Pepperl Fuchs PGV100R-F200-R4-1.5M Instruction manual

PGV100R-F200-R4-1.5M

Incident Light Positioning

System

Manual

With regard to the supply of products, the current issue of the following document is applicable: The General Terms of Delivery for Products and Services of the Electrical Industry, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the supplementary clause: "Expanded reservation of proprietorship"

Worldwide

Pepperl+Fuchs Group

Lilienthalstr. 200

68307 Mannheim

Germany

Phone: [phone] - 0

E-mail: [e-mail]

North American Headquarters

Pepperl+Fuchs Inc.

1600 Enterprise Parkway

Twinsburg, Ohio 44087

USA

Phone: [phone]

E-mail: [e-mail]

Asia Headquarters

Pepperl+Fuchs Pte. Ltd.

P+F Building

18 Ayer Rajah Crescent

Singapore 139942

Phone: [phone]

E-mail: [e-mail] https://www.pepperl-fuchs.com

PGV100R-F200-R4-1.5M

Contents

1	Introduction................................................................................................................			5
	1.1	Content of this Document.............................................................................		5
	1.2	Target Group, Personnel ...............................................................................		5
	1.3	Symbols Used ................................................................................................		6
2	Product Description ..................................................................................................			7
	2.1	Use and Application ......................................................................................		7
	2.2	RS-485 Interface ............................................................................................		9
	2.3	LED Indicators and Operating Elements...................................................		10
	2.4	Accessories..................................................................................................		11
3	Installation................................................................................................................			12
	3.1	Mounting the Read Head.............................................................................		12
	3.2	Affixing the Code Tape ................................................................................		13
	3.3	Electrical Connection ..................................................................................		23
4	Commissioning........................................................................................................			25
	4.1	Direction Decision .......................................................................................		25
	4.2	Parameterization Using Code Cards..........................................................		26
	4.2.1 The code cards "CANCEL", "USE", and "DEFAULT" .......................			27
5	Operation and communication...............................................................................			28
	5.1	Communication via the RS-485 Interface..................................................		28
	5.1.1		Request Telegram ............................................................................	28
	5.1.2		Position Response Telegram............................................................	29
	5.1.2.1		Number of Lanes LC (Lane Count) ........................................................................................	32
	5.1.2.2		Orientation O .........................................................................................................................	33
	5.1.2.3		Side S ....................................................................................................................................	34
	5.1.2.4		Position/Lane .........................................................................................................................	34
	5.1.3		Direction Decision Request Telegram ..............................................	35
	5.2	Operation Using Control Codes .................................................................		36
	5.3	Operation Using Repair Tape......................................................................		37
6	Appendix		..................................................................................................................	38

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Contents

6.1 Code Cards for External Parameterization................................................	38
6.1.1 Code Cards with Special Functions..................................................	38
6.1.2 Code Cards for Setting the Read Head Address ..............................	41
6.1.3 Code cards for setting the transfer rate ............................................	43
6.1.4 Code Cards for Adjusting the Resolution..........................................	45
6.1.5 Code cards for adjusting the terminator............................................	46

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Introduction

1Introduction

1.1Content of this Document

This document contains information required to use the product in the relevant phases of the product life cycle. This may include information on the following:

•Product identification

•Delivery, transport, and storage

•Mounting and installation

•Commissioning and operation

•Maintenance and repair

•Troubleshooting

•Dismounting

•Disposal

Note

For full information on the product, refer to the further documentation on the Internet at www.pepperl-fuchs.com.

The documentation comprises the following parts:

•This document

•Datasheet

In addition, the documentation may comprise the following parts, if applicable:

•EU-type examination certificate

•EU declaration of conformity

•Attestation of conformity

•Certificates

•Control drawings

•Instruction manual

•Other documents

1.2Target Group, Personnel

Responsibility for planning, assembly, commissioning, operation, maintenance, and dismounting lies with the plant operator.

Only appropriately trained and qualified personnel may carry out mounting, installation, commissioning, operation, maintenance, and dismounting of the product.The personnel must have read and understood the instruction manual and the further documentation.

Prior to using the product make yourself familiar with it. Read the document carefully.

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Introduction

1.3Symbols Used

This document contains symbols for the identification of warning messages and of informative messages.

Warning Messages

You will find warning messages, whenever dangers may arise from your actions. It is mandatory that you observe these warning messages for your personal safety and in order to avoid property damage.

Depending on the risk level, the warning messages are displayed in descending order as follows:

Danger!

This symbol indicates an imminent danger.

Non-observance will result in personal injury or death.

Warning!

This symbol indicates a possible fault or danger.

Non-observance may cause personal injury or serious property damage.

Caution!

This symbol indicates a possible fault.

Non-observance could interrupt the device and any connected systems and plants, or result in their complete failure.

Informative Symbols

Note

This symbol brings important information to your attention.

Action

This symbol indicates a paragraph with instructions.You are prompted to perform an action or a sequence of actions.

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Product Description

2Product Description

2.1Use and Application

Intended Use

This device, when used together with a Data Matrix code tape affixed to the floor, constitutes a high-resolution lane tracking and positioning system. It can be used in all applications where auto-guided transport systems are to be positioned precisely at marked positions along a given lane.

The read head forms part of the positioning system in the Pepperl+Fuchs incident light process.The read head includes a camera module and an internal illumination unit, which the read head uses to detect a strip of Data Matrix code tape stuck to the floor for lane tracking and navigation. The read head also detects Data Matrix tags to navigate within a grid.

The read head is located on an auto-guided transport system and guides this system along the Data Matrix code tape.

Figure 2.1 Auto-guided transport system with Data Matrix code tape

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Product Description

Tag Mode

In addition to lane tracking, the read head can also be used in tag mode.The read head detects Data Matrix tags, which are typically glued onto the floor in a grid. The individual Data Matrix tags are numbered consecutively and include position information. The read head reports the position of the auto-guided transport system in relation to the zero point of the Data Matrix tag to the control panel.

Tag mode allows the auto-guided transport system to move freely in as large a grid as desired, without having to mark the traverse distances with code tapes.

Figure 2.2 Auto-guided transport system with Data Matrix tags

The read head switches automatically between tag mode and lane tracking. This allows a transport system to be guided from one Data Matrix tag grid to another via a Data Matrix code tape.

Thanks to its comprehensive and simple parameterization options, the read head can be optimally adapted to suit any application.

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Product Description

2.2RS-485 Interface

The read head is equipped with an RS-485 interface for communication purposes, i.e. parameterizing the read head functions or reading out current process data during operation. This interface is operated in 8-E-1 operating mode and is fitted with a terminator that can be activated or deactivated by parameterizing the sensor head. The RS-485 interface supports the following transfer rates:

•9600 bit/s

•19200 bit/s

•38400 bit/s

•57600 bit/s

•76800 bit/s

•115200 bit/s (default value)

Data structure of the RS-485 interface

		Bit 0	Bit 1	Bit 2	Bit 3	Bit 4	Bit 5	Bit 6	Bit 7	Parity
	Start	LSB							MSB		Stop

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Product Description

2.3LED Indicators and Operating Elements

The read head is equipped with two indicator LEDs for carrying out visual function checks and quick diagnostics.

ADJUST

CONFIG

<![if ! IE]> <![endif]>COM ERROR	<![if ! IE]> <![endif]>NO CODE/ ERROR
1	2
<![if ! IE]> <![endif]>COM STATE	<![if ! IE]> <![endif]>POWER ON

Figure 2.3	Display elements
LEDs
LED		Color	Label	Meaning
1		Green/yellow	COM STATE	RS-485 communication active
			COM ERROR	RS-485 communication error
2		Green/red	POWER ON	Code detected/not detected, error
			NO CODE/ ERROR

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Product Description

Function Indicator LED

LED		1		2
					NO CODE/
Mode		COM STATE	COM ERROR	POWER ON	ERROR
Color		Green	Yellow	Green	Red	Description
State		Off	Flashing	x	x	General con-
						figuration error
		Off	Off	x	x	No communi-
						cation
Table 2.1	fflash = 2.5 Hz (one request line for flashing with three on statuses)
	x: LED status has no meaning
LED		1		2
					NO CODE/
Mode		COM STATE	COM ERROR	POWER ON	ERROR
Color		Green	Yellow	Green	Red	Description
State		x	x	Lights up	Off	Codes
						detected
		x	x	Off	Flashing	Codes not
						detected
		x	x	x	Lights up	System error
		x	x	Lights up for	Off	Code card
				1 s		read
		x	x	Off	Lights up for	Code card not
					1 s	read
Table 2.2	Sensor switched on: At least one of the LEDs is lit or flashing

x:LED status has no meaning

2.4Accessories

Compatible accessories offer enormous potential for cost savings. Such accessories not only save you a great deal of time and effort during initial commissioning, but also when replacing and maintaining our products.

If products are used in harsh ambient conditions, appropriate Pepperl+Fuchs accessories can be used to extend the service life of these products.

Model number		Description
PGV*-CA25-*		Data Matrix code tape
PGV-CC25-0*		Data Matrix control codes
PGV*M-CA25-*		Data Matrix positioning tape
PGV85-CT4		Data Matrix tag
PGV25M-CD100-CLEAR		Protective film
Table 2.3	Accessories

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Installation

3Installation

3.1Mounting the Read Head

Mount the read head on the auto-guided transport system using the four screws on the mounting adapter on the read head. Mount the read head so that the lens with ring light and camera module are aligned toward the floor.

The mounting must be stable enough so that the read head does not leave its depth of focus range during operation.

The distance between the read head and the floor should be the same as the read distance of the read head.

Optimum Read Distance

											Field of vision (w x h)
Model number	Read distance [mm]			Depth of focus [mm]							[mm]
PGV100R*	100			±30							115 x 73
Read Head Dimensions
											<![if ! IE]> <![endif]>4 x M6

<![if ! IE]> <![endif]>51	<![if ! IE]> <![endif]>25
	<![if ! IE]> <![endif]>ø
		<![if ! IE]> <![endif]>22
			1
	<![if ! IE]> <![endif]>80	<![if ! IE]> <![endif]>70	2
<![if ! IE]> <![endif]>9
			38.5
			70

Figure 3.1 Housing dimensions

Caution!

When selecting the length of the mounting screws, ensure that the maximum insertion depth of the screws in the threaded inserts on the read head is 8 mm.

Using longer screws may damage the read head.

Caution!

The maximum torque of the mounting screws must not exceed 9 Nm.

Tightening the screws to a higher torque may damage the read head.

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Installation

3.2Affixing the Code Tape

Dimensions of the Code Tape

Figure 3.2 Dimensions of the Data Matrix code tape

Caution!

Alignment

The Data Matrix code is not on the center line of the code tape.

Caution!

Stop edges

If you attach another code tape at the end of a previous code tape, the code pattern of 20 mm must be retained.

The code tape is made of silicone-free polyester film. A position marker appears every 100 mm along the lower edge of the code tape (see "Code Tape Dimensions"). These position markers are used to affix the code tape in the correct position.

The back of the code tape is covered with a modified acrylate-based adhesive designed for permanent adhesion. Affix the self-adhesive code tape along the desired traverse distance. To do so, proceed as follows:

Position the code tape so that the www.pepperl-fuchs.com label and the position markings are to the right of the Data Matrix code in the X direction. The position values then increase along the X direction.

Data Matrix Code Tapes with a Starting Position of 0 m

Model number		Description
PGV10M-CA25-0		Code tape, length: 10 m
...		...
PGV100M-CA25-0		Code tape, length: 100 m
Table 3.1	Data Matrix code tapes
	See also data sheet PGV*-CA25-* at www.pepperl-fuchs.com

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Installation

Data Matrix Control Codes

Model number		Description
PGV-CC25-001		Code tape, Control Code 001, length: 1 m
...		...
PGV-CC25-999		Code tape, Control Code 999, length: 1 m
Table 3.2	Data Matrix control codes

Affixing the Code Tape

1.Clean the surface of any greasy or oily deposits and dust.

2.Ensure that the surface is dry, clean, and stable.

3.Pull away a few centimeters of the protective film at the beginning of the code tape. Place the code tape at the precise point of the required starting position on the surface, and press to attach.

4.Then affix the code tape along the desired traverse distance. Please note the following information:

5.Remove the protective film gradually so that the code tape does not accidentally adhere to the surface in an incorrect position. When affixing the code tape, ensure that it does not become creased or trap air bubbles.

The adhesive on the code tape hardens after 72 hours.

Note

Thermal Expansion of the Code Tape

The affixed code tape corresponds to the heat expansion coefficient of the surface with regard to its thermal expansion. Keep this in mind when installing expansion joints, for example.

Note

Expansion Joints and Code Tapes

If the system covers longer distances, the plant structure usually contains expansion joints. In this case, we recommend creating breaks along the code tape. The resulting gap must not exceed 75 mm.

Note

Inclines and Declines

If you affix the code tape on inclines or declines, cut the code tape several times at the transition point to the horizontal as shown.

Figure 3.3 Schematic diagram: preparing Data Matrix code tape bends

1.Bend to the left

2.Bend to the right

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Installation

Cleaning the Code Tape

Significant contamination on code tapes can impair detection by the read head. Clean the code tapes with isopropanol if necessary. If the contamination is severe, you can use a non-corrosive plastic cleaner, e.g., Caramba®.

Note

To avoid polishing the surface, do not apply strong pressure when cleaning. If the code tape has a shiny surface, this impairs detection by the read head.

Angle Output

Note

Angles are specified as absolute values. The respective value is calculated from the resolution selected under "Angle Resolution." With a resolution of 0.1°, an angle of 60° is output as 60°/0.1° = 600.

The read head detects the absolute angle in relation to the tracked lane with a maximum resolution of 0.1°. The angle is specified as an absolute value relative to the tracked lane, as a Data Matrix code tape contains direction information. The output angle covers the range from 0° to 360°. The resolution can be set to the following values:

•	0.1°
•	0.2°
•	0.5°
•	1°
	X	X
	α
		α
	Y	Y

Figure 3.4 Absolute angle

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