Proton InteliSENS DG3200-K Instruction Manual

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Instruction Manual

InteliSENS DG3200-K CCD 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 70

Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)

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Page 1 Instruction Manual InteliSENS DG3200-K CCD 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 2 ACCESS LEVELS ..........................39 ..........40 TANDARD OMMUNICATIONS NTERFACES CAN- ....................... 40 BUS COMMUNICATIONS CAN-bus interface ............................40 CAN-bus LED indicator ..........................40 RS-232 C ......................... 41 OMMUNICATIONS Page 2 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 3 Reading a continuous stream of a single output parameter ............... 59 Reading a continuous stream of a block of output parameters ..............60 ..........61 ODBUS PARAMETER ACCESS PROTOCOL .................. 62 NPUT PARAMETERS Page 3 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 4 ONTACT DETAILS FOR ENQUIRIES SALES AND SERVICE ............................70 EB SITE ......................... 70 NQUIRIES AND SALES ..........................70 ERVICE ENQUIRIES ............70 ANUAL FEEDBACK AND COPYRIGHT Page 4 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 5 (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: EMC - EN 61326-1:2013 Low Voltage - EN 61010-1:2010 (Scientific and measuring instruments)
Page 6 NTRODUCTION The InteliSENS DG3200-K dual axis CCD diameter gauge provides super fast and highly accurate non-contact diameter measurement of cables or other objects manufactured in a continuous process. Unlike traditional laser diameter gauges which use a mechanically scanned laser beam, the InteliSENS DG3200-K diameter gauge uses an entirely solid state technique.
Page 7 (line speed: feet / minute, length: feet) Solid Solid object diameter Measurement modes Glass Transparent object diameter Helix Twisted / braided multi-core cable envelope diameter Page 7 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 8 RS-232*, RS-422, RS-485, CAN-bus**, Ethernet, WiFi *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 CDI4 interface display unit. PTIONAL INTERFACES 3x Analogue outputs ±10 Vdc output of diameters or errors, user scalable...
Page 9 IMENSIONAL RAWINGS Page 9 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 10 Latch handle Adjustable height stand Height stand adjusting screws DB25 interface CAN/POWER RS232/485 PROFI/EIP/DEV RJ45 Ethernet socket AC power inlet Earth bolt Air wipe air inlet Page 10 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 11 PI feedback diameter control via adjustment of insulation extruders or capstan drives. • Isolated ±20V analogue input and ±10V analogue output for connection to insulation extruders or capstan drives. Proton part number 00047MC061 Page 11 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 12 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 12 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 13 Input voltage range: 90 – 260 VAC @ 45 – 65 Hz. • Select the required length of DB25 cable from below. Proton part number 00047MC360 Page 13 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 14 DB25 “INTERFACE” port to PSU-BOB-DG, Terminal Strip-DIN or CS1G-SL cable Name Length / m Proton part number SLMKII-BOB-003 00041CT003 SLMKII-BOB-005 00041CT005 SLMKII-BOB-010 00041CT010 SLMKII-BOB-020 00041CT020 SLMKII-BOB-030 00041CT030 Page 14 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 15 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 4. Install speed input (analogue or pulse). 5. 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. 6. Configure the gauge either via the CDI4 interface display unit or any of the above interfaces.
Page 17 NSTALLATION The gauge must be securely mounted by its base to a fixed surface. It can either be secured to an end user supplied mount or to an optional Proton Products adjustable height stand. • Optimum measurement accuracy is achieved if the object is centred in the optical gate cavity.
Page 18 Installation on the adjustable height stand Proton Products supplies an adjustable height stand which can position the measurement axis of the gauge within the height range from 955 to 1045mm. The height can be adjusted by releasing the adjusting screws.
Page 19 0.5 - 1 μm solid particle count 1 - 5 μm solid particle count Water vapour pressure dew point °C Oil aerosol and vapour 0.01 mg / m Page 19 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 20 • Ensure that the shields of cables connecting to the end user’s equipment are clamped to earth at their destination. Page 20 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 21 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 22 1. Press the “Click to calibrate touch screen” message during gauge power on to access the screen calibration function. 2. Tap the screen as directed, the screen will be calibrated. Page 22 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 23 - Z error (Z diameter – Preset Z diameter) Press the button to access the function menu page. Press the button to advance to “Home Page 3”. Page 23 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 24 - Position of last neck flaw - Neck flaw count Press the button to access the function menu page. Press the button to advance to “Home Page 5”. Page 24 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 25 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 25 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 26 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 26 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 27 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 27 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 28 Output diameter = (Measured diameter) x [1– (Shrinkage/100)] ABS: absolute shrinkage mode deducts the Shrinkage from the averaged measured diameter. Output diameter = (Measured diameter) – (Shrinkage) Page 28 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 29 • 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 29 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 30 If the “Reference Average Time” is set to too short a duration (i.e. close to the time duration of the flaws), then the flaws will significantly affect the value of the “Reference Diameter” and may result in the detection of false flaws. Page 30 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 31 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 31 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 32 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 32 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 33 • 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 33 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 34 Under any (limit); Lump&Neck; Lump; Neck; Over average; Under average; Over X; Under X; Over Y; Under Y; Over Z; Under Z; Over ovality; Under ovality. Page 34 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 35 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 36 - 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 37 - 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 38 - 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 39 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 40 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 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 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 42 Shield via the plug shield connection. 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 42 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 43 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 43 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 44 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 44 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 45 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 45 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 46 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 46 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 47 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 48 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 48 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 49 • 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 49 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 50 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 50 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 51 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 51 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 52 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 52 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 53 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 53 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 54 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 54 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 55 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 55 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 56 The system cannot function if R2 > 5 × R1 since the maximum control range will be < 10%, which is normally not sufficient. Page 56 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 57 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 57 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 58 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 Response [Input parameter value]<CR><LF> format Only consecutive parameter values may be requested in a block parameter request. Page 58 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 59 For a data transfer rate of 1200 bit / s and a data length of seven 8-bit characters per parameter value, approximately 10 individual parameter values can be transferred per second. Page 59 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 60 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 60 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 61 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 62 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 62 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 63 0=Active low; 1=Active The polarity of logic input 2 high Relays 0=Gauge OK;1=Over all limit; 2=Under all DW50 Relay 1 function limit;3=Flaw;4=Lump;5=N eck, 6=Over Average Upper limit;7=Under Page 63 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 64 0~100 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=Average DW63 error;6=X error;7=Y error;8=Z error;9=Ovaity error; Analogue O/P 2 Analogue O/P 3 Page 64 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 65 CAN BUS baud rate er=500 0=4800;1=9600;2=19200 DW85 RS232 baud rate ;3=38400;4=115200 0=Modbus;1=Proton;2=S DW86 RS232 protocol LP;3=Print 0=Modbus;1=Proton;2=S DW87 RS422/RS485 protocol 0=4800;1=9600;2=19200 DW88 RS422/RS485 baud rate ;3=38400;4=115200;5=2 50K;6=500K;7=1M Page 65 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 66 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 DW123 Zero of analogue O/P3 DW124 Page 66 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 67 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 67 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 68 Cable position on X axis 1=1% 0~±100 DW39 Cable position on Y axis 1=1% 0~±100 DW40 Cable position on Z axis 1=1% 0~±100 DW41 Line speed 1=0.1m/min{1=1ft/min} -32768~32767 Page 68 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 69 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 69 of 70 Proton Products InteliSENS DGK3200 Diameter Gauge Instruction Manual (Issue 1a)
Page 70 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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