Proton InteliSENS DG2030-i4 Instruction Manual

Dual axis laser scanning diameter gauge

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Instruction Manual

InteliSENS DG2030-i4 Dual Axis Laser Scanning

Diameter Gauge

Issue 1f

1 March 2023

Proton Products Co. Ltd.

10 Aylesbury End

Beaconsfield

Buckinghamshire HP9 1LW

England

www.protonproducts.com

Page 1 of 71

Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)

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Summary of Contents for Proton InteliSENS DG2030-i4

Page 1 InteliSENS DG2030-i4 Dual Axis Laser Scanning Diameter Gauge Issue 1f 1 March 2023 Proton Products Co. Ltd. 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Page 1 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 2 ..............................38 TORE ............................38 TATISTICS FFT ..............................39 ACCESS LEVELS ..........................40 ..........41 TANDARD OMMUNICATIONS NTERFACES CAN- ....................... 41 BUS COMMUNICATIONS CAN-bus interface ............................41 Page 2 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 3 Reading a block of output parameters ......................59 Reading a continuous stream of a single output parameter ............... 59 Reading a continuous stream of a block of output parameters ..............60 Page 3 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 4 ONTACT DETAILS FOR ENQUIRIES SALES AND SERVICE ............................71 EB SITE ......................... 71 NQUIRIES AND SALES ..........................71 ERVICE ENQUIRIES ............71 ANUAL FEEDBACK AND COPYRIGHT Page 4 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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: Radio -⁠ ETSI EN 300 328 V2.1.1 (2016-⁠ 1 1)
Page 6 When fitted with the optional CDI4 interface display unit, the InteliSENS DG2030-i4 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 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 71...
Page 8 (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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 9 IMENSIONAL RAWINGS Page 9 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 10 Air wipe air inlet RS-232, RS-422/485 communications interface Logic and speed pulse inputs, relay outputs, optional analogue input, optional PI feedback controller I/O Gauge head mounting holes Page 10 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 11 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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 12 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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 13 Input voltage range: 90 – 260 VAC @ 45 – 65 Hz. • Select the required length of DB25 cable from below. Proton part number 00047MC660 Page 13 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 14 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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 NSTALLATION SEQUENCE Unpack the gauge and check for missing accessories and shipping damage. Mechanical installation: 1. Mount the gauge securely on a user supplied mount or on an optional Proton Products height stand. Electrical installation: 1. Install earth connections.
Page 17 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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 18 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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 19 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 19 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 20 REG.GND Power supply ground (0 V) +24V +24 V power supply Ensure that the cable shield is connected to this Shield via the plug shield connection. Page 20 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 23 - Y error (Y diameter – Preset Y diameter) Press the button to access the function menu page. button to advance to “Home Page 3”. Press the Page 23 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 24 - Position of last neck flaw - Neck flaw count Press the button to access the function menu page. button to advance to “Home Page 5”. Press the Page 24 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 25 Press the button to reset length to zero. Press the button to access the function menu page. button to return to “Home Page 1”. Press the Page 25 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 26 Press the button to access the function menu page. Press the button to advance to the next page. Page 26 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f) Press the button to return to the home page.
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 28 • 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 28 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 29 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 29 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 30 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 30 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 31 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 31 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 32 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 32 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 33 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 33 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 34 • 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 34 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 35 Under average (lower limit); Over X (upper limit); Under X (lower limit); Over Y (upper limit); Under Y (lower limit); Over ovality (upper limit); Window Dirty. Page 35 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 36 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 36 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 37 - 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 37 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 38 - 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 38 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 39 - 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 39 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 40 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 40 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 41 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 42 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 42 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 43 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 43 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 44 The PROFIBUS interface may be accessed through the “PROFI/EIP/DEV” connector. Connector type: DB9 female (socket) PROFIBUS Comments Shield Ensure that the cable shield is connected to this via the plug shield connection. PROFIBUS LED indicator Page 44 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 50 Range/Remark 0=OK No reading 1=No Reading 0=OK No object 1=No Object 0=OK Lens dirty 1=Lens Dirty 0=OK Line speed too low for helix mode 1=Too Low Page 50 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 =Neck, 6=Over Average Upper Page 63 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 64 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=Averag DW63 e error;6=X error;7=Y error;8=Z error;9=Ovaity error; Analogue O/P 2 Analogue O/P 3 Page 64 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 65 CAN BUS baud rate ther=500 0=4800;1=9600;2=192 DW85 RS232 baud rate 00;3=38400;4=115200 0=Modbus;1=Proton;2= DW86 RS232 protocol SLP;3=Print 0=Modbus;1=Proton;2= DW87 RS422/RS485 protocol 0=4800;1=9600;2=192 DW88 RS422/RS485 baud rate 00;3=38400;4=115200; 5=250K;6=500K;7=1M Page 65 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
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 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 67 Zero of analogue input DW127 Parameter Group Number 1~50; 0 is not used 1=Load parameters from specified DW128 Parameter Group Control group;2=Save current parameters to specified group DW129 Page 67 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 68 External Alarm 1 0=OK,1=Alarm External Alarm 2 0=OK,1=Alarm Average diameter/Envelop 1=0.01um{mil} 0~20000000 X diameter 1=0.01um{mil} 0~20000000 Y diameter 1=0.01um{mil} 0~20000000 Z diameter 1=0.01um{mil} 0~20000000 DW10 Ovality 1=0.01um{mil} 0~20000000 Page 68 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 69 Length 1=0.001m{1=0.001ft} DW43 Statistics Normal distribution 0=No;1=Yes DW44 Not used SPC is available 0=No;1=Yes DW45 Statistics remain time 1=1s{1=1m{ft}} 0~65535 DW46 Standard deviation 1=0.01um{mil} 0~20000000 DW47 Page 69 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 70 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 70 of 71 Proton Products InteliSENS DG2030-i4 Diameter Gauge Instruction Manual (Issue 1f)
Page 71 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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