Leuze electronic IPS 208i User manual

Original operating instructions
EN 2017/11 - 50137619 We reserve the right to make technical changes
IPS 208i
Camera-based positioning sensor

© 2017
Leuze electronic GmbH & Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]
Leuze electronic IPS 208i 2

Table of contents
Leuze electronic IPS 208i 3
Table of contents
1 About this document ............................................................................................6
1.1 Used symbols and signal words ............................................................................................. 6
2 Safety .....................................................................................................................8
2.1 Intended use ...........................................................................................................................8
2.2 Foreseeable misuse ............................................................................................................... 8
2.3 Competent persons ................................................................................................................ 9
2.4 Disclaimer ............................................................................................................................... 9
3 Device description ..............................................................................................10
3.1 Device overview....................................................................................................................10
3.1.1 IPS200i positioning sensor...............................................................................................10
3.1.2 Performance characteristics..............................................................................................11
3.1.3 Accessories .......................................................................................................................11
3.1.4 Device model with heating ................................................................................................11
3.2 Device construction .............................................................................................................. 12
3.3 Connection technology ......................................................................................................... 13
3.4 Indicators and operational controls....................................................................................... 14
3.4.1 LED indicators ...................................................................................................................15
3.4.2 Function selection and program selection.........................................................................16
3.4.3 Control buttons ..................................................................................................................17
4 Functions.............................................................................................................18
4.1 Programs .............................................................................................................................. 19
4.2 Camera operating modes ..................................................................................................... 19
4.2.1 Single trigger mode ...........................................................................................................19
4.2.2 Reading gate control .........................................................................................................19
4.3 Quality score......................................................................................................................... 19
4.4 Offset .................................................................................................................................... 19
4.5 Teach position ...................................................................................................................... 20
4.6 Detection status .................................................................................................................... 20
4.7 Leuze webConfig tool ........................................................................................................... 20
5 Applications ........................................................................................................21
5.1 Compartment fine positioning of a high-bay storage device................................................. 21
5.2 Compartment fine positioning in a small-part container storage system .............................. 22
6 Mounting..............................................................................................................23
6.1 Determining the mounting position of the positioning sensor ............................................... 23
6.1.1 Selecting a mounting location ...........................................................................................23
6.1.2 Mounting bracket...............................................................................................................24
6.1.3 Determining the working distance .....................................................................................24
6.2 Mounting the positioning sensor ........................................................................................... 26
6.2.1 Mounting with M4 fastening screws ..................................................................................26
6.2.2 Mounting with the BTU320M-D12 mounting system ........................................................27
6.2.3 Mounting with the BT320M mounting bracket ..................................................................27
6.2.4 Mounting with the BTU320M-D12-RL70 mounting bracket.............................................. 27
6.3 Replace housing hood .......................................................................................................... 28

Table of contents
Leuze electronic IPS 208i 4
7 Electrical connection..........................................................................................29
7.1 Overview ............................................................................................................................... 30
7.2 PWR/SWI/SWO – voltage supply and switching inputs/outputs........................................... 31
7.3 HOST - Host input / Ethernet................................................................................................ 33
7.4 Ethernet star topology...........................................................................................................34
7.5 Cable lengths and shielding..................................................................................................35
7.6 Connecting positioning sensor to MA150 connection unit ................................................... 35
7.7 Connecting positioning sensor to Ethernet switch ................................................................ 37
8 Starting up the device – Basic configuration...................................................38
8.1 Measures to be performed prior to the initial commissioning ............................................... 38
8.2 Starting the device ................................................................................................................ 38
8.3 Configuring and aligning the device via control buttons ....................................................... 39
8.4 Setting the communication parameters ................................................................................ 40
8.4.1 Manually setting the IP address ........................................................................................40
8.4.2 Automatically setting the IP address .................................................................................41
8.4.3 Address Link Label............................................................................................................41
8.4.4 Ethernet host communication............................................................................................41
8.4.5 FTP client ..........................................................................................................................42
8.5 Configuration via configuration codes...................................................................................43
8.6 Activating device functions ................................................................................................... 43
9 Commissioning – Leuzeelectronic webConfig tool........................................44
9.1 System requirements............................................................................................................ 44
9.2 Start webConfig tool ............................................................................................................. 44
9.3 Short description of the webConfigtool ................................................................................ 46
9.3.1 Change operating mode....................................................................................................46
9.3.2 Menu options of the webConfig tool ..................................................................................47
9.3.3 CONFIGURATION menu ..................................................................................................47
9.3.4 Configuring applications with the wizard ...........................................................................48
9.4 Configuring compartment fine positioning ............................................................................ 49
9.4.1 Selecting the program .......................................................................................................49
9.4.2 Configuring image acquisition ...........................................................................................49
9.4.3 Configuring markers ..........................................................................................................50
9.4.4 Assigning measurement values to digital switching outputs .............................................51
9.4.5 Outputting measurement values via Ethernet ...................................................................52
10 Interfaces – Communication..............................................................................53
10.1 Online commands................................................................................................................. 53
10.1.1 Overview of commands and parameters...........................................................................53
10.1.2 General online commands ................................................................................................53
10.1.3 Online commands for system control ................................................................................56
10.2 XML-based communication .................................................................................................. 56
11 Care, maintenance and disposal .......................................................................57
12 Diagnostics and troubleshooting......................................................................58
13 Service and support ...........................................................................................59
13.1 What to do should servicing be required? ............................................................................ 59

Table of contents
Leuze electronic IPS 208i 5
14 Technical data .....................................................................................................60
14.1 General specifications .......................................................................................................... 60
14.2 Optical data........................................................................................................................... 61
14.3 Reading performance ........................................................................................................... 61
14.4 Device with heating............................................................................................................... 62
14.5 Dimensioned drawings ......................................................................................................... 62
14.6 Dimensioned drawings - Accessories................................................................................... 63
15 Order guide and accessories.............................................................................66
15.1 Nomenclature ....................................................................................................................... 66
15.2 Type overview....................................................................................................................... 66
15.3 Optical accessories............................................................................................................... 67
15.4 Cables accessories............................................................................................................... 67
15.5 Other accessories................................................................................................................. 68
16 EC Declaration of Conformity............................................................................69
17 Appendix..............................................................................................................70
17.1 ASCII character set............................................................................................................... 70
17.2 Configuration via configuration codes................................................................................... 73
17.3 License terms........................................................................................................................ 74

About this document
Leuze electronic IPS 208i 6
1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for dan-
ger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Tab.1.3: Terms and abbreviations
CMOS Semiconductor process for implementing integrated
circuits
(Complementary Metal-Oxide-Semiconductor)
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
FOV Field of view of the sensor (Field of View)
IO or I/O Input/Output
IP address Network address, which is based on the Internet
Protocol (IP)
IPS Camera-based positioning sensor
(Imaging Positioning Sensor)
Actual position Actual position of the marker (center point)
LED LED
(Light Emitting Diode)
MAC address Hardware address of a device in the network
(Media Access Control address)
Offset Shift of the nominal position in the X/Y direction
Marker Marking on which the sensor determines the posi-
tion (hole or reflector)
PELV Protective extra low voltage with reliable disconnec-
tion
(Protective Extra Low Voltage)
HBS High-bay storage device

About this document
Leuze electronic IPS 208i 7
Bar Material on which the marker is located, e.g., steel
beam
ROI Region of interest of the sensor in which a marker is
detected (Region of Interest)
Nominal position Position of the region of interest (coordinate center)
PLC Programmable Logic Control
(corresponds to Programmable Logic Controller
(PLC))
SWI Switching Input
SWO Switching Output
TCP/IP Internet protocol family (Transmission Control Pro-
tocol/Internet Protocol)
Tolerance range Symmetrical area in X/Y direction around the nomi-
nal position
UDP Network transmission protocol (User Datagram Pro-
tocol)
UL Underwriters Laboratories

Safety
Leuze electronic IPS 208i 8
2 Safety
This sensor was developed, manufactured and tested in line with the applicable safety standards. It corre-
sponds to the state of the art.
2.1 Intended use
The positioning sensors of the IPS200i series are designed for optical, contactless fine positioning relative
to a marker for use in steel construction, e.g. on high-bay storage devices in conveyor and storage sys-
tems.
Areas of application
The camera-based positioning sensors of the IPS200i series are especially designed for the following ar-
eas of application:
• Compartment fine positioning in high-bay pallet storage systems
• Small-part container storage systems
CAUTION
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
ÄOnly operate the device in accordance with its intended use.
ÄLeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
ÄRead these operating instructions before commissioning the device. Knowledge of the oper-
ating instructions is an element of proper use.
NOTICE
Integrated illumination!
The camera-based positioning sensors of the IPS200i series correspond to the following classi-
fication with respect to the integrated lighting:
ÄInfrared illumination: Exempt group in acc. with EN 62471
NOTICE
Comply with conditions and regulations!
ÄObserve the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
2.2 Foreseeable misuse
Any use other than that defined under "Intended use" or which goes beyond that use is considered im-
proper use.
In particular, use of the device is not permitted in the following cases:
• in rooms with explosive atmospheres
• in circuits which are relevant to safety
• In food processing
• for medical purposes
NOTICE
Do not modify or otherwise interfere with the device!
ÄDo not carry out modifications or otherwise interfere with the device.
The device must not be tampered with and must not be changed in any way.
ÄThe device may only be opened for exchanging the housing hood.
ÄThere are no user-serviceable parts inside the device.
ÄRepairs must only be performed by Leuze electronic GmbH + Co. KG.

Safety
Leuze electronic IPS 208i 9
2.3 Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the operating instructions for the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant standards
and regulations, certified electricians are able to perform work on electrical systems and independently de-
tect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations BGV A3
(e.g. electrician foreman). In other countries, there are respective regulations that must be observed.
2.4 Disclaimer
LeuzeelectronicGmbH+Co.KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.

Device description
Leuze electronic IPS 208i 10
3 Device description
3.1 Device overview
3.1.1 IPS200i positioning sensor
The camera-based positioning sensors of the IPS 200i series enable fast and simple positioning of high-
bay storage devices in conveyor and storage systems.
• Positioning is designed for high-bay container or pallet warehouses.
• The positioning sensor detects holes or reflectors in bars in the rack construction and determines the
position deviation in the X and Y direction relative to the nominal position.
• The position deviation is output to the control via four digital outputs or via the interface.
• The positioning sensor can be operated and configured using the integrated webConfig tool via the Eth-
ernet service interface.
The positioning sensor consists of the following components:
• Camera
• Control panel
• Lighting unit: Infrared
• Evaluation unit with the following interfaces:
• Digital I/Os
• Ethernet
The positioning sensors of the IPS 200i series are operated as a "stand-alone" single device with individual
IP address in an Ethernet topology.
The positioning sensor is optionally available with integrated heating.
Information on technical data and characteristics: see chapter 14 "Technical data".
Markings
The positioning sensor detects the following markers:
• Hole: Dark marking on light background
• Reflector: Light marking on dark background

Device description
Leuze electronic IPS 208i 11
3.1.2 Performance characteristics
The most important performance characteristics of the camera-based positioning sensor:
• Typical absolute accuracy ±2% +2.5mm
• Working distances: 100mm to 600mm
• Marker diameter 5mm to 20mm
• Integrated IR illumination (infrared LED, 850nm) offers high interference rejection against ambient
light.
• Intuitive alignment via four feedback LEDs and webConfig tool
• Two control buttons for intuitive operation without PC
• webConfig, a web-based configuration tool for configuration of all device parameters.
No additional configuration software necessary
• Installation wizard for simple configuration in just a few steps
• Integrated teach functions for automatic adjustment of the exposure time and hole geometry
• Four programs
• Measurement value output: Four digital switching outputs or Ethernet
• Diagnostics in process mode through image transfer via FTP
• Diagnostics using the output of quality scores and detection status
• Optional model with heating for use to -30°C
• Variously coded M12 connections for unique assignment of the connections:
• Voltage supply, switching inputs/outputs
• Ethernet connection
3.1.3 Accessories
Special accessories are available for the positioning sensor (see chapter 15 "Order guide and acces-
sories"):
• Mounting systems for mounting
• Connection and interconnection cables for M12 connectors
• Housing hood with integrated protective screen made of glass for increased protection against
scratches
• Reflectors
• MA150 modular connection unit for decentralized distribution of the signals (see chapter 7.6 "Connect-
ing positioning sensor to MA150 connection unit")
• Connection to Ethernet switch (see chapter 7.7 "Connecting positioning sensor to Ethernet switch")
3.1.4 Device model with heating
The positioning sensor is optionally available as a model with integrated heating. In this case, heating is
permanently installed ex works.
Features of the integrated heating:
• Extension of the application range -30°C…+50°C
• Supply voltage: 18V…30V DC
• Average power consumption: 12W

Device description
Leuze electronic IPS 208i 12
3.2 Device construction
2
8
3
3
8
1
8
5
7
6
4
1 Lens
2 Control panel with indicator LEDs, control buttons and function/program selection display
3 LEDs for illumination (infrared light)
4 M4 mounting thread
5 Device housing
6 Housing hood
7 M12 connection technology
8 Feedback LEDs (4x green, +X -X +Y -Y)
Fig.3.1: Device construction

Device description
Leuze electronic IPS 208i 13
3.3 Connection technology
The device is connected using variously coded M12 connectors:
• A-coded, 12-pin, M12 connection for operating voltage, switching inputs/outputs
• D-coded, 4-pin, M12 connection for the Ethernet connection
PWR / SWIO HOST
1 2
1 PWR/SWIO, M12 plug, 12-pin, A-coded
2 HOST, M12 socket, 4-pin, D-coded
Fig.3.2: Electrical connections
NOTICE
Ready-made cables are available for all connections (see chapter 15.4 "Cables accessories").
NOTICE
Shielding connection!
ÄThe shielding is connected via the M12 connector housing.

Device description
Leuze electronic IPS 208i 14
3.4 Indicators and operational controls
The device is equipped with the following indicators and operational controls:
• Three indicator LEDs (PWR, NET, LINK)
• Two control buttons
• Six indicator LEDs for function selection (AUTO, ADJ) and program selection (PROGRAM 1…4)
• Four green feedback LEDs for aligning the positioning sensor
The positioning sensor depicts the deviations in the directions -X, +Y, +X, -Y using four green feedback
LEDs. These LEDs are activated upon shipment of the device from the factory and can be deactivated
via the webConfig tool.
1 2 3
4
6
75
8
1 LED indicators: PWR, NET, LINK
2 Function selection
3 Program selection
4 Control buttons
5 -X position; signals whether the positioning sensor is located in the tolerance range
6 +Y position; signals whether the positioning sensor is located in the tolerance range
7 +X position; signals whether the positioning sensor is located in the tolerance range
8 -Y position; signals whether the positioning sensor is located in the tolerance range
Fig.3.3: Indicators and operational controls

Device description
Leuze electronic IPS 208i 15
3.4.1 LED indicators
PWR LED
Tab.3.1: PWR indicators
Color State Description
--- OFF Device off
No operating voltage
Green Flashing Device ok
• Initialization phase
• Positioning not possible
• Operating voltage applied
• Self test running
ON (continuous light) Device ok
• Positioning possible
• Self test successfully finished
• Device monitoring active
Orange ON (continuous light) Service mode
• Positioning possible
• No data on the host interface
Flashing Wave function (synchronous with NET LED)
• Positioning possible
Red Flashing Device ok, warning set
• Positioning possible
• Temporary operating fault
ON (continuous light) Device error/parameter enable
No positioning possible
NET LED
Tab.3.2: NET indicators
Color State Description
--- OFF No operating voltage
• No communication possible
• Ethernet protocols not released
Green Flashing Initialization of the device
Establishing communication
ON (continuous light) Operation ok
• Network mode ok
• Connection and communication to Host established
Red Flashing Communication error
• Temporary connection error
• If DHCP active: No IP address could be obtained
ON (continuous light) Network error
• No connection established
• No communication possible

Device description
Leuze electronic IPS 208i 16
LINK LED
Tab.3.3: LINK indicators
Color State Description
Green ON (continuous light) Ethernet connected (LINK)
Yellow Flashing Data communication (ACT)
Feedback LEDs
Tab.3.4: Feedback LED indicators
Color State Description
--- OFF Device off
No operating voltage
No positioning operation active
No marker found or marker not in the corresponding quadrant
Green Flashing Flashing frequency signals the marker distance to the nominal
position:
• Low frequency: Large distance
• High frequency: Short distance
ON (continuous light) Marker is in nominal position (coordinate origin).
The positioning sensor is optimally positioned if all four feed-
back LEDs illuminate.
3.4.2 Function selection and program selection
Function selection
The following functions are selected and displayed via the bar graph display (see chapter 8.6 "Activating
device functions"):
•AUTO: Auto setup function for determining the optimum exposure and marker settings. Additional
teaching of the position in the selected program, if possible.
•ADJ: Adjustment function for aligning the device and for teaching-in the position in the current program
The individual functions are selected and activated with the control buttons.
• Select function with the navigation button : The function LED flashes.
• Activate function with the enter button : The function LED illuminates continuously.
NOTICE
If you activate the AUTO or ADJ function via the control buttons, the device accepts no com-
mands via the process interface. Process mode is thereby interrupted.
Program selection
The control buttons and PROGRAM display can be used to select, activate and display programs that are
stored in the device.

Device description
Leuze electronic IPS 208i 17
3.4.3 Control buttons
Function selection and program selection are controlled via the control buttons.
NOTICE
In the Service operating mode (which is set using the webConfig tool), the positioning sensor
cannot be operated using the control buttons.
•  –navigation button: Scroll through the functions in the function and program selection display from
left to right.
•  –enter button: Scroll through the functions in the function and program selection display.
NOTICE
A preselected function (flashing LED) does not yet have any influence on the functionality. If no
button is pressed for a longer period of time, flashing of the LED is ended automatically by the
device.
NOTICE
The AUTO and ADJ functions always apply to the currently valid program. Both functions must
be deactivated again by pressing the enter button .
Example: Auto setup of program 2
ÄPress the navigation button twice.
ðThe PROGRAM2 LED flashes and the program is preselected.
ÄPress the enter button once.
ðProgram2 is active.
ÄPress the navigation button until the AUTO LED flashes.
ðThe AUTO function is preselected.
ÄPress the enter button .
ðAuto setup is active and the four feedback LEDs indicate the alignment.
ÄAlign the positioning sensor so that all four feedback LEDs permanently illuminate green.
ÄPress the enter button .
ðAuto setup is concluded.

Functions
Leuze electronic IPS 208i 18
4 Functions
This chapter describes the functions of the positioning sensor:
• Programs (see chapter 4.1 "Programs")
• Camera operating modes (see chapter 4.2 "Camera operating modes")
• Quality score (see chapter 4.3 "Quality score")
• Offset (see chapter 4.4 "Offset")
• Teach position (see chapter 4.5 "Teach position")
• Detection status (see chapter 4.6 "Detection status")
The sensor operates in two dimensions, X and Y:
• X corresponds to the horizontal axis.
• Y corresponds to the vertical axis.
1
2
3
5
4
7
8
6
+X -X
+Y-Y
1 Working distance
2 Field of view (FOV)
3 Region of interest (ROI)
4 Tolerance range
5 Nominal position (marker)
6 Actual position (marker)
7 X deviation
8 Y deviation
Fig.4.1: Mode of operation of the positioning sensor

Functions
Leuze electronic IPS 208i 19
4.1 Programs
There are four programs stored in the positioning sensor. The programs can be configured, e.g., to com-
pensate for the position difference between the loading position and unloading position of the high-bay stor-
age device.
Switch between or activate programs in the device as follows:
• Via the webConfig tool (see chapter 4.7 "Leuze webConfig tool")
• Via the SWI3 and SWI4 switching inputs (default setting)
• Via control buttons on the device
• Via an Ethernet online command
On delivery, all programs are optimized as follows:
• Working distance: 300mm
• Hole diameter: 13mm
• Offset X/Y: 0mm
• Tolerance +/- X/Y: 4mm
• Marker tolerance: 15%
4.2 Camera operating modes
The camera operating mode defines how the positioning sensor starts and ends a positioning operation.
4.2.1 Single trigger mode
In the "Single trigger mode" camera operating mode, the positioning sensor captures one image and at-
tempts to determine the actual position of the marker relative to the nominal position.
4.2.2 Reading gate control
Upon activation, the reading gate control opens a time window in the device for the positioning operation. In
this time window, the positioning sensor continuously determines the relative position and outputs the posi-
tion. The reading gate control must be deactivated again via the trigger signal.
The "Reading gate control" camera operating mode is activated upon shipment from the factory.
4.3 Quality score
The quality score is a measure of the quality of the found marker and refers to the shape factor, the scaling
factor and the contrast of the taught marker. The quality score is output in percent [%].
Limit values can be defined in the positioning sensor via the quality score:
• Limit value at which a switching output is set as a warning if the value is less than or exceeds the limit.
• Limit value at which images are transferred via Ethernet / interface (FTP).
• In addition, the determined quality score can be output via the interface.
4.4 Offset
Offset in the X/Y direction that is taken into account for the positioning, e.g., when moving goods in and out
of storage. Here, the offset shifts the nominal position relative to the center point of the region of interest.
The offset can be in the positive or negative direction.
NOTICE
You can set one offset value per program.

Functions
Leuze electronic IPS 208i 20
Example
You would like the positioning sensor to be 20mm higher when moving a pallet into storage than when
moving it out of storage. This offset is stored in program1.
1
2
3
4
5
6
+X -X
+Y-Y
webConfig
1 Working distance
2 Field of view (FOV)
3 Region of interest (ROI)
4 Actual position (marker)
5 Nominal position
6 Offset
Fig.4.2: Example: Offset
4.5 Teach position
For fine adjustment and as an alternative to precise mechanical alignment, you can teach-in the position of
the device. When teaching-in the position, the coordinate system of the region of interest is placed in the
center point of the detected marker.
You can activate the function in the device as follows:
• Via the webConfig tool (see chapter 4.7 "Leuze webConfig tool")
• Via control buttons on the device (via AUTO mode or ADJ mode)
• Via an Ethernet online command
If the teaching-in of the position fails, it may be due to the following reasons:
• The marker is not located in the device's region of interest.
• The limits of the new region of interest determined by teaching-in are not completely in the field of view.
4.6 Detection status
The detection status signals the status of the current detection:
•0: Detection successful – one marker detected in region of interest
•1: Detection not successful – several markers detected in region of interest
•2: Detection not successful – no markers detected in region of interest
4.7 Leuze webConfig tool
The webConfig configuration tool offers a graphical user interface for the configuration of the positioning
sensor via a PC (see chapter 9 "Commissioning – Leuzeelectronic webConfig tool").
The wizard of the webConfig tool can be used to easily configure the positioning sensor in just a few steps.