Pepperl+Fuchs PCV100-F200-B17-V1D-6011 User manual

R
Safe Position Detection
with PCV100-F200-B17-
V1D-6011
Data Matrix Positioning
System for TIA Portal
FACTORY AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the Electrical Indus-
try, published by the Central Association of the Electrical Industry (Zentralverband
Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the
supplementary clause: "Expanded reservation of proprietorship"
Safe Position Detection with PCV100-F200-B17-V1D-6011

Safe Position Detection with PCV100-F200-B17-V1D-6011
3
1 Introduction................................................................................. 4
1.1 Content of this Document ................................................................... 4
1.2 Target Group, Personnel...................................................................... 4
1.3 Symbols Used ...................................................................................... 4
2 Product Description ................................................................... 6
2.1 System Requirements ......................................................................... 6
3 Installation................................................................................... 7
3.1 Mechanical Structure........................................................................... 7
3.2 Electrical Connection .......................................................................... 8
3.3 PROFINET Connection ........................................................................ 9
3.4 PLC Hardware Configuration ............................................................ 10
4 Software..................................................................................... 13

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Introduction
1Introduction
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
■Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation,
commissioning, 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.
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
property damage.
Note!
Visit www.pepperl-fuchs.com to access further documentation for full information about the
product.

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Introduction
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Depending on the risk level, the warning messages are displayed in descending order as
follows:
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.

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Product Description
2 Product Description
To ensure safe position detection, two PCV100-F200–B17-V1D-6011 readers are used based
on the Data Matrix code. The two readers for the reflected light positioning system are fitted at a
defined distance from one another to ensure safe position detection. The readers are
connected to a fail-safe SIMATIC CPU S7–1500 via PROFINET.
The position values determined by the readers are processed in the control panel. The control
panel uses these values to determine a safe position. The data is evaluated by two program
modules created using Step 7 Safety (TIA Portal). One module determines the safe position
around continuous code tapes, the other module determines the safe position in the case of
code jumps.
For applications focused on safety, with TIA program modules it must be possible to provide a
safety function in line with EN ISO 13849–1 that you can then have certified.
2.1 System Requirements
■SIMATIC S7 Safety PLC version S7–1510 S and up.
The application can be used for the SIMATIC Step 7 Safety TIA Portal.

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3 Installation
3.1 Mechanical Structure
Secure the two readers on a moving part of the system such that they are mechanically stable.
The readers must be secured at a defined distance from one another. Both readers must read
the same code tape.
The maximum distance is 5000 mm.
The master reader returns the position value for outputting the position. A second control
reader verifies the position. Mount the control reader in a position rotated by 180°. Mount the
master reader in the main conveying direction at the front and the control reader at the back. If
necessary, you can invert the mounting.
Attach the code tape in the main conveying direction ascending. In case of breaks in the
support rail, e.g., due to track switches or expansion joints, the code tape must be interrupted
for 20 mm (= 2 grids on the code). The area of the code tape between 0 mm and 50 mm must
not be used. Note that in the case of code jumps (code tape beginning with a new position
value), the counting direction of the code tape is the same on both sides of the code jump. This
applies in particular to code jumps at moving transitions (track switches, jacks, rotary tables). A
maximum of one code jump is permitted between the two readers.
For details of further requirements with regard to routing the code tape, securing the device and
handling the electrical connection of the readers, refer to the manual for the readers. The
manual "PCV...-F200-B17-V1D" can be found on the Pepperl+Fuchs website at www.pepperl-
fuchs.com.
Safe Position Detection PCV…-F200-B17-V1D —Example

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3.2 Electrical Connection
The PCV... reader is connected to the side of the housing by means of an 8-pin M12 x 1
connector plug. This connection is used to provide the power supply and communicate with the
Vision Configurator. The configurable inputs and outputs for the reader are also available on
this connection.
Figure 3.1
Figure 3.2
Color Assignment
Pepperl+Fuchs single-ended female cordsets are manufactured in accordance with EN 60947-
5-2. When using a type V19-... single-ended female cordset with an open cable end () on the
Main connection, the following color assignment applies:
Communication
PROFINET is used for communication.
Connector Assignment
Connection Pin Strand Color Color Abbreviation
1White WH
2Brown BN
3Green GN
4Ye l l o w YE
5Gray GY
6Pink PK
7Blue BU
8Red RD
1
2
3
4
5
6
7
8
OUT 2 / IN 2
+ UB
USB_DM
USB_DP
OUT 1
IN 1
GND
OUT 3 / IN 3
Main
1
4
6
7
8
53
2
Main

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Shielding Cables
The shielding of connection lines is required to suppress electromagnetic interference.
Establishing a low resistance or low impedance connection with the conductor or equipotential
bonding circuit is a particularly important factor in ensuring that these interference currents do
not become a source of interference themselves. Always use connection lines with braided
shield; never use connection lines with a film shield. The shield is integrated at both ends, i.e.,
in the switch cabinet or on the controller and on the read head. The grounding terminal
available as an accessory allows easy integration in the equipotential bonding circuit.
In exceptional cases, the shielding of a connection at one end may be more favorable if
■An equipotential bonding cable is not laid or cannot be laid.
■A film shield is used.
The following points relating to shielding must also be noted:
■Use metal cable clips that cover large areas of the shield.
■After installing the cable shield in the control cabinet, place it directly on the equipotential
bonding rail.
■Direct the protective grounding connections to a common point in a star configuration.
■The cross-section of the cables used for grounding should be as large as possible.
Additional Ground Connection
3.3 PROFINET Connection
The PCV... read head is connected to PROFINET via two 4-pin, D-coded device sockets, M12
x 1, PROFINET 1 and PROFINET 2, on the side of the housing.
Figure 3.3
Order Designation Description
PCV-SC12 Clip for mounting an additional ground
connection.
PCV-SC12A
Caution!
Damage to the device
Connecting an alternating current or excessive supply voltage can damage the device or cause
the device to malfunction.
Electrical connections with reversed polarity can damage the device or cause the device to
malfunction.
Connect the device to direct current (DC). Ensure that the supply voltage rating is within the
specified device range. Ensure that the connecting wires on the female cordset are connected
correctly.
1
2
3
4
TX +
RX +
TX -
RX -
Bus

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Figure 3.4
For details of suitable PROFINET cables, .
3.4 PLC Hardware Configuration
Modules Status_1 and X-Position_1 are required as a minimum when configuring the hardware
for the reader in order to ensure safe position detection. Additional modules for specific
evaluations can be added if necessary.
Figure 3.5 Modules contained in the hardware configuration
To determine the safe position, the following settings are required when configuring the
readers:
Connector Assignment
Profinet 1 & 2
1
3
42

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Orientation of Master Reader
Position the master reader at an angle of 0°in relation to the code tape. If the text on the back of
the reader can be read from the same direction as the text on the code tape, the reader is in the
correct position.
The corresponding value must be specified in the module parameters.
Figure 3.6 Orientation of the master read head
Orientation of Control Reader
Position the control reader at an angle of 180°in relation to the code tape. When the position is
correct, the text on the code tape appears on the reader if the text on the back of the reader is
legible.
Define the corresponding value in the module parameters.
Figure 3.7 Orientation of the control read head

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Resolution of X Position
The "Safe position detection" application is set up for a resolution of 1 mm for the X position.
The default value must be set accordingly. The other values for the resolution can be
configured individually as required.
Figure 3.8 Default X position resolution settings
Behavior in the Event of a Missing Position
Define how the readers should respond if no position is detected. To do this, enter "0" as a fixed
output value.
Figure 3.9 X position No Pos behavior

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4Software
Basic Process
For the "Safe position detection" application, the F_SPOS program module processes the data
from 2 readers. The status of the master reader is checked first during this process. If this
status is free from errors (no errors and position detection OK), the position value of the master
reader is written to the output value.
Once the status of the control reader has been successfully checked, the F_SPOS program
module calculates the difference between the position value of the master reader and that of
the control reader. The program module compares the differential value with the mechanical
distance between the two readers. If both values are the same within a defined tolerance, the
status "Position safe" is output. If this is not the case, the F_SPOS program module issues the
status "Code jump evaluation".
Another program module, F_SPOS_Codesprung, evaluates the safe position around code
jumps. This program module is called up once for each code jump. F_SPOS_Codesprung is
only activated if F_SPOS has issued the status "Code jump evaluation".
The F_SPOS_Codesprung program module then compares the position differential of the two
readers with a value calculated from the size of the code jump and the distance between the
readers. If both values are the same within a defined tolerance, the status "Position safe" is
output.
A general "Position safe" message is generated through a logical "OR" link between the
"Position safe" status values determined by the two program modules.
For details, see the "Safe position detection" and "Safe response to code jumps" block
diagrams below.

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Figure 4.1 Block diagram for safe position detection

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Figure 4.2 Block diagram for a safe response to code jumps

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Calling Up the Program Modules
F_SPOS program module: Safe position detection
As an initial step, call up the program module for safe position detection in the safety program
on your control panel.
Figure 4.3 Calling up the F_SPOS component
The parameters for the F_SPOS program module must be configured as follows:
Inputs
Reader distance and hysteresis
In practical terms, the distance is determined from the difference between the two measured
values from the master reader and control reader. The Abstand_Hyst hysteresis is the
compensation needed in case the readers move mechanically, e.g. in curves.
Wert_Offs position offset
The Wert_Offs position offset is only to be considered as such; only one value is used in the
user program. The reference point for the means of transport is somewhere on the mounting
point and allows accurate "calibration" up to +/- 10 mm.
Wert_M DINT Position value of the master reader
Status_M UDT_PF_SPOS_
STATUS
Status of the master reader as UDT at the hardware
address for the status
Wert_K DINT Position value of the control reader
Status_K UDT_PF_SPOS_
STATUS
Status of the control reader as UDT at the hardware
address for the status
Abstand DINT Mechanical distance between the master reader and
control reader in mm (max. 5000 mm)
Abstand_Hyst DINT Permissible tolerance of the reader distance in mm
(max. 30 mm)
Wert_Offs DINT Offset for the position output value; for compensating
mechanical differences in mm (max. +/- 10 mm)

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Outputs
CodeSprung output
The CodeSprung output is the direct counterpart to the S_OK parameter. This output activates
the functions to control actual code jumps that exist.
F_SPOS_Codesprung program module: Safe position monitoring in
case of code jumps
The F_SPOS_Codesprung program module can only be used together with the F_SPOS
program module. The program module must be programmed once for each code jump. The
F_SPOS_Codesprung program module is only activated if F_SPOS has output the
"CodeSprung" status.
As this output is only set if the status of the reader is OK, it is no longer possible to query
statuses within this program module.
The jumps can be entered in F_SPOS_Codesprung. Depending on demand, the data structure
of the program module must be extended in order to do this. The last valid position before the
code jump and the first valid position after the code jump must always be entered during this
process.
The code jump must always be > 20 mm as a minimum.
The size of the code jump itself is not limited and can cover the entire range.
A code jump can only be configured within the distance between the two readers.
Figure 4.4 Calling up F_SPOS_Codesprung component
Wert_S DINT Output position (position of master reader + Wert_Offs)
S_OK BOOL Position is safe
CodeSprung BOOL Code jump has been detected; calls up the modules for
the code jump evaluation
Plaus_F BOOL Plausibility error; the parameters "Abstand",
"Abstand_Hyst", or "Wert_Offs" are outside of the
defined limit values

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The parameters for the program module must be configured as follows:
Inputs
Reader distance and hysteresis
In practical terms, the distance is determined from the difference between the two measured
values from the master reader and control reader. The Abstand_Hyst hysteresis is the
compensation needed in case the readers move mechanically, e.g. in curves.
Outputs
Use of Safe Signals
Figure 4.5 Network of position safe "F_Safepos_"
Freigabe BOOL Release of the function; the main function is activated
using the "CodeSprung" output
Wert_M DINT Position value of the master reader
Wert_K DINT Position value of the control reader
Abstand DINT Mechanical distance between the master reader and
control reader in mm (max. 5000 mm)
Abstand_Hyst DINT Permissible tolerance of the reader distance in mm
(max. 30 mm)
CodeSprg_Anfan
g
DINT Last code position before the code jump; in the
example, activated with the value from DB. The
numerical value can also be entered directly
CodeSprg_Ende DINT First code position after the code jump; in the example,
activated with the value from DB. The numerical value
can also be entered directly
S_OK BOOL Position is safe
Plaus_F BOOL Plausibility error; the parameters "Abstand",
"Abstand_Hyst", or "Wert_Offs" are outside of the
defined limit values

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The "Position safe" status is generated through an "OR" link between the "Position safe"
outputs from the F_SPOS and F_SPOS_Codesprung program modules. The position value
output by the F_SPOS program module is only to be considered safe together with this
information.

Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany
www.pepperl-fuchs.com
FACTORY AUTOMATION –
SENSING YOUR NEEDS
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Pepperl+Fuchs GmbH
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Tel. [phone]
E-mail: [email protected]
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/ DOCT-5674B
08/2017