Proton InteliSENS DG1060 MKII Instruction Manual
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Proton InteliSENS DG1060 MKII Instruction Manual

Single axis laser scanning diameter gauge
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InteliSENS DG1060 MKII Single Axis Laser Scanning
Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
Instruction Manual
Diameter Gauge
Issue 1a
11 June 2021
Proton Products Co. Ltd.
10 Aylesbury End
Beaconsfield
Buckinghamshire HP9 1LW
England
www.protonproducts.com
Page 1 of 72

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Summary of Contents for Proton InteliSENS DG1060 MKII

  • Page 1 InteliSENS DG1060 MKII Single Axis Laser Scanning Diameter Gauge Issue 1a 11 June 2021 Proton Products Co. Ltd. 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Page 1 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 2: Table Of Contents

    FFT ..............................38 ACCESS LEVELS ..........................39 ..........40 TANDARD OMMUNICATIONS NTERFACES CAN- ....................... 40 BUS COMMUNICATIONS CAN-bus interface ............................40 CAN-bus LED indicator ..........................40 Page 2 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 3 Reading a block of input parameters ......................60 ....................... 61 RITING INPUT PARAMETERS Writing a single input parameter ........................ 61 ......................61 EADING OUTPUT PARAMETERS Reading a single output parameter ......................61 Page 3 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 4 ONTACT DETAILS FOR ENQUIRIES SALES AND SERVICE ............................72 EB SITE ......................... 72 NQUIRIES AND SALES ..........................72 ERVICE ENQUIRIES ............72 ANUAL FEEDBACK AND COPYRIGHT Page 4 of 72 Proton Products InteliSENS DG1060 MKII 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

    User configurable logic inputs are provided as standard to reset gauge measurements and trigger printing. User configurable relay outputs are provided as standard to signal gauge status, lump and neck detection and measurements exceeding preset error limits. Page 6 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • 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 72...

  • 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 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 9: Dimensional Drawings

    IMENSIONAL RAWINGS Page 9 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 10: Annotated Drawings

    Logic and speed pulse inputs, relay outputs, optional analogue input, optional PI feedback controller I/O Earth bolt Ethernet communications interface CDI4 mounting holes WiFi antenna hole Gauge head mounting brackets Page 10 of 72 Proton Products InteliSENS DG1060 MKII 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 72 Proton Products InteliSENS DG1060 MKII 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 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 13 • 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 72 Proton Products InteliSENS DG1060 MKII 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 72 Proton Products InteliSENS DG1060 MKII 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

    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 16 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 17: Mechanical Installation

    Ensure that the cable alignment is perpendicular to the face of the gauge with the least error practically possible, an angle error of one degree gives a measurement error of 0.013%, at two degrees this becomes 0.05%. Page 17 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 18: Electrical Installation

    CAN-bus extension cable. • The remote CDI4 interface display unit can also power DC powered gauges through a CAN- bus port connected power supply. Page 18 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 19: Dc Power Supply

    PSU-BOB Power supply unit and break out box connected to the “INTERFACE” connector. Alternatively, power may be directly supplied to the gauge via either of the following connectors: • “CAN / POWER” connector. • “INTERFACE” connector. Page 19 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 20: Powering On The Gauge

    If an optional CDI4 interface display is attached to the gauge, then correct power up is indicated by the display of the welcome screen followed by the home page. Page 20 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 21: Powering Off The Gauge

    Powering off the gauge The gauge has no power switch; it may be powered off by switching off or disconnecting the power supply to the unit. Page 21 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 22: Configuration Via Cdi4

    CDI4 ONFIGURATION VIA Power on screen When the gauge is powered on, the Proton welcome screen will be displayed momentarily. Page 22 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 23: Home

    - Ovality error bar to indicate above value pictorially Press the button to access the function menu page. button to advance to “Home Page 4”. Press the Page 23 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 24: Home

    Press the button to access the function menu page. button to return to “Home Page 1”. Press the Page 24 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 25: Function Menus

    Press the Home icon to return to the home page; or press the other icons to access the respective configuration pages. Page 25 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 26: Preset

    Press the button to access the function menu page. Press the button to advance to the next page. Page 26 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 27 • 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 27 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 28 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 28 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 29: 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 29 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 30 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 30 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 31: Communications

    Press the button to access the function menu page. Press the button to advance to the next page. Page 31 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 32 Press the button to access the function menu page. Press the button to advance to the next page. Page 32 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 33: Interface

    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 33 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 34 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 34 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 35: 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 35 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 36: 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 36 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 37: 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 37 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 38: 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 38 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 39: 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 39 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 40: 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 41: 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 41 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 42: Reading Data

    Example 1: To read the diameter, send the following ASCII string to the gauge: A<CR> For a 05.000mm object diameter, the gauge will respond with the following ASCII string: Page 42 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 43: Writing Data

    Example 2: To set the “Control mode” to “Run”, send any ONE of the following ASCII strings to the gauge: k00008 k8<CR> k8<LF> k8<CR><LF> Page 43 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 44: Continuous Data Output

    The four-wire RS-422 interface may be converted to two-wire RS-485 operation by installation of the 2 shorting links shown above. Page 44 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 45: Ethernet Communications

    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 45 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 46: 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 46 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 47: 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 47 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 48: 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 48 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 49: 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 50: 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 50 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 51: 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 51 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 52: Logic Inputs Configuration

    Set output parameter bit DW1.9 = 1 Line Rev Decrement the length of the line. Direction Input DW logic input polarity bit setting Logic input active state Active low Active high Page 52 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 53: Interrogating External Alarm 1 And External Alarm 2 Logic Input Status

    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 53 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 54: 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 54 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 55: 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 55 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 56: 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 56 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 57: 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 57 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 58 The system cannot function if R2 > 5  R1 since the maximum control range will be < 10%, which is normally not sufficient. Page 58 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 59: Interface Connector Pin Outs

    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 59 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 60: 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 60 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 61: 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 61 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 62: 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 62 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 63: Modbus Parameter Access Protocol

    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 64: Input Parameters

    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 64 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 65 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 65 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 66 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 66 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 67 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 67 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 68 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 68 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 69: 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 69 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 70 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 70 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)
  • Page 71 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 71 of 72 Proton Products InteliSENS DG1060 MKII Diameter Gauge Instruction Manual (Issue 1a)

  • Page 72: Contact Details For Enquiries

    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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