Roland SND30 Manual

ROLAND

WELD SEAM DETECTION SND30

For positioning tasks

For steel and non magnetic stainless steel tubes with a diameter ranging from 10 to 250 mmand a wall thickness up to 5 mm depending on the sensor type

Digital display of operations parameter

Programmable for 30 different tubes

Opto coupled 8-Bit PLC parallel-interface for input and output

Output relay for motor control

Weld seam detection in tubesR 2000 series SND30Magnetic functional principleMicrocontroller based

Sensor

Rohr

OPERATING INSTRUCTIONSWELD SEAM DETECTOR SND30

Rev. 3.0

ROLAND ELECTRONIC GMBH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Telefon +49 (0)7236-9392-0 · Telefax +49 (0)7236-9392-33

ROLAND

Page 1/ B0001566 / 26.11.2008

Table of Contents

Table of Contents Attachment A Page2Table of Contents Attachment B Page21. General Page3

1.1 Safety instructions and warnings for user Page31.2 Declaration of conformity according to EC directives Page3

2. System Configuration Page43. Introduction Page64. Systems description and measuring principle Page65. Systems components Page6

5.1 Technical data Page65.2 Technical data sensor NS9S Page75.3 Technical data sensor NS12 Page85.4 Sensor cable KNS9S Page95.5 Metal rubber Page9

6. System installation Page106.1 Sensor mounting Page106.2 Tube drive Page106.3 Ground earth requirements of the system components SND30 Page116.4 Operating parameter Page11

6.4.1 Tube diameter and wall thickness Page116.4.2 Tube rotational speed Page116.4.3 Weld seam positioning Page116.4.4 Elapsed time for weld seam detection Page126.4.5 Elapsed time for parameter programming Page126.4.6 Reliability of detection Page12

6.5 Interface wiring Page137. Start-up Page138. Operation Page14

8.1 Functions of the keys Page148.2 Funktionen der LED´s Page148.3 Menu structure Page158.4 Parameter programming Page16

8.4.1 Parameter programming with optimization automatically Page168.4.2 Parameter programming with manual optimization Page19

8.5 Measurement mode Page248.5.1 Parameter program selection Page248.5.2 Measurement operation Page258.5.3 Re-Teach (automatic Re Teach via the PLC) Page25

8.6 Diagnostics and service functions Page268.6.1 D1 - Systems installation Page268.6.2 D2 - System configuration Page268.6.3 D3 - Analog board test Page318.6.4 D4 - Tube signal analysis Page318.6.5 D5 - Reset of program parameters Page338.6.6 D6 - Tube statistics Page33

9. Maintenance Page349.1 Control unit Page349.2 Sensor Page349.3 Hardware - Diagnostics Page349.4 Firmware update Page359.5 Order data Page35


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Table of Contents Attachment A

A1 Wiring diagram Optocoupler - Interface - Board (Schematic diagram) Page36A2 Connection Diagram Optocoupler - Interface - Board Page37

Table of Contents Attachment B

B1 Timing Diagram Optocoupler- Interface - Board, minimum Interface Connection Page38B2 Timing Diagram Optocoupler- Interface - Board, minimum Interface Connection Page39B3 Timing Diagram Optocoupler- Interface - Board, Standard Interface Connection Page40B4 Timing Diagram Optocoupler- Interface - Board, Standard Interface Connection Page41B5 Timing Diagram Optocoupler- Interface - Board, Standard Interface Connection Page42

B6 Timing Diagram Optocoupler- Interface - Board, Standard Interface Connection Page43


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1. General

1.1 Safety instructions and warnings for user

This handbook contains all necessary information for the correct operation of the R 2000 family ofsystems.It has been written for technically qualified personnel.Unauthorized tampering with the unit, especially ignoring the warnings in this handbook, can causemalfunction and damage to the unit. Only authorized personnel should be allowed to make changes tothe unit and perform cable connections especially the power supply.Should it be necessary, e.g. in case of service or repair, to make measurements within the unit, then allcustomary accidents prevention procedures should be observed. Only professional electrical toolsshould be used.

1.2 Declaration of conformity according to EC directives

Manufacturer: Roland Electronic GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern

Product name: Double Sheet Detector

Product type: R2000 - SND30

Roland Electronic GmbH declare that the product listed above complies with the requirements of theEMC directives listed below.

Applied Directives:

73/23/EWG: Directive regarding electrical equipment to be used within specified voltagelevels; modified by Directive RL93/68/EWG.EN61010-1:2001

89/336/EWG: Generic emission standard;modified by Directive RL 91/263/EWG, 92/31/EWG and 93/68/EWG.

61000-6-3: 2001 61000-6-1: 200161000-6-4: 2001 61000-6-2: 2001

Year of mark´s apposition: 1998

Keltern, 01.04.1998 Managing Director...............................................................................................................................Place, Date ^ Signature Function of the signer

DIN EN ISO 9001 Reg.-no. 5152


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2. System Configuration

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3. Introduction

The processing of tubes requires the fully automatic location of weld seams and the positioning of thetubes. The weld seam detector SND30 was specifically developed for this task and is an advancedversion of the proven system SND8.

4. Systems description and measuring principle

The SND30 enables the positioning of weld seams in tubes in any pre-determined position. Locationand positioning are based on the magnetic leaking flux principle and auto-optimizing methods (teach-in) of digital signal proccessing concepts.The SND30 communicates with a programmable logic controller (PLC) via an 8- bit parallel interface.The drive to position the weld seam can be controlled via the built-in relay (max. 250 VAC / 30 VDC /10 Amps). For positioning application where mis-positioning cannot be tolerated, the SND30 issuesan interface signal ”reduced detection capability“.

5. Systems components

The system consists of the control unit, the sensor and the cable.

5.1 Technical data

Dimensions: see drawing above

Protection category: IP65

Ambient temperature: 0 - 50 °C

Weight: 5.3 kg

Operating voltage: 230 V / 115 VAC switchable; 50 / 60 Hz

Dimensions inmm / inch W H D

R 2000 - SND30 240 / 9.45 160 / 6.30 150 / 5.90

fixing holes M6


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5.2 Technical data sensor NS9S

Note!In the case of use of the supplied metal rubbers (see chapter 5.5) the overall width of 165 mmis altered around 50 mm (25 mm each rubber) on 215 mm.

Technical data:

Ambient temperature: 10 - 40OC 50 - 105°FProtection category: IP53Weight: 9.5 kg 21lbEnclosure made of: nickelplated brass

The fixing screws shouldNOT be screwed deeperthan 20 mm into the brass plate. Otherwise the sensor function could be destroyed.

Attention!

Attention!

Attention !

active sensor area

magnetic poles

These two screwsmust not be used

or removed !

33

165- A -

- A -

- B -

- B -

9217

53

ø10

132.5

fixin

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ole

s M

8

24.8

17.5 35

70

17.5

26

M6 x 10

79

4 pcs. SKF ball bearing 9x24x7 mm (order no.: 2390924)

2 pcs. 8x22x7 mm (order no.: 2390822)

SKF ball bearing


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5.3 Technical data sensor NS12

Note!In the case of use of the supplied metal rubbers (see chapter 5.5) the overall width of 165 mmis altered around 50 mm (25mm each rubber) on 215 mm.

Technical data:

Ambient temperature: 10 - 40OC 50 - 104°FProtection category: IP53Weight: 14 kg 31 lbEnclosure made of: nickelplated brass

115

33

165

"A"

"B"

"A" "B"

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17

5 3

0

ø10

132,5

M8ø24

M8

90

110

70

35

17

,52

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M6 x 10

55

Achtung!

Achtung!

The fixing screws shouldNOT be screwed deeperthan 10 mm into the brass plate. Otherwise the sensor function could be destroyed.

Attention !


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Material: NBR (Acrylnitril-Butadien)metal parts galvanized and chromated

Hardness: 45+/-5 Shore A

30

M8

2510

M8

8

5.4 Sensor cable KNS9S

The sensor cable KNS9S must be used for the connection of the sensor to the control unit. The cable hasa cable receptacle at the sensor side and terminal leads for the connection to the control unit.

5.5 Metal rubber

receptacle sensor

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1

76

5

4

8

2

3


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6. System installation

6.1 Sensor mounting

The sensor can be mounted in any position. Mounting the sensor vertically above the tube isadvantageous to reduce collection of dirt. For best performance there should be no ferrous materialimmediately adjacent to the sensor. Keep a distance of 50 mm.

The sensor should be in continuous contact with the tube during the detection phase.For this reason the sensor should be metal rubber mounted in order to allow the sensor follow themovement of the tube.

Use Metal Rubber:

GM Type B (30 mm dia., 25 mm height). Metal rubber are supplied with the sensor but can be orderedalso separately from ROLAND ELECTRONIC.

6.2 Tube drive

The rotational drive of the tube can be accomplished axially or radially. The rotational speed shouldbe in the specified range. Within a second the rotational speed should be reached and remain constantduring the whole detection phase. The sensor should touch the tube within 1 second after "MeasurementStart" and should not vibrate at the tube during the detection process. If these conditions cannot beachieved within 1 second contact Roland Electronic for additional information.

Control of the tube drive can be accomplished:

- via the relay output "motor"

- Über die SPS

If the interface output "motor" is used then it is easier to position the weld seam more precisely,because the PLC is not used for this control purpose.If the drive is controlled via the PLC, then the PLC must monitor the output "motor" and control thedrives immediatly according to the output signals.

M8

M8

M8

M8

Sensor NS9S:Four metal rubbermountings come witheach sensor.Two of each are mounteddiagonally on the narrowside of the sensor.

Sensor NS12S:Eight metal rubbermountings come witheach sensor.Four of each are mountedon the narrow side of thesensor.


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6.3 Ground earth requirements of the system components SND30

All systems components should use the same ground earth (PA).The leads should have a cross section of 1.5 mm² minimum.

6.4 Operating parameter

6.4.1 Tube diameter and wall thickness

The SND 30 can detect and position weld seams in tube diameters ranging from 10 mm to 250 mm (0.4to 9.8 inch). The tube wall thickness should in general not exceed 3 mm with NS9S resp. 4mm withNS12.

6.4.2 Tube rotational speed

The possible tube rotational speed (N) is a function of the tube diameter and should be within the range.

< N < but higher than 5 RPM

N = RPMø = tube diameter in mm (1 inch 25.4 mm)

Tube rotation should stay constant during the detection phase.

6.4.3 Weld seam positioning

The positioning of the weld seam can be selected in steps of 1O.

NS9SNS12S


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6.4.4 Elapsed time for weld seam detection

The necessary detection time per tube depends on the rotation of the tube.

The times for placing the tube onto the sensor and removing it after detection have to be added to theabove.

6.4.5 Elapsed time for parameter programming

The total time for parameter programming depends on the tube diameter, rotational speed and timenecessary to input the parameters. An approximate value is the elapsed time for 25 revolutions.

6.4.6 Reliability of detection

The SND 30 is based on the magnetic leaking flux principle and auto-optimizing methods of digitalsignal analysis in order to obtain a high degree of reliability for detecting and positioning the weld seam.However, poorly manufactured tubes with surface defects or material faults can lead to mispositioningthe weld seam. The option "reduced detection capability" enables the PLC to mark those tubes andexclude them from the manufacturing process.If correct positioned tubes are indicated as "critical" then parameter programming should be repeatedwith one such tube. If the tubes to be positioned contain many manufacturing faults and material faults,then it may not be possible to detect and position the weld seam correctly.

During parameter programming this condition is indicated by the message "weld seam location critical"(compare section "Parameter programming").

TS = System settle time

N = RPM

TD = Detection time in secondsT = T +D S

250N


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6.5 Interface wiring

Minimum wiring

The control unit can be operated with a minimal interface wiring. This means that the selection of themeasuring menues made via the keyboard and not via the PLC.For this version the output OUT 7 "Motor" or relay contact (Terminal 9, 10) and the input IN0"Measurement start / Teach-In ENABLE" are required. The timing diagrams for parameter programmingand the measurement process are documented in Attachment B 1 and B 2.In addition, the interface signal OUT 6 "Reduced detection capability" can be used if required. Theoutput signals are opto coupled and require an external 24 V power supply.

Standard wiring

For this version the inputs IN 0 to IN 6 and the outputs OUT0 to OUT7 are required. It is possible touse fewer inputs and outputs if not all of the measuring menues are required.The standard version allows the selection of measuring menues either with the PLC (see AttachmentB3) or the keyboard.The timing diagrams for parameter programming and measurement are in Attachment B4 and B5.

Interface wiring with Re-Teach

If repeated fully automatic teach-in is desired via the PLC interface, then IN7 must also be wired.

7. Start-up

1. All systems components should be connected to power according to the legal requirements of thecountry. Attachement A contains the connection diagram of the interface board as well as theinformation for grounding the system components; see also installations instructions of thesensor.

2. Review the position of the voltage selector switch and compare to available power. If necessarychange position of voltage selector switch.


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8. Operation

After applying power the following display appears.

The system is factory adjusted according to the requirements of specific customers. Activation offunction key D is generally only necessary to select a language. Press function key P in order to inputparameters, if no measuring programs have been keyed-in before.

8.1 Functions of the keys

M : Measuring mode

P : Parameter -Programming

D : Diagnostics, Service-Functions and Systems-Installation

↑↑↑↑↑ : Change of Parameters (forward)

↓↓↓↓↓ : Change of Parameters (backward)

ENTER : Confirmation of input

BACK : Return to main menu / abort

T : (active only in diagnostics)

Key- : Keyboard Enable : Allows inputs via keyboardswitch RUN : Disables the keyboard; activates the outputs in the measuring mode

8.2 Funktionen der LED´s

FAULT : Lights up, in case of hardware fault. Contact ROLAND ELECTRONIC or your localrepresentative

RUN : Blinking when keyboard is enabled, or lights up constantly when the system is in themeasuring mode and the key switch is in the position RUN (outputs are active).

ACTIVE : Lights up, if the system accepts measuring data and shows them on the display.

< : Lights up, together with > if reduced detection capability exists.

NORM : Lights up, if weld seam is detected.

> : Lights up, together with > if reduced detection capability exists.

LED RUN blinks

The key switch has to be in theposition KEYBOARD ENABLEin order to input data


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Key M

Measuring mode

Select measuring program

Parameter optimization

8 digits

8 - 250 mm / 0.3 - 9.85 inch

(positioning)0 - 359°

/ no

/ high / standard /

Test run with automatic arameter impovement

8 digits

8 - 250 mm / 0.3 - 9.85 inch

(positioning)0 - 359°

/ no

4 - 11

Filter type0 - 6

Magnetic field strength ar. imp.: extented manual) 30% / 50% / 100%

Signal gain1 - 800

Description

Tube diameter

Number of revolutions 5 - 600 rpm

After-run

Critical detection yes

Treshold of critical very high very low

p

Description

Tube diameter

Speed 5 - 600 rpm

After-run

Critical detection yes

Treshold of critical very high / high / standard / very low

Sampling rate

(only with P

automatically

manual

System installation

Language

System Configuration

(fix)

Logic input signals24V active / 0V active

Inputs mja / nein

Logic output signals OUT0 - 624V active / 0V active

Logik output signals OUT7 / Relay24V active / normal closed

/ no

mm / inch

Parameter improvementutomatically / automatically-manual /

extended manual

System settle time0.0 - 5.0 seconds

magnetic field0.0 - 5.0 seconds

Default speed5.0 - 600 rpm

automatic menu selection / no

/ no

Re-teach via PLCno / standard / extra

Default filter type0 - 6

2:1, 1:2 / 2:1, 1:4 / 4:1, 1:4

3% / 5% / 8%

Analog board test

Tube signal analysis

Reset all parameter programs

Tube statistic

D1

D2

D3

D4

D5

D6

D / E / F / NL / I

Backup memory

onitoring

Outputs monitoring yes Dimension diameter

a

Switch off delay

yes

Test sensor cable yes

Modification weld seam

Masking of weld seam

Key D

Installation mode

Key P

Programming mode

Select parameter program

Initial state(Key switch keyboard Enable)

8.3 Menu structure


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8.4 Parameter programming

This section explains the menues and the operation of the SND30.The timing diagram and the communication with the PLC is contained in Attachment B.

1. Key switch is in position keyboard ENABLE.

2. Press key P in order to activate parameter menu.

3. Select one parameter program (P1-P30 are available) with the arrow keys and confirm withENTER.

4. Depending on the adjustment in the systems configuration under "parameter optimization" thefollowing operational sequence is possible:

1. Adjusted systems configuration "parameter optimization automatically only"

Only the automatic parameter optimization procedure available, continue with "8.4.1 parameterprogramming - automatic optimization"

2. Adjusted systems configuration "parameter optimization automatic/manual" or "parameteroptimization specifically manually".

The following display appears:

Now has to be decided whether the parameter optimization should take place automaticallyor manually. The automatic parameter optimization is described under 8.4.1. The manualoptimization under 8.4.2.

8.4.1 Parameter programming with optimization automatically

1. Optional input of an 8 digit alphanumeric material code and confirmation with ENTER. This entrycan remain blank.

2. Input of tube diameter with arrow keys and confirmation with ENTER.

3. Input of speed (RPM) of the tube and confirmation with ENTER (approx. by ±15 % is sufficient).

P12 Parameter

Diameter 50mmDescription M14512 The following display appears if a parameter menue has been

previously programmed. Each blinking field can be changed andhas to be confirmed with ENTER.

In this display the speed is 60 RPM and the after-run is 120°.

P12 Parameter

automaticallyoptimizationparameter

P12 Parameter

After-run 120°Speed 60.0rpm


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4. Input of after-run (position of the weld seam) with arrow keys; (relative to the direction of thesensor). Confirmation with ENTER.

5.1 If SND 30 is not able to properly locate the weld seam, it issues a warning. This warning can beused to mark the tubes and or exclude them from the normal manufacturing process. (Comparesection "Reliability of detection"). Confirm selection with ENTER key.

If the unit indicates that correctly positioned tubes are ”critical“ (difficult to detect), then it isadvisable to repeat parameter programming with a ”critical“ tube.

5.2 Under this menu the threshold of critical seam detection for the output "reduced detectioncapability" is adjusted. Available selections are "very high", "high", "standard", and "very low".

If "very high" is selected for the measuring process many tubes may be classified as "criticaldetection". However, it is unlikely that a tube with an incorrectly positioned tube is classified as"weld seam detected".

In the case of a "very low" selection many tubes with an incorrectly positioned tube may not beclassified as "critical detection" (reduced detection capability). For this reason the adjustment"standard" is a reasonable starting point.

6. This display appears if the PLC has not yet prepared a tube for parameter programming. It isreplaced as soon as the PLC has prepared the tube for parameter programming.

7. The SND 30 determines the exact rotational speed of the tube.

P12 Parameter

yesweld seam detectioninform at critical

This display means that reduced detection capabil ity iscommunicated to the PLC.

-

Note:This menu point is availabe since Software-Version 161.

P12 Parameter

standard (3)

P12 Parameter

clearance from SPSwaiting for

P12 Parameter

please wait

Correlation aktive


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8. This display appears if it is not possible to determine the exact rotational speed of the tubeautomatically. Then it is necessary to key-in the exact speed (within ± 2%).

9. The SND30 optimizes the filter algorithms for weld seam detection.

10. The SND 30 positions the weld seam.

11. This display appears only, if it is not possible to detect the weld seam.Repeat with another tube and review the number of revolutions of the tube. If these actions arenot successful then it is not possible to detect the weld seam with the system

Return to point 10.

P12 Parameter

continue with ENTERspeed not possiblecalculation of exact

P12 Parameter

speed 62.9 rpmexact speed(+/-2%) please put in the

P12 Parameter

please waitaktive

filter optimization

P12 Parameter

please waitaktive

tube positioning

P12 Parameter

continue with ENTERnot detected

the weld seam was

P12 Parameter

continue with ENTERwith another tube!repeat proceeding

12. User information about the detection reliability of the weld seam.

P12 Parameter

continue with ENTERgood

weld seam detection

Relative values:very good - good - satisfactory - problematic


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13. After the positioning process it is necessary to review whether the weld seam is in the desiredposition. Select answer with arrow keys.

If this question has been answered with yes, then parameter programming is completed and theunit returns to the main menu.

14. This menu only appear, if the question in 13. was answered "no". Input new after-run with the arrowkeys.

Return to point 13.

8.4.2 Parameter programming with manual optimization

The individual parameters are entered manually during the manual optimization procedure. Anautomatic optimization, determination of the number of revolutions or a test run do not take place. Theverification of the detection must take place in the measurement mode.

1. Enter the alphanumeric materials number with the arrow keys in the spaces of the 8-digit field andconfirm with ENTER. However this entry is not compulsory.

2. Enter the tube diameter with the arrow keys and confirm with ENTER.

3. Enter the number of revolutions of the tube with the arrow keys and confirm with ENTER(exactly ±2%).

4. Enter the after-run (weld seam positioning) with the arrow keys (relative to the position of thesensor head) and confirm with ENTER.

In this example the after-run is corrected to 115°

P12 Parameter

noof the w.seam right?is the positioning

P12 Parameter

After-run new 115°After-run old 120°

P12 Parameter

After-run 120°Speed 60.0rpm


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5.1 Select with the arrow keys whether a decreased recognition capability should be signaled tothe machine controls (see section "detection capability"). Confirm selection with the ENTER key.

This message enables the PLC the selection, marking and elimination of the tube from theprocess. If correctly positioned tubes are displayed as critical, then the parameter programmingshould be repeated with another tube.

5.2 The threshold for the output "decreased recognition reliability" is adjusted here. The followingthreshold steps are available "very high", "high", "standard" or "very low" for adjustment.In the case of "very high" very small detection variations can lead to the message "criticaldetection" (decreased recognition reliability). On the other hand however it is unlikely that the twowas a difficult to detect weld seam will be associated with the signal "seam (correctly) detected".In the other extreme "very low" it can happen that tubes are incorrectly positioned,without themessage "critical detection" (recognition reliability decreased) is issued.At the beginning of a Teach in of process "normal" should be initially selected as the basicadjustment.On the basis of the positioning results further fine tuning should then be made.

6. The scanning rate for the measuring operation is entered here.

The scanning rate has an influence on the noise suppression during the weld seam detectionoperation.

The following into relationships can be expected:

- Broad weld seams require smaller values (4-6)

- Narrow welding seams (lasers) require values between 6 and 10

- Tube diameter smaller 20 mm require values between 6 and 8

- Values between 4 and 6 suppress fault messages due to scratches on the tube surface

Meaningful values are between 4 and 10. Other adjustments very seldom result in improvements.

P12 Parameter

yesweld seam detectioninform at critical

Note:This menu is only available starting from software version 161.

P12 Parameter

standard (3)

P12 Parameter

(10=standard) 10Scanning rate


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7. With the filter type the following signal filter procedures can be selected.

0 = standard flank 4 = flank extreme

1 = max/min filter 5 = positive amplitude

2 = max/min difference 6 = negative amplitude

3 = absolute value

The following example demonstrates the effect of the individual filters selected.

Standard flank:

Max/min filter:

Min/max difference:

P12 Parameter

standard flanke (0) Filter type

filter

sensor-signal

filter

sensor-signal

filter

sensor-signal


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Absolute value:

Flanke extreme:

Positive amplitute:

Negative amplitude:

Filter

Sensor-Signal

filter

sensor-signal

filter

sensor-signal

filter

sensor-signal


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8. This menu option is available only with the system adjustment "filter optimization manually”.

The strengths of the magnetic field is adjusted here. As a rule it should be adjusted to 100%.Only with tubes with a wall thickness smaller than 1.2 mm a reduction to 50% can be advantageous.The adjustment 30% should not be used.

9. In this menu option the gain of the analog signal is adjusted.This value should be transferred from the automatic parameter optimization. If it is not knowndefault values should be set to 1 or 2.The control unit optimizes this adjustment during themeasuring operation.

Summary:

- 30 measurement programs are available

- each measuring program contains the following parameter adjustments

- parameter program number

- tube diameter

- number of revolutions of the few

- after run (welding seam position)

- ?Aussonderungsschwelle? threshold

- message in case of reduced to recognition reliability (yes/no)

P12 Parameter

100%Magn. field stength

P12 Parameter

1Gain


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8.5 Measurement mode

The measurement mode consists of the selection of the parameter program and the measuringprocedure.

8.5.1 Parameter program selection

There are two alternatives for parameter program selection in the measurement mode:

A At the SND30

1. Place key switch to keyboard ENABLE (LED RUN blinks).

2. SND30 display should be in main menue (press key BACK).

3. Press key M to activate measuring menu.

4. Use arrow keys to select a program previously keyed-in in the parameter program and confirmwith ENTER.If a measurement program without parameters is selected, an error message is displayed.

5. Turning the key switch to the position RUN after the selection of a measurement programactivates the interface to the PLC. The system is now ready for measurement. Operating theSND30 via the keyboard is no longer possible.

B Via the external PLC (not during minimum wiring of the interface)

1. Set the SND30 to the base menu and turn to the key switch to RUN (it may be necessary toturn the key switch to ENABLE, press the BACK key and then turn the key switch back toRUN).

2. Select the measuring program via the interface of the PLC (see Timing Diagram in theAppendix B). If a measuring program is selected which does not containing parameter sets,then an error message is generated. At the same time the input data are not mirrored from IN2to IN6 at the outputs OUT2 to OUT6, thus the unit is not ready for operation (ENABLE).

M12 Measurement G=1

Diameter 50mmDescription M14512

! Attention Error !

tube firstplease teach-in

! Attention Error !

tube firstplease teach-in


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8.5.2 Measurement operation

The measurement operation is controlled via the PLC only. The key switch at the SND30 must be inthe position RUN. A valid parameter measurement program must have been selected. The duration ofthe measu measuring is described in section "Operating Parameters".

1. The measurement procedure is now performed in accordance with the timing diagram in theAttachment B.

2. After the successful weld seam detection the following message appears:

In case of a critical weld seam detection the following message appears:

If the option „reduced detection reliability“ has been selected in parameter programming, then aninterface signal „reduced detection capability“ signal will be issued. (see section "Reliability ofdetection"). This enables the PLC to issue a command to mark the tube and exclude it from furtherprocessing.

Attention!If "no" has been selected in the systems configuration menu "automatic menu selection" then itis necessary to select an existing Parameter program of the SND 30 when recycling power or incase of a brief power failure. See page 29 for adjustment of "automatic menu selection".

8.5.3 Re-Teach (automatic Re Teach via the PLC)

The Re-Teach is available only if it in the systems configuration the "Re-Teach" has been enabled.There are two modes:

1. normalIf a Re-Teach is activated via the the PLC interface, then the control unit determines againthe best scanning rate and the best gain.

2. separateIf a Re-Teach is activated via the PLC interface, then the control unit determines again thenumber of revolutions, the best scanning rate, and the best gain is.

Attention!A Re-Teach without a properly turning tube can lead to an incorrect determination of parameters(RPM's); the weld seam detection process resulting in the faulty detection procedure. The timingdiagram is described in the Appendix.

M12 Measurement G=1


weled seam detected

M12 Measurement G=1



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8.6 Diagnostics and service functions

The diagnostics menue D contains the following 7 sub-menus:

D1 = Systems installation

D2 = System configuration

D3 = Analogboard test

D4 = Tube signal analysis

D5 = Reset all parameter programs

D6 = Tube statistik

8.6.1 D1 - Systems installation

1. Press key D and confirm menu D 1, systems installation with ENTER.

Use arrow keys to select menues D2 to D7 which are used for service purposes. Confirm withENTER to reach Systems Installation.

2. Select language with arrow keys. Confirm with ENTER.

D1 Diagnose

System-Installation

System-Installation

English

8.6.2 D2 - System configuration

The configuration of the system is adjusted here.

Attention!Modifications change the function of the control unit. After input of the password the following displayappears:

This equipment adjustment must be set to "no". A back up memory is not available.

System-Configuration

noBackup-Memory


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Press the the ENTER key to continue.

In this menu option the logic of the inputs is selected. Selections between 24 VDC active (accordingto the timing diagrams) and 0 VDC active are possible.


+24 VDC aktiveInput signals


yesInputs

Power control

Possible adjustments:

yes: The connecting terminal 11 (+24V) and 12 (GND) are monitored for the availability of 24 VDC.

no: The monitoring does not take place.

It is therefore possible to monitor the control cable for a cable break.

The following menu option is for adjusting the logic of the outputs OUT0 to OUT6.

Selections between "+24 VDC active" (according to the timing diagrams) and "0 VDC" active arepossible.

The logic of the output OUT7 and motor relay is determined.

Possible adjustments:+24 VDC active/relay N.O.:The output OUT 7 and the relay work function according to the timing diagrams.

0 VDC active/relay N.C:The output OUT7 and the relay function with inverted switching logic.


+24 VDC aktive(OUT0 to OUT6)

Outputs


+24 VDC aktiveRelay normal open

Motor relay and OUT7


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yes

Power control


yes: The connecting terminal 21 (+24V) und 22 (GND) are monitor for the available in the of 24 VDC

no: The monitoring does not take place

It is therefore possible to monitor the control cable for a cable break.

Attention!In order to use OUT0 to OUT7 an external supply voltage has to be applied to terminal 21 (+24V) andterminal 22 (GND).

The next menu option allows the selection between mm and inch as measurement unit of the tube anddiameter.

The selections of parameter programming are adjusted here.


Dimension diametermm


automaticallyoptimizationParameter


only automatically:For parameter programming only the automatic parameter optimization procedure is available.

automatic/manually:Parameter programming can be selected between manual or automatic parameter optimization.special manual:Same as automatic/manually, however with the additional possibility of adjusting the "magnetizingforce" during parameter programming.

After the adjusted system settl if ing time the following conditions must be fulfilled:

- Sensor must be in the measuring position

- Tube drive must be adjusted to the target number of revolutions

- In case of sensor NS9S and NS12S: The magnetic field must be at full strength


1.0 secrun-in periode

System


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The standard adjustment is 1.0 second. It should be reduced only after consultation with ROLANDELECTRONIC.

After termination of the measuring procedure the magnetic field should be be switched off with a delay.The tube remains positioned on the sensor and cannot not rotate.

The adjusted number of revolutions is used as default value after the deletion of the parameters.


yes: The program which was used last for measurement is stored and been selectedautomatically when reapplying power. The key switch has to be set to "RUN".

no: The control unit remains in the base menu of the applying power and waits for a programselection via the PLC.


yes: The current for the magnetization of the sensor is monitored. If current is interrupted, thecontrol unit displays a fault (only meaningful with NS9S and NS12S).

no: Magnetization of the sensor is not monitored (necessary for optical sensors)

System-Konfiguration

0.0 secswitch off delayMagnetic field

System-ConfigurationDefaultSpeed81.0 rpm


nomenu selection

automatic


yestest sensor cable

Note:If a program change is done very often (i.e. after each measurement),this parameter should be set to "no". Otherwise the life time of theinternal storage unit will be shortened.

This is used to check cable and sensor for defects.


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System-ConfigurationRe-teach

via PLC-inputstandard


normal: Is active with measurement start IN7, then a Re-Teach is performed.(see "8.5.3 Re-Teach")

special: Is active with measuring start IN7, then a special Re-Teach is performed.(see "8.5.3 Re-Teach" )

no: No Re-Teach possible.

The adjusted filter type is used during automatic teach-in.

The following filter types are available for selection:

0 = standard flank

1 = max/min filter

2 = max/min difference

3 = absolute value

4 = Flank extreme

5 = positive amplit.

6 = negative amplit.

Entered here are the necessary changes of the weld seam signal amplitude in order to determine thatthe detected weld seam is correct. If larger changes are detected, the output "decreased recognitionreliability" is activated and the message "critical detection" is issued.

Possible adjustments:Threshold 2:1 1:2: The amplitude can be smaller by the the factor ½, or larger by the factor 2

Threshold 2:1 1:4: The amplitude can be smaller by the the factor ½, or larger by the factor 4

Threshold 4:1 1:4: The amplitude can be smaller by the the factor ¼, or larger by the factor 4


flanke standard(0)(0=standard)

Default filter type


ratio 2:1 1:2weld turn 1 to 2

maximum variation of

Während der Positionierung wird die Konstanz des Schweissnaht-signals überwacht.


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System-ConfigurationMasking of weld seam

for calculation+/- 5%

For the weld seam detection procedure the surrounding environment regarding the weld seam is notincluded in the algorithm. In case of broad weld seams this adjustment should be extended +/- 8%because the system issues the message "critical detection" even with correct weld seam positioning.

The standard adjustment is +/- 5%. For very high requirements the positioning accuracy and goodsignal quality the adjustment shall be set to +/-3%.

8.6.3 D3 - Analog board test

This point refers to testing the analog part of the SND30. At BNC1 a "saw tooth" type signal is issued.The gain can be adjusted for the test. The entered A/D values displayed for diagnostic purposes. Thisvalue should be around 0 (+/-50) with disconnected sensor cable and an gain adjustment of 1-800.

8.6.4 D4 - Tube signal analysis

This analysis serves the purpose of displaying the tube weld seam signal in analog form. An storageoscilloscope should be used for this purpose.This can contribute to the error identification in case offfault the weld seam positioning.

without Filter: the BNC 2 signal is the raw signal

with Filter: the BNC 1 signal is the filtered signal

Analogueboard-TestD/A-Converter 128

Gain 2A/D-Converter -5

BNC1

BNC2

BNCtest receptacle

sensor module


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If the second channel of the oscilloscope is connected simultaneously to the TESTBNC (switchposition 4), then the following signal is can be measured.

Explanation:The signal at the BNC2 is the analog signal. After the High impulse starts in the signal to be measured.The signal at the TESTBNC indicates with short High impulses the position of the detected weld seam.

Explanation:The signal at the BNC1 shows the filtered tube signal . This signal is between 0 and 5 V. The largerthe difference between the level of the weld seam signal (position where short impulses are issued atthe TESTBNC) and the noise signals between weld seam position 1 and 2 is, the better can the weldseam be detected.

BNC 1

TEST BNC

1 revolution

beginning of detection end of detection

weld seam weld seam

beginning of detection end of detection

weld seam weld seam

BNC 1

TEST BNC

1 revolution


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8.6.5 D5 - Reset of program parameters

After input of the password the parameters are reset to the default values.

8.6.6. D6 - Tube statistics

After applying power the control unit starts the statistics regarding the tubes with detected weld seamsand those with critical detection.

This statistics is deleted:

a) by pressing the T key in the menu option above

b) when switching the control unit off; the statistics is also deleted!

Tube statistic

clear with T-keycritical 1weld det. 100


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9. Maintenance

9.1 Control unit

The control unit does not require special maintenance. The positions of the fuses are designated in thesketch:

a) Fuse TR3 1 slow blow for magnetization (sensor)

b) Fuse TR3 200 mAmps. for PLC inputs

c) Fuse TR3 400 mAmps. for PLC outputs

d) 1 Amps. slow blow in case of 230 VAC; 2 Amps. in case of 115 VAC power supply

9.2 Sensor

The sensors are not affected by oil pollution. Chips and shavings should occasionally be cleaned outby using compressed air or by simply wiping off.Adhering chips impair the function of the sensor bearings and the actual sensor element.

9.3 Hardware - Diagnostics

On the back of the enclosure cover is a BNC-receptacle located and a switch with twelve switchingpositions.Signals can be entered into the BNC-receptacle for analysis with an oscilloscope of the various switchpositions.These signals can be used to make a quick evaluation of faults in case of service requirements.For the user the first four switching positions are valuable for measuring the operating voltages.

Switching position 1 +5 VDCSwitching position 2 +15 VDCSwitching position 3 -15 VDCSwitching position 4 Diagnostic signal for signal analysis

The signals of the switching positions 5 - 12 are not assigned.


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9.4 Firmware update

The revised SND30 mainboard offers the feature of firmware update.(new mainboard with BOOT and MENUE key on board)

Required:- SND30- RS232 cable to connect to SND30 terminals 31-34 and to PC- Computer with RS232 interface resp. USB-RS232 converter- Phytec Flash Tools for firmware flashing- Firmware

Procedure:1. Install the flashloader from CD (if not already done).2. Switch-off the supply voltage.3. Connect the RS232 cable to the SND30 terminals 31-34 and to the PC4. Press the BOOT key on the board in the upper section of the unit (see previous illustration)

and keep pressed. Switch-on the supply voltage. Then release the pressed BOOT key.5. Start the „Phytec Flash Tools“ at the PC.6. Confirm with OK.7. Select MINIMODUL 515C and press „connect“. If the board is not found,

select the correct RS232 interface under „Conifig, Protocol, Properties“.8. Select „Download“.9. Select „Erase needed sectors“.10. Set „Bank-Offset“ to „Bank1“.11. Select the download file „V0173“ (example) with „open“.12. Download with „Start“. Await the completion.13. Select „Disconnect“.14. Perform power OFF-ON at the unit.The unit must then power up with the previously loaded version.

9.5 Order data

.on-redrO noitpircseD

03DNS tinulortnoC

S9SN llawebutdnamm052otmm01morfØ-ebutroftnemelerosnesdetroppusgniraeBm5htgneldradnats,S9SNKelbachtiw;mm0.4.xamotssenkciht

21SN llawebutdnamm052otmm01morfØ-ebutroftnemelerosnesdetroppusgniraeBm5htgneldradnats,S9SNKelbachtiw;mm0.3.xamotssenkciht

S9SNK )yriuqninohtgnelrehto(m5htgneldradnats,elbacrosneS

G-S9SNK )noitcennocrosnesrofelcatpecerelgnahtgirhtiw(m5htgneldradnats,elbacrosneS

0079922 rebburMG

4290932 selopcitengamrofmm7x42x9gniraebllabFKS

2280932 tnemelerosnesrofmm7x22x8gniraebllaB


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ATTACHMENT A

A1 Wiring diagram Optocoupler - Interface - Board (Schematic diagram)

8

76

3

5

2

4

1

76

1

2

5

3

4

- Coil

Cable shield

Relay motor

+ Coil

+ 15 V

+ 24 VDC

MotorSwitch

+ 24 VDC

Common

Common

Start measurem. Teach-In Enable

Measurement active

Menue select

Menu select

M1

ENABLE M1

Da

ta I

ND

ata

OU

T

M2

Parameter prog. M2

M4

M4

M8

M8

M16

Reduced detection M16

(Re-teach)

Motor

- 15 V

Measuring signal 2

AGND

Measuring signal 1

R2000 SND30

NS XX

PLC

PLC earth ground

Earth groundR 2000

Central machine ground

Line

GND

RxD

Neutral

TxD

GND+

-

24 VDC


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ATTACHMENT A

A2 Connection Diagram Optocoupler - Interface - Board

Connector Sensor / Sensors

Terminal-no.

12345678

Pin 4Pin 5Pin 1Pin 3Pin 2Pin 6Pin 7n.c.

Function

Sensor Measuring signal 1Sensor Measuring signal 2Sensor +15 VSensor AGNDSensor -15 VSensor + CoilSensor - CoilSensor Cable shield

Inputs

PWRCommon ( - )

IN 0IN 1IN 2IN 3IN 4IN 5IN 6IN 7

Function

Power control (only used when configurated)Common for all inputsStart measurement / Teach-in ENABLEMenu selectM 1M 2M 4 Menu numberM 8 Binary codedM 16(Re-teach)

Specification

+ 24 VDC min. 13VDC max. 30VDC 0 VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC+ 24 VDC min. 13VDC max. 30VDC

OUT PWR L

OUT PWR L

OUT PWR L

OUT PWR L

OUT PWR L

OUT PWR L

OUT PWR L

OUT PWR L

Specification

+ 24 VDC min. 18VDC max. 30VDC 0 VDCU = U - 1 V R

> 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

U = U - 1 V R > 1200 Ohm

Terminal-no.

21222324252627282930

Outputs

PWR-InputCommon ( - )

OUT 0OUT 1OUT 2OUT 3OUT 4OUT 5OUT 6OUT 7

Terminal-no.

31323334

Input

RxDGND

Function

Receiver Input RxD RS 232Receiver Input GND RS 232Transmitter Output GND RS 232Transmitter Output TxD RS 232

Output

GNDTxD

Terminal-no.

3536

Function

230 VAC 80 VA 115 VAC 80 VA

recommended Fuse 1 A Slow blow recommended Fuse 2 A Slow

Function

Power input (+24VDC max.500mA) supplied by CustomerCommon for all outputs and PWR inputMeasurement active

ENABLEParameter programming

Reduced detection reliabilityMotor

SensorConnector

yellowred

whitebrowngreengreypink

blank

Cablecorecolour

Terminal-no.

11121314151617181920

Input power

LineNeutral

Connector Parallel Data Outputs

Connector Serial Interface RS232 (optional )

Connector POWER

Connector Parallel Data Inputs

Terminal-no.

910

max. 250 VAC / 30 VDC / 10 Amps

N.O. if 24 VDC is active / N.C. if 0 V is active(see Systems Configuration page 2)

Relay Motor

Menu selectM 1M 2M 4 Menue numberM 8 Binary codedM 16


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ATTACHMENT B

B1 Timing Diagram Optocoupler- Interface - Board, minimum Interface ConnectionParameter-Programming

t1: Time required by the operator in order to select the parameter program to be programmed (see section 5.3 Parameterprogramming).

t2/t6: Time required by the PLC in order to prepare the tube for parameter programming (Placing tube on the sensor)

t3/t7: < 10 milliseconds.

t4/t8: Time required for auto optimizing routine depending on tube diameter and rotational speed.

t5: User to evaluate positioning (see section 5.3 Parameter programming, point 15).

t9: Point t6 to t8 repeated several times depending on the operation of the SND30.

t10: Parameter programming is completed.

The total time of parameter programming depends on the tube diameter, the rotational speed and the inputs of theparameters.Estimated time is the time required for 25 revolutions.

* The in- and outputs not described here are not required for parameter programming.

** Not necessary or is repeated several times depending on the operation of the SND30.


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ATTACHMENT B

B2 Timing Diagram Optocoupler- Interface - Board, minimum Interface ConnectionMeasurement by external PLC

In order to start measurement with IN0, a valid measuring menue must have been selected (externallyor via the keyboard) and the key switch must be in RUN position.

t1: < 5 milliseconds.

t2: > 10 milliseconds.

t3: Depending on tube diameter and rotational speed.



** This output is used only if the option ”Reduced detection reliability“ (see section 5.3 parameterprogramming, point 8). A high could mean the weld seam has not been positioned properly (seesection 9. Operating parameters, point 6. Reliability of detection).


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B3 Timing Diagram Optocoupler - Interface - Board, Standard Interface ConnectionMeasurement Menue select by external PLC, Menue adress Binary coded.(Strobe-Input IN1, Data-Inputs IN2 to IN6)

To be able to select a Measurement Menu externally, the key-switch must be in position RUN.If a measurement menue has been selected, that was the not pre-programmed, than there will be norelease by ENABLE and the input data IN2 to IN6 will not be mirrowed to the outputs OUT2 to OUT6.On the display a note will appear with the indication of missing parameters.

IN0 and IN1 are edge triggered interrupt inputs. In the standard-configuration, the positive edge is active. Do not activateIN0 and IN1 simultaneonsly. A time gap more than 10 milliseconds has to be provided between two command. IN1 is Strobe-Input for Data-Input IN2 to IN6.

** Signals of the outputs OUT2 to OUT6 have two different functions.By activating Menue select IN1, inputs IN2 to IN6 are mirrowed at the outputs OUT2 to OUT6 in order to monitor correcttransmission.By activating the external control command Start measurement IN0, Status messages and Measurement results arereported. In the standard configuration high level active.

ATTACHMENT B

Parallel Data Inputs

Parallel Data Outputs

IN0

IN1Selection of measuring menu

IN2Binary value 1

IN3 2Binary value

IN4 4Binary value

IN5 8Binary value

IN6 16Binary value

IN7

OUT0Measurement active

OUT1Selection of measuring menu

OUT2 1Binary value

OUT3 2Binary value

OUT4 4Binary value

OUT5 8Binary value

OUT6 16Binary value

OUT7Motor

ca. 25ms ≤ 5 ms

Measurement Start

**

**

**

**

**

≥ 0 ms

M1

M2

M4

M8

M16

M1

M2

M4

M8

M16

Enable


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ATTACHMENT B

B4 Timing Diagram Optocoupler- Interface - Board, Standard Interface ConnectionParameter-Programming

t1: Time required by the operator in order to select the parameter program to be programmed (see section 5.3 Parameterprogramming).

t2/t6: Time required by the PLC in order to prepare the tube for parameter programming (Placing tube on the sensor)

t3/t7: <10 milliseconds.

t4/t8: Time required for auto optimizing routine depending on tube diameter and rotational speed.

t5: User to evaluate positioning (see section 8.4 Parameter programming).

t9: Point t6 to t8 repeated several times depending on the operation of the SND30.

t10: Parameter programming is completed.

The total time of parameter programming depends on the tube diameter, the rotational speed and the inputs of theparameters. Estimated time is the time required for 25 revolutions.


** Not necessary or is repeated several times depending on the operation of the SND30.


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ATTACHMENT B

B5 Timing Diagram Optocoupler- Interface - Board, Standard Interface ConnectionMeasurement by external PLC




t3: Depending on tube diameter and rotational speed.



IN0 and IN1 are edge triggered interrupt inputs. In the standard-configuration, the positive edge is active. Do not activateIN0 and IN1 simultaneonsly. A time gap of more than 10 milliseconds has to be provided between two command. IN1 isStrobe-Input for Data-Input IN2 to IN6.

Signals of the outputs OUT2 to OUT6 have two different functions. By activating Menue select IN1, inputs IN2 to IN6are mirrowed at the outputs OUT2 to OUT6 in order to monitor correct transmission.By activating the external control command Start measurement IN0 Status messages and Measurement results are

reported. In the standard configuration is high level active.


** This output is used only if the option ”Reduced detection reliability“ (see section 5.3 parameter programming, point 8).A high could mean the weld seam has not been positioned properly.


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B6 Timing Diagram Optocoupler- Interface - Board, Standard Interface ConnectionRe-Teach


t1: > 5 milliseconds

t2: < 5 milliseconds

t3: Depending on tube diameter and rotational speed

t4: < 10 milliseconds

t5: > 5 milliseconds

IN0 and IN1 are edge triggered interrupt inputs. In the standard-configuration, the positive edge is active. Do not activateIN0 and IN1 simultaneonsly. A time gap of more than 10 milliseconds has to be provided between two command. IN1 isStrobe-Input for Data-Input IN2 to IN6.

Signals of the outputs OUT2 to OUT6 have two different functions. By activating Menue select IN1, inputs IN2 to IN6are mirrowed at the outputs OUT2 to OUT6 in order to monitor correct transmission.By activating the external control command Start measurement IN0 Status messages and Measurement results are

reported. In the standard configuration is high level active.


** This output is used only if the option ”Reduced detection reliability“ (see section 5.3 parameter programming, point 8).A high could mean the weld seam has not been positioned properly.

OUT0

IN0

Parallel Data Outputs *

Parallel Data Inputs *

Mode

OUT2

OUT3

OUT6

and relay outputterminal 9 and 10High = closedLow = open

t1

t2

t3

t4 t5

Reduced detection reliability

Parameter programming

ENABLE

Measurement active

Measurement start

IN1

IN2

OUT7 Motor

Selection of measuring menu

Re-Teach

Position key switch

Condition for starting adetection cycle from the PLC

Start of Re-Teach

ATTACHMENT B

Roland SND30 Manual

Documents

Transcript of Roland SND30 Manual