Pepperl+Fuchs PGV100R-F200-R4-1.5M User manual

PGV100R-F200-R4-1.5M
Incident Light Positioning
System
Manua

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 proprietor-
ship"
Wor dwide
Pepperl+Fuchs Group
Lilienthalstr. 200
68307 Mannheim
Germany
Phone: [phone] - 0
E-mail: inf[email protected]
North American Headquarters
Pepperl+Fuchs nc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [email protected]
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [email protected]hs.com
https://www.pepperl-fuchs.com

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PGV100R-F200-R4-1.5M
Contents
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1 Introduction................................................................................................................ 5
1.1 Content of this Document............................................................................. 5
1.2 Target Group, Personne ............................................................................... 5
1.3 Symbo s Used ................................................................................................ 6
2 Product Description .................................................................................................. 7
2.1 Use and App ication ...................................................................................... 7
2.2 RS-485 Interface ............................................................................................ 9
2.3 LED Indicators and Operating E ements..................................................... 9
2.4 Accessories.................................................................................................. 11
3 Insta ation................................................................................................................ 12
3.1 Mounting the Read Head............................................................................. 12
3.2 Affixing the Code Tape ................................................................................ 13
3.3 E ectrica Connection .................................................................................. 22
4 Commissioning........................................................................................................ 24
4.1 Direction Decision ....................................................................................... 24
4.2 Parameterization Using Code Cards.......................................................... 25
4.2.1 The code cards "CANCEL", "USE", and "DEFAULT" ....................... 26
5 Operation and communication............................................................................... 27
5.1 Communication via the RS-485 Interface.................................................. 27
5.1.1 Request Telegram ............................................................................ 27
5.1.2 Position Response Telegram............................................................ 28
5.1.2.1 Number of Lanes LC (Lane Count) ........................................................................................31
5.1.2.2 Orientation O .........................................................................................................................32
5.1.2.3 Side S ....................................................................................................................................33
5.1.2.4 Position/Lane .........................................................................................................................33
5.1.3 Direction Decision Request Telegram .............................................. 33
5.2 Operation Using Contro Codes ................................................................. 34
5.3 Operation Using Repair Tape...................................................................... 35
6 Appendix .................................................................................................................. 36

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6.1 Code Cards for Externa Parameterization................................................36
6.1.1 Code Cards with Special Functions.................................................. 36
6.1.2 Code Cards for Setting the Read Head Address .............................. 39
6.1.3 Code cards for setting the transfer rate ............................................ 41
6.1.4 Code Cards for Adjusting the Resolution.......................................... 43
6.1.5 Code cards for adjusting the terminator............................................ 44

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ntroduction
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1 Introduction
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
1.2 Target Group, Personne
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.

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ntroduction
1.3 Symbo s Used
This document contains symbols for the identification of warning messages and of informative
messages.
Warning Messages
You will find warning messages, whenever dangers may arise from your actions. 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:
Informative Symbo s
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
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.
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 and App ication
Intended Use
This device, when used together with a Data Matrix code tape affixed to the floor, constitutes a
high-resolution lane tracking and positioning system. t can be used in all applications where
auto-guided transport systems are to be positioned precisely at marked positions along a given
lane.
The read head forms part of the positioning system in the Pepperl+Fuchs incident light pro-
cess. The read head includes a camera module and an internal illumination unit, which the read
head uses to detect a strip of Data Matrix code tape stuck to the floor for lane tracking and nav-
igation. The read head also detects Data Matrix tags to navigate within a grid.
The read head is located on an auto-guided transport system and guides this system along the
Data Matrix code tape.
Figure 2.1 Auto-guided transport system with Data Matrix code tape

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PGV100R-F200-R4-1.5M
Product Description
Tag Mode
n addition to lane tracking, the read head can also be used in tag mode. The read head detects
Data Matrix tags, which are typically glued onto the floor in a grid. The individual Data Matrix
tags are numbered consecutively and include position information. The read head reports the
position of the auto-guided transport system in relation to the zero point of the Data Matrix tag
to the control panel.
Tag mode allows the auto-guided transport system to move freely in as large a grid as desired,
without having to mark the traverse distances with code tapes.
Figure 2.2 Auto-guided transport system with Data Matrix tags
The read head switches automatically between tag mode and lane tracking. This allows a
transport system to be guided from one Data Matrix tag grid to another via a Data Matrix code
tape.
Thanks to its comprehensive and simple parameterization options, the read head can be opti-
mally adapted to suit any application.

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2.2 RS-485 Interface
The read head is equipped with an RS-485 interface for communication purposes, i.e. parame-
terizing the read head functions or reading out current process data during operation. This
interface is operated in 8-E-1 operating mode and is fitted with a terminator that can be acti-
vated or deactivated by parameterizing the sensor head. The RS-485 interface supports the fol-
lowing transfer rates:
•9600 bit/s
•19200 bit/s
•38400 bit/s
•57600 bit/s
•76800 bit/s
•115200 bit/s (default value)
Data structure of the RS-485 interface
2.3 LED Indicators and Operating E ements
The read head is equipped with two indicator LEDs for carrying out visual function checks and
quick diagnostics.
Figure 2.3 Display elements
LEDs
Bit 0
LSB MSBStart Stop
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Parity
LED Co or Labe Meaning
1 Green/yellow COM STATE
COM ERROR
RS-485 communication active
RS-485 communication error
2 Green/red POWER ON
NO CODE/ ERROR
Code detected/not detected, error
ADJUST
COM STATE COM ERROR
POWER ON NO CODE/
ERROR
CONFIG
12

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PGV100R-F200-R4-1.5M
Product Description
LED fau t indicator
Function Indicator LED
LED 1 2
Description
Mode COM STATE COM ERROR POWER ON
NO CODE/
ERROR
Co or Green Ye ow Green Red
State
Off Off x x No communication
Off Flashing x x Communication
active
Off Lights up once x x Warning limit
reached
Off Lights up twice x x "Control Event" error
Off Lights up three times x x Synchronization error
Off Lights up four times x x "Event Timer" error
Off Lights up x x Bus off
LED 1 2
Description
Mode COM STATE COM ERROR POWER ON
NO CODE/
ERROR
Co or Green Ye ow Green Red
State
Off Flashing x x General configuration error
Off Off x x No communication
Off Lights up Off Lights up Bootloader starts
Off Flashing Off Flashing Bootloader communication
active
Lights up Off Off Off Bootloader ready for
communication
Off Off Lights up Off Bootloader flash memory
ready
Off Off Off Lights up Bootloader flash memory
error
Table 2.1 f
flash
= 2.5 Hz (one request line for flashing with three on statuses)
x: LED status has no meaning
LED 1 2
Description
Mode COM STATE COM ERROR POWER ON
NO CODE/
ERROR
Co or Green Ye ow Green Red
State
x x Lights up Off Codes detected
x x Off Flashing Codes not detected
x x x Lights up System error
x x Lights up for 1 s Off Code card read
x x Off Lights up for 1 s Code card not read
Table 2.2 Sensor switched on: At least one of the LEDs is lit or flashing
x: LED status has no meaning

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2.4 Accessories
Compatible accessories offer enormous potential for cost savings. Such accessories not only
save you a great deal of time and effort during initial commissioning, but also when replacing
and maintaining our products.
f products are used in harsh ambient conditions, appropriate Pepperl+Fuchs accessories can
be used to extend the service life of these products.
Mode number Description
PGV*-CA25-* Data Matrix code tape
PGV-CC25-0* Data Matrix control codes
PGV*M-CA25-* Data Matrix positioning tape
PGV85-CT4 Data Matrix tag
PGV25M-CD100-CLEAR Protective film
Table 2.3 Accessories

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3 Insta ation
3.1 Mounting the Read Head
Mount the read head on the auto-guided transport system using the four screws on the mount-
ing adapter on the read head. Mount the read head so that the lens with ring light and camera
module are aligned toward the floor.
The mounting must be stable enough so that the read head does not leave its depth of focus
range during operation.
The distance between the read head and the floor should be the same as the read distance of
the read head.
Optimum Read Distance
Read Head Dimensions
Figure 3.1 Housing dimensions
Mode number Read distance [mm] Depth of focus [mm] Fie d of vision (w x h) [mm]
PGV100R* 100 ±30 115 x 73
70
80
38.5
70
1
2
22
51
ø 25
9
4 x M6
Caution!
When selecting the length of the mounting screws, ensure that the maximum insertion depth of
the screws in the threaded inserts on the read head is 8 mm.
Using longer screws may damage the read head.
Caution!
The maximum torque of the mounting screws must not exceed 9 Nm.
Tightening the screws to a higher torque may damage the read head.

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3.2 Affixing the Code Tape
Figure 3.2 Dimensions of the Data Matrix code tape
The code tape is made of silicone-free polyester film. A position marker appears every 100 mm
along the lower edge of the code tape (see "Code Tape Dimensions"). These position markers
are used to affix the code tape in the correct position.
The back of the code tape is covered with a modified acrylate-based adhesive designed for
permanent adhesion. Affix the self-adhesive code tape along the desired traverse distance. To
do so, proceed as follows:
Position the code tape so that the www.pepper -fuchs.com label and the position markings
are to the right of the Data Matrix code in the X direction. The position values then increase
along the X direction.
Data Matrix Code Tapes with a Starting Position of 0 m
Dimensions of the Code Tape
Caution!
Alignment
The Data Matrix code is not on the center line of the code tape.
Caution!
Stop edges
f you attach another code tape at the end of a previous code tape, the code pattern of 20 mm
must be retained.
Mode number Description
PGV10M-CA25-0 Code tape, length: 10 m
... ...
PGV100M-CA25-0 Code tape, length: 100 m
Table 3.1 Data Matrix code tapes
See also data sheet PGV*-CA25-* at www.pepperl-fuchs.com

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Data Matrix Contro Codes
Affixing the Code Tape
1. Clean the surface of any greasy or oily deposits and dust.
2. Ensure that the surface is dry, clean, and stable.
3. Pull away a few centimeters of the protective film at the beginning of the code tape. Place the
code tape at the precise point of the required starting position on the surface, and press to
attach.
4. Then affix the code tape along the desired traverse distance. Please note the following
information:
5. Remove the protective film gradually so that the code tape does not accidentally adhere to the
surface in an incorrect position. When affixing the code tape, ensure that it does not become
creased or trap air bubbles.
The adhesive on the code tape hardens after 72 hours.
Mode number Description
PGV-CC25-001 Code tape, Control Code 001, length: 1 m
... ...
PGV-CC25-999 Code tape, Control Code 999, length: 1 m
Table 3.2 Data Matrix control codes
Note
Therma Expansion of the Code Tape
The affixed code tape corresponds to the heat expansion coefficient of the surface with regard
to its thermal expansion. Keep this in mind when installing expansion joints, for example.
Note
Expansion Joints and Code Tapes
f the system covers longer distances, the plant structure usually contains expansion joints. n
this case, we recommend creating breaks along the code tape. The resulting gap must not
exceed 75 mm.
Note
Inc ines and Dec ines
f you affix the code tape on inclines or declines, cut the code tape several times at the
transition point to the horizontal as shown.
Figure 3.3 Schematic diagram: preparing Data Matrix code tape bends
1. Bend to the left
2. Bend to the right

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C eaning the Code Tape
Significant contamination on code tapes can impair detection by the read head. Clean the code
tapes with isopropanol if necessary. f the contamination is severe, you can use a non-corrosive
plastic cleaner, e.g., Caramba®.
Ang e Output
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 as an absolute value relative to the tracked lane, as a Data
Matrix code tape contains direction information. The output angle covers the range from 0° to
360°. The resolution can be set to the following values:
•0.1°
•0.2°
•0.5°
•1°
Figure 3.4 Absolute angle
Note
To avoid polishing the surface, do not apply strong pressure when cleaning. f the code tape
has a shiny surface, this impairs detection by the read head.
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

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Distance Output
The read head detects the distance from the zero point in the Y direction a Data Matrix code
tape and transmits this value to the control panel.
The reader indicates the vertical distance of the zero point in relation to the Data Matrix code
tape.
Figure 3.5 Distance A for Data Matrix code tape
X
Y
A
Note
Direction Decision
The direction decision at a branch of a Data Matrix code tape remains in effect until the read
head has moved more than 50 cm away from the branch.
t is not possible to change the direction decision within a branch!
Note
Branches/Intersections with Data Matrix Position Code
Observe the following guidelines with regard to the area 1 m before and after branches or
intersections of a lane with a position code:
•The position codes of the main lane must run continuously for 2 m. The position codes of
the branching/intersecting lane must run continuously for 1 m. The read head outputs the
X-value of the Data Matrix code tape that is specified via the direction decision. .
•The difference between the absolute position of the main lane and the starting position of
the branching/intersecting lane must be greater than 1 m.

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Figure 3.6 Distances
Behavior of the Read Head at Branches and Curves
The read head behaves differently depending on the type of branch and the specified lane. The
read head must know the upcoming direction decision.
A second lane branches off to the left from the straight lane:
The read head follows the straight lane if the direction decision "follow right-hand lane" has
been made.
A second lane branches off to the right from the straight lane:
The read head follows the straight lane if the direction decision "follow left-hand lane" has been
made.
A single lane with a position code turns to the left or right:
The read head follows the position code if the direction decision "straight ahead" has been
made.
1 m 1 m
1 m
Note
Loss of Information
Ensure that Data Matrix codes are not positioned over one another at a branch, as otherwise
data may be lost.

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Control codes can be mounted in the immediate vicinity of a branch with Data Matrix codes for
positioning, but not near an intersection. The control code must be mounted directly next to the
guiding lane.
Figure 3.7 Branch with control code
Distances
To ensure that the read head can clearly detect and assign Data Matrix codes, minimum and
maximum distances must be observed when creating the lanes.
Offset V between position codes of a lane must not be greater than 5 mm.
Figure 3.8 Offset: 0 mm  V  5 mm
V

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The distance between the Data Matrix code tapes at a branch or intersection as a separate lane
must be between 0 mm and 5 mm.
Figure 3.9 Distance: 0 mm  D  5 mm
The distance between a Data Matrix position code and a Data Matrix control code must be
between 0 mm and 5 mm.
Figure 3.10 0 mm  D  5 mm
25 mm D D 25 mm25 mm

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Data Matrix Tag (8 digit number)
A Data Matrix tag contains position information and a specific 8 digit number. A cross in the
center of the Data Matrix tag marks the zero point. The X and the Y axes are marked starting
from the zero point. The black arrow indicates the positive axis and the white arrow indicates
the negative axis.
Figure 3.11 2x2 Data Matrix tag with the number 123456789 and position information
Figure 3.12 4x4 Data Matrix tag with the number 99999999 and position information
+Y
-Y
www.pepperl-fuchs.com
TAG 12.345.678
42
54
TAG
1234.5678
55
54
44
45
4 5 1234 5678
=
5
85
85