface Display Modules

    Select the required length of DB25 cable from below. Proton part number 00041MC730 DB25 “INTERFACE” port to PSU-BOB-DG, Terminal Strip-DIN cable Length / m Proton part number 00041CT003 00041CT005 00041CT010 00041CT020 00041CT030 Page 14 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 15: Installation

    Measured objects threaded through the optical gate cavity must be secured against contact with the optical windows or catching upon the gauge body. For cable production line applications, Proton Products can supply optional adjustable cable guides for securing the passage of a cable through the optical gate cavity.

  • Page 16: Optical Window Cleaning Procedure

    5. Install speed input (analogue or pulse). 6. Install optional electrical interfaces (Logic inputs, Relay outputs, Analogue outputs, PI feedback controller connections) using the optional Proton Products PSU-BOB breakout box or terminal strip. 7. Configure the gauge either via an optional CDI4 interface display unit or any of the above interfaces.

  • Page 17: Mechanical Installation

    Use shielded cable for all signal connections. • Ensure that all cable shields are correctly clamped and electrically connected to their connectors and metal connector shells at both ends. Page 17 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 18: Optional Cdi4 Interface Display Unit Installation

    1. Connect the remote CDI4 interface display unit to the CAN/POWER connector using a CAN- bus extension cable. 2. Connect an optional PSU-CAN mains power supply unit to the second CAN-bus port on the remote CDI4 interface display unit. Page 18 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 19: Dc Power Supply

    Powering on the gauge The gauge has no power switch; as soon as power is applied it will power up, perform self tests and then commence measurement. Page 19 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 20: Power Indications

    The gauge has no power switch; it may be powered off by switching off or disconnecting the power supply to the unit. CDI4 ONFIGURATION VIA Power on screen When the gauge is powered on, the Proton welcome screen will be displayed momentarily. Page 20 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 21: Home

    - Ovality error bar to indicate above value pictorially Press the button to access the function menu page. Press the button to advance to “Home Page 4”. Page 21 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 22: Home

    Press the button to reset above length to zero. Press the button to access the function menu page. Press the button to return to “Home Page 1”. Page 22 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 23: Function Menus

    Press the Home icon to return to the home page; or press the other icons to access the respective configuration pages. Page 23 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 24: Preset

    Press the button to return to the home page. Press the button to access the function menu page. Press the button to advance to the next page. Page 24 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 25 • SMFD (Single Scan Flaw Detection) is NOT available in “Helix” mode. Units: Metric; Imperial Metric: Millimetre (mm) and metre (m) measurement units. Imperial: Inch (in) and feet (ft) measurement units. Page 25 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 26 If the gauge has just been powered on or a cable has just been inserted into the empty optical gate, then the calculated “Reference Diameter” will only be valid after the “Reference Average Time” has Page 26 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 27: Start Speed

    Setting a minimum “Start speed” prevents the SMFD function from logging flaws during line start-up and shutdown. Start length Setting a minimum “Length” prevents the SMFD function from logging flaws during line start-up and shutdown. Page 27 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 28 Do not forget to set to “OFF” to exit simulation mode and resume normal measurement operation. Dia compensation All measured diameter values are multiplied by this “Diameter Compensation” factor before display or reading through a communications interface. Page 28 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 29: Interface

    • For bipolar outputs, the most negative measured error corresponds to a -10V output voltage. AOP response: Instant; Average. Instant: Analogue output voltage represents the value of each individual measurement. Average: Analogue output voltage represents the time averaged measured value. Page 29 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 30 Select form the following options: Gauge OK; Over any (limit); Under any (limit); Lump&Neck; Lump; Neck; Over average (upper limit); Under average (lower limit); Window dirty. Page 30 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 31: Speed Source

    Preset: Use the fixed “Preset speed” value for the line speed. Pulse: Determine the line speed from the pulse input. Analogue: Determine the line speed from the analogue input voltage. Page 31 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 32: Gauge Information

    - CDI4 software version. - CDI4 software issue date. Press the button to return to the home page. Press the button to access the function menu page. Page 32 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 33: Store

    - Count down of the remaining statistics time or length until the next statistics result. Press the button to return to the home page. Press the button to access the function menu page. Page 33 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 34: Fft

    - FFT peak value. - FFT sampling window remaining time. Press the button to return to the home page. Press the button to access the function menu page. Page 34 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 35: Access Levels

    The Home pages 2, 3, 4, 5 can be set to be displayed or hidden by selecting “TRUE” or “FALSE”. It is necessary to unlock the relevant pages before their parameters can be set via the CDI4 interface. Page 35 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 36: Standard Communications Interfaces

    This CAN-bus interface is fitted as standard. It operates independently of the other communications interfaces and may be accessed at the same time as them. The CAN-bus interface uses a proprietary Proton Products protocol. It is exclusively used to communicate between the unit and other Proton Products modules. The unit automatically detects connection to other modules and configures the bus appropriately;...

  • Page 37: Rs-232 Communications

    The SLP RS-232 data format is: Number of data bits Parity Number of stop bits Flow control Default baud rate None None 115200 bit / s Page 37 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 38: Rs-422 / Rs-485 Communications

    Connector type: RJ45 8P8C female (socket) Designation Comments LAN TX+ LAN TX- LAN RX+ LAN RX- Shield Ensure that the cable shield is connected to this via the plug shield connection. Page 38 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 39: Ethernet Led Indicator

    Ethernet LED indicator LED status Indication Continuous green Online and connected Ethernet communications Flashing green Online but not connected Continuous red Critical link failure Flashing red Connection timeout Page 39 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 40: Optional Communications Interfaces

    Ensure that the cable shield is connected to this via the plug shield connection. PROFIBUS LED indicator LED status Indication i-BUS Continuous green Online PROFIBUS communications Continuous red Communication error Extinguished No communication Page 40 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 41: Profinet Communications

    Ensure that the cable shield is connected to this via the plug shield connection. PROFINET LED indicator LED status Indication i-BUS Continuous green Online PROFINET communications Continuous red Communication error Extinguished No communication Page 41 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 42: Ether Net / Ip Communications

    Ensure that the cable shield is connected to this via the plug shield connection. EtherNet / IP LED indicator LED status Indication i-BUS Continuous green Online EtherNet / IP communications Continuous red Communication error Extinguished No communication Page 42 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 43: Standard Electrical Interfaces

    LECTRICAL NTERFACES PEED PULSE INPUT The speed pulse input may be connected to a line speed gauge (such as a Proton Products SL or SLR series non-contact laser speed and length gauge). Measured line speed input is required for: •...

  • Page 44: Analogue Input

    The analogue input and its ground reference are isolated from earth. Specification Minimum Typical Maximum Units Input voltage measurement range Input voltage absolute range Input-to-earth voltage kΩ Input resistance Page 44 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 45: Logic Inputs

    • For 24V signals (such as from a PLC), the power dissipation in the 820Ω resistor can be reduced by connecting another 820Ω in series between the pull-up signal source and logic input. Page 45 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 46: Logic Inputs Configuration

    Range/Remark 0=OK No reading 1=No Reading 0=OK No object 1=No Object 0=OK Window dirty 1=Window Dirty 0=OK Line speed too low for helix mode 1=Too Low Page 46 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 47 0=OK Line speed too high for helix mode 1=Too High 0=OK Gauge overheat 1=Gauge overheat 0=OK External alarm 1 1=Alarm 0=OK External alarm 2 1=Alarm Page 47 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 48: Relay Outputs

    If the relay contacts are used to switch inductive loads, then suppressors must be fitted to clamp voltage spikes. Specification Minimum Typical Maximum Units DC voltage between contacts Contact-to-earth voltage Current Ω On resistance (at a current of 10mA) Page 48 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 49: Optional Electrical Interfaces

    Analogue outputs and their shared ground reference are isolated from earth. • Analogue outputs are short circuit proof. Specification Minimum Typical Maximum Units Output voltage Output-to-earth voltage kΩ Load resistance Page 49 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 50: Pi Feedback Controller

    PIN input to earth voltage kΩ PIN input impedance POUT output voltage POUT output voltage (absolute forced) POUT output to earth voltage POUT output current Ω POUT output impedance Page 50 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 51: Pi Feedback Controller Connection To Production Equipment

    In this configuration, the PI feedback controller output voltage is added to a fixed control voltage from a potentiometer or PLC via the auxiliary control input on the extruder or capstan driver. The fixed Page 51 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 52 The system cannot function if R2 > 5 × R1 since the maximum control range will be < 10%, which is normally not sufficient. Page 52 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 53: Interface Connector Pin Outs

    Low < +3 V; High > +10.5 LIN1 Logic inputs Logic input 1 V; Max ±30V REG.GND Power supply Power supply ground (0 V) +24V Power supply +24 V power supply Shield Page 53 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 54: Proton Standard Parameter Access Protocol

    Reading a block of input parameters Use the following request format to read a contiguous block of input parameter values: Request ?[Input parameter number][Space][Number of parameters]<CR><LF> format Page 54 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 55: Writing Input Parameters

    Use the following request format to read a single output parameter value as a continuous stream: Request #[Output parameter number]<CR><LF> format Response [Output parameter value]<CR><LF> format Page 55 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 56: Reading A Continuous Stream Of A Block Of Output Parameters

    The data stream can be terminated by sending an escape character to the gauge (ASCII code decimal 27 or the ‘Esc’ key or the ‘Ctrl’’[‘ key combination on a PC keyboard). Page 56 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 57 ODBUS PARAMETER ACCESS PROTOCOL This protocol provides access to individual parameters or blocks of parameters and is typically used in a production environment where the Proton Products instrument is connected to a computer, Modbus connected PLC or similar device. The parameters consist of 16-bit words (DW) and are divided into input and output groups: •...

  • Page 58: Input Parameters

    DW20 Preset Y upper limit 1=0.01um/0.01mil 0~20000000 50000 DW21 DW22 Preset Y lower limit 1=0.01um/0.01mil 0~20000000 50000 DW23 DW24 Preset Z upper limit 1=0.01um/0.01mil 0~20000000 50000 Page 58 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 59 0=Active low; The polarity of logic input 2 1=Active high Relays 0=Gauge OK;1=Over all limit; 2=Under all DW50 Relay 1 function limit;3=Flaw;4=Lump; 5=Neck, 6=Over Average Upper Page 59 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 60 DW62 P gain 1=1% 0~100 Analogue O/P Analogue O/P 1 0=Average ;1=X;2=Y; 3=Z;4=Ovality;5=Aver DW63 age error;6=X error;7=Y error;8=Z error;9=Ovaity error; Analogue O/P 2 Analogue O/P 3 Page 60 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 61 CAN BUS address 0~255 0=250;1=500;2=1000; DW84 CAN BUS baud rate other=500 0=4800;1=9600;2=19 DW85 RS232 baud rate 200;3=38400;4=1152 0=Modbus;1=Proton; DW86 RS232 protocol 2=SLP;3=Print 0=Modbus;1=Proton; DW87 RS422/RS485 protocol 2=SLP Page 61 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 62 Gain of analogue O/P1 10000 DW119 Zero of analogue O/P1 DW120 Gain of analogue O/P2 10000 DW121 Zero of analogue O/P2 DW122 Gain of analogue O/P3 10000 Page 62 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 63: Output Parameters

    Line speed too low in helix mode 0=OK,1=too low Line speed too high in helix mode 0=OK,1=too high Gauge too hot 0=OK;1=Gauge Hot External Alarm 1 0=OK,1=Alarm External Alarm 2 0=OK,1=Alarm Page 63 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 64 1=0.01um{mil} 0~20000000 DW35 DW36 Running average diameter 1=0.01um{mil} 0~20000000 DW37 DW38 Cable position on X axis 1=1% 0~±100 DW39 Cable position on Y axis 1=1% 0~±100 Page 64 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 65 IP address for ETH xx.xx.xx.xx DW65 DW66 IP address for iBUS xx.xx.xx.xx DW67 DW68 Sub net Mask xx.xx.xx.xx DW69 DW70 Gateway xx.xx.xx.xx DW71 DW72 Gauge temperature 1=0.1℃ Page 65 of 66 Proton Products InteliSENS DG1030 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 66: Sales And Service

    Proton Products is not responsible for consequential or incidental damage related to the provision or use of the information contained in this manual. • The information contained in this manual is the property of Proton Products and may not be circulated or distributed to third parties. •...

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