Pepperl+Fuchs PXV100AQ-F200-R4-V19 User manual

PXV100AQ-F200-R4-V19
Data Matrix
Positioning System
Manual

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 Industry, published
by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elek-
troindustrie (ZVEI) 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]om
North American Headquarters
Pepperl+Fuchs Inc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [e-mail]
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [e-mail]
https://www.pepperl-fuchs.com

PXV100AQ-F200-R4-V19
Contents
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1 Introduction................................................................................................................ 5
1.1 Content of this Document............................................................................. 5
1.2 Target Group, Personnel ............................................................................... 5
1.3 Symbols Used ................................................................................................ 6
2 Safety Information ..................................................................................................... 7
2.1 Intended Use .................................................................................................. 7
2.2 Useful Lifetime ............................................................................................... 7
3 Product Description .................................................................................................. 9
3.1 Components of the Positioning System...................................................... 9
3.2 Use and Application .................................................................................... 10
3.3 LED Indicators and Operating Elements................................................... 13
3.4 Accessories.................................................................................................. 15
4 Transport and Storage ............................................................................................ 16
5 Planning.................................................................................................................... 17
5.1 Position Detection –Structural Principle .................................................. 17
5.2 Plant Design ................................................................................................. 17
5.3 Safety-Related Reading Range of the Read Head .................................... 18
5.4 Read Head Orientation for the Data Matrix Code Tape ............................ 19
5.5 Characteristics of the Data Matrix Codes and Code Redundancy ......... 20
5.6 Read Head Orientation................................................................................ 22
5.6.1 Horizontal Tolerance –Read Distance z ........................................................................... 22
5.6.2 Vertical Tolerance - Height Tolerance y ............................................................................. 23
5.6.3 Inclination Angle ...............................................................................................................26
5.6.4 Rotational Tolerance in the z Axis ..................................................................................... 27
5.7 Expansion Joints / Gaps ............................................................................. 28
5.8 Behavior of the Read Head When Cornering ............................................ 35
6 Installation and Commissioning ............................................................................ 38
6.1 General ......................................................................................................... 38
6.2 Applying the Data Matrix Code Tape.......................................................... 38
6.3 Mounting and Alignment of the Read Head .............................................. 41
6.3.1 Mounting the Read Head.................................................................................................. 42
6.3.2 Alignment of the Read Head............................................................................................. 45
6.4 Electrical Connection .................................................................................. 48

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Contents
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6.5 Connecting the Read Head to the PUS Evaluation Unit...........................50
6.6 The RS-485 Interface ...................................................................................51
6.7 Commissioning the Read Head with the PUS Evaluation Unit
via safeControl Expert.................................................................................52
7 Maintenance .............................................................................................................56
7.1 Maintenance .................................................................................................56
7.2 Testing...........................................................................................................56
7.3 Cleaning........................................................................................................57
7.4 Repairs ..........................................................................................................57
8 Disposal ....................................................................................................................58

PXV100AQ-F200-R4-V19
Introduction
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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
In addition, the documentation may comprise the following parts, if applicable:
•EU-type examination certificate
•EU declaration of conformity
•Attestation of conformity
•Certificates
•Control drawings
•Instruction manual
•Functional safety manual
•Other documents
1.2 Target 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 Internet at
www.pepperl-fuchs.com.
Note
For specific device information such as the year of construction, scan the QR code
on the device. As an alternative, enter the serial number in the serial number search
at www.pepperl-fuchs.com.

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PXV100AQ-F200-R4-V19
Introduction
1.3 Symbols 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. It 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 Symbols
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.

PXV100AQ-F200-R4-V19
Safety Information
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2 Safety Information
Read the information in this document carefully and observe this information when working
with the device. Failure to observe the safety information and warning messages in this docu-
mentation can lead to malfunctions of the safety devices of the machines or plants in which
they are fitted.
This can result in serious personal injury or death.
Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance,
and dismounting lies with the plant operator.
The personnel must be appropriately trained and qualified in order to carry out mounting,
installation, commissioning, operation, maintenance, and dismounting of the device. The
trained and qualified personnel must have read and understood the instruction manual.
Prior to using the product make yourself familiar with it. Read the instruction manual carefully.
Reference to Further Documentation
Observe directives, standards, and national laws applicable to the intended use and the oper-
ating location.
2.1 Intended Use
Use
The Data Matrix Positioning System is the positioning system in the Pepperl+Fuchs incident
light process. The heart of the system is the read head, which consists of a camera module
with an internal illumination unit. This enables the read head to detect position markers printed
onto a self-adhesive code tape in the form of 2-D Data Matrix codes.
The Data Matrix code tape is mounted on a fixed part of the plant (e.g., the wall of an elevator
shaft or the rail of a monorail conveyor). The read head is mounted on a moving "vehicle" posi-
tioned in parallel with the code tape (e.g., on the elevator cab or on the chassis of a monorail
conveyor).
The read head is connected to the PUS evaluation unit. In the PUS evaluation unit, the
red/blue color switching of the read head is activated, and a safe position and safe speed are
calculated from the position marks detected.
Misuse
Use the read head only in conjunction with the PUS evaluation unit as described in the docu-
mentation and in accordance with the technical specifications. The use of unapproved or inap-
propriate Data Matrix code tapes or Data Matrix metal code bars, or the use of the read head
outside the specified use will cause a predictable malfunction. In this case, any warranty or lia-
bility of the manufacturer shall cease.
2.2 Useful Lifetime
The useful lifetime is specified in the characteristic safety values. .
Although, on the basis of a probabilistic estimate, a constant failure rate is assumed, this only
applies under the condition that the useful lifetime of the components is not exceeded. The
result of this probabilistic estimate is only applicable until the useful lifetime ends, as the proba-
bility of a failure significantly increases thereafter. This useful lifetime largely depends on the
component itself and its operating conditions, particularly the temperature. For example, elec-
trolytic capacitors are very sensitive to the operating temperature.
This assumption of a constant failure rate is based on the course of a typical bathtub curve for
electronic components.

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PXV100AQ-F200-R4-V19
Safety Information
It is therefore clear that this failure calculation only applies to components that have this con-
stant range, and that the validity of the calculation is limited to the useful lifetime of each com-
ponent.
It is assumed that the majority of early failures are detected during installation and that, there-
fore, a constant failure rate applies during the useful lifetime.
Use the device only within the specified ambient and operating conditions.

PXV100AQ-F200-R4-V19
Product Description
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3 Product Description
3.1 Components of the Positioning System
The positioning system described in this manual consists of the following components:
Figure 3.1 System overview
•Read head PXV100AQ-F200-R4-V19, hereinafter referred to as "read head" in this docu-
ment.
•2-colored Data Matrix code tape PXV*-AA25-*, hereinafter referred to as "Data Matrix
code tape" in this document.
Data Matrix metal code bars PXV*-AAM-*, hereinafter referred to as "Data Matrix metal
code bars" in this document.
•Safe evaluation unit PUS-F161-B*-PXV, hereinafter referred to as "PUS evaluation unit" in
this document.

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PXV100AQ-F200-R4-V19
Product Description
3.2 Use and Application
Data Matrix Positioning System
The Data Matrix Positioning System is the positioning system in the Pepperl+Fuchs incident
light process. The heart of the system is the read head, which consists of a camera module
with an internal illumination unit. This enables the read head to detect position markers printed
onto a self-adhesive code tape or metal code bar in the form of 2-D Data Matrix codes. Each
individual code contains information that is made visible by a two-color red and blue LED light-
ing and is read by the camera.The data is output to the PUS evaluation unit. The data can be
processed there and used for process control. The PUS evaluation unit is a device that can be
used to implement safety shutdowns and safety functions. It enables the calculation of safe
position and velocity data for an axis from the data of the read head. The PUS evaluation unit
ensures the safety-related evaluation and transmission of data via a safe and non-safe fieldbus,
including x position, speed and diagnostic data, and safe input and output signals.
PUS-F161-B**-PXV

PXV100AQ-F200-R4-V19
Product Description
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Data Matrix Code Tape
The Data Matrix code tape is mounted on a fixed part of the plant (e.g., the wall of an elevator
shaft, or the rail on a monorail conveyor). The read head is mounted on a "carrier" that moves
parallel to the code tape (e.g., on the elevator cabin or on the chassis of a monorail conveyor).
The two-color Data Matrix code tape is illuminated by the red/blue illumination unit on the read
head and is read by the camera. If the red LED ring of the read head is active, the blue and
black areas of the Data Matrix code are visible. If the blue LED ring of the read head is active,
the red and black areas of the Data Matrix code are visible.
Figure 3.2 Schematic diagram: 2-colored Data Matrix code tape
12-colored Data Matrix code tape
2Data Matrix code with red lighting
3Data Matrix code with blue lighting
4Monochrome Data Matrix codes
000 000.0 m PXV-AA25 www.pepperl-fuchs.com
PXV-AA25 www.pepperl-fuchs.com 000 000.1 m
1
2
3
4
Note
Note the type of code tape!
The positioning system only works if the read head is used together with the 2-colored Data
Matrix code tape of the following type: PXV*-AA25-*.
The use of other code tapes is not permitted!

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PXV100AQ-F200-R4-V19
Product Description
Data Matrix Metal Code Bars
The metal code bars are an extension of the conventional code tapes and are made of robust
aluminum. Compared to conventional code tapes, the metal code bars are more robust and
resistant to external influences. They are specifically designed for use in environments where
conventional code tapes can be quickly damaged due to the conditions in which they are used.
Like conventional code tapes, the metal code bars can be glued on directly. They also have a
special connection system that can be joined together like puzzle pieces. This allows the code
bars to be seamlessly connected to form a continuous line.
The code bars are modular and available in nominal lengths of 100, 200, and 500 mm.
Note
Observe the code bar type!
The positioning system only works if the read head is used together with the 2-colored Data
Matrix metal code bars of the following type: PXV*-AAM-*.
Other code bars are not permitted!

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Product Description
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3.3 LED Indicators and Operating Elements
The read head has seven indicator LEDs for visual function checks and quick diagnosis.
Activate the alignment aid and parameterization mode using the two control buttons on the
back of the device.
Button 1 is labeled "ADJUST." Button 2 is labeled "CONFIG."
COM OUT1 OUT2 / ADJ Y OUT3 / ADJ Z PWR / ADJ ERR / NO CODE
INTERNAL
DIAGNOSTIC
ADJUST
CONFIG
1
2

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PXV100AQ-F200-R4-V19
Product Description
x = LED status has no meaning
LED
[#1]
COM
[#2]
PWR/ADJ
ERR/NO
CODE
[#3]
OUT 1
[#4]
OUT
2/ADJ
Y
[#5]
OUT
3/ADJ Z
[#6]
Internal
diagnostics
DescriptionColor
Ye l -
low Green/red
Ye l -
low
Ye l -
low Ye l l o w
Ye l -
low
Ye l -
low
State Off Flashes green Off Off Off Off Off Orientation, Y > setpoint value
fflash = 2 Hz
Off Flashes green Off On Off Off Off Orientation, Y < setpoint value
fflash = 2 Hz
Off Flashes green Off Flash-
ing
Off Off Off Orientation, Y = setpoint value
fflash = 2 Hz
Off Flashes green Off Off Off Off Off Orientation, Z > setpoint value
fflash = 2 Hz
Off Flashes green Off Off On Off Off Orientation, Z < setpoint value
fflash = 2 Hz
Off Flashes green Off Off Flashing Off Off Orientation, Z = setpoint value
fflash = 2 Hz
Off Flashes red Off Off Off Off Off Alignment
Code tape outside read range
fflash = 2 Hz
Off Lights up red Off Off Off Off Off System error
Off Lights up
green
x x x Off Off Normal operation, no communi-
cation
LEDs marked with x indicate the
status of the relevant output.
Flash-
ing
Lights up
green
x x x Off Off Normal operation, communica-
tion active
fflash = 2 Hz
LEDs marked with x indicate the
status of the relevant output.
Flash-
ing
Flashes red x x x Off Off No code tape within read range,
communication active
fflash = 2 Hz
LEDs marked with x indicate the
status of the relevant output.
Flash-
ing
Flashes red Flash-
ing
Flash-
ing
Flashing Off Off Normal operation. Indication for 2
secs if a button is pressed when
the time lock is enabled.
Off Off Flash-
ing
Off Off Off Off Preconfiguration/configuration
mode active
fflash = 2 Hz
Off Lights up red Flash-
ing
Off Off Off Off Code card faulty
fflash = 2 Hz for 3 sec
Off Green, 1 sec Flash-
ing
Off Off Off Off Code card detected
fflash = 2 Hz for 3 sec
x Off x x x Off Off Time lock for buttons disabled
xx xxx Lights
up
Lights
up
Internal error
Return to Pepperl+Fuchs
Ta b l e 3 . 1 L E D I n d i c at o r s

PXV100AQ-F200-R4-V19
Product Description
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3.4 Accessories
The right 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.
In harsh ambient conditions, appropriate Pepperl+Fuchs accessories can be used to extend
the service life of these products.
More information on accessories can be found in the datasheet for the read head at www.pep-
perl-fuchs.com.
Model number Description
PXV*-AA25-* Data Matrix code tape
PXV*-AAM-* Data Matrix metal code bars
PUS-F161-B28-PXV Safe evaluation unit for position and velocity monitoring
for safePUS/PXV read heads; PROFINET with
PROFIsafe protocol
PUS-F161-B31-PXV Safe evaluation unit for position and velocity monitoring
for safePUS/PXV read heads; EtherCAT with FSoE
protocol
V19-G-ABG-PG9 M12 single-ended female cordset, 8-pin, shielded,
field-attachable
V19-G-ABG-PG9-FE Grounding terminal and plug (set)
V19-G-BK3M-PUR-U/ABG-V19-G Cordset, M12 socket, straight, to M12 plug, straight, A-
coded, 8-pin, PUR cable, black, shielded
PCV-SC12 Grounding clip
PCV-MB1 Mounting bracket
PCV-LM25 Marker head for 25 mm code tape
PCV-AG100 Alignment guide for read head 100 mm

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PXV100AQ-F200-R4-V19
Transport and Storage
4TransportandStorage
Retain the original packaging. Always store or transport the device in the original packaging to
protect it from electrostatic discharge (ESD) and mechanical damage.

PXV100AQ-F200-R4-V19
Planning
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5 Planning
5.1 Position Detection –Structural Principle
The Data Matrix positioning system is an incident light positioning system consisting of a read
head, the Data Matrix code tape, and a PUS evaluation unit. The read head is the central ele-
ment of the system and includes a camera module with integrated lighting unit.The read head
detects two-dimensional Data Matrix codes printed on a self-adhesive code tape or on metal
code bars. Each individual code contains information that is made visible by a two-color red
and blue LED lighting and is read by the camera. In the PUS evaluation unit, the red/blue color
switching of the read head is activated, and a safe position and safe speed are calculated from
the position marks detected. The prepared data is made available to the plant control system.
Figure 5.1 Schematic structure of the Data Matrix positioning system
5.2 Plant Design
Before selecting and using the product, the plant designer must evaluate whether this product
is suitable for the intended application. Pepperl+Fuchs has no influence on the selection and
use of this product. The warranty therefore only covers the consistent quality of the product.
Ensure that this device is used only in accordance with the technical specification described in
these instructions. The device must not be used in a hazardous area.
000 000.0m PXV-AA25 www.pepperl-fuchs.com
PXV-AA25 www.pepperl-fuchs.com 000 000.1 m
z
y
0x
1
2
1
4
6
78
53
2
≤ 100 000 m
PUS-F161-B31-PXV
Warning!
Danger due to ambiguous position information
Using double code areas can result in duplicate position information. This can lead to unclear
position information. This can result in an incorrect control logic, which poses a risk to the per-
sonnel and plant.
During planning, make sure that the position information for the read head is unique in every
component of the plant. Never use double code areas.

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PXV100AQ-F200-R4-V19
Planning
5.3 Safety-Related Reading Range of the Read Head
The safety-related reading range is the part of the field of view of the read head in which Data
Matrix codes can be decoded. The safety-related reading range is smaller than the field of
view. It must be ensured that the Data Matrix code is completely within the field of view and a
quiet zone is present.
Field of View of the Read Head
The field of view is the maximum image on the sensor chip that is determined by the optical
properties of the camera. The size of the field of view varies with the distance between the read
head and the Data Matrix code tape. If the read head is positioned farther away from the Data
Matrix code tape, the field of view is larger. If the read head is closer to the Data Matrix code
tape, the field of view is smaller due to the shorter distance.
Safety-Related Accuracy
•The secure position can be determined with an accuracy of code position +/- half of the
safety-related reading range.
•The safety-related reading range depends on the distance between the read head and the
Data Matrix code tape and the orientation of the read head to the Data Matrix code tape.
•The accuracy changes in line with the read distance (z) to the Data Matrix code tape. The
closer the sensor is to the Data Matrix code tape, the smaller the safety-related reading
range and the more accurately the safety-related position can be determined.
Size of the reading window in relation to the read distance z
Read distance z
to
Data Matrix
code tape [mm]
Reading win-
dow size x [mm]
Reading win-
dow size y [mm]
Number of Data
Matrix codes
in the reading
window
Min. 70 88 57 max. 4
Nominal 100 120 77 max. 6
Max. 130 152 96 max. 7
z
130 mm
100 mm
70 mm
z = 70 mm
x I y = 88 mm x 57 mm
x
y
z = 100 mm
x I y = 120 mm x 77 mm
z = 130 mm
x I y = 152 mm x 96 mm

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Planning
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5.4 Read Head Orientation for the Data Matrix Code Tape
The following section shows the number of visible Data Matrix codes depending on the read
distance. The read head in the image is positioned in an orientation of 0°to the Data Matrix
code tape.
Number of Data Matrix codes at 100 mm read distance z to the Data Matrix code tape
Read distance z to the Data Matrix code
tape [mm] max. number of Data Matrix codes
70 4
100 6
130 7
0°orientation
000 000.0 m PXV-AA25 www.pepperl-fuchs.com
PXV-AA25 www.pepperl-fuchs.com 000 000.1 m
z
y
0x
1
2
0°

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PXV100AQ-F200-R4-V19
Planning
5.5 Characteristics of the Data Matrix Codes and Code Redundancy
Characteristics of the Data Matrix Code
The position marks in the code tape contain information about the absolute position of the tape,
and serve as reference points for the read head. The read head uses its camera to capture the
image of the code and uses the information contained in the position marks to determine the
exact position of the code in the camera image. This enables accurate positioning of the read
head.
The code tape uses fail-safe Data Matrix codes. This is a special type of Data Matrix code
(ECC200) that is encoded using the Error Correction Code (ECC) procedure. This means that
it contains additional information to correct errors when reading or transmitting the code. As a
result, codes can be damaged or partially obscured without the readability of the code being
affected.This is especially important because in some cases the codes can be subject to a lot
of wear and dirt.
Figure 5.2 Data Matrix code ECC200
A Data Matrix code ECC200 consists of several areas that are relevant for code reading:
12-color Data Matrix codes according to ECC200
2 Alternating Pattern: The Alternating Pattern is a pattern of alternating black and white
modules. The number of modules is even. It allows the data density to be determined.
The Alternating Pattern is used for symbol size recognition and ECC200 type recognition.
3 Finder Pattern: The Finder Pattern is a characteristic pattern of black modules arranged
in an L shape. It is used to locate the Data Matrix code in any rotation. Distortions are also
detected. The Finder Pattern is used to clearly determine the location and size of the Data
Matrix code.
4DataRange: The data range is the actual data field in the Data Matrix code in which the
information to be encoded is stored. It consists of a matrix of black, white, blue, and red
squares representing the binary data.
Error correction range: The error correction range is a portion of the Data Matrix code that
contains additional data to detect and correct errors in reading and transmitting the code.
The error correction range is encoded using the Error Correction Code (ECC).
5 Quiet Zone: The quiet zone (shown in yellow here) is a white area around the Data Matrix
code. It is used to distinguish the code from other objects or the background. This makes
it easier for the read head to read the code. The width of the quiet zone is 2 mm. To en-
sure that the read head can read the Data Matrix codes, the quiet zone of 2 mm around
the Data Matrix code must not be violated when cutting the code tape.
31 2 4 5