Baumer Ident OIS-P PC 3100, OIS-P PC 3101, PC3141/03 Installation Manual

OIS-P

OIS-P PC 3100/01 series

8 kbyte Communicators PC3141/03

System Description and Installation Manual

B 1030 200

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Reg. No. B1030 200 Edition 4

May 2001 Subject to alteration without prior notice.

Baumer Ident GmbH, Hertzstrasse 10, D-69469 Weinheim © Copyright Baumer Ident GmbH 2001 Tel +49 6201 9957-0 Fax +49 6201 9957-99 Printed in Germany.

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4 Baumer Ident OIS-P, PC3141/03 Manual

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OIS-P, PC3141/03 Manual Baumer Ident 5

The products described in this document may be subject to modifications without corresponding updating of the document.

This product contains parts, that are sensitive against electrostatic discharges. Please heed the particular instructions for protection. Ground yourself before you touch the appliance.

FCC ID: PNTOIS-P3100

The device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause

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OIS-P, PC3141/03 Manual Baumer Ident 7

Contents

1 System description ............................................................................. 9

1.1 General ........................................................................................ 9

1.2 System components ..................................................................... 9

1.3 Mechanical description .................................................................9

1.4 EUROX_4-Software ................................................................... 10

1. 4.1 General ............................................................................ 10

1.4.2 Commands .......................................................................10

2 System performance ........................................................................ 13

2.1 Communication speed ................................................................ 13

2.1.1 Data Tag communication .................................................. 13

2.1.2 Host communication times ................................................ 14

2.1.3 Total communication time .................................................. 15

2.2 Communication area ................................................................... 16

2.3 Distance between Data Tags ..................................................... 17

2.4 Distance between antennas ....................................................... 18

3 Environmental influence .................................................................. 19

3.1 General ...................................................................................... 19

3.2 Metallic objects........................................................................... 20

3.3 Foreign substances between antenna and Data Tag ................. 21

3.4 Temperature ............................................................................... 21

3.5 Electromagnetic immunity .......................................................... 21

3.6. Conclusions on environmental influence .................................... 22

4 Health aspects .................................................................................. 23

4.1 Emitted power levels .................................................................. 23

4.2 Health and safety cautions ......................................................... 23

5 Maintenance aspects ....................................................................... 25

5.1 General ...................................................................................... 25

5.2 Battery life .................................................................................. 25

6 Installation ........................................................................................ 27

6.1 Mechanical installation ............................................................... 27

6.2 Electrical connection .................................................................. 28

6.2.1 Power supply and object detect ......................................... 28

6.2.2 Serial communication ........................................................ 28

6.2.3 Antenna connection........................................................... 30

6.2.4 Test terminal ..................................................................... 30

7 Installation and trouble-shooting ................................................... 31

7.1 Communicator Set-Up ................................................................31

7.2 Test methods and error codes .................................................... 33

7.3 PC program for communication test ...........................................34

7.4 Built-in communication reliability statistics .................................. 34

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Contents

7.5 Internal inspections and tests ..................................................... 35

7.5.1 General ............................................................................. 35

7.5.2 Connector Board and fuse ................................................ 35

7.5.3 LED indications ................................................................. 35

7.5.4 Power Board ...................................................................... 36

7.5.5 CPU Board ........................................................................ 37

8 Technical Data .................................................................................. 39

8.1 Communication parameters ........................................................ 39

8.2 Mechanical specification ............................................................. 39

8.3 Electrical specification ................................................................ 39

8.4 Cable specifications .................................................................... 40

8.5 Environmental specification ......................................................... 41

OIS-P, PC3141/03 Manual Baumer Ident 9

System description

1.1 FCC Statements

The users manual or instruction manual for an intentional or unintentional radiator shall caution the user that changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

The unit described in this document complies to FCC. It´s FCC ID is: PNTOIS-P3100

1.1 General

The Central Unit PC3141/03 is a product within the OIS-P PC3100/01 family. The unit will read and program the following 8 kbyte PC3100 Data Tags: PC3104/32A, PC 3104/22A and PC3105/00D. The contents in the Data Tags is however of an uncompatible format compared to the earlier PC3100/00 system.

PC3141/03 uses an external antenna to communicate to the Data Tags. This gives a high flexibility for antenna mounting.

The serial interface for the host is alternatively RS485, RS232 or CL interface. The protocol used is either the 3964R or the OIS-P communication protocol EUROX_4.

1 System description

1.2 System components

Main components:

PC3141/03A Central unit PC3114/00A Antenna PC3114/01A Antenna, long range PC3104/32A Data Tag, normal temperature,

medium speed

PC3104/22A Data Tag, normal temperature,

high speed

PC3105/00D Data Tag, heat resistant

Accessories:

PC3117/11A Antenna cable with connectors, 10 m PC3117/12A Antenna connector set PC3017/02A Antenna cable on reel, 100 m PC3117/13A Antenna cable with connectors,

length is to be specified 1–100 m.

Installation tools

PC3104/01A Test Data Tag with LED indicators PC3100/90A PC test software

1.3 Mechanical description

The central unit consists of an enclosure with a CPU-board, a power supply and connection terminals.

The CPU-board is accessable (for switch settings etc) by opening the cover which is mounted with hinges. Connections of power, digital I/O and serial communication are done with connectors. There are four separate connectors, one for power, one for I/O, one for serial communication, one for a test terminal and one for the antenna.

The unit is equipped with mounting flanges in each corner.

10 Baumer Ident OIS-P, PC3141/03 Manual

1.4 EUROX_4-Software

1. 4.1 General

The software EUROX_4 in PC3141/03 is mainly compatible with earlier versions of software EUROX in OIS-P communicators PC3000 and the communicators PC3120.

The PC3141/03 with EUROX_4 software will communicate with 8 kbyte Data Tags PC3104/32A, PC3104/22A and PC3105/00D.

Detailed information is available in “ID System, PC 3100/01, System firmware EUROX_4 Programmers Manual”.

1.4.2 Commands

The following parameter types are referenced in the command list. The fixed number of characters is only necessary if the optional ‘,’ in the commands is not used:

bufno 0 - 4 hex data max 4 kbyte, 8 bit characters destpos 000 - FFF hex or three ASCII

characters ‘???’ represent end

of buffer filelen 000 - FFF hex fileno 00 - FF hex filetype Any two ASCII characters id addr 0 - FFFFFF hex (00 - FF if fixed

length format) reject previuos ‘0’ or ‘1’ len 000 - FFF hex

or three ASCI characters ‘???’

represent end of buffer (not for

RP) offs 000 - FFF hex prot ASCII characters ‘WR’ or ‘RO’

(‘Write and Read’ or ‘ Read

Only’) srcpos 000 - FFF hex I/O-value ‘0’, ‘1’ or ‘-’ EX mode ‘0’ multiple or ‘1’ single

execution

System description

Parameter dictionary

bufno Buffer number data ASCII 8 bit characters destpos Start position in destination buffer filelen File length fileno File number filetype File type, any two ASCII

characters. Use ‘?’ as wildcard in

any or both positions id addr Data Tag address reject previous Reject previous Data Tag, 0 or 1

( 1= reject) len Length, number of bytes offs Offset number of bytes prot File protection code srcpos Start position in source buffer

I/O-value Output value, ‘0’ = off, ‘1’ = on

and ‘-’ = no change EX mode Command buffer execution mode

OIS-P, PC3141/03 Manual Baumer Ident 11

System description

Command buffer

Define DF End define EN Execute EX[,<EX mode>]

Maintaining files

Alter protection AP,<fileno>,<prot> Directory DI,<bufno>,<filetype> Format file FM,<fileno>,<filelen> Mark filetype MK,<fileno>,<filetype>

(wildcard not allowed)

Reset files RF,<fileno>[,<fileno>]

Initiating Data Tag

Battery change BC,<bufno> Initiate IN[,<id addr>]

Miscellaneous

Status request ST Get battery date BD,<bufno> Break BR Copy buffer to buffer CO,<bufno>,<srcpos>,

<len>,<bufno>,<destpos> End Data Tag EE New Data Tag NE,<reject previous> Reset buffer RB,<bufno>[,<bufno>]

Command list

The ‘,’ may be omitted. If ‘,’ is not used the parameter format has to be of a fixed length.

Moving data between Communicator buffer and Data Tag

Append to buffer AB,<bufno>,<fileno> Append to tag AT,<bufno>,<fileno> Load circulating file LC,<bufno>,<fileno> Load LD,<bufno>,<fileno> Load file part LP,<bufno>,<fileno>,

<offs> Read RD,<bufno>,<fileno> Read file part RP,<bufno>,<fileno>,

Moving data between host and Communicator buffer

Buffer length BL,<bufno> Get buffer GE,<bufno> Put append PA,<bufno>,<data> Put PU,<bufno>,<data>

Digital I/O

Read inputs RI Set outputs SO,<I/O-value>,...

<I/O-value> (6 values)

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System description

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OIS-P, PC3141/03 Manual Baumer Ident 13

2.1 Communication speed

2.1.1 Data Tag communication

The data transmission speed between communicator and the Data Tag depends on the amount of data to read or write.

Table 2.a shows the minimum microwave communication time needed under ideal circumstances. If a disturbance would occur, the communicator will automatically initiate a retransmission of the data block (16 bytes).

2 System performance

System performance

File size bytes

10 100 1000 4000

Write one file LD

PC 3104/32A, PC3105/00D 0.14 0.16 0.39 1.2 PC 3104/22A 0.06 0.07 0.14 0.37

Read one file RD

PC 3104/32A, PC3105/00D 0.12 0.14 0.32 0.95 PC 3104/22A 0.06 0.06 0.12 0.31

Table 2.a Communication time microwave link

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System performance

to commands) and reaction time in the host computer. The host is assumed to react to command replies in 10 ms. Both this table and the Data Tag communication time table must be used to calculate the total time required at a OIS-P station, when conducting calculations on passage frequency.

2.1.2 Host communication times

The host communication can be up to 19.200 baud.

The table below displays the time required for communication between the Host computer and the Central Unit. The table presents the time required to transfer file data and commands (or responses

Table 2.b Serial communication times host–central unit (EUROX_4 protocol/8/E/1). Send one

file from the host to the control unit and start the writing into the tag.

Transfer speed File size

bits/sec 10 100 1000 4000

4800 0.16 0.34 2.3 8.5

9600 0.09 0.19 1.13 4.3

19200 0.06 0.11 0.58 2.2

Table 2.c Communication sequence used for calculation of time values in table 2.b.

Host to central unit Central unit to host Time included in table 2.b

PU, 0, <Data> ACK X

LD, 0, 2 ACK X

ST 101 X

ST _ _ _

_ _ _ _ _ _

ST 001

NEXT FILE

OIS-P, PC3141/03 Manual Baumer Ident 15

2.1.3 Total communication time

Point-to-point connection

The total time required for communication between the host system and the Data Tag is calculated by adding the Data Tag communication time (Table

2.a) to the host communication time (Table 2.b).

This will result in a total communication time based on the following conditions:

* The host has a response time of 10 ms. * The OIS-P system is connected to the host

in point-to-point connection.

If the serial interface response time in the host is significantly longer than the stipulated 10 ms, the additional time will have to be added three times.

Multidrop connection

In case OIS-P communicators are connected in a multidrop configuration, the following guidelines will apply for determining the total time required for moving data between Data Tag and host:

a/ If each Communicator’s task is performed

from start to finish, without delay due to host communication with other units, the total time required for moving data between Data Tag and host will be the same as for a point-topoint connected unit.

b/ However, if the system engineer designs the

application software program in a way, that the process of moving data between Data Tag and host may be interrupted by host communication with other Communicators, an object must remain in front of an antenna for a longer time than in a point-to-point situation.

How much longer this required time will be, depends on how the system engineer has designed the application specific software in the host.

Example

Let’s assume initial production requirements are to be written to a PC 3105/00D Data Tag at the start of a production line. The Data Tag is present (moving or stationary) in the communication zone for 10 seconds. 30 files with an average size of 100 bytes are to be written. The host communication baudrate can be chosen to satisfy the time requirements. The OIS-P is connected to the host in a point-to-point configuration and the response time for the host is less than 10 ms.

Time required

at different baud rates

Sequence: 9600: 19200:

Host to central unit time (30 x 0.19/30 x 0.11) 5.7 3.3

Central unit to escort memory time 30 x 0.16 4.8 4.8

Total: 10.5 8.1

Table 2.c Example on total communication time.

Result:

The baudrate 19200 should be used for sufficient margins. A faster solution would be to use the command buffer. All data can be loaded into one buffer before the Data Tag arrives to the communication zone. With a command buffer containing CO (Copy Buffer to Buffer) and LD (Load) there is no need for a communication to the host for every file. The resulting time in the example above would be less than 5.0 s., i.e. a recommendable margin of a factor 2.

System performance

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System performance

2.2 Communication area

The communication area for the antenna PC3114/ 00A (maximum 2 m distance) is shown in Figure

2.1. The diagram assumes a Data Tag temperature of -40oC - +40oC and a pitch and tilt angle of 0o. The antenna PC3114/01A has almost twice as long communication distance (Figure 2.2).

It is always recommended to only utilise 50 to 75% of the range in free space due to influences in the actual installation.

Figure 2.1 Communication area, PC3114/00A

Figure 2.2 Communication area, PC3114/01A

Figure 2.3 shows the allowed alignment between Data Tag and antenna.

Figure 2.3 Freedom of alignment.

0.5

0

0.5

Radium (metres)

0.5 1.0 1.5 2.0

1

0

1

Radium (metres)

1234

OIS-P, PC3141/03 Manual Baumer Ident 17

System performance

2.3 Distance between Data Tags

Narrow antenna field

The data transmission frequency of 2,45 GHz offers many excellent characteristics, of which one is the ability to “focus” the microwaves on a desired area, much like a flash light throws out a narrow beam of light.

Figure 2.4 Focussing on the “right” object thanks to the narrow antenna field.

Data Tag ID-address

To further enhance installation flexibility and ensure optimum communication reliability, each Data Tag has a unique identity. The so called ID-address is factory programmed from a range of more than 16 million (224) ID-addresses. The unique IDaddresses will ensure that communication initiated with an Data Tag also can be finalized with the that particular Data Tag, even if another Data Tag would come in closer to the antenna. It is thus important that the ID-addresses remain unique even if the user reinitialises the tags. The system is, however, basically designed for one tag in the lobe and other situations should be avoided.

Distance between Data Tags

It is important that the Data Tag with which communication is to be established, returns the strongest signal to the antenna, as the Data Tag communication is initiated by OD or user command. To translate that into a minimum distance between Data Tags, an antenna lobe diagram must be studied.

The graph lines in figures 2.1 and 2.2 represent positions of similar signal strength in front of an antenna. The distance between two graph lines represent a signal strength difference of 3 dB.

18 Baumer Ident OIS-P, PC3141/03 Manual

The recommendations for how close Data Tags may be to each other at a communication point are:

1. Ensure at least a 3 dB difference in signal strength between the intended Data Tag and all other Data Tags, when communication starts. If a major difference in Data Tag exposure to foreign substances like paint etc can be expected, this difference should be added to the 3 dB mentioned above. Please refer to section

3.3.

2. The closer to each other the Data Tags must come, the shorter the communication distance should be. By reducing the communication distance, it is easier to maintain a significant difference in signal strength between the intended Data Tag straight in front of the antenna and not intended Data Tags.

The closer Data Tags come to each other, the more important also the timing of object detect activation becomes. If objects come very close to each other, OD should be activated as the correct Data Tag is located straight in front of the antenna. This however means that part of the theoretical access range is lost. For communication with objects at standstill this means that the object stop position is more critical. For communica-tion with objects in motion, it means that the available communication time is reduced.

3. Recommendation 1 and 2 above prevents that no communication with other Data Tags will occur, provided that the intended Data Tag is present and in operating order. For a better protection against communication with nearby Data Tags, these cannot be allowed within an area, corresponding to 2–5 times the size of the 0 dB graph line in figure 2.1 and 2.2.

Microwaves can, however, be influenced and reflected by metal and directed into unwanted areas, which has to be considered in the installation layout.

Should this description not cover your installation requirements or should you have any questions, please consult your OIS-P system specialist for advice.

2.4 Distance between antennas

To ensure that the antenna only communicates with the proper Data Tag the recommendations under section 2.3 must be followed.

To avoid interference between adjacent antennas, the Interlock function should be used. This means that two or more antennas avoid to communicate simultaneously. Since the microwave communication time is short, this Interlock will normally not influence the total communication time notably. An Interlock function can also be realised by sequencing the commands in the host (PLC) to the different control units. Without Interlock the antennas should be separated 4–10 times the size of the 0 dB graph line in figure 2.1 and 2.2.

If for some reason the Interlock function can't be used there is a possibility to use frequency separated antennas. Please contact your OIS-P system specialist for advice.

System performance

OIS-P, PC3141/03 Manual Baumer Ident 19

Environmental influence

3.1 General

Since the OIS-P system is a vital part in a usually complex production process, where products of high value are manufactured, the highest priority has been set on maximizing communication reliability. This means that top performance must be guaranteed even under severe industrial environmental conditions.

The OIS-P technology has proven itself capable, during more than a decade in the automotive

industry, where the environment at times can be testing; oils, water and other fluids have to be dealt with, as has electromagnetic fields from welding robots, paint layers, high temperatures, shock and vibration and much more.

In the following, the potentially influencing environmental factors and their consequences for the installation planning is described.

3 Environmental influence

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3.2 Metallic objects

Microwaves at 2.45 GHz have an excellent capability of penetrating through foreign substances, as described in section 3.3. However, like all electromagnetic waves, microwaves cannot penetrate through metallic objects.

Therefore, installations should be planned in such a way that metallic objects are not present between antenna and Data Tag when communication with an Data Tag is to take place. However, small metallic objects like metal shavings etc will not influence negatively on the communication. Further, both Antenna and Data Tags can be mounted directly onto metal surfaces.

Any system operating in the MHz range or higher, will have a communication range in which the signal strength varies, due to wave reflections.

To minimize this phenomenon, the PC3100 system features circular polarization, which suppresses microwaves reflected from metal surfaces an odd number of times. The suppression is equivalent to 6 dB or more.

To avoid the risk of negative interference from metal surfaces, one of the following situations should be established.

Environmental influence

A. Communication with the Data Tag is

performed in motion.

Any negative influence of reflections will result in a slightly longer communication time. This should be added to the communication time with a margin dependent on the actual case, normally a factor 2 (See section 2.1).

B. Communication is performed with the Data

Tag at standstill.

Metal surfaces in positions where they could reflect microwaves from the antenna towards the Data Tag should be studied. Generally they should be at a position equivalent to a 6 dB lower signal strength than the Data Tag, to avoid negative influence. This can usually be achieved by reducing the distance between antenna and Data Tag.

Depending on reflections there may be points with stronger or weaker signals and the position of the antenna and/or the Data Tag should then be adjusted to achieve a strong signal. The distance between points with strong signal is normally 12.4 cm.

OIS-P, PC3141/03 Manual Baumer Ident 21

Environmental influence

3.3 Foreign substances between antenna and Data Tag

Microwaves penetrate through many foreign, nonmetallic substances with no or very little loss of signal strength. However, if the reduction in signal strength should be considerable, an appropriate reduction in communication distance is recommended as shown in table 3.a.

Substance Rec. signal strength

adjustment (dB/mm)

1st mm Thereafter

Water 7 0.5 Oil 1 0.2 Grease 1 0.1 Regular car paint 1 Note 1 Metallic car paint 3 Note 2 Paper 0.02 0.02 Plastic 0 - 1 0 - 0.05 Snow 0 - 0.5 0 - 0.2 Ice 0.5 0.1

Table 3.a Recommended reduction of

communication distance as a function of foreign substance layer thickness.

The signal strength adjustment will vary slightly, depending on the exact composition of the contamination, where it is applied etc. Note 1: Layers beyond 1 mm not

likely. Adjustment for 0.2 mm amounts to 0.5 dB.

Note 2: Layers beyond 1 mm not

likely. Adjustment for 0.2 mm amounts to 1.5 dB.

How the recommended signal strength adjustment relates to the communication distance can be seen in diagrams in section 2.2.

3.4 Temperature

The antenna lobe diagrams in section 2 are valid for temperatures up to +40 °C.

If the ambient temperature increases or if the Data Tags are exposed to higher temperatures than +40 °C, this will result in a reduced signal strength and a corresponding increase by reduction of the

communication distance should be ensured, as indicated in table 3.c below.

Product Recommended signal

strength adjustment

+40

°°

°C +70

°°

°C +110

°°

°C

Data Tag PC3104/32A,/22A 0 dB 2 dB n/a Data Tag PC3105/00D 0 dB 2 dB 4 dB

Note 3

Table 3.b Recommended signal strength

adjustment due to ambient temperature. Note 3: The internal temperature must

be calculated, which will be done by Baumer Ident on request.

How the recommended signal strength adjustment relates to the communication distance can be seen in diagrams in section 2.2.

Long term exposure of Data Tags to high temperatures should generally be avoided, as can be concluded from section 5.2.

3.5 Electromagnetic immunity

The PC3141 system has been EMC-tested according to the pr ETS 300339 which is required for the CE-marking. This assures trouble-free operation in demanding electromagnetical environments.

Electromagnetic interference in cables

By selecting a suitable communication interface, using specified cables and proper grounding, optimum communication reliability is ensured.

Electromagnetic interference on the microwave link

Industrial noise is typically present in the kHz and low MHz frequency band. The OIS-P system is only receptive for frequencies of 2,45 GHz +/- 5%, so typical industrial noise will not affect the microwave communication.

Transients from spot-welding equipment or from switching on other welding equipment, soldering machines and fluorescent lighting fixtures may produce short pulses around 2,45 GHz. However, since the OIS-P system, if interfered, will continue

22 Baumer Ident OIS-P, PC3141/03 Manual

Environmental influence

communication from the point of interference, rather than having to retransmit an entire message, such short transients would merely increase the required communication time by a small fraction.

If strong microwave fields from for instance industrial microwave dryers can be suspected, an on-site survey by a OIS-P specialist should be carried out to determine proper installation procedures.

3.6. Conclusions on environmental influence

As shown, the OIS-P PC3141 system is highly unsensitive to the typical industrial environment. Still, common sense must be used when planning an installation and some general rules of thumb can be established.

1. It is recommended that installation is planned

in such a way, that communication at maximum specified distance and maximum specified misalignment is avoided at the same time. Thereby the access range becomes longer, thus making object positioning less critical and the communication capacity higher.

2. To establish if a reduction of the communi-

cation distance should be considered, the following table will be of help. By adding the recommended dB signal strength increase for the factors that apply for your particular installation and comparing the total with diagrams in section 2.2, a general understanding of a suitable decrease in communication distance is received.

Aspect Rec. signal

strength

adjustment

Metal in/close to the comm. lobe

(section 3.2)

- Communication in motion 0 dB

- Communication at standstill 0 - 6 dB

Foreign substances between Data Tag and antenna 0 - 3 dB

(section 3.3)

Temperature

(section 3.4)

- Data Tag below +40 °C0 dB

- Data Tag at +70 °C2 dB

- Data Tag at +110 °C4 dB

Electromagnetic interference 0 dB (section 3.5)

Table 3.c Summary on environmental influence

on communication distance.

Electromagnetic interference and metal in the communication area when reading in motion, will not require a reduction of the communication distance. This will only result in a slightly longer communication time, which should be added to the data from the table 2.1.

3. To finally define the optimum communication distance, on-site testing is recommended. This is especially important when there is plenty of metal in the communication area and communicating is performed at standstill, as table 3.c indicates.

On-site testing is facilitated by the installation tools available.

OIS-P, PC3141/03 Manual Baumer Ident 23

Health aspects

4 Health aspects

4.1 Emitted power levels

The only emitted power worth mention is the emission at the data transmission frequency 2,45 GHz. As can be seen from the graph below, the emitted power is far below all known international health standards.

Figure 4.1 International health standards for exposure to emitted microwave power.

Radiation density for PC3114/00A at a distance of 0 and 1 meters.

The distance from the antenna in the graph is defined straight out from the antenna surface, where the intensity is the highest.

4.2 Health and safety cautions

Normal caution is required when removing the central unit’s cover. Humans beings have to keep a safety distance of 20 cm to the antenna.

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Health aspects

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OIS-P, PC3141/03 Manual Baumer Ident 25

Maintenance aspects

5 Maintenance aspects

5.1 General

The PC3141 OIS-P system is basically a maintenance-free system. Once correctly installed, it will deliver many years of trouble-free operation.

In important processes, the user usually collects and evaluates communication reliability statistics on a regular basis. These statistics can be retrieved from the OIS-P communicator as described in section 7.4 or can be collected at the user control system level.

5.2 Battery life

General

In order to obtain communication distances in the meter range, high data speed and still comply to international telecommunications and health standards, the Data Tags must be equipped with a battery.

To get maximum life out of the batteries, the OIS-P Data Tags are of semi-passive type. The majority of the time, the Data Tags are passive and only consuming a few µA. Only during communication, which typically is ended in a fraction of a second, will they be active with an increased current consumption.

The batteries chosen are long-life lithium batteries, whose life expectancy depend on the amount of data communication, the data transmission speed of the Data Tag and the ambient temperature in which it is used. If the ambient temperature is high, the battery life will be somewhat reduced. Long term exposure to high temperatures should therefore be avoided.

However, for most industrial applications, the battery life will be longer than 6 to 8 years, as specified on the Data Tag data sheets.

Battery-low alarm

The remaining battery capacity is automatically monitored every time communication is established with an Data Tag. When “battery-low” status is reported to the user control system, the remaining battery capacity is 5% and the Data Tag should be taken out and receive a new battery.

Note: Battery low indication is not reliable

in sub-zero °C temperatures. If battery-low indication is received in temperatures below freezing, no adequate conclusion can be made from this.

26 Baumer Ident OIS-P, PC3141/03 Manual

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Maintenance aspects

OIS-P, PC3141/03 Manual Baumer Ident 27

Installation

6 Installation

6.1 Mechanical installation

The communicator should be mounted by means of the four mounting flanges (Diam 8,5 mm) in the corners of the unit. See Figure 6.1. Use mounting screws with diam. 8 mm.

Warning

The antenna must be installed at least 20 cm of persons off.

Figure 6.1 Mechanical dimensions PC 3141/03

I/O TERMINAL

85

HOST ANTENNA POWER

28 Baumer Ident OIS-P, PC3141/03 Manual

6.2 Electrical connection

6.2.1 Power supply and object detect

The unit should be connected to power supply 24 VDC. An active OD-signal should be represented by a 24VDC voltage on the OD input. There are totally 6 digital inputs and 6 digital outputs available.

The connection is done to POWER and I/O, see Figure 6.2, 6.3 and 6.4. POWER is a male 9 pin DSub 9 connector. Use cable connector D-Sub 9 female.

Figure 6.2 Power and I/O connection

Installation

POWER

PC3141/03

1

2

3

4

OV

5

6

+24VDC

7

8

9

}

I/O

PC3141/03

OUT5 OUT3 OUT1 (BSY) +24VDC IN5 IN3 IN1 (RALA) OV OUT4 OUT2 (LOCK) OUT0 (ALA) +24VDC IN4 IN2 (LOCK) IN0 (OD)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

For RS485 and current loop connection also see figure 6.6, 6.7, 6.8.

HOST

PC3141/03

CLIRxD RS232 TxD RS232 CLO-B

RxD –RS485 GND TxD +RS485 CLI+ RTS CTS CLO-A

RxD +RS485 TxD –RS485

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Figure 6.3 Interface circuit, input









Figure 6.4 Interface circuit, output







6.2.2 Serial communication (HOST)

The serial interface is RS232, RS485 or passive current loop. The connection is done to HOST, see Figure 6.5. HOST is male 15 pin D-Sub connector. Use cable connector D-Sub 15 female.

Figure 6.5 Serial connection

OIS-P, PC3141/03 Manual Baumer Ident 29

PC 3141/03

8

15

7

14

6

SHIELD

HOST

8

15

7

14

6

SHIELD

HOST

8

15

7

14

6

Installation

Figure 6.6 RS485 multidrop configuration

HOST

PC3141/03

30 Baumer Ident OIS-P, PC3141/03 Manual









Installation

6.2.4 Test terminal

The test terminal is connected to TERMINAL, see Figure 6.10. TERMINAL is a male 9 pin D-Sub connector.1500AO. Use cable connector D-Sub 9 female.

Figure 6.10 Test terminal connection

6.2.3 Antenna connection

The central unit PC3141/03A uses a separate antenna conntected to ANTENNA according to figure 6.9. ANTENNA is a D-Sub 9 female connector.

Figure 6.9 Antenna connection

For order codes of antenna connection cables, see section 1.2.

The connection to the antenna must be done with a shielded cable.

Figure 6.7 Current loop passive transmitter

Figure 6.8 Current loop passive receiver

HOST

CLI+

CLI-

CLO B

CLO A

ANTENNA

PC3141/03

GND RESERVED IN RESERVED IN PF– EN+ +18V RESERVED OUT PF+ EN–

1 2 3 4 5 6 7 8 9

RESERVED RxD TxD

GND

RTS (NOT USED) CTS (NOT USED)

1 2 3 4 5 6 7 8 9

TERMINAL

PC3141/03

When the test terminal is not connected, the contact must be protected with the cover.

This connection is only intended for test purpose and is not optoisolated. This means that it should be used with care, e.g. with a short, shielded cable and should not be permanently connected.

The terminal can also be used to examine the list of the most recent error codes, host communication messages and to test the communicator to a Data Tag.

HOST

4

12

9

1

{{

{

{{

{

OIS-P, PC3141/03 Manual Baumer Ident 31

Installation and trouble-shooting tools

7.1 Communicator Set-Up

The Set-Up of selectable communicator functions is done by opening the cover of the unit. This will reveal the CPU4-board that contains DIL-switches as in Figure 7.1 below.

Figure 7.1 CPU4 board lay-out

boar

The CPU-4 board has 3 sets of DIL switches which are used to set functional options.

SW1:1

On: Object detect to be used (default)

SW1:2

On: Status to be sent automatically Off: (default)

SW1:3

On: Extended I/O ( 5 inputs and

6 outputs available)

Off: (default)

SW1:4

On: Timeout option used (4 s) (default)

SW1:5

On: Delayed response (50 ms) Off: (default)

SW1:6

On: High priority commands

allowed (AP)

Off (default)

SW1:7

Off

SW1:8

Off The use of SW2 is depending on the used communication protocol.

7 Installation and trouble-shooting

32 Baumer Ident OIS-P, PC3141/03 Manual

If 3964R protocol is used:

SW2:1-3:

Block length:

Block length 2:3 2:2 2:1

16* Off Off Off

32 Off Off On

64 Off On Off

128 Off On On

256 On Off Off

512 On Off On

1024 On On Off

252 On On On

SW2:4,5:

Character timeout:

Character

timeout ms 2:5 2:4

220* Off Off

330 Off On

440 On Off

550 On On

SW2:6,7:

Acknowledge timeout:

Acknowledge

timeout s 2:7 2:6

2* Off Off

3OffOn

4OnOff 5OnOn

*Default

Installation and trouble-shooting tools

SW 2:8

Off: Eurox protocol used On: 3964 R protocol used

If EUROX protocol is used:

SW2:1-5:

Communicator address

Addr 2:5 2:4 2:3 2:2 2:1

0* Off Off Off Off Off

1 Off Off Off Off On

2 Off Off Off On Off

3 Off Off Off On On

4 Off Off On Off Off

5 Off Off On Off On

6 Off Off On On Off

7 Off Off On On On

8 Off On Off Off Off

9 Off On Off Off On

: Off On Off On Off

; Off On Off On On

< Off On On Off Off

= Off On On Off On

> Off On On On Off

?OffOnOnOnOn

@ On Off Off Off Off

A On Off Off Off On

B On Off Off On Off

C On Off Off On On

D On Off On Off Off

E On Off On Off On

F On Off On On Off

GOnOffOnOnOn

H On On Off Off Off

I On On Off Off On

J On On Off On Off

KOnOnOffOnOn

L On On On Off Off

MOnOnOnOffOn

NOnOnOnOnOff

OOnOnOnOnOn

OIS-P, PC3141/03 Manual Baumer Ident 33

Installation and trouble-shooting tools

SW3:1

On Host 8 bits data (default) Off 7 bits data

SW3:2

On Host Even parity (default) Off Odd parity

SW3:3

On Parity bit used (default)

SW3:4

On Host 2 stop bits. Off 1 stop bit (default)

SW3:5

On Host CTS signal is used. Off: (default)

SW3:6-8:

Host baudrate:

Baud SW3:8 SW3:7 SW3:6

150 Off Off Off

300 Off Off On

600 Off On Off

1200 Off On On

2400 On Off Off

4800 On Off On

9600* On On Off

19200** On On On

* Default ** Not for current loop

WT3, WT4 jumpers

WT3 present = long INTERLOCK WT4 present = short INTERLOCK Default is no jumper.

After any change of DIL switch or jumper

settings, the communicator must be reset

(power on).

7.2 Test methods and error codes

The status of the Central Unit can be observed by: – Test terminal. A PC with a terminal emulating

software can be connected to the connector TERMINAL of the PC3141/03. Here the list of the most recent error codes as well as the host communication can be observed. See below.

– LEDs on the CPU and power board show the

present status on data communication and power supply.

The error code on the TERMINAL consists of 2 characters CH0 and CH1. The meaning of this code is more described in the Programmers' Manual.

CH0 Central Unit Operation status

The value 3 means that an error has been detected.

CH1 Error codes

0 Illegal file number 1 File overflow 2 Data buffer overflow 3 File protection alarm 4 High priority alarm 5 Not used, reserved for future use 6 Invalid data 7 Data Tag test failed 8 Data Tag unreadable 9 File unreadable A Object detect alarm B Object detect alarm, no command C Not used D Data Tag communication timeout E Not used F Initialized (“power on”)

34 Baumer Ident OIS-P, PC3141/03 Manual

Installation and trouble-shooting tools

7.3 PC program for communication test

The PC3100 product range includes a menu driven PC program for the EUROX_4 protocol PC 3100/ 90A, (CMD3120) which allows communication with the OIS-P system from an IBM compatible PC/XT/ AT personal computer, operating on DOS and having at least one serial port, configurable as “COM1” or “COM2”.

The program features three modes:

High level: Commands can be issued in a very simple way, such as “read file”, “write to file” etc. Basic system functionality is easily executed, to get acquainted with the system or for basic installation testing.

Low level: Commands are entered in low-level language, exactly as they are described in the Programmer’s Manual. The entire command list can be executed, offering, for instance the programmer, a hands-on possibility to get acquanted with the full range of user commands and command parameters.

Verifier level: Allows verification of execution reliability for user-definable communication tasks.

The user can enter a sequence of low-level commands including possible time-delays, to resemble a typical communication task and situation. The entered sequence is executed repeatedly, when Object detect is indicated “active” to the central unit. Communication reliability statistics and measured execution time (maximum, average and minimum) is continously stored and displayed.

7.4 Built-in communication reliability statistics

The PC3141/03 central units have a built-in statistics function, which keeps a count on the system’s communication reliability. The statistics count is initiated as soon as power is connected to the system and a command is received.

These communication statistics are available by connecting a VT100 (19200 baud, 7 bits, even parity, one stopbit) compatible terminal to the Terminal ports RS232 interface. The accumulated status of four different communication parameters is displayed simultaneously:

E Successful microwave commands E Unsuccessful microwave commands E Successful microwave operations

EE

E Unsuccessful microwave operations

Definitions: Microwave commands are user commands that request communication with an Data Tag.

The execution of every microwave command requires a number of microwave operations.

EE

E Every unsuccessful microwave command

verifies that a user request for any reason was not executed, i.e. a reading or a writing task was not performed. An investigation of the Data Tag and/or Communicator in question should be undertaken.

EE

E An unsuccessful microwave operation does

not verify that any communication between user system and Data Tag has failed. It only states that a greater number of microwave operations that the theoretical minimum was needed to execute the requested communication task. The installation should however be made and verified in such a way that the number of unsuccessful microwave operations are as insignificant as possible compared to the successful ones. This way, a highly reliable communication point is ensured.

The stored statistics will be erased as power to the central unit is shut off. A new statistics count will automatically start when the power is switched on again.

All counters are limited to 65 535 (then restart from

0).

OIS-P, PC3141/03 Manual Baumer Ident 35

7.5 Internal inspections and tests

7.5.1 General

If the investigations in the previous sections is not sufficient to find the cause of a problem or if the communicator does not operate at all an internal inspection is required to find out if there is a connection error or if any main part of the communicator fails.

The Figure 7.3 shows an internal view of the communicator. The main parts are the Connector Board (down), the CPU Board (left) and the Power Board (right).

Figure 7.3

Installation and trouble-shooting tools

7.5.2 Connector Board and fuse

The power to the unit is supplied via the connector (down right), the protection diode CR1 and the fuse F1.

The type of fuse is: Fast 1 A, 5 mm * 20 mm.

7.5.3 LED indications

The positions of the internal LED’s are shown in Figure 7.3.

CR2 and CR3 show the power status and CR9 to CR14 show the status of the host and antenna communication.

LED Description

CR2 Electronics supply voltage OK

CR3 Antenna voltage OK

CR9 CPU is running

CR10 Object detect is active

CR11 Host receive signal

CR12 Host transmit signal

CR13 Antenna transmit signal

CR14 Antenna receive signal

Table 7.a

PLD

–

C50

+

C9 10 11 12 13 14

PROM

CR2

CR3

IA–F

F1

CR1

24V + 0

10

9

IC40

36 Baumer Ident OIS-P, PC3141/03 Manual

Installation and trouble-shooting tools

7.5.4 Power Board

The power board contains power supplies for the internal electronics, the antenna and the host communication current loop transmitter.

Figure 7.4 and 7.5 show the recommended measuring points and table 7.b the specified voltage values.

Figure 7.4

Figure 7.5

G

A

B

C D E

F

H

I

JP2 JP1

R2

CR3

R1

CR2

JP3

C14

CR4

CR6

A

B

H

I

F

G

C

E

D

24 V 1,2

0V 3,4

CL 5

CL 6

+5V 2

04

+18V 1

CR6

R1 CR2

FILTER

24V/ 5V

24V/

±15V

24V/

±12V

R2 CR3

CR4

R5

C14

+

R5

NOT USED

OIS-P, PC3141/03 Manual Baumer Ident 37

Installation and trouble-shooting tools

Points Description Voltage value

A - B External supply +24 V

C - G Antenna voltage +18V +/- 0,5 V (with

antenna connected)

E - D Not used +24V +5/-2V

F -G Antenna supply + 30V +/- 0,5V

H - I Electronics supply +5V +/- 0,1 V

Table 7.b

Figure 7.6 shows the power supply connection circuit with the protection diode CR1 and the fuse F1.

7.5.5 CPU Board

The Figure 7.3 shows the CPU Board in the upper left corner.

The upper part of the figure shows the position of the PROM and PLD which may have to be replaced in the case of a system upgrade.

The Figure 7.3 also shows two voltage measuring points:

E Insulated external I/O supply: measure 24V

between IC40:9 and IC40:10 (if this voltage is connected).

E CPU supply voltage: measure 5 V between

C50 + and C50 -

+24V

CR1 F1

4 5

0

6 9

0

+

Fig 7.6

POWER

38 Baumer Ident OIS-P, PC3141/03 Manual

Installation and trouble-shooting tools

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OIS-P, PC3141/03 Manual Baumer Ident 39

Technical Data

8.1 Communication parameters

Compatibility

Compatible with 8 kbyte Data Tags PC3104/32A,/22A and PC3105/00D. Data Tag format not compatible with earlier PC3100/00.

Communication range

Depending on antenna type used, 0 to 2 meter for PC3114/00A and 0 to 4 m for PC3114/01A in free space, see figure 2.1. It is always recommended to only utilise 50 to 75% of the range in free space due to influences in the actual installation.

Communication speed

(Antenna to tag)

See table in chapter 2.

Communication protocol

EUROX_4 3964R

8.2 Mechanical specification

Weight

3,8 kg

Size

300 x 200 x 85 mm

Casing material

Steel

Casing integrity

IP41 IP65 with extra protection for connectors ref. IEC 529

Colour

Grey

Mounting

by means of 4 mounting flanges for M8 bolts.

8.3 Electrical specification

Power supply

18 to 36 VDC

Power consumption

10 W maximum (operation) Startup current 6 times higher 6 W maximum (idle mode)

Digital inputs

24 V AC or DC, 15 mA, optoisolated.

Digital outputs

24 V DC, 60mA, optoisolated.

Interfaces

Host (optoisolated)

RS 232 (150-19200 baud) RS 485 (150-19200 baud) Current loop (20 mA) passive (4800,9600 baud)

Terminal (not optoisolated)

RS232 19200 baud 7 bit, Even parity,

1 stopbit

Connectors

One connector for power (D Sub 9 male) One connector for serial communication

(D Sub 15 male)

One connector for test terminal

(D Sub 9 male)

One connector for antenna

(D Sub 9 female)

One connector for digital I/O

(D Sub 15 female)

Frequency

2,45 GHz

Emitted power intensity

Max 25 µW/cm2 at 0 cm distance from the unit. Max 1,5 µW/cm2 at 100 cm distance from the unit, for PC3114/00A. Max 4 µW/cm2 at 100 cm distance from the unit, for PC3114/01A.

8 Technical Data

40 Baumer Ident OIS-P, PC3141/03 Manual

Technical Data

8.4 Cable specifications

Host connection cable

Depending of the interface chosen the cable with the following specification must be used :

Common data :

Max AWG 24 AWG Min copper area 0.22 mm

2

Design Twisted pairs, Note 1 Shielding Per pair Nominal impedance 100 Ohm Maximum diameter12 mm Minimum diameter 8 mm Number of wires 2 x 2 (twisted pairs)

Note 1

Voltage rating 150 V

Cable for current loop interface

Maximum length 1000 m Nominal capacitance

between conductors 28.5 pF/m

Recommended cable type Belden 9184

Cable for RS-485 interface

Maximum length 1200 m Nominal capacitance

between conductors 50 pF/m

Recommended cable type Belden 9729

Cable for RS-232-C interface

Maximum length 15 m

Note 1. For RS232: 5 separate wires.

Antenna cable

The connection to the antenna must be done with a shielded cable. Available Premid Antenna cables and connectors are listed under “accessories” in section 1.2 Cable specification is as follows:

Common data :

Max AWG 24 AWG Min copper area 0.22 mm

2

Maximum diameter 8,5 mm Minimum diameter 7,8 mm Design Twisted pairs Impedance +/- 20% 120 Ohm Shielding Common Temperature rating 70oC Voltage rating 30 V Nominal capacitance between conductors 50 nF/1000m DCR of conductors 80 Ohm/1000 m Number of wires 4 twisted pairs. Note Maximum cable length100 m Cable type Belden 9831, DUE

4404 (DUE 7065), Pirelli, Dataflex 55

Recommended cable PC 3017/02A

Note: Two pairs for power supply must be connected in parallel to achieve the following specification:

Total DC resistance max 8 ohm (loop) DC resistance max 40 ohm/Km Copper area min 0,44mm

2

OIS-P, PC3141/03 Manual Baumer Ident 41

Technical Data

Terminal cable

For connection of the terminal a cable with the following specification must be used :

Max AWG 24 AWG Min copper area 0.22 mm

2

Shielding Common Maximum diameter12.0 mm Minimum diameter 8 mm Maximum length 3 m Number of wires 3

Digital inputs/outputs cable

Max AWG 24 AWG Min copper area 0.22 mm

2

Maximum diameter12.0 mm Minimum diameter 8 mm Maximum length 100 m Shielding Common

Other parameters as the cable length, number of pairs, DC resistance etc. must be chosen according to the application requirements.

All cables.

Metal housing connected to shield and ferrite close to Central Unit is required.

8.5 Environmental specification

Temperature range

-40 to +70 °C (storage) +5 to +40 °C (operating)

Vibration

Sine: ±0.35 mm 10-60 Hz,

1g 60-150 Hz in ± 3 axis.

Ref.: IEC 68-2-6 Test Fc

EMC

According to pr ETS 300339 including: Emission EN550022, class B Immunity ENV 50141 80-1000 MHz

3V, AM 80% at 400 Hz EFT/burst IEC 801-4 2 kV ESD test IEC 801-2 4/8 kV

42 Baumer Ident OIS-P, PC3141/03 Manual

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OIS-P, PC3141/03 Manual Baumer Ident 43

Notes

_____________________________________________________________________________________

44 Baumer Ident OIS-P, PC3141/03 Manual

_____________________________________________________________________________________

_______________________________________________________________________________________

Notes

OIS-P, PC3141/03 Manual Baumer Ident 45

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