Pepperl+Fuchs PHA-F200-R3 Series User manual

PHA...-F200*-R3*
Vision Sensor
for Rack Fine Positioning
FACTORY AUTO ATION
ANUAL

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 ndustry, published by the
Central Association of the Electrical ndustry (Zentralverband Elektrotechnik und Elektroindustrie
(ZVE ) e.V.) in its most recent version as well as the supplementary clause: "Expanded reservation
of proprietorship"
PHA...-F200*-R3*

PHA...-F200*-R3*
Contents
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1 Introduction......................................................................... 5
2 Declaration of Conformity ................................................. 6
3 Safety................................................................................... 7
3.1 Symbols Relevant to Safety ..........................................................................7
3.2 ntended Use ................................................................................................7
3.3 General Safety nstructions ...........................................................................7
4 Product Description ........................................................... 8
4.1 Vision Sensor for Rack Fine Positioning — Use and Applications.................8
4.2 Displays and Controls ...................................................................................9
4.3 nterfaces and Connections ........................................................................ 11
4.4 Scope of Delivery........................................................................................13
4.5 Accessories ................................................................................................ 13
4.5.1 Power Supply .........................................................................................13
4.5.2 Network Cable ........................................................................................14
4.5.3 RS-422 nterface ....................................................................................14
5 Installation......................................................................... 15
5.1 Storage and Transport................................................................................. 15
5.2 Preparation .................................................................................................15
5.3 Mounting the Sensor...................................................................................15
5.4 Connecting the Sensor ...............................................................................17
6 Commissioning................................................................. 19
6.1 Sensor Functionality ...................................................................................19
6.2 Operating Modes ........................................................................................26
6.3 Communication via the RS-422 nterface.................................................... 27
6.4 Request Telegrams .....................................................................................27
6.5 Response Telegrams ..................................................................................28
6.6 Warning and Error Codes ...........................................................................29
6.7 Timing Charts .............................................................................................31
7 Operation........................................................................... 32
7.1 PHA* Vision Configurator Menu Structure ...................................................32
7.1.1 Connecting the Service nterface ...........................................................32
7.1.2 Structure of the Application Window .......................................................32
7.1.3 Menu Bar................................................................................................34
7.1.4 Configuration Window ............................................................................ 34

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PHA...-F200*-R3*
Contents
8 aintenance and Repair.................................................. 36
8.1 Maintenance .............................................................................................. 36
8.2 Repair ........................................................................................................ 36
9 Troubleshooting ............................................................... 37
9.1 What to Do in the Event of an Error ............................................................ 37

PHA...-F200*-R3*
ntroduction
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1 ntroduction
Congratulations
You have chosen a device manufactured by Pepperl+Fuchs. Pepperl+Fuchs
develops, produces and distributes electronic sensors and interface modules for
the market of automation technology on a worldwide scale.
Symbols used
The following symbols are used in this manual:
Handling instructions
You will find handling instructions beside this symbol
Contact
f you have any questions about the device, its functions, or accessories, please
contact us at:
Pepperl+Fuchs GmbH
Lilienthalstraße 200
68307 Mannheim, Germany
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Note!
This symbol draws your attention to important information.

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PHA...-F200*-R3*
Declaration of Conformity
2 Declaration of Conformity
This product was developed and manufactured under observance of the
applicable European standards and guidelines.
The product manufacturer, Pepperl+Fuchs GmbH, D-68307 Mannheim, has a
certified quality assurance system that conforms to SO 9001.
Note!
A declaration of conformity can be requested from the manufacturer.
ISO9001

PHA...-F200*-R3*
Safety
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3 Safety
3.1 Symbols Relevant to Safety
3.2 ntended Use
The device is a Vision Sensor for rack fine positioning to a hole reference mark.
The sensor is used in high-rack warehouses. Use the sensor only for its intended
purpose.
3.3 General Safety nstructions
Always operate the device as described in these instructions to ensure that the
device and connected systems function correctly. The protection of operating
personnel and plant is only guaranteed if the device is operated in accordance
with its intended use.
The operating company bears responsibility for observing locally applicable
safety regulations.
nstallation and commissioning of all devices may be performed only by personnel
specially trained for that purpose.
User modification and or repair are dangerous and will void the warranty and
exclude the manufacturer from any liability. f serious faults occur, stop using the
device. Secure the device against inadvertent operation. n the event of repairs,
return the device to your local Pepperl+Fuchs representative or sales office.
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.
Danger!
Moving parts
n applications involving stock feeders and moving carriages, care must be taken
to ensure that the applicable safety regulations are observed at all times. Failure
to do so may result in serious or fatal injury.

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PHA...-F200*-R3*
Product Description
4 Product Description
4.1 Vision Sensor for Rack Fine Positioning — Use and Applications
The PHA*...-F200* Vision Sensor for rack fine positioning from Pepperl+Fuchs
facilitates fast and simple positioning of stock feeders. The Vision Sensor detects
circular holes in the rack structure and determines their position deviation in the X
and Y directions relative to the target position.
The Vision Sensor comprises:
■Camera
■Lighting unit
■Evaluation computer with digital input and output signals
■Service interface
Figure 4.1

PHA...-F200*-R3*
Product Description
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4.2 Displays and Controls
The Vision Sensor unit has 7 LED indicators on the top that provide information on
the various statuses of the device.
Figure 4.2 ndication operating side
LEDs are mounted around the camera element on the front of the Vision Sensor.
The LEDs are used for light, to align the X and Y position, and for the status
display.
+X position
LED yellow. ndicates wether the sensor is within the tolerance range.
-X position
LED yellow. ndicates wether the sensor is within the tolerance range.
+Y position
LED yellow. ndicates wether the sensor is within the tolerance range.
-Y position
LED yellow. ndicates wether the sensor is within the tolerance range.
POWER (PWR)
LED green: Lights up, when the sensor is operational.
DIAG 1
Dual-LED: Flashing red / yellow with approx. 1 Hz when the vision sensor is op-
erational.
DIAG 2
Dual-LED: Flashing red / yellow with approx. 1 Hz when the vision sensor is op-
erational.
1 2 3 4 5 6 7
1
2
7
6
5
4
3
2
1

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PHA...-F200*-R3*
Product Description
Figure 4.3 Displays on the camera side
1. Camera
2. nfrared illumination LEDs
3. -X position
Red LED. ndicates whether the sensor is within the tolerance range.
4. -Y position
Red LED. ndicates whether the sensor is within the tolerance range.
5. +X position
Red LED. ndicates whether the sensor is within the tolerance range.
6. Normal operation
Red LED. Flashes when the sensor is in normal operation.
7. +Y position
Red LED. ndicates whether the sensor is within the tolerance range.
Two operating buttons are mounted on the back of the Vision Sensor. You can use
these operating buttons to reset the P address of the device to the default value.
see "Resetting the P Address" on page 32
Figure 4.4 Controls
Operating buttons 1 and 2
1
2
3
4
5
6
7
1
2
1
1

PHA...-F200*-R3*
Product Description
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4.3 nterfaces and Connections
The device includes the following connections:
Figure 4.5 Device connections
Service interface
There is a 4-pin M12 socket on the side of the housing for connecting a PC. The
reader can be configured using the "Vision Configurator" software. This software
is available to download from www.pepperl-fuchs.com
The following diagram shows the pin assignment of the service interface:
Figure 4.6 Layout service interface
LAN (service interface, 4-pin M12 socket, D-coded)
RS422 connection (PLC, 5-pin M12 socket)
24 VDC + O (power supply, inputs and outputs,
8-pin M12 connector)
1TX+ Ethernet
2RX+ Ethernet
3TX- Ethernet
4RX- Ethernet
1
2
3
1
2
3
1
1
3
42

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PHA...-F200*-R3*
Product Description
RS 422
There is a 5-pin M12 socket on the side of the housing for connecting to the PLC.
The following diagram shows the pin assignment:
Figure 4.7 RS 422 connection layout
24 VDC + IO (power supply, inputs and outputs)
There is an 8-pin M12 connector on the side of the housing to connect the power
supply and the inputs and outputs. The following diagram shows the pin
assignment:
Figure 4.8 Connection operating voltage, inputs and outputs
1RX+
2TX-
3RX-
4TX+
5NC
1OUT +X
2+UB
3OUT +Y
4OUT -Y
5OUT -X
6N 1 Cycle stop
7GND
8N 2 Relative position
2
1
5
3
2
4
3
1
4
6
7
8
53
2

PHA...-F200*-R3*
Product Description
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4.4 Scope of Delivery
■PHA*
Appropriate mounting hardware, cables, and other information can be found in the
Accessories section and at http://www.pepperl-fuchs.com.
4.5 Accessories
Various accessories are available.
4.5.1 Power Supply
Use the following double-ended cordset to connect the power supply, inputs, and
outputs to the sensor.
Female field connector
Other lengths on request.
Field-attachable 12 socket
odel
number
V19-G-2M-
PUR-ABG
8-pin M12
socket,
straight
L = 2 m Open cable end with multistranded conductors
V19-G-5M-
PUR-ABG
8-pin M12
socket,
straight
L = 5 m Open cable end with multistranded conductors
V19-G-
10M-PUR-
ABG
8-pin M12
socket,
straight
L = 10
m
Open cable end with multistranded conductors
odel number
V19-G-ABG-PG9 ■8-pin M12 socket, straight
■Screw terminals for max. 0.75 mm2 PG9 cable gland
■Cable diameter: 5 mm ... 8 mm
L

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PHA...-F200*-R3*
Product Description
4.5.2 Network Cable
The sensor is connected to the network using an M12 plug.
4.5.3 RS-422 nterface
The sensor's RS-422 interface is connected via an M12 plug.
Note
f you use your Vision Sensor in a refrigeration application at below -20 °C, please
ask us for special cables.
Designation Description
V45-G RJ45 network plug, field attachable
V1S-G M12 plug, 4-pin, field attachable
V1SD-G-2M-PUR-
ABG-V45X-G
Cordset, RJ45 network plug with M12 plug, crossed, 4-pin
V1SD-G-2M-PUR-
ABG-V45-G
Cordset, RJ45 network plug with M12 plug, 4-pin
Designation Description
V15S-G-5M-PUR-ABG Male single-ended cordset, M12, 5-pin, PUR cable, shielded
cap nut
V15S-G-5M-PUR-ABG-
SUBD9
Cordset, M12 plug, 5-pin, to D-Sub housing, 9-pin

PHA...-F200*-R3*
nstallation
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5 nstallation
5.1 Storage and Transport
For storage and transport purposes, package the unit using shockproof
packaging material and protect it against moisture. The best method of protection
is to package the unit using the original packaging. Furthermore, ensure that the
ambient conditions are within allowable range.
5.2 Preparation
Unpacking the unit
1. Check that all package contents are present and undamaged.
f anything is damaged, inform the shipper and contact the supplier.
2. Check that all items are present and correct based on your order and the
shipping documents.
f you have any questions, please contact Pepperl+Fuchs.
3. Keep the original packing material in case you need to store or ship the unit at
a later time.
5.3 Mounting the Sensor
The device is equipped with a mounting block with four symmetrical M6 threads.
The operating distance differs depending on the sensor. The correct operating
distance can be found in the technical data for the sensor to be installed.
The following illustration shows the housing dimensions in mm:
Note!
Mounting an optical device
■Do not aim the sensor at the sun.
■Protect the sensor from direct long-term exposure to sun.
■Prevent condensation from forming by not exposing the sensor to any
major fluctuations in temperature.
■Do not expose the sensor to the effects of any aggressive chemicals.
■Keep the lenses and reflector of the device clean. Clean with a soft cloth,
using standard commercial glass cleaner if necessary.
We recommend to clean the optical surface and to check screw fittings and
electrical connections at regular intervals.

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PHA...-F200*-R3*
nstallation
The surface must be level to prevent the housing from becoming distorted when
the fittings are tightened. We advise securing the screws with spring disks in order
to prevent the sensor becoming misaligned. After mounting the sensor, ensure
that there is still sufficient space for the connecting cable.
Housing variant: PHA*-F200-*
Housing variant: PHA*-F200A-*
70
80
38.5
70 14.5
1
2
22
50
ø 25
12.5
M12 x 1
9
4 x M6
20 20
10 70 12
94.5
70
50
22
ø 25
M6 x 9 (4x)
12.5 20 20

PHA...-F200*-R3*
nstallation
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5.4 Connecting the Sensor
Connecting the Supply Voltage
To supply voltage to the sensor, proceed as follows:
1. Plug the 8-pin M12 socket into the 24 VDC + IO connector on the side of the
housing. .
2. Screw the cap nut onto the connector as far as it will go. This ensures that the
power cable cannot be pulled out accidentally.
3. Next connect the power supply to the corresponding pin on the M12 socket.
Figure 5.1 Connection operating voltage, inputs and outputs
The supply voltage has now been connected.
1OUT +X
2+UB
3OUT +Y
4OUT -Y
5OUT -X
6N 1 Cycle stop
7GND
8N 2 Relative position
1
4
6
7
8
53
2
Tip
To connect the sensor to the supply voltage more quickly, you can also use the
preconfigured connecting cable. This can be found in the Accessories section.

PHA...-F200*-R3*
Commissioning
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6 Commissioning
6.1 Sensor Functionality
The PHA...-F200* Vision Sensor detects circular holes in the rack structure and
determines their position deviation from the target position. The Vision Sensor
operates in two dimensions: X and Y. X is the horizontal direction and Y the
vertical direction. see Figure 6.1 on page 19. The operating distance
(distance between the rack profiles and the front panel of the sensor) must be
within the working range of the sensor.
Figure 6.1
f the hole is located in the target position, a deviation zero is output.
The Vision Sensor detects dark holes on a light background. Observe the
following points:
■Only one circular hole may be present in the capture range.
■All holes to be detected must have the same diameter.
■The surface surrounding the hole should only reflect diffusely.
■The area behind the hole should be unobstructed to a range of 500 mm.
■There should be no light source behind the hole.
■The Vision Sensor must be aligned parallel to the capture range.
■The actual operating distance must correspond to the operating distance of
the Vision Sensor.
Orientation coordinate system
dX
dY
Capture range X (width)
operating distance
capture range Y (height)
actual position
nominal position

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PHA...-F200*-R3*
Commissioning
Capture Range
The capture range is the area in the camera's line of vision, within which the
Vision Sensor can detect a hole.
The hole diameter should be 10 % to 15 % of the capture range width.
Zero Position and Relative Position
The actions to place an object (e.g., a pallet) in storage or remove an object from
storage are controlled via the zero position (ZP) and relative position (RP).
You can also use the zero position to align the Vision Sensor with the hole to be
detected, if a central alignment is not possible during assembly.
Figure 6.2 = index hole
= pallet
= sensor
Target Position
1
2
3
1
2
3

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Commissioning
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Figure 6.3 = index hole
= pallet
= sensor
The zero position moves the target position relative to the center point of the
detection/capture range
■Downward if a positive vertical value is entered.
■To the left if a positive horizontal value is entered.
Zero position (ZP)
ZP+
1
2
3
1
2
3