Banner PTL110S User manual

PTL110S Pick-To-Light Devices
Instruction Manual
Original Instructions
206185 Rev. A
16 January 2019
©Banner Engineering Corp. All rights reserved
206185

Contents
1 Models ............................................................................................................................................................................3
1.1 Overview of the PTL110S ................................................................................................................................................................ 3
1.1.1 Communications ..................................................................................................................................................................... 3
1.1.2 Common ID ............................................................................................................................................................................. 4
1.1.3 Timeout ................................................................................................................................................................................... 4
2 Configuration Instructions .............................................................................................................................................. 5
2.1 Operational Modes ......................................................................................................................................................................... 5
2.2 Indicator Touch Surface and Optical Sensor Operation .................................................................................................................6
2.3 7-Segment Display Operation ........................................................................................................................................................ 7
2.4 Maximum System Size ................................................................................................................................................................... 9
2.5 Set the Slave ID .............................................................................................................................................................................. 9
3 Installation Instructions .................................................................................................................................................11
3.1 PTL110S Wiring ............................................................................................................................................................................. 11
4 Troubleshooting ............................................................................................................................................................12
4.1 Error Codes ....................................................................................................................................................................................12
5 Specifications ............................................................................................................................................................... 13
5.1 Dimensions ................................................................................................................................................................................... 13
6 Accessories ................................................................................................................................................................... 14
6.1 Cordsets ....................................................................................................................................................................................... 14
6.2 Brackets ........................................................................................................................................................................................14
7 Product Support and Maintenance .............................................................................................................................. 16
7.1 Contact Us .....................................................................................................................................................................................16
7.2 Banner Engineering Corp. Limited Warranty ................................................................................................................................ 16
7.3 FCC Part 15 and CAN ICES-3 (B)/NMB-3(B) .................................................................................................................................16
PTL110S Pick-To-Light Devices

1 Models
Family
PTL
T = Touch Sensor with Indicator
T
FF100 = 100 mm fixed field
FF100
D3 = 3-digit LED display
Blank = No display
D3
DisplaySensor
FF200 = 200 mm fixed field
Blank = No sensor input
L = Indicator only
QP150 = Dual 150 mm PVC cable with
M12/Euro-style quick disconnects
QP150
Connection*
Touch
––
* Models not connected in a series with a
quick disconnect require a mating cordset
Housing
S = Pick-IQ® Serial
Communication
Control
110 S
1.1 Overview of the PTL110S
Indicator and Touch Area
Each PTL110 device contains an indication area. This indicator area is completely customizable with a variety of
colors, intensities, and animations. In the touch sensor models, this indicator area has a laser marked logo and is
also a touch surface. The touch sensor can be disabled.
Sensor
Optical sensor models contain a Banner fixed field optical sensor for actuation. Two distance models are available,
100 mm (4 in) and 200 mm (8 in). The optical sensor can be disabled.
Display
Display models contain a 3-digit, 7-segment display with three decimal points. The display is completely
customizable and can show numbers as well as a set of letters and symbols. The decimal points can be configured
to show various device statuses.
Pigtail Connectors
Each PTL110 device has two 4-pin M12 pigtails, one male and one female. These devices may be connected
directly into each other. Patch cables may also be used. If needed, additional power may be injected into any part
of the system.
1.1.1 Communications
The PTL110 devices communicate using PICK-IQ®, an intelligent communication method for pick- and put-to-light related
applications compatible with Modbus RTU.
The standard Modbus protocol structure does not offer the performance required to operate medium to large sized pick-to-
light systems with low latency response times. Adding more devices to a pick-to-light system running standard Modbus
protocol eventually makes a pick-to-light system unusable because of the request/response nature of the protocol. The
communication latency to and from the master device is too slow.
Using PICK-IQ®adds a simple change to the PTL110 devices that allow the Modbus master controller to run standard
Modbus protocol, but achieve the performance required by a medium to large sized pick-to-light system. This change is the
addition of a common ID addressing scheme.
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1.1.2 Common ID
The PTL110 devices respond to a common address and a unique slave device address. The addition of this common
address functionality allows the overall system to run much faster than a standard polling Modbus network.
By adding a common ID, the device responds to an additional address that can be shared among all devices in the system.
For example, if a device has a slave ID of 5 and a common ID of 195 the device responds to all messages addressed to ID
5, regardless of activation status, and messages addressed to ID 195 when the device is touched or the optical sensor is
activated.
When the Modbus master in the system is looking for an activated touch or optical sensor somewhere in the network, it only
needs to poll the common ID instead of the entire system. There is no need to poll all devices in the system as most
Modbus network communicate. When a device is activated, it responds to the common ID. Through the common ID, the
master can read the device's slave ID stored in register 7940. When polling the common ID, Banner recommends reading a
minimum of the slave ID register 7940 and the output state register 7941. These registers hold the slave ID of the device
that was activated and the status of what was activated on the device. When reading information from the common ID, only
registers 7940 through 7942 are accessible. All other registers should be accessed through the devices' slave ID.
After the slave ID of the activated device is known, use direct communication to the device through its unique slave ID.
To prevent the device from responding to the same activation event, reset the output state register 7941 to 0 by either
changing the value directly or by resetting the device job state in register 8700 before polling the common ID for new
activations. Write these values through the devices' unique slave ID and not the common ID. When the value in register
7941 is 0, the device will not respond to the common ID.
Summary of registers:
•7940—Defines the unique slave ID
•7941—Defines the output state
•8700—Defines the device job state
•8810—Defines the common ID
1.1.3 Timeout
When the system is running in normal operation, the master will experience communication timeouts, which are normal and
expected. If no devices have been activated, there will be no responses in the system. For this reason, it is important to
configure your system with adequate communication timeouts.
Set the Modbus Master Timeout Adjustment parameters accurately to ensure all activation events are captured. Modbus
master messages polling the common ID result in a timeout most of the time. Set the master polling speed close to the
minimum value allowed by the master. 100 ms is acceptable for a fast system response.
The timeout is because a device only responds to the common ID request when it is touched or the sensor has been
activated. After that event, the value in register 7941 will be non-zero. The register remains non-zero until either the master
reverts the value back to 0 (acknowledging the event) or the value times out.
Set the output latch timeout value to a value ten times the system polling speed of the master device. For example, if the
master is polling the common ID every 100 ms, set the output latch timeout to 1000 ms. These values can be adjusted
depending on the desired system performance.
Output latch timeout is defined in register 8812.
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2 Configuration Instructions
2.1 Operational Modes
Basic Mode—This operating mode is the most straight forward to configure. In basic mode, the master controls all aspects
of the device. The master must define all logic functions by defining what the transitions will look like.
Register Description Values
8701 Changes the visual animation of the
indicator
0—Indicator is off
1—Indicator is on
2—Indicator flashes with a 50% duty cycle
3—Indicator strobes with a 20% duty cycle
11–20—Indicator flashes N times (i.e. 5-pulse will
flash 5 times, then repeat)
8702 Selects the color of the indicator
0 = Off
1 = Red
2 = Green
3 = Yellow
4 = Blue
5 = Magenta
6 = Cyan
7 = White
8 = Amber
9 = Rose
10 = Lime Green
11 = Orange
12 = Sky Blue
13 = Violet
14 = Spring Green
State Mode—State mode requires the configuration of the device to define the visual settings for the four standard pick-to-
light logic states, defined below. These settings are embedded inside the device and do not require communication from
the master device to change visual states after the device is activated. This allows the device to respond immediately to any
interaction and allows the communication to the master to happen simultaneously.
Register Description Values
6300 Enables state mode
0 = Disabled (device will operate in Basic Mode)
1 = Enabled (device will operate in State Mode and use the configurations defined
below)
6301 through
6354 Defines visual settings for pick to light states.
Registers 6301 to 6310 define the Waiting State
Registers 6312 to 6321 define the Mispick State
Registers 6323 to 6332 define the Job State
Registers 6334 to 6343 define the Acknowledge State
Registers 6345 to 6354 define the Secondary Acknowledge State
* Refer to PTL110S Register Map for descriptions and enumerations of these visual
states
8700 Moves a device from the Wait state to the Job
state
0 = Wait. Device is waiting and should not be triggered. If the device is triggered it
will move to the Mispick state.
1 = Job. Device is active and should be triggered. If the device is triggered it will
move to the Acknowledge state.
The job state animation and color may also be modified using registers 8701 and 8702 when in State Mode. Any values
written to these registers override the values in registers 6323 and 6324. This allows the device to maintain a common set of
Waiting, Acknowledge, and Mispick settings. This functionality allows the on-the-fly customization of the Job animation and
color, which can be useful when multiple operators are picking from the same area.
Primary Output Logic Tables in State Mode
Job Input Logic (Register 8700) Touch or Sensor Not Activated Touch or Sensor Activated
Not Active (0) Wait State Mispick State
Active (1) Job State Acknowledge State
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Registers Animation Description
6301, 6312, 6323, 6334, 6345
Off Indicator off
Steady Color 1 solid on at defined intensity
Flash Color 1 flashes at defined speed, intensity and pattern
Two Color Flash Color 1 and color 2 flash alternatively at defined speed, intensities and pattern
Half/Half Top/Bottom Color 1 is displayed on the top 50% of the indicator and color 2 is displayed on the bottom
50% of the indicator at defined intensities
Half/Half Left/Right Color 1 is displayed on the left 50% of the indicator and color 2 is displayed on the right 50%
of the indicator at defined intensities
Half/Half Rotate Color 1 is displayed on 50% of the indicator and color 2 is displayed on 50% of the indicator
while rotating at defined speed, intensities and rotational direction
Chase Color 1 is displayed on 25% of the indicator and color 2 is displayed on 75% of the indicator
while rotating at defined speed, intensities and rotational direction
Intensity Sweep Color 1 repeatedly increases and decreases intensity between 0% and 100% at defined
speed
Registers Pattern Description
6307, 6318, 6329, 6340, 6351
Normal Flash with a 50% duty cycle
Strobe Strobe with an 20% duty cycle
3-Pulse Flash three times, then off, repeat
SOS Flash three times quickly, three times slowly, then three times quickly
Random Randomized pattern
Registers State Delays Description
6309, 6310, 6320, 6321, 6331,
6332, 6342, 6343, 6353, 6354
State On-delay
Defines the amount of time the device waits to move into the next visual state after activation.
State On-Delay defines the operation of the visual state while Input On-Delay (registers 6001
and 6002) defines the operation of output register change. (e.g.) If the device's job input is
active and the On-Delay is set to 1000 ms it will remain in the Job state for 1000 ms after the
sensor is triggered or the touch surface is touched.
Job state
Defines the amount of time the device will stay in the visual style of the current pick to light
state after activation before moving to the next state. (e.g.) After a successful pick from the
Job state the device will move to the Acknowledge state. If the Acknowledge state Off-Delay is
set to 3000 ms the device will remain in the Acknowledge state for 3000 ms before moving to
the next visual state. This parameter is useful to show a pick was acknowledged.
2.2 Indicator Touch Surface and Optical Sensor Operation
Each input method can be defined as primary or secondary. This allows the input methods (touch or optical sensor) to be
used combined as one or independently of each other.
Primary Input Operation—
• Input 1—Touch function
• Input 2—Optical sensor
Input Register Description
Input 1 6001 On-delay—Defines the time the button must be pushed or the sensor must be tripped to change the output from 0
to 1.
For example, if input 1 has an on-delay of 1000 ms, the touch surface must be held for 1000 ms before the output
register 7941 changes from 0 to 1.
Input 2 6003
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Output Registers Register Description Values
Output 7941
Holds the latched statuses of the inputs. This register is designed to be
cleared by the master upon receipt. If the register is not cleared, the
status will be cleared by the timeout (default 1000 ms) defined in register
8812.
0 = None activated
1 = Primary activated
2 = Secondary activated
3 = Both activated
Output Status 7942 Holds the real time status of the inputs.
Secondary Input Operation—Enabling one input as the secondary input allows separate use of the other input. For example,
use the primary input in a standard pick-to-light application and the secondary input as a call for parts. The secondary input
has a different logic table.
Logic table for secondary input
Job Input Logic Touch or Sensor Not Activated Touch or Sensor Activated
Not Active (0) Wait State
Secondary Acknowledge State
Active (Non 0) Job State
The indicator in the device is fully customizable. A variety of colors, animations, and intensities are available to customize
the device for any application or system.
Registers Description Values
6200 (in Basic Mode) or
6304, 6305, 6315, 6316,
6326, 6327, 6337, 6338,
6348, and 6349 (in State
Mode)
Customize the intensity of the
indicator
0 = High
1 = Medium
2 = Low
3 = Off
6202 Customize the sensitivity of the touch
button
0—A more deliberate touch is needed to active the touch output. Useful to
avoid accidental triggers, such as in areas where water is present.
1—Balanced sensitivity (default setting)
2—A less deliberate touch is need to active the touch output. Useful for faster
operation or when operators are wearing gloves.
2.3 7-Segment Display Operation
The display in the device is fully customizable, including both the digits and decimal points.
Registers Description Values
8703 through 8799
Customizable 3-digit, 7-segment display
• In Primary operation, the values are right justified and null terminated. See Appendix for available characters. Note that
upper case and lower case are differentiated and some representations are limited by the nature of the 7-segment
display. (ASCII encoded)
• In Secondary operation, decimals stored in register 8703 and show on the display. (decimal encoded)
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Registers Description Values
6209
Value Character Value Character Value Character Value Character
0x30 0 0x61 a 0x6B k 0x75 u
0x31 1 0x62 b 0x6C l 0x76 v
0x32 2 0x63 c 0x6D m 0x77 w
0x33 3 0x64 d 0x6E n 0x78 x
0x34 4 0x65 e 0x6F o 0x79 y
0x35 5 0x66 f 0x70 p 0x7A z
0x36 6 0x67 g 0x71 q
0x37 7 0x68 h 0x72 r
0x38 8 0x69 i 0x73 s
0x39 9 0x6A j 0x74 t
Value Character Value Character Value Character Value Character
0x41 A 0x4B K 0x55 U 0x2F /
0x42 B 0x4C L 0x56 V 0x3C <
0x43 C 0x4D M 0x57 W 0x3D =
0x44 D 0x4E N 0x58 X 0x3E >
0x45 E 0x4F O 0x59 Y 0x3F ?
0x46 F 0x50 P 0x5A Z 0x5B [
0x47 G 0x51 Q 0x20 "blank" 0x5C \
0x48 H 0x52 R 0x24 $ 0x5D ]
0x49 I 0x53 S 0x2C ' 0x5E ^
0x4A J 0x54 T 0x2D - 0x5F _
0x60 '
0x7C |
6203 Enables the ability to scroll a message longer than 3-digits
0 = Off
1 = Enabled, slow speed
2 = Enabled, standard speed
3 = Enabled, high speed
6205 Controls the scroll timing
6201 Changes the display's orientation. Standard orientation shows the
decimals on the bottom of the display.
0 = Standard (touch sensor/indicator located on the right)
1 = Flipped (touch sensor/indicator located on the left)
6204 Customizes the display's message on startup
0 = None
1 = Show Modbus settings (slave ID, baud, data bits, parity
bit, stop bit)
2 = Show custom message (6400-6409)
6206 through 6208 The display contains three decimal points; each decimal point is
customizable
0— Decimal point remains off
1—Decimal point remains on
2—Decimal point flashes
3— Decimal point turns on when receiving communication
4— Decimal point is on when idle and off while
communicating
5— Decimal point turns on while the touch sensor or
optical sensor is active
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2.4 Maximum System Size
The maximum size of the system depends on several factors. Changes to any of these items will affect the maximum
number of devices that can be used together in one system.
• Modbus Master—Different Modbus masters may place restrictions on the number of devices it can address
• Power Supply—The size of the power supply determines how many devices are able to run at one time. Additional
power may be injected into the system anywhere.
• Cable Length—Total length of cabling, both from the master to the first device and all cabling connecting the
devices. The total amount of cable influences the overall voltage available in the system.
• Devices Status—The number of devices typically on or active at any given time. The devices draw power at different
levels depending on what features are active in the device.
Device Status Average Watts (W)
Indicator Off, Display Off, Sensor Off 0.21
Indicator Off, Display Off, Sensor On 0.58
Indicator On, Display On (123), Sensor Off 0.91
Indicator On, Display On (123), Sensor On 1.30
Indicator On, Display On (888), Sensor Off 0.98
Indicator On, Display On (888), Sensor On 1.35
System Examples (at 24 V dc)
Device Status Average Watts
per Device (W)
Initial Cable
Length (m)
Interconnect Cable
Length (m)
Maximum Number of
Devices *
All Devices: Indicator Off Display Off Sensor Off 0.21 10 0.5 119
All Devices: Indicator On Display On (123) Sensor Off 0.58 10 0.5 49
All Devices: Indicator On Display On (123) Sensor On 1.30 10 0.5 40
* Additional power may be injected anywhere into the system to overcome the voltage drop.
2.5 Set the Slave ID
The slave ID can be set two ways:
• Assign a unique slave ID to each device by individually connecting the device and changing the slave ID register
6100 (or 7940). This method is consistent with traditional Modbus devices and uses the existing slave ID of the
device (default ID of 1)
• Write the new slave ID to the active slave ID register 7940 while the device output register 7941 is active. Output
register 7941 is active when the device's touch or optical sensor is activated.
In this way it is possible to wire a complete system and address multiple devices quickly and easily. The following example
is a recommended process to set slave ID values through the common ID.
1. Initial the starting addresses.
Determine the range of device addresses to be used. Use a broadcast message to change all slave device IDs to
the last address to be used. The initial slave ID addresses do not need to be unique. The common ID address must
be different than the addresses being assigned to the devices. If you are using 50 devices in the system, set all
device slave IDs to 50.
2. Poll system for an active state.
Program the Modbus master to continuously poll the Common ID address requesting the active slave ID address
register 7940 and device output register 7941. Set the Master's polling speed to a time value less than the latched
output time out value in register 8812. A polling speed of 100 msec works well in most configurations.
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3. Activate a unique device.
Manually trigger the active state of the device you wish to assign the unique slave ID. Continue to manually trigger
the active device until the visual state changes. Changing the physical state of the device must be done intentionally
as in step 5.
4. Set a unique slave ID.
The device output register 7941 value will be non-zero when the device touch sensor or optical sensor is triggered.
During this time the device responds to Modbus commands through the Common ID address. Write the desired
slave ID value to register 7940 by sending the command to the Common ID device address.
5. Clear the output status and give visual feedback.
a) Clear the output latch register 7941 by writing directly to the unique slave ID that was defined in the previous
step.
b) Write to the unique slave ID and change the test mode register 6500 to a value of 1.
Enabling test mode at this time gives visual feedback to the user that the device has been addressed and displays
the actual slave ID of the unit on the display. This has the additional function of disabling state changes to register
7941 to prevent accidentally addressing the device again.
6. For additional addressing, repeat steps 2 through 5, incrementing the assigned unique slave ID values to each
device.
7. Initialize the system for use. Send a broadcast message to all devices to clear (set to 0) the test mode register.
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