Sylvac SCAN S145 V3 User manual

Automation Manual for
SCAN S145 V3
Robot
English

2
TABLE OF CONTENTS
1 Schematic Diagram of Sylvac Solution 3
2 Safety System 4
2.1 Functioning of the safety system 4
2.2 Activating the robot mode 5
2.3 Activating the after-sales service mode 5
2.4 Connections of the Scan S145 5
2.5 Description of the D-SUB 15p safety connector 6
2.6 Functioning of the safety system with a robot 7
2.7 Safety application diagram with a robot 8
2.8 Description of the safety application diagram with a robot 9
2.9 Chronogram of safety operation with a robot 10
2.10 Safety schematic diagram with a robot 11
3 Remote Mode 12
3.1 Location of the Remote Mode button 12
4 Program Mapping 13
5 Wired Solution 14
5.1 Configuration 14
5.2 Diagnostics 14
5.3 Description of the diagnostics I/O 15
5.4 Description of the main D-SUB 37p I/O pins 16
5.5 Description of pin D-SUB 15p I/O additional tools 18
6 OPC/UA Server 19
6.1 Configuration 19
6.2 Diagnostics 20
6.3 Methods 20
6.4 Nodes 21
7 Modbus TCP/IP Server 22
7.1 Configuration 22
7.2 Diagnostics 23
7.3 Input table (Coils, Read-Write, FC1, FC5, FC15) 23
7.4 Input table (Holding Register, Read-Write, FC3, FC6, FC16) 24
7.5 Output table (Discrete Input, Read-Only, FC2) 24
7.6 Output table (Input Register, Read-Only, FC4) 25
8 Profinet via Gateway 26
8.1 Configuration of the local IP address 26
8.2 Gateway configuration 27
8.3 Changing the IP address 28
8.4 I/O data mapping 29
9 Example of a Robot Sequence 31
9.1 I/O sequence 32
9.2 Modbus TCP/IP sequence 33
9.3 OPC/UA sequence 34
10 Pneumatic System 35
10.1 Features 35
10.2 Pneumatic connections 35
11 Footswitch Connection 35
12 Troubleshooting 36
12.1 In case of failure 36
12.2 Problems at start up 36
12.3 FAQ 36

3
1. SCHEMATIC DIAGRAM OF SYLVAC SOLUTION
Profinet
Modbus
TCP/IP
OPC/UA
Cable I/O
Camera/controler
Modbus
TCP/IP

4
2. SAFETY SYSTEM
The Scan S145 has the following safety elements :
• An emergency stop button.
• A safety contact on the Top security sensor.
• A safety contact on the Side(s) door(s)
• A light curtain in front of the access to the measurement area.
Top Security Sensor
Light Curtains Emergency Stop
Button
Reset Button
Side Doors Sensor
In the case of the following states:
- Emergency Stop button is pressed
- Or/and the top sliding roof open
- Or/and the side(s) door(s) open
- Or/and the light curtains are switched off
The power in the Scan is switched off, the motors are no longer under power and the Scan S145 switches in a
fault condition.
To restore the power in Scan S145 and be able to continue the measurements, two actions are required (in this
order) :
1. Check the safety elements and restore them to their normal operating state (reset the safety signals).
2. Restart the Scan (using the Reset Button on the Scan).
2.1 Functioning of the safety system
Dashed : depends on model

5
B
C
DE
A
2.2 Activating the robot mode
To use the machine in robot mode, simply switch the key
position to Robot Mode in the side of the machine, next to
the main ON/OFF switch.
As of now the Scan S145 is in fault mode, the robot is consi-
dered as an additional safety element and he must provide a
doubled safety signal on the DSUB Security connector on the
back of the machine (described in the section 2.6 Functioning
of the safety system with a robot).
2.4. Connections of the Scan S145
A. Ethernet plug controller and camera
B. I/O connectors
C. Security connector
D. Pneumatic input
E. Footswitch input
2.3. Activating the service mode
To be able to operate the machine in service mode, the safety key must be turned to the Service position (positioned on
the right side of the machine). The key cannot be removed in this position.
This mode should only be used by a Sylvac service operator!
In this mode, the only active safety feature is the emergency stop button.

6
Pin Function Description Direction Type
1 +24V_ROB Input +24V robot (common with
other connectors) Input Persistent
2 SCAN_OK1 Safety output Scan ready 1 Output Persistent
3 SCAN_OK2 Safety output Scan ready 2 Output Persistent
4 ROBOT_OK1 Safety input robot ready 1 Input Persistent
5 ROBOT_OK2 Safety input robot ready 2 Input Persistent
6 +24V_SCAN Output +24V Scan (common with
the other connectors) Output Persistent
7 RESTART_ROB Restart impulse from the robot Input Rising flank
8 RESTART_SCAN Restart impulse from the Scan Output Rising flank
9 ROB_MUT1 Signal 1 to momentarily inhibit the
light curtain Input Momentary
10 ROB_MUT2 Signal 2 to momentarily inhibit the
light curtain Input Momentary
11 Not allocated
12 Not allocated
13 GND_ROB Robot ground (common with the
other connectors) Input Persistent
14 GND_SCAN Scan ground (common with the
other connectors) Output Persistent
15 SHIELD Shielding - -
2.5. Description of the D-SUB 15p safety connector
All inputs and outputs, to and from the Scan, must either be at +24V (binary 1) or at GND (binary 0). All signals
to the Scan must come from the robot.

7
In addition, the robot will be able to provide two «muting» signals that will temporarily disable operation of the
light curtain to allow time for the robot to put down a part and exit.
For the robot to be able to send these signals to Scan S145, it must be provided with a +24V supply on +24V_ROB
pin 1 and a GND on GND_ROB pin 13.
The status of the robot must be provided to the Scan by the ROBOT_OK1 pin 4 and ROB_OK2 pin 5, a binary 1
state indicates that the robot is ready and a binary 0 state that the robot is faulty.
The status of the Scan S145 is provided to the Robot by a doubled signal SCAN_OK1 pin 2 and SCAN_OK2 pin 3,
a binary 1 indicates that the Scan is ready and a binary 0 that the Scan S145 is faulty.
The light curtain can be disabled with the aid of the doubled signal ROB_MUT1 pin 9 and ROB_MUT2 pin 10, a
binary 1 inhibits the light curtains and a binary 0 leaves them operating normally.
After one or more of the safety elements have been in the fault condition (emergency stop button, robot, trap
safety contact, door safety contact, light curtain), the following two actions must be carried out (in this order) for
the Scan to be ready again :
1. Check the safety elements and restore them to their normal operating state (restore the safety signals).
2. Start a measurement, from the Scan S145, ReflexScan or robot, or restart the Scan from the robot using the
RESTART_SCAN pin8 (signal of at least 200 ms).
For the Scan and the robot to work together, the diagram in the next Section 2.6 must be observed.
Top Security Sensor
Light Curtains
Robot
Emergency Stop
Button
Reset Button
2.6. Functioning of the safety system with a robot
All red signals represent a D-SUB 15p safety connector pin.
When using the Scan with a robot, a double signal must be provided, which becomes a new safety element in
addition to the emergency stop button.
Side Doors Sensor
Dashed : depends on model

8
A.0
B.2.0
B.2.1
B.2.2
B.2.3
B.2.4
B.2.5
H.0
B.1
C.0
D.0
E.0
F.0
G.0
Scan ON
Scan FaultyScan OK
Check E-Stop
Check Top
and Door
Check Light
Curtain
Check Robot
Security
Rearm
Remote mode ON
Muting-Signals ON
Muting-Signals OFF
Tailstock can be
moved with the Robot
inside the Scan
Scan ready
to operate with
the robot
Scan Faulty
2.7. Safety application diagram with a robot

9
2.8. Description of the safety application diagram with a robot
Each red signal refers to a pin of the D-SUB 15p safety connector.
Each signal must remain in the last defined state if not otherwise specified.
Binary 1 defines a state where there is +24V present.
Binary 0 defines a state where there is GND.
When the robot is connected to the Scan, the robot must provide the signals +24V_ROB Pin 1
((Binary 1) and GND_ROB pin 13 (Binary 0) and all other necessary signals at the Scan input.
A.0 The Scan is turned on and a ReflexScan session is opened.
B.1 Scan OK (signals SCAN_OK1 pin 2 and SCAN_OK2 pin 3 in logic 1), go to step C.0.
B.2.0 Scan in fault state (signals SCAN_OK1 pin 2 and/or SCAN_OK2 pin 3 in logic 0).
B.2.1 Check the Scan emergency stop button (must be pulled out).
B.2.2 Check the Scan trap and door(s) (they must be closed).
B.2.3 Check the Scan light curtain (it must not be interrupted).
B.2.4 Check the safety signal from the robot (signal ROBOT_OK1 pin 4 and signal ROB_OK2 pin 5 in logic 1).
B.2.5 Restart the Scan (Logic 1 for at least 200 ms on the RESTART_SCAN pin 8 signal, then return to
logic 0).
C.0 The remote control mode must be activated in ReflexScan.
D.0 The Scan is ready to work with the solution of your choice: Wired, OPCA/UA, Modbus TCP/IP,
Profinet.
At this stage, the light curtain must not be interrupted, otherwise the Scan will fail !
E.0 The Scan must receive the Muting signals (signals ROB_MUT1 pin 9 and ROB_MUT2 pin 10
in Binary 1). Measurement commands must not be sent to the Scan when these signals are present !
F.0 Now the Scan tailstock can be moved even if the robot crosses the light curtain. Once the robot has
finished its operation, it must not cross the light curtain anymore!
G.0 The Scan should no longer receive Muting signals (signals ROB_MUT1 pin 9 and ROB_MUT2 pin 10
in Binary 0). Measurement commands can now be sent to the Scan.
H.0 In the event of a fault occurring in the Scan or the robot during operation (signals SCAN_OK1 pin 2
and/or SCAN_OK2 pin 3 in logic 0 and/or signal ROB_OK1 pin 4 and/or signal ROB_OK2 pin 5 in logic
0), return to step B.2.1.

10
2.9. Chronogram of safety operation with a robot
1. Normal operation, no fault.
2. Light curtain disabled, crossing the barrier no longer creates an error.
3. Normal operation, light curtain fault, then Safety Relay OK after a Reset.
4. Light curtain disabled, no fault.
5. Normal operation, fault in one of the safety elements, then Safety Relay OK after a Reset, then fault in one
of the safety elements
6. Light curtain disabled, no fault.
7. Normal operation, fault in one of the safety elements, then Safety Relay OK after a Reset.
Light curtain mode
Time (10s)
Light curtain status
Robot muting signals
Safety relay status
Status of Trapdoor, Door, Robot, Emergency Stop
Restart signal

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1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
D D C C
B B A A
Format: C Bu25.0 7.19
Vu : Dessi né:
Modifica tions :
CH-1023 Cris ser
Sy lvac SA
C ontrôlé:
.
A4
S ecurity Concept D145
.
(Suis se)
R Op ................
SCAN D145
Sh eet 1 1/
MO T HE R B O AR DS C AN D 145
48=
24=
R EL _R OB_ OK
R O B OT _O K
R EL _UE4 10
RE L.S E CU RE L.P OW.S R
PAR K E M AE 2
E ME R G E NC Y-S T OP AU XILI A R Y P O WE R MA IN MO T OR S PO W ER E NABLE
S C A N_O K
RE L _RO B _S TAR T
R OBO T_R E S TAR T
RE L _G E N_S TAR T
G E NE R AL_R E S TAR T
RE S TAR T
BLE U
R E S TA R T-S E C UR IT Y
U E 410 2 -IN P U T S
R E S TAR T
S E C U R IT Y _ OK
+24V
S T AR T LA MP /S LI DE BR AK E /R OTAT ION B R AKE
RE L.B RK .T
S LIDE B R AK E
R O TATI ON B R AK E
TAI LS TO C K B R A K E
ME M-S V 103-1930-02
TA IL S T O C K F O R C E
TAILS TO C K HAL L
RE L.B RK .S
RE L.B RK .R
NO -UE 410
+48VI N
MAIN
+48VM
+24V M
+24VR
RE S TAR T'
RE S TAR T
E NAB -S R
+24VS
VE R T
S TANDA R D
R OB OTIZAT ION
LIGHT B AR R IE R
TA ILS T OC K
NO -RO B
S AV.RO B
+24V E S
S AV.UE 410
E -S TOP
SL IDE + R OTAT ION
PAR K E M AE M
AU XILI A R Y P O WE R MA IN MO T OR S PO W ER E NABLE /T AILS T OC K B R AK E TA ILS T OC K F OR C E MAN UAL TA ILS T OC K S WI T C H TA ILS T OC K HA LL TA IL ST O C K
RE L.P OW.T
WAT C H -DO G
WAT C H -DO G
PARK
NO 1
NC1
MAN.T AIL
A
(I.max=7A)
(I.max=3A)
+24V .R O BOT
+48VMW.S R
+48VMW.T
PAR K
B AR _O K S E C U_O K
TOP
S E C UR IT Y R E LAIS
E R
xx.xx. 19
NO
E NAB -T
C AME R A ILLU MIN LA MP S FANS
DO OR
M M P MT
Diodes (M) : Maintien des relais.
Diode (P) : E mpêche le relachementdu relais R EL.P OW.SR s i SC AN parquée.
Diode (T) : Activation du relais RE L.POW.T en mode manuel même si la barrière estcoupée.
Relais (A) représenté aurepos (=avec défaut barrière). Contact ouvert sans défaut: E mpêche le
réarmementbarrière.
REL.POW.T nécessaire car il faut pouvoir conserver la puissance sur le moteur Contre-Poupée
même si lerelais REL.POW.SR est relâché (barrière coupée etScannonparquée).
Possibilités de Restart(à la mise sous tension
ou après un défaut) :
Bouton bleu SCAN ou Restartgénéral cellule
ou via PC. Condition de R estart :
E-STOP OK et RobotOK etParkemOK.
Lampe Restartbleue :
Eteinte si défaut.
Rallumée après action sur bouton R estartsi
plus de défaut.
Lampe Reflex-Click Verte :
Eteinte si E-STOP pas OK ou R obot pas OK.
Sinon pilotable par PC (normallement allumée
en mesure, éteinte au repos).
2.10. Safety schematic diagram with a robot

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3. REMOTE MODE
Before starting any command with the Scan, regardless of the communication protocol chosen, the robot must
check that “Remote Mode” is activated.
To activate the remote mode, go to the ReflexScan main screen (Home) and click on the Remote Mode button.
The robot can also choose to send the “Remote Lock” command to lock ReflexScan in the remote control
mode.
3.1 Location of the Remote Mode button

13
4. PROGRAM MAPPING
To be able to load programs from I/Os or Modbus, you have to assign them in the Setup of the «Automation»
plugin using the “Service->Plugin->Automation->Setup” menu, then in the “Programs Mapping” tab.
For the I/Os, each program can be assigned to a 3-bit binary code, allowing up to 7 programs with code 111
indicating no active program.
For Modbus, each program can be assigned to an identifier from 1 to 7, with 0 indicating no active program.

14
5. WIRED SOLUTION
The Scan can be controlled by electrical signals grouped on two D-SUB connectors.
This approach is the most direct to implement, but also the most limited in its possibilities. For example, it is
not possible to exchange analog values (e.g. axes position). Note that the number of available functions depends
directly on the number of input/output signals of the Scan.
The first time you use them, the IOs have to be activated.
Go to the Setup ot the “Automation” plugin from the menu“Service->Plugin->Automation->Setup” and check IOs
Enable in the IOs tab.
If you do not use IOs, IOs Enable must be unchecked.
To check the status of the IOs, go to the Diagnostics of the “Automation” plugin from the menu“Service->Plu-
gin->Automation->Diagnostics” and check the status of the IOs in the drop-down window at the bottom of the
IOs tab.
5.1 Configuration
5.2 Diagnostics

15
5.3 Description of the I/O diagnostics
Inputs
Type Name Details
Commands
Park Axis All axes move to their parking position.
Start Program Starts the loaded program.
Start Calibration Starts a calibration cycle.
Status
Remote Lock Locks the Scan in remote mode.
Program Loading
Select Program 0
3-bit code (0 to 7) for program selection.
Select Program 1
Select Program 2
Load Program Loads (or unloads) the program according to the 3-bit code (0 to 7).
Tailstock + Chuck
Lock Tailstock Lowers and locks the tailstock. The position and the force are
defined by the program which is loaded.
Unlock Tailstock
Raises and unlocks the tailstock. The position is defined by the
loaded program. If there is no program, the tailstock moves up to
the maximum position. **
Close Chuck Closes the pneumatic chuck. *
Open Chuck Opens the pneumatic chuck. *
Outputs
Type Name Details
Status
Remote mode “True” state when the Scan is in remote mode.
Machine Ready “True” state when the Scan is ready to receive a new command from
the robot (e.g.: unlock tailstock).
Is Calibrated “True” state when the machine has been calibrated.
Is Parked (SW) “True” state when the axes are in parking position.
Is Tailstock Locked
(SW) “True” state when the tailstock is locked on a part.
Is Tailstock Unlocked
(SW) “True” state when the tailstock is unlocked. No longer on a part.
Is Chuck Closed “True” state when the pneumatic chuck is closed.
Is Chuck Open “True” state when the pneumatic chuck is open.
Is Footpedal active True if of the foot pedal is active once connected
Loaded Program
Loaded Program 0 3-bit code (0 to 7) of the currently selected program.

16
Loaded Program 1
Loaded Program 2
Results
Result Ready “True” state when the program has finished its execution and the
results are ready.
No Result “True” state when the program has not returned any results.
Pass “True” state when all measurement results are within the
tolerances defined by the loaded program.
Failed “True” state when all measurement results are not within the
tolerances defined by the loaded program.
Warning “True” state when one of the dimensions needs to be corrected
in the program.
* Optional, you must install a pneumatic chuck to use these signals.
**Warning! A part that is not held properly before this signal is sent may fall and cause damage or injuries.
All inputs and outputs, to and from the Scan, must either be at +24V (binary 1) or at GND (binary 0). All signals
to the Scan must come from the robot.
5.4 Description of the main D-SUB 37p I/O pins
Pin I/O SCAN Function Type of signal
1+24V (Robot) +24V from the robot (common
with the other connectors)
2 GND (Robot)
Ground from the robot
(common with the other
connectors)
3+24V (Scan) +24V from the Scan (common
with the other connectors)
4GND (Scan)
Ground from the Scan
(common with the other
connectors)

17
5 IN1 Park axis Rising edge
6 IN2 Start Program Rising edge
7 IN3 Start Calibration Rising edge
8 IN4 Remote Lock Persistent
9 IN5 Select Program 0 Persistent
10 IN6 Select Program 1 Persistent
11 IN7 Select Program 2 Persistent
12 IN8 Load Program Rising edge
13 IN9 Lock Tailstock Rising edge
14 IN10 Unlock Tailstock Rising edge
15 IN11 Reserve IN
16 IN12 Reserve IN
17 IN13 Reserve IN
18 IN14 Reserve IN
19 IN15 Reserve IN
20 IN16 Reserve IN
21 OUT1 Remote mode Persistent
22 OUT2 Machine Ready Persistent
23 OUT3 Is Calibrated Persistent
24 OUT4 Is Parked (SW) Persistent
25 OUT5 Tailstock Locked (SW) Persistent
26 OUT6 Tailstock Unlocked (SW) Persistent
27 OUT7 Loaded Program 0 Persistent
28 OUT8 Loaded Program 1 Persistent
29 OUT9 Loaded Program 2 Persistent
30 OUT10 Reserve OUT
31 OUT11 Result Ready Persistent
32 OUT12 No Result Persistent
33 OUT13 Pass Persistent
34 OUT14 Failed Persistent
35 OUT15 Warning Persistent
36 OUT16 Is Foot Pedal Active
37 Earth Shielding

18
PIN #8
PIN #15 PIN #9
FEMALE
PIN #1
All inputs and outputs, to and from the Scan, must either be at +24V (edge 1) or at GND (edge 0). All signals
to the Scan must come from the robot.
This connector is used for more I/Os.
5.5 Description of pin D-SUB 15p I/O additional tools
PIN I/O SCAN Function Type of signal
1 +24V (Robot) +24V from the robot (common
with the other connectors)
2 GND (Robot) Ground from the robot (common
with the other connectors)
3 IN17 Close Chuck
4 IN18 Open Chuck
5 IN19
6 IN20
7 IN21
8 IN22
9 OUT17 Chuck Open (SW) Persistent
10 OUT18 Chuck Closed (SW) Persistent
11 OUT19
12 OUT20
13 OUT21
14 OUT22
15 Earth Shielding

19
6. OPC/UA SERVER
OPC UA is a communication protocol for the automation industry using an Ethernet port. It is the most flexible
automation solution supported by the Scan (e.g. access to the details of a measurement result).
Note that the Scan only supports the binary protocol opc.tcp.
The first time you use it, you must activate the OPC Server to be able to use the protocol.
Go to the Setup of the “Automation” plugin from the menu“Service->Plugin->Automation->Setup” and check OPC
Server Enable in the OPC Server tab.
If you are not using OPC/UA, OPC Server Enable must be unchecked.
To check the status of the OPC Server, go to the Diagnostics of the “Automation” plugin from the menu “Ser-
vice->Plugin->Automation->Diagnostics” and check the status of the OPC Server in the drop-down window at the
bottom of the OPC Server tab.
Note that the address of the Automation Ethernet port on the PC where ReflexScan is installed must be the same.
6.1 Configuration

20
6.2 Diagnostics
6.3 Methods
Methods Description
Clear All Runs Clear all runs from the memory
Close Chuck Close the pneumatic chuck
Get Programs Get the list of available programs
Get Results Get the last measurement results
Load Program Load a program using the program file name
Lock Tailstock Move down and lock the tailstock
Move Rotation To Position Move the Rotation axis to a specific position
Move Slide to Position Move the Slide axis to a specific position
Move Tailstock to Position Move the Tailstock axis to a specific position
Open Chuck Open the pneumatic chuck
Park Axis Move all axes to the parking/loading position
Remote Lock Block the 'automation mode'
Set Custom SPC <special>
Start Calibration Start the execution of the calibration
Start Program Start the execution of a measurement program
Stop Program Stop the execution of the current program
Unlock Tailstock Move up and unlock the tailstock
GetToolCorrections Get the proposition for each corrector in an XML format or text format
ResetCorrectionStatus Reset the 'Correction Status’