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Proton InteliSENS DG2120-K Instruction Manual

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Instruction Manual
InteliSENS DG2120-K CCD Diameter Gauge
Issue 1a
26 August 2019
Proton Products Co. Ltd.
10 Aylesbury End
Beaconsfield
Buckinghamshire HP9 1LW
England
www.protonproducts.com
Page 1 of 72
Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

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Summary of Contents for Proton InteliSENS DG2120-K

  • Page 1 Instruction Manual InteliSENS DG2120-K CCD Diameter Gauge Issue 1a 26 August 2019 Proton Products Co. Ltd. 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Page 1 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 2: Table Of Contents

    ACCESS LEVELS ..........................38 ..........39 TANDARD OMMUNICATIONS NTERFACES CAN- ....................... 39 BUS COMMUNICATIONS CAN-bus interface ............................39 CAN-bus LED indicator ..........................39 RS-232 C ......................... 40 OMMUNICATIONS Page 2 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 3 Reading a continuous stream of a single output parameter ............... 61 Reading a continuous stream of a block of output parameters ..............62 ..........63 ODBUS PARAMETER ACCESS PROTOCOL Page 3 of 72 Proton Products InteliSENS DGK2120 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 DGK2120 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: EMC - EN 61326-1:2013 Low Voltage - EN 61010-1:2010 (Scientific and measuring instruments)

  • Page 6: Introduction

    NTRODUCTION The InteliSENS DG2120-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 DG2120-K diameter gauge uses an entirely solid state technique.

  • Page 7: Specifications

    (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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 8: Standard Interfaces

    Communication interfaces 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 CDI4 interface display unit. PTIONAL INTERFACES Must be specified for installation at time of manufacture, cannot be retrofitted.

  • Page 9: Dimensional Drawings

    IMENSIONAL RAWINGS Page 9 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 10: Annotated Drawings

    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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 11: Optional Accessories

    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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 12: Optional Firmware

    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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 13: Interface Display Modules

    Proton part number 00049MC023 CAN-bus extension cable Name Length / m Proton part number DG_SL-AIG2-005 00041CN005 DG_SL-AIG2-010 00041CN010 DG_SL-AIG2-015 00041CN015 DG_SL-AIG2-020 00041CN020 DG_SL-AIG2-030 00041CN030 DG_SL-AIG2-050 00041CN050 Page 13 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 14: Power Supplies And Connectivity

    DB25 “INTERFACE” port to PSU-BOB-DG, Terminal Strip-DIN or CS1G-SL cable Name Length / m Proton part number SLMKII-BOB-003 00041TC003 SLMKII-BOB-005 00041CT005 SLMKII-BOB-010 00041CT010 SLMKII-BOB-020 00041CT020 SLMKII-BOB-030 00041CT030 Page 14 of 72 Proton Products InteliSENS DGK2120 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

    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

    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: Air Wipe Air Supply Installation

    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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 20: Electrical Installation

    • Ensure that the shields of cables connecting to the end user’s equipment are clamped to earth at their destination. Page 20 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 21: Power Supply

    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 DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 22: Configuration Via Cdi4

    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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 23: Home

    - Y error (Y diameter – Preset Y diameter) Press the button to access the function menu page. Press the button to advance to “Home Page 3”. Page 23 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 24: Home

    - 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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 25: 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 25 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 26: Function Menus

    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 72 Proton Products InteliSENS DGK2120 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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • 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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • 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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 30: 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 30 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • 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 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 32: 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 32 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 33 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 33 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 34 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 34 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 35: 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 35 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 36: Store

    - Process capability Cpk - Count down of the remaining statistics time or length until the next statistics result. Press the button to return to the home page. Page 36 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 37: 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 37 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 38: 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 38 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 39: 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 40: 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 40 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 41: 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: A05000<CR><LF> Page 41 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 42: 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 42 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 43: Continuous Data Output

    Example continuous data output string: $8050000+10<CR><LF>MY 05000 <CR> <LF> Start Gauge Position Carriage Line Diameter Status Units Axis character type in gate Return Feed 05.000 Gauge Metric DGK2120 +10% (millimetres) Page 43 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 44: Rs-422 / Rs-485 Communications

    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 44 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 45: Ethernet Communications

    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 45 of 72 Proton Products InteliSENS DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 52: 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 52 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 53 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 DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 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 DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 59: 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 59 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 60: Proton Standard Parameter Access Protocol

    ?[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. RITING INPUT PARAMETERS Page 60 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)

  • Page 61: Writing A Single Input Parameter

    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 61 of 72 Proton Products InteliSENS DGK2120 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 DGK2120 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

    DW20 Preset Y upper limit 1=0.01um/0.01mil 0~12000000 50000 DW21 DW22 Preset Y lower limit 1=0.01um/0.01mil 0~12000000 50000 DW23 DW24 Preset Z upper limit 1=0.01um/0.01mil 0~12000000 50000 Page 64 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 65 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 65 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 66 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 66 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 67 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 67 of 72 Proton Products InteliSENS DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 68 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 68 of 72 Proton Products InteliSENS DGK2120 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 DGK2120 Diameter Gauge Instruction Manual (Issue 1a)
  • Page 70 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 70 of 72 Proton Products InteliSENS DGK2120 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 DGK2120 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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