Pepperl+Fuchs PGV F200A User manual

PGV...-F200/-F200A...-R4-
V19
Incident Light Positioning
System
M nu l

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 Elek-
troindustrie (ZVE ) 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: [email protected]
North Americ n He dqu rters
Pepperl+Fuchs nc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [email protected]
Asi He dqu rters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [email protected]rl-fuchs.com
https://www.pepperl-fuchs.com

PGV...-F200/-F200A...-R4-V19
Contents
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1 S fety .......................................................................................................................... 5
1.1 Introduction.................................................................................................... 5
1.1.1 Content of this Document ................................................................................................... 5
1.1.2 Manufacturer ...................................................................................................................... 5
1.1.3 Target Group, Personnel ..................................................................................................... 5
1.1.4 Symbols Used .................................................................................................................... 6
2 Product Description .................................................................................................. 7
2.1 Use nd Applic tion ...................................................................................... 7
2.2 The RS-485 Interf ce ..................................................................................... 9
2.3 LED Indic tors nd Controls ...................................................................... 10
2.4 Accessories.................................................................................................. 12
3 Inst ll tion................................................................................................................ 13
3.1 Mounting the Re d He d............................................................................. 13
3.2 Mounting the Colored T pe nd Code T pe .............................................. 15
3.3 Electric l Connection .................................................................................. 30
4 Commissioning........................................................................................................ 32
4.1 Specifying the First Direction Decision..................................................... 32
4.2 Direction Decision ....................................................................................... 32
4.3 P r meter ssignment ................................................................................ 34
4.3.1 nternal Parameterization Using Parameterization Software.............................................. 34
4.3.2 External Parameterization Using Code Cards................................................................... 35
4.3.2.1 The code cards "CANCEL", "USE", and "DEFAULT"..............................................................36
5 Oper tion nd communic tion............................................................................... 37
5.1 Communic tion vi the RS-485 Interf ce.................................................. 37
5.1.1 Request Telegram............................................................................................................. 37
5.1.2 Position Response Telegram ............................................................................................ 38
5.1.2.1 Number of Lanes LC (Lane Count) ........................................................................................42
5.1.2.2 Orientation O .........................................................................................................................43
5.1.2.3 Side S ....................................................................................................................................44
5.1.2.4 Position/Lane .........................................................................................................................45
5.1.3 Direction Decision Request Telegram ............................................................................... 45
5.1.4 Color Choice Request Telegram ....................................................................................... 46
5.2 Oper tion Using Control Codes ................................................................. 48
5.3 Oper tion Using Rep ir T pe...................................................................... 49
6 Appendix .................................................................................................................. 50

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Contents
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6.1 Code C rds for Extern l P r meteriz tion................................................50
6.1.1 Code Cards with Special Functions .................................................................................. 51
6.1.2 Code Cards for Setting the Read Head Address............................................................... 53
6.1.3 Code Cards for Adjusting the Resolution .......................................................................... 55
6.1.4 Code cards for setting the transfer rate ............................................................................. 57
6.1.5 Code cards for adjusting the terminator ............................................................................ 59
6.1.6 Code Cards for Adjusting nput/Output 3........................................................................... 60

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Safety
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1 S fety
1.1 Introduction
1.1.1 Content 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
The documentation comprises the following parts:
•This document
•Datasheet
n addition, the documentation may comprise the following parts, if applicable:
•EU-type examination certificate
•EU declaration of conformity
•Attestation of conformity
•Certificates
•Control drawings
•nstruction manual
•Other documents
1.1.2 M nuf cturer
1.1.3 T rget Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismount-
ing lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation, com-
missioning, 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.
Note
For full information on the product, refer to the further documentation on the nternet at
www.pepperl-fuchs.com.
Pepperl+Fuchs Group
Lilienthalstraße 200, 68307 Mannheim, Germany
nternet: www.pepperl-fuchs.com

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Safety
1.1.4 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
W rning Mess ges
You will find warning messages, whenever dangers may arise from your actions. t is mandatory
that you observe these warning messages for your personal safety and in order to avoid prop-
erty damage.
Depending on the risk level, the warning messages are displayed in descending order as fol-
lows:
Inform tive Symbols
Action
1. This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
D nger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
W rning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
C ution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Note
This symbol brings important information to your attention.

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Product Description
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2 Product Description
2.1 Use nd Applic tion
Intended Use
This device, when used together with a colored tape affixed to the floor and code tapes printed
with Data Matrix codes, constitute a high-resolution lane tracking and positioning system. t can
be used in all applications where automated guided vehicles (AGV) are to be positioned pre-
cisely at marked positions along a given lane.
The read head forms part of the positioning system in the Pepperl+Fuchs incident light pro-
cess. The read head's features include a camera module and an integrated illumination unit.
The read head uses these features to detect a colored tape stuck to the floor or a painted color
lane to track the lane. The read head detects Data Matrix tags to navigate within a grid. The
read head also detects control codes and position markers in the form of Data Matrix codes
printed on a self-adhesive code tape. Data Matrix code tapes and Data Matrix tags have priority
over colored tapes or colored lanes.
The Data Matrix code tapes are installed in a fixed position instead of or along with the colored
tape. The read head is located on an automated guided vehicle (AGV) and guides this vehicle
along the colored tape.
Figure 2.1 Automated guided vehicle with green colored tape
Note
Priority
Data Matrix code tapes and Data Matrix tags have priority over colored tapes or colored lanes.
f the read head detects a Data Matrix code tape or Data Matrix tags in the field of view, colored
tapes or colored lanes in the field of view are ignored.

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Product Description
T g Mode
n addition to the tracking, you can use the read head 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 AGV in relation to the zero point of the Data Matrix tag to the controller.
The tag mode allows the AGV to move freely in as large a grid as desired, without having to
mark the crossing paths with lane tapes.
Figure 2.2 Automated guided vehicle with Data Matrix tags
The read head switches automatically between tag mode and lane tracking. This allows an
automated guided vehicle to be guided from one Data Matrix tag grid via a colored or Data
Matrix lane to another Data Matrix tag grid.
The extensive yet user-friendly parameterization options as well as the configurable inputs and
outputs mean that the read head can easily be adapted to suit each application.

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Product Description
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2.2 The RS-485 Interf ce
The read head is equipped with an RS-485 interface for communication purposes, i.e., param-
eterizing the read head functions or reading out current process data during operation. This
interface is operated in 8-E-1 mode and fitted with a terminator that can be activated or deacti-
vated by parameterizing the sensor head accordingly. The RS-485 interface supports the fol-
lowing transfer rates:
•38400 bit/s
•57600 bit/s
•76800 bit/s
•115200 bit/s (preset value)
•230400 bit/s
D t structure of the RS-485 interf ce
Bit 0
LSB MSBStart Stop
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Parity

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Product Description
2.3 LED Indic tors nd Controls
The read head is equipped with seven indicator LEDs for carrying out visual function checks
and rapid diagnostics. The read head is equipped with two buttons at the back for activating
parameterization mode. Button 1 is labeled ADJUST. Button 2 is labeled CONF G.
Figure 2.3
ADJUST
CONFIG
1
2
LED 1 2 3 4 5 6 7

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Product Description
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LED [#1] COM [#2] PWR ERR/NO CODE [#3] LANE AVAILABLE [#4] FOLLOW LEFT [#5] FOLLOW RIGHT [#6] & [#7] INTERNAL DIAGNOSTIC
DescriptionColor Yellow
Green/
red Yellow Yellow Yellow
Red/
green/
yellow
St tus
x
1
1. LED status has no meaning
Flashes
red
x x x
x
Code tape outside read range
f
flash
= 2 Hz
x Lights
up red
x x x
x
System errorError Codes40
2
2. No lane selected, for example. .see table "Error Codes" on page 40
x Lights up
green
x x x x
Code tape detected, absolute position
available
x x Lights up x x x
Colored tape detected
x x Off x x x
Colored tape outside read range
x x x Off Off x
No direction selection activated4
3
3. See chapter 4
x x x Lights
up
Off
x
"Follow left-hand lane" activated
x x x Off Lights up x
"Follow right-hand lane" activated
x x x Lights
up
Lights
up
x
"Straight ahead" activated
Flashes x x x x x
RS-485 data transfer
Flashes Flashes
red
Flashes Flashes Flashes Off
Normal operation. ndication for 2 secs if
a button is pressed when the time lock is
enabled.
Off Red, 3
sec
Flashes Off Off Off
Code card faulty
f
flash
= 2 Hz for 3 sec
Off Green,
1 sec
Flashes Off Off
Off
Code card detected
f
flash
= 2 Hz for 1 sec
x Off x x x Off
Time lock for buttons disabled
x x x x x Lights up
nternal error
Return to Pepperl+Fuchs
Table 2.1

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Product Description
2.4 Accessories
Compatible accessories offer enormous potential for cost savings. Such accessories not only
save you a great deal of time and effort when commissioning for the first time, but also when
replacing and maintaining our products.
f products are used in harsh ambient conditions, appropriate Pepperl+Fuchs accessories can
be used to extend the service life of these products.
Order design tion Description
PGV-CC25-0* Data Matrix control codes
PGV*M-CA25-* Data Matrix position tape
PGV-CR25 Repair tape
PGV85-CT4 Data Matrix tag
PGV25M-CD100-CLEAR Protective film for code and colored tape
PGV33M-CB19-BU Colored tape; blue
PGV33M-CB19-GN Colored tape; green
PGV33M-CB19-RD Colored tape; red
PCV-SC12
PCV-SC12A
Grounding clip
V19-G-ABG-PG9-FE Grounding terminal and plug (set)
PCV-USB-RS485 converter set USB/RS-485 interface converter
PCV-KBL-V19-STR-RS485 Cable unit with 24 V power supply and V19
connection cable to RS-485 interface
V19-G-*M-* Configurable connection cable
1
1. Ask your contact person at Pepperl+Fuchs

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3 Inst ll tion
3.1 Mounting the Re d He d
Mount the PGV... read head on the automated guided vehicle using the four screws on the
mounting adapter on the read head. Mount the read head in such a way that the lens with the
ring light and camera module are directed toward the colored tape.
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 Re d Dist nce
Hysteresis
f the read head has detected a colored tape, this colored tape can move in the Y direction from
the zero point within the viewing window. The maximum Y value at which the read head can still
capture this distance is designated as Y V lue Out in the following table.
f the read head swivels onto a colored tape, the read head can capture the distance of the col-
ored tape from the zero point only if the tape is less than a certain distance away from the zero
point. This distance is designated as Y v lue In in the following table. The difference between
Y Value Out and Y Value n is the hysteresis. See "Distance Output" on page 18.
Order design tion Re d dist nce [mm] Depth of focus [mm]
Field of vision
(w x h) [mm]
PGV100* 100 ±20 117 x 75
PGV150 * 150 ±30 170 x 105
Order design tion M x. Y V lue Out [mm] Min. Y V lue In [mm]
PGV100* 60 45
PGV150 * 60 60

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Re d He d Dimensions
Figure 3.1 Housing *-F200-*
Figure 3.2 Housing *-F200A-*
12.5
54
2020
M12
M12
M6 x 9 (4x)
25
21.75
25
12
70 13.8
70
80
10 70 12
94.5
70
50
22
ø 25
M6 x 9 (4x)
12.5 20 20

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3.2 Mounting the Colored T pe nd Code T pe
Colored t pe
The colored tape must be flexible, conformable, and resistant to abrasion, with a matte finish.
The colored tape must meet the following specifications:
•Tape width: 10 mm ... 40 mm
•Color of the tape
•Blue = RAL 5015
•Green = RAL 6032
•Red = RAL 3001
•Tape thickness > 0.1 mm
The thickness of the tape is irrelevant to read head operation.
•Breaking load > 25 N/cm
•Breaking elongation > 180%
•Adhesive strength > 2 N/cm
•Temperature resistance: -20 °C ... 70 °C
Secure the colored tape to the floor such that the following conditions are met:
•Data Matrix code tapes for positioning are used instead of the colored tape.
•Data Matrix control codes are positioned parallel to the colored tape.
Color Selection
Select the color of the colored tape so that the contrast between the floor color and the color of
the colored tape is as great as possible. deally, use the complementary color.
Due to the integrated lighting of the read head, some floor colors appear to be different in the
camera. f you have problems with the color selection of the colored tapes, please consult your
contact at Pepperl+Fuchs.
Mounting the Colored T pe
1. Clean the surface of any greasy or oily deposits and dust.
2. Ensure that the surface is dry, clean, and stable.
3. Please observe the following section "Basics" when mounting the colored tape and, if
necessary, the instructions from the colored tape manufacturer.
C ution!
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.
C ution!
The maximum torque of the mounting screws must not exceed 9 Nm.
Tightening the screws to a higher torque may damage the read head.
Note
Priority
Data Matrix code tapes and Data Matrix tags have priority over colored tapes or colored lanes.
f the read head detects a Data Matrix code tape or Data Matrix tags in the field of view, colored
tapes or colored lanes in the field of view are ignored.

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Cle ning Colored T pe/Code T pe
Significant contamination on the colored or code tapes can impair the detection by the read
head. Clean the colored and code tapes with isopropanol if necessary. f the contamination is
severe, you can use a non-corrosive plastic cleaner, e.g., Caramba®.
B sics
The read head detects a colored tape on a floor as a lane. The width of the colored tape must
be between 10 mm and 40 mm; the default width is 18 mm. The zero point is located in the cen-
ter of the colored tape. You can use 3 defined colors. See the section entitled "Colored tape"
The sensor always moves in the X direction. n the sensor's field of view, X indicates an upward
movement.
Figure 3.3 Field of view and coordinates of the sensor
Figure 3.4 Curve radius: R  50 cm
Select a curve radius that can handle the turning circle of your automated guided
vehicle. The colored tape must always be located in the reading window of the read
head.
Note
To avoid polishing the surface, do not apply strong pressure when cleaning. A shiny surface of
the colored or code tapes leads to impairment in detection by the read head.
+Y
+X
+Z
R

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Angle Output
The read head detects a change of the angle of the colored tape and the Data Matrix code tape
and outputs this value to the controller. The output value is different for colored tapes and Data
Matrix code tapes.
Colored t pe
The read head detects the angle in relation to the tracked lane with a resolution of 360 (corre-
sponds to 1°). The angle is specified relative to the tracked lane because a colored tape does
not include any direction information. The output angle covers the range from -45° to 45°. The
resolution is 1°.
Figure 3.5 Relative angle
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.
X
Y
X
Y
β
✓
✗

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D t M trix code t pe
The read head detects the absolute angle in relation to the tracked lane with a maximum reso-
lution of 0.1°. The angle is specified absolutely relative to the tracked lane, since a Data Matrix
code contains tape 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°
Figure 3.6 Absolute angle
Dist nce Output
The read head detects the distance from the zero point in the Y direction of a colored tape or a
Data Matrix code tape and outputs this value to the controller. The output value is different for
colored tapes and Data Matrix code tapes due to the lack of an X position for colored tapes.
Colored t pe
The read head outputs the Y value at which the colored tape intersects the Y axis as the dis-
tance.
Figure 3.7 Distance A for colored tape
X
Y
X
Y
X
Y
A

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D t M trix code t pe
The read head indicates the vertical distance of the zero point in relation to the Data Matrix
code tape.
Figure 3.8 Distance A for Data Matrix code tape
Br nches
The read head detects one lane at the lower edge of the field of vision and two lanes at the
upper edge of the field of vision; the read head indicates this as a branch.
The read head detects two lanes at the lower edge of the field of vision and one lane at the
upper edge of the field of vision; the read head indicates this as an intersection.
Branches or intersections can be displayed as follows:
Figure 3.9 Separate lane branches off/converges
X
Y
A

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The read head can make the following direction decisions based on the lane and possible
branches:
•Follow left-hand lane
•Straight ahead
•Follow right-hand lane
The direction decision is signaled to the read head via the controller. f there is no direction
decision, the read head displays an error message.
Code T pes for Control nd Positioning
n addition to tracking the lane, the read head can also detect Data Matrix codes. This process
involves evaluating both control and position information. Data Matrix control codes are used
as event markers. Control codes provide information on branches. Data Matrix code tapes for
positioning indicate the absolute position of the read head.
Note the following conditions:
Data Matrix code tapes for positioning are used instead of the colored tape.
Data Matrix control codes are used in tandem with the colored tape or Data Matrix position
code.
Branches or intersections with position information can be displayed as follows:
1Colored tape
2Data Matrix position code
3Data Matrix control code
1
3
2