Pepperl+Fuchs PGV...-F200...-R4-V19 Series User manual

PGV...-F200/-F200A...-R4-V19
Incident Light Positioning System
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"
PGV...-F200/-F200A...-R4-V19

PGV...-F200/-F200A...-R4-V19
3
1 Safety ........................................................................................... 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 and Application............................................................................. 7
2.2 The RS-485 Interface ........................................................................... 9
2.3 LED Indicators and Controls............................................................... 9
2.4 Accessories ........................................................................................ 11
3 Installation................................................................................. 12
3.1 Mounting the Read Head................................................................... 12
3.2 Mounting the Colored Tape and Code Tape .................................... 14
3.3 Electrical Connection ........................................................................ 30
4 Commissioning......................................................................... 32
4.1 Specifying the First Direction Decision ........................................... 32
4.2 Direction Decision.............................................................................. 32
4.3 Parameter assignment....................................................................... 34
4.3.1 Internal Parameterization Using Parameterization Software ............. 34
4.3.2 External Parameterization Using Code Cards .................................. 35
5 Operation and communication................................................ 37
5.1 Communication via the RS-485 Interface ........................................ 37
5.1.1 Request Telegram............................................................................ 37
5.1.2 Position Response Telegram ........................................................... 38
5.1.3 Direction Decision Request Telegram .............................................. 44
5.1.4 Color Choice Request Telegram ...................................................... 44
5.2 Operation Using Control Codes ....................................................... 46
5.3 Operation Using Repair Tape ............................................................ 47

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PGV...-F200/-F200A...-R4-V19
6 Appendix ................................................................................... 48
6.1 Code Cards for External Parameterization ......................................48
6.1.1 Code Cards with Special Functions.................................................. 48
6.1.2 Code Cards for Setting the Read Head Address .............................. 51
6.1.3 Code Cards for Adjusting the Resolution.......................................... 52
6.1.4 Code cards for setting the transfer rate............................................. 53
6.1.5 Code cards for adjusting the terminator............................................ 55
6.1.6 Code Cards for Adjusting Input/Output 3.......................................... 56

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Safety
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1Safety
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
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
1.1.2 Manufacturer
1.1.3 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.
Note!
For full information on the product, refer to the further documentation on the Internet at
www.pepperl-fuchs.com.
Pepperl+Fuchs GmbH
Lilienthalstraße 200, 68307 Mannheim, Germany
Internet: 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.
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.
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
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2 Product Description
2.1 Use and Application
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. It
can be used in all applications where automated guided vehicles (AGV) 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
process. 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.
If 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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PGV...-F200/-F200A...-R4-V19
Product Description
Tag Mode
In 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 Interface
The read head is equipped with an RS-485 interface for communication purposes, i.e.,
parameterizing 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
deactivated by parameterizing the sensor head accordingly. The RS-485 interface supports
the following transfer rates:
38400 bit/s
57600 bit/s
76800 bit/s
115200 bit/s(preset value)
230400 bit/s
Data structure of the RS-485 interface
2.3 LED Indicators and 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 CONFIG.
Figure 2.3
Bit 0
LSB MSBStart Stop
Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Parity
ADJUST
CONFIG
1
2
LED 1 2 3 4 5 6 7

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Product Description
LED
[#1]
COM
[#2]
PWR
ERR/NO
CODE
[#3]
LANE
AVAILA
BLE
[#4]
FOLLO
W LEFT
[#5]
FOLLO
W
RIGHT
[#6] &
[#7]
INTERN
AL
DIAGN
OSTIC
DescriptionColor Yellow
Green/
red Yellow Yellow Yellow
Red/
green/
yellow
Status
x1
1.LED status has no meaning
Flashes
red
xxxxCode tape outside read range
fflash = 2 Hz
xLights
up red
xxxxSystem errorError Codes402
2.No lane selected, for example. .see table "Error Codes" on page 40
xLights
up green
xxxxCode tape detected, absolute position
available
x x Lights
up
xxxColored tape detected
x x Off xxxColored tape outside read range
x x x Off Off xNo direction selection activated43
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 xxxxxRS-485 data transfer
Flashes Flashes
red
Flashes Flashes Flashes Off Normal operation. Indication 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
fflash = 2 Hz for 3 sec
Off Green, 1
sec
Flashes Off Off Off Code card detected
fflash = 2 Hz for 1 sec
xOff xxxOff Time lock for buttons disabled
xxxxxLights
up
Internal error
Return to Pepperl+Fuchs
Table 2.1 LED Status

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Product Description
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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 when commissioning for the first time, but also when
replacing and maintaining our products.
If products are used in harsh ambient conditions, appropriate Pepperl+Fuchs accessories can
be used to extend the service life of these products.
Order designation 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 cable1
1.Ask your contact person at Pepperl+Fuchs

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Installation
3Installation
3.1 Mounting the Read Head
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 Read Distance
Hysteresis
If 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 Value Out in the following table.
If the read head swivels onto a colored tape, the read head can capture the distance of the
colored 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 value In in the following table. The difference
between Y Value Out and Y Value In is the hysteresis. See "Distance Output" on page 17.
Order designation Read distance [mm] Depth of focus [mm]
Field of vision (w x h)
[mm]
PGV100* 100 ±20 117 x 75
PGV150I* 150 ±30 170 x 105
Order designation Max. Y Value Out [mm] Min. Y Value In [mm]
PGV100* 60 45
PGV150I* 60 60

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Read Head 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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Installation
3.2 Mounting the Colored Tape and Code Tape
Colored tape
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. Ideally, use the complementary color.
Due to the integrated lighting of the read head, some floor colors appear to be different in the
camera. If you have problems with the color selection of the colored tapes, please consult your
contact at Pepperl+Fuchs.
Mounting the Colored Tape
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.
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.
Note!
Priority
Data Matrix code tapes and Data Matrix tags have priority over colored tapes or colored lanes.
If 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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Cleaning Colored Tape/Code Tape
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. If the contamination is
severe, you can use a non-corrosive plastic cleaner, e.g., Caramba®.
Basics
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
center of the colored tape. You can use 3 defined colors. See the section entitled "Colored
tape"
The sensor always moves in the X direction. In 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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Installation
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 tape
The read head detects the angle in relation to the tracked lane with a resolution of 360
(corresponds 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
Data Matrix code tape
The read head detects the absolute angle in relation to the tracked lane with a maximum
resolution 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°
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
α
X
Y
α
β



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Figure 3.6 Absolute angle
Distance 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 tape
The read head outputs the Y value at which the colored tape intersects the Y axis as the
distance.
Figure 3.7 Distance A for colored tape
X
Y
α
X
Y
α
X
Y
A

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Installation
Data Matrix code tape
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
X
Y
A

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Branches
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
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. If there is no direction
decision, the read head displays an error message.
Code Tapes for Control and Positioning
In 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.

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Installation
Branches or intersections with position information can be displayed as follows:
Figure 3.10 Separate lane branches off/converges
Colored tape
Data Matrix position code
Data Matrix control code
1
3
2
1
2
3