Proton InteliSENS DG1030 Instruction Manual

Single axis diameter gauges

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INSTRUCTION MANUAL

DG1030 AND DG1060

SINGLE AXIS DIAMETER GAUGES

ACCESSORIES

Issue 11l

7 March 2016

Proton Products Co Ltd

10 Aylesbury End

Beaconsfield

Buckinghamshire HP9 1LW

England

www.protonproducts.com

Note: DG1030 and DG1060 pictured here without DGI display and interface unit.

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Page 1 INSTRUCTION MANUAL DG1030 AND DG1060 SINGLE AXIS DIAMETER GAUGES & ACCESSORIES Issue 11l 7 March 2016 Proton Products Co Ltd 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Note: DG1030 and DG1060 pictured here without DGI display and interface unit.
Page 2: Table Of Contents
........................59 PECIFICATIONS ..........................59 AUGE PECIFICATIONS ..................63 ERVICE AND SALES CONTACT DETAILS ..............................63 ALES NQUIRIES ................................63 EB SITE ..................63 ANUALS EEDBACK AND COPYRIGHT Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 2...
Page 3: Declaration Of Conformity
Proton Products International Limited 10 Aylesbury End Beaconsfield Bucks HP9 1LW ENGLAND Proton Products is an ISO9001:2008 registered company. The declaration is signed by: Paul Sives ……………………… Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 3...
Page 4: Introduction
Connect the gauge head directly to a USB socket. Use in conjunction with RS232 converter cable. 500mm cable, with male DB9 connector and USB connector, and includes driver software. Proton part number: GP00000624 Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 4...
Page 5 (more advanced) CS3G, rather than the CS2G. - Two analogue outputs (Average error, ØX, ØY or ØXY), user-programmable. - PID control output - Four relay outputs, programmable to multiple options Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 5...
Page 6: Dg Series : Mechanical Accessories
Height stand HST3 HST3 is an adjustable height stand for use with both the 30 and 60mm gauge heads. The HST3 is also suitable for use with all other Proton DG gauges: DG2030, DG2060, DG1100 and DG2100. Height range for top of HST3: 700mm to 1100mm Cable guides GRS-30 &...
Page 7: Operation - Precautions
- from a PSU-CAN power supply unit connected directly to the mains - from a CAN cable from a NEXiS CS2G or CS3G-10 control and display unit. When the 24V supply is connected, the gauge starts with the PROTON PROTON PRODUCTS LTD message.
Page 8: Otential Error Messages At Power On
NO READING message Set the Access levels before adjusting other parameters - Note that the Access levels must be set before any other parameters can be adjusted Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 8...
Page 9: Operation : Dg Gauge Head
When the message has an embedded variable or option list, this button is used to enter the new value or option. NEXiS™ CS3G-10 control system screen and keypad Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 9...
Page 10: Accessing And Adjusting Dg Parameters And Settings
& buttons to select an option, the Enter button to confirm. LANGUAGE OPTIONS English Metric English Imperial German Spanish ∧ ∨ for more [French is next option] Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 10...
Page 11: Access Levels
When the access passcode (180018) has been keyed in, press the button. The Access level Page will be displayed: LOCK = UNLOCK = Basic ∅ Data Averaging Stats & FFT Control mode ∧ ∨ for more Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 11...
Page 12 The presets will re-lock if the Menu button ( ) or Home button ( ) is pressed or if no buttons are pressed for 60s. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 12...
Page 13: Basic ∅ Data
Press ↵ to reset Press the Enter button to reset the minimum and maximum values. Press the Page button ( ) to move to the next page. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 13...
Page 14 Note: After setting the parameters, please remember to press the Menu button or the Home button to store them in the non-volatile memory otherwise they will be lost when the gauge is powered off. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 14...
Page 15: Single Scan Flaw Detection (Ssfd)
False neck detected +Flaw limit: SSFD Averaging period Average diameter: -Flaw limit: SSFD Averaging period Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 15...
Page 16: Measuring Mode
(Use the >,<, to the Switch preset.) Note: If access levels are set to allow adjustment of these parameters, the variables will have a black background when selected. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 16...
Page 17: Speed
Set the Source to Pulse or Analogue depending on the speed signal input used Set the Calibration value to give the correct Line speed [the line must be running to do this]. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 17...
Page 18: Statistics
Cpk = [maximum – ∅ preset or ∅ preset – minimum {whichever is the largest} / 3 × sigma] × 100% Instructions on setting statistics functions are on the next page. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 18...
Page 19 The data will continue to update after the elapse of each Time period. To stop the data from updating, press the PAGE button ( ) to return to the STATISTICS page and set Mode to Hold. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 19...
Page 20: Fft (Fast Fourier Transform )
Press the PAGE button ( ) to display the FFT GRAPH RESULTS page. IF NO GRAPH IS OBTAINABLE Note that the FFT function is not available in Helix Mode. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 20...
Page 21: Control
Note: If access levels are set to allow adjustment of these parameters, the first option will have a black background. To access the Control Tuning page, press the PAGE button ( Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 21...
Page 22 HOLD, it will revert to the ON state when the gate becomes CLEAN. When the power is applied to the gauge, the initial control state is forced to RESET. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 22...
Page 23: Analogue
Enter the full-scale value. scale Minimum value: 0.1 mm value Note: If access levels are set to allow adjustment of these parameters, the first option will have a black background. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 23...
Page 24: Store
Select Recall Group? or Save Group? or Exit. ∧ ∨ (Use the & buttons to change options, and the Enter button ( ) to confirm the option and move to the next preset) Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 24...
Page 25: System Settings
Note: If access levels are set to allow adjustment of this parameter, the current option will have a black background. Press the PAGE button ( ) to access the CAN configuration page. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 25...
Page 26: Language Options
Note: German, Spanish and French options use metric units. Note: If access levels are set to allow adjustment of this parameter, the current option will have a black background. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 26...
Page 27: Helix Measuring Mode
Set the Error limits (The error is measured on the envelope diameter) by pressing the Enter button ) and >,<, ∧,v, and then Enter to confirm. Note that Flaws are not measured in this mode. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 27...
Page 28: Statistical Process Control [Spc] - On Cs3G-10 Only
4. The Effective state shows whether the adaptation has actually occurred. If the conditions stated above are not met then the Effective state will remain OFF until the conditions are met. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 28...
Page 29: Installation - System Configuration
Control and Indicator module CS2GXY • Control and Indicator module CS3G-10 The PROFIBUS operation is totally independent of the CANBUS so the two can be used together. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 29...
Page 30: Dg Gauge Head Connected To Profibus
Control and Indicator module CS2GXY • Control and Indicator module CS3G-10 The PROFIBUS operation is totally independent of the CANBUS so the two can be used together. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 30...
Page 31: Dg Gauge Head Connected To Ethernet Ip
8. Connect the Ethernet cable to the DG gauge, and connect it to the network device. 9. Configure the network device based on the DG gauge head IP address and the Settings given on the next page. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 31...
Page 32: Settings And Wiring For Ethernet Industrial Protocol Communication
DG gauge head) Function Pin 1 RS232/ Pin 2 PROFI Pin 3 Pin 4 Pin 5 Refer also to the "Gauge to master and RS232/EIP output parameters" (DW 52~59) Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 32...
Page 33: Dg Gauge Head With Control System / Indicator Module
Length up to 50m for each lead. INDICATOR Indicator to MODULE and Customer CONTROL Connections SYSTEM: CS2G RS232 CS2GXY Analogue CS3G-10 Relays PSU-RS2-AR Controller Line speed Mains Supply Input Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 33...
Page 34: Optional Built In Relay Outputs
Configure the host RS-232 port as below and connect to the gauge using suitable terminal software (e.g. Microsoft Windows HyperTerminal): Number of data bits Parity Number of stop bits Flow control Default baud rate None None 9600 bit / s Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 34...
Page 35 Measured diameter over the upper limit or under the lower limit. Under Lower Limit Lump Single Scan Flaw Detection (SSFD) lump flaw detected. Single Scan Flaw Detection (SSFD) neck flaw detected. Neck Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 35...
Page 36: Installation - Mechanical
– NSTALLATION MECHANICAL AUGE HEAD DIMENSIONS Gauge Head DG1030 – side view Gauge Head DG1030 – base Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 36...
Page 37 Gauge Head DG1030 – front and back view Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 37...
Page 38 Gauge Head DG1060 – side view Gauge Head DG1060 – base Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 38...
Page 39 Gauge Head DG1060 – front and back view Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 39...
Page 40 8 mm diameter bar supplied. This is particularly important where the production line height is 1200 mm. This must be done before the Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 40...
Page 41 • The stand is designed to support the gauge. However, it cannot withstand side loads above 400N caused, for example, by the cable catching on the stand or gauge, even for short periods. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 41...
Page 42 Cable guide GRS-30 and GRS-60 : installation notes • The cable guide set can be mounted on the Proton height stand or to the customers stand using an adaptor plate; the correct screws are supplied with the cable guide. •...
Page 43 The bus driver, 24V supply and the shield pin are isolated from earth at the gauge head but referenced to earth at the CS2G/CS2GXY, PSU-RS2-AR or CS3G-10 modules, the cable screen must be connected to the EMC gland on these modules. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 43...
Page 44 Right angle connector version = B8251 – 0 Pin designations: Pin 1 = Shield Pin 2 = +24V Pin 3 = 0V Pin 4 = CANH Pin 5 = CANL Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 44...
Page 45 TURCK RSSW451 connector Standard cable lengths are as the input port. Rewireable male mating connector: TURCK BMSWS 8151 – 0 Line terminator male connector: TURCK RSS4.5-PDP – TR Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 45...
Page 46: Cable Types
-- -- Pin 2 GND -- -- -- -- Pin 5 Note that the 0V terminal is referenced to earth and the RTS & CTS are not used. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 46...
Page 47: Rs232 Port
RS232 PORT Note that the 0V terminal is referenced to earth and RTS & CTS are not used. The data format for the Proton Standard RS232 Protocol is as follows: • No parity • No flow control • Data bits = 8 •...
Page 48: Serial Communications
ERIAL COMMUNICATIONS CANBUS This is used to communicate between the gauge heads and the other Proton modules. The gauge automatically recognises that it is connected to a module and configures the bus appropriately. It is the only way that the modules and gauge head can be interconnected.
Page 49: Rs232
Please be aware that both RS232 in the gauge head and PROFIBUS access the same parameter list table, so they can NOT work simultaneously. The data format for the Proton Standard RS232 Protocol is as follows: • No parity •...
Page 50 Reply format : [First output parameter value] [Carriage return][Line feed] [Second output parameter value] [Carriage return][Line feed] ... and so on, until the end of the range. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 50...
Page 51 Note: after each Value is output, a Carriage Return and Line Feed is output e.g. 18793 <CR> <LF> Format for requesting a continuously repeating XY average diameter: con1sec [Carriage return][Line feed] Reply format : [Two digits][Decimal point][Three digits][Carriage return] Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 51...
Page 52: Parameter Lists
ARAMETER LISTS Notes : Parameters correct for DG1030, DG2030, DG1060 and DG2060. Based on Proton DG message table v. 3.47 : PROFIBUS RS232 AUGE INPUT MASTER TO GAUGE AND INPUT PARAMETERS Data bits 0.0 ~ 0.15 Data bit Comments Resolution Range DW 0.0...
Page 53 D 18.1 Controller ON the 3 options can be D 18.2 Controller RESET selected at one time) D 18.3 Controller output polarity 1=Norm, 0=Rev D 18.4 Reserved Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 53...
Page 54 0 = Y; >0 = Error (For single DW 29 Analogue output 2 type, Y-axis or XY error axis gauges [DG1030, DG1060], must be set to 1) Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 54...
Page 55: Gauge Output : Gauge To Master And Rs232 Output Parameters
RS232 AUGE OUTPUT AUGE TO MASTER AND OUTPUT PARAMETERS Notes : Parameters correct for DG1030, DG2030, DG1060 and DG2060. Based on Proton DG message table v. 3.47 Data bits 0.0 ~ 0.15 Data bit Comments Resolution Range Solid Glass Helix...
Page 56 DW36 ~ DW51 Statistical graph data; 16 points covering the range +/-3.2 sigma in 0.4 sigma steps; 10 = 1% 0 to 99.99% Each data point represents the percentage of data set in that group. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 56...
Page 57 COMMUNICATIONS DW56~57 Glass mode diameter value for Y-axis 1=0.1µm or 1=0.00001” Diameter error value 1=0.1µm or 1=0.00001” DW58~59 Solid mode diameter XY average value 1=0.1µm or 1=0.00001” Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 57...
Page 58: Alternative Ars232 Single Letter Identifier Protocol
Line feed <LF> Units M or I M = metric; I = imperial Axis X or Y X = X axis reading; Y = Y axis reading Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 58...
Page 59: Specifications
With a 1mm sample: max = +0.3µm, min = -0.3µm, σ = 0.1µm With a 10mm sample: max = +3µm, min = -3µm, σ = 1µm Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 59...
Page 60 With a 1mm sample: max = +0.6µm, min = -0.6µm, σ = 0.2µm With a 30mm sample: max = +9µm, min = -9µm, σ = 3µm Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 60...
Page 61: Measurement Modes
There are always 750 samples and each sample is a diameter measurement from a single scan. A sample is taken at 8 scan intervals for a 10s period, 16 scan intervals for a 20 period etc. Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 61...
Page 62: Canbus Port
Voltage = 11 to 25Vdc, the input is isolated from earth, maximum voltage on any line to earth = 50Vdc. Reverse polarity protected. Power consumption < 12W [with display] Environment Protection = IP65 Ambient temperature range = 0°C to +45°C (32°F to +118°F) Proton Products DG1030 and DG1060 Diameter Gauge instruction manual issue 11l Page 62...
Page 63: Service And Sales Contact Details
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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