Roland R4000 Manual Download

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Weld Seam Detection System R4000 SND40

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Drive monitoring and control of detection reliability

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Industrial standard interfaces for automation

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Graphical user interface with 10 inch touchscreen

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Data backup via USB or Ethernet

Weld Seam Detector SND40

QUICK MENU:

Start-up ........................................... 6

Menu tree ........................................ 6

Operation ........................................

Technical data ................................ 8

Timing diagrams ............................ 1

Order data ....................................... 1

Service ............................................ 1

Troubleshooting .............................

169

for Tubes, Cans and Drums

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For positioning applications

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Material diameters from 5 to 500 m

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Magnetic Leak Flux and Eddy Current

measuring principles

Summary of Contents for R4000

Page 1: ...with 10 inch touchscreen Data backup via USB or Ethernet Weld Seam Detector SND40 QUICK MENU Start up 63 Menu tree 64 Operation 69 Technical data 87 Timing diagrams 143 Order data 167 Service 154 Troubleshooting 169 for Tubes Cans and Drums For positioning applications Material diameters from 5 to 500 mm Magnetic Leak Flux and Eddy Current measuring principles ...

Page 2: ...urer Str 17 DE 75210 Keltern All rights on this document are at Roland Electronic GmbH Reproduction also partly electronical coverage translation transmission to third parties only with our prior permission Subject to change without further notice ...

Page 3: ...f the dB value 23 2 7 Measures for improvement of Weld Seam Detection 25 3 Mounting 27 3 1 Mounting of sensor 27 3 2 Mounting of Eddy Current probes 31 3 3 Mounting the SND40 Control Unit 32 4 Electrical installation 35 4 1 Cables 35 4 2 Mains connection 36 4 3 Connection of PLC 37 4 4 Connecting of sensor 40 4 5 Connecting of probe 40 4 6 Connection schedule Leakage flux sensors 42 4 7 Connection...

Page 4: ...S 95 9 7 Leak flux sensor NS9 GMR S 95 9 8 Combination sensor NS9 EC5x30NT10 100 S 97 9 9 Combination sensor NS9NH EC8x18NT10 100 S 99 9 10 Eddy current sensor EC9 8x60NT10 100 S 101 9 11 Eddy current sensor EC9 8x60NF10 100 S 101 9 12 Leakage flux sensor NS12S 102 9 13 Combination sensor NS12 EC8x80NF10 100 S 102 9 14 Combination sensor NS12 EC8x80NT10 100 S 103 9 15 Combination sensor NS12NH EC8...

Page 5: ...al status 129 10 5 SND40StoreV2 130 10 6 Setting the System Time Date 136 10 7 Calibrating the touchscreen 138 11 Technical records 143 11 1 Timing Diagrams Round material application 143 11 2 Service 154 11 3 Hints on Hardware and Software versions 163 11 4 Other informations 165 12 Order data 167 12 1 Control units 167 12 2 Sensors 167 12 3 Cables Accessories 168 13 Appendix 169 13 1 Checklist f...

Page 6: ... and Drums Safety advice B0059001 Rev 2 3 6 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 5 Komponenten allgemein EG Konformitätserk lärung 115 230V AC 0 mod_1173707333875_501 docx 3827 2 1 ...

Page 7: ...lies with the requirements of the directives listed below Applied Directives 2014 35 EU Low Voltage Directive EN 61010 1 2010 2014 30 EU EMC Directive EN 61000 6 2 2005 AC 2005 EN 61000 6 4 2007 A1 2011 Date of mark s apposition 10 05 2016 Keltern 10 05 2016 Managing Director Place Date Signature Function of the signer The declaration confirms the compliance with the cited directives However it is...

Page 8: ...ubes Cans and Drums Safety advice B0059001 Rev 2 3 8 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 7 Kapitelübe rsicht 01 Siche rheitshinweise 0 mod_1121421059859_501 docx 505 1 1 ...

Page 9: ...ld be observed Only professional electrical tools should be used Note The factory pre settings especially the upper lower limit values have been chosen such that an optimal machine protection is ensured Diverging settings can impair the machine protection Safety advice for persons with cardiac pacemakers Persons with cardiac pacemakers are to stay away from the sensors The strong magnetic electrom...

Page 10: ...tern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 1 3 Fieldbus terminology Within this manual the following Fieldbus specific expressions are used Term used in the manual Fieldbus specific expression Master Scanner Slave Node Baud rate Data rate Bus address Mac ID node address Pos 11 Kapitelübersicht 03 System beschreibung 0 mod_1121421150062_501 docx 507 1 1 ...

Page 11: ...lowing steps are required with which Roland Electronic can provide assistance Feasibility studies on representative samples in the Roland laboratory Review of the requirements of cycle time positioning accuracy and process reliability Conception of the weld seam detection station Once a station is built Roland Electronic can offer support during commissioning of the SND40 In addition services for ...

Page 12: ...ctions 1 the system places the tube into the rotational drive 2 the tube is fixed in the rotating drive for example in a chuck or with cones 3 the rotation device places the sensor on the tube so that the rollers are in contact 4 the SND40 is started via the PLC signal measurement start By this the SND40 activates the drive signal motor and the magnetization 5 after the settling time has expired t...

Page 13: ...contact the Roland laboratory Provide additional necessary information about welding processes materials and post weld treatment maximum cycle time or number of pieces per minute positioning accuracy Set value reliability of detection Set value Roland Electronic provides a Questionnaire to enter all available data 2 3 2 Send tubes during operation Reason new tube dimension or tube type to be intro...

Page 14: ... in dependence of the tube diameter and rotation speed The settling time TS of 1 5 seconds is considered here Fig 2 Duration of weld seam detection in dependency of tube diameter and rotation speed Note Not valid for the type of filter cross correlation To calculate the detection time TD for another settling time TS use following formulas For drives with clamping chucks or cone points N 200 T T S ...

Page 15: ...mula below D A K N D A 750 however 5 rpm and 300 rpm N Rate of tube turns rpm D Tube Diameter mm A Scanning values per cm item in program parameter 5 120 K 1 000 000 There are no restrictions if the rate of tube turns N is within the limits Important During the detecting procedure the rotation rate of the tube must be constant 2 3 6 Speed At friction roller drive the speed of the surface of the pe...

Page 16: ... progress in the welding technology and in the production processes of tubes the detection of weld seams is a constantly increasing challenge Therefore some tubes can be encountered where the weld seams are not reliably detectable Reliable weld seam detection can be affected by a variety of factors such as grooves deviations from concentricity material defects or hard spots in the tube wall from r...

Page 17: ...oise ratio ultra larger 18 dB factor 8 1 extra larger 12 dB factor 4 1 very good larger 6 dB factor 2 1 good larger 2 5dB factor 1 33 1 satisfactory larger 1 1dB factor 1 14 1 If the measured dB value falls below the value for the selected stage the message critical detection is displayed and the signal reduced detection capability is set to sort out the tube Note Setting the sort out threshold to...

Page 18: ...Note Please also refer to chapter 2 7 Measures for improvement of Weld Seam Detection Pos 15 Schweissnaht Geräte SND40 3 System beschreibung Rundkörpe r Wichtige Hinweise 1 mod_1225107989937_501 docx 7683 24333332323 1 2 4 Important notes for machine manufacturers The following components have decisive influence on the function of the system the rotation device for the tube Bending mandrels within...

Page 19: ... the torque so that the tube reaches quickly the nominal speed 2 Servo motor is obligatory for positioning accuracy better than 8 3 If no servo motor use speed controlled motor with precise brake 4 Without speed control dimension the motor drive larger so that dependence on the speed of the engine and transmission temperature is as low as possible 5 Without any speed or brake control the positioni...

Page 20: ... touchdown on tube surface Availability of compensation of mounting tolerances and tube geometry Availability of lateral displacement of the axis Clear view on sensor NS9S mounted with rubber buffers in a tube rotator Fig 4 NS9S Application A stable placement device is considered to be a device which can place the sensor correctly on the tube with a high degree of reproducibility Proven solutions ...

Page 21: ...loading device for the tube Special attention should be paid to the twist safe grip and transport of the tube Reason The achieved positioning accuracy at the measuring point is required at the processing station A poorly designed transporter device causes angular errors of more than 90 Important Comply to positioning accuracy over the entire transportation 2 4 6 Notes on applying eddy current sens...

Page 22: ...r element For other positions the parameter position offset can be adjusted in steps of 1 For commissioning and service of the weld seam detection system the control system needs a separate operating mode for set up and calibration This is to assist with optimizing of programs When setting the operator should have the possibility to load a tube into the turning mechanism to place the sensor onto t...

Page 23: ...at the sensor is working with magnetic fields Safety advice Persons with pacemakers are not permitted to work on the sensor Pos 13 Schweissnaht Geräte SND40 3 System beschreibung Rundkörpe r Planungsinformation 0 mod_1126528190453_6 doc 403 2333333 1 2 6 Details of the dB value For determining the signal to noise ratio the SND40 automatically calculates and displays the dB value of the signal to n...

Page 24: ...d is set The smaller the weld seam width is chosen the harder it is to reach the detection grade threshold for class good But the setting of the weld seam width also affects the positioning accuracy Rule small weld seam high positioning accuracy This coheres with the fact that the likelihood of having similar peaks to those of a weld in this area decreases A signal peak being almost as large could...

Page 25: ...ut If a seam cannot be detected with enough certainty the tube must be sorted out in order to avoid the processing of wrongly positioned seams Eventually after a test with an alternative program on 2 nd location 2 7 1 5 Factors that influence the Weld Seam Characteristic and the Detectability of Weld Seams of tubes Tube material Tubes forming process tube coating Welding technology and welding pro...

Page 26: ...or Tubes Cans and Drums System description B0059001 Rev 2 3 26 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 17 Kapitelübersicht 03 Montage 0 mod_1121421173015_501 docx 508 1 1 ...

Page 27: ...s are intended for the installation of the sensor Thus the sensor adapts to the tube Description For the explanation of principle the sensor is shown here under the tube In the practical case the sensor should be preferably set above the tube 1 Weld seam 2 NS Sensor Fig 6 Mounting of sensor The sensor mounting bracket substantially influences the correct function If the sensor is mounted in a rigi...

Page 28: ...tically It has to be considered that a strong magnetic field is generated while measuring Magnetic steel must not be present within a distance of 5 cm to the sensor head guide rollers of the sensor The same also meets the rear of the material inside of tube It must be free from any metallic matter especially support rollers tapered guidance or mandrels Note In special cases the usage of a mandrel ...

Page 29: ...Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 29 Mounting errors to be avoided under all circumstances WRONG mounting distance existing WRONG mounting not centered or slanting CORRECT mounting Fig 8 Wrong and correct mounting of sensors Pos 19 Schweissnaht Sensoren NS9 NS9 Zeichnung Montage Gumm ipuffe r 0 mod_1127212216218_501 docx 574 3 1 ...

Page 30: ... sides Fig 9 NS9 Rubber mount Pos 20 Schweissnaht Sensoren NS12 NS12 Zeichnung Montage Gummipuffer 0 mod_1127212704421_501 docx 585 3 1 3 1 2 Rubber mount assembly of the NS12 NS24 Eight rubber mounts are contained in the scope of supply In each case four buffers are installed on the narrow sensor sides Note For the NS24 sensor use only the rubber mounts intended for this sensor Refer to chapter 9...

Page 31: ...n flushed standing out mounting can also be done in metallic holders Then care for an utmost large distance between the active side of the sensor and the holder Fig 12 Standing out mounting of EC probes Note When the probe is mounted in a holder made of steel the probe should look of the holder for at least 10 mm This can necessitate that the probe must be protected from damage by additional baffl...

Page 32: ...ounted such it can be monitored and easily operated during production The place where the unit is mounted is to be safely accessible and clearly arranged For service purposes it might be required to open the door from the rear Attention must be paid to this fact when mounting the unit Ideally the unit is mounted at a place from which the sensor can be watched Note The unit must not be mounted with...

Page 33: ...tr 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 33 Source Finow A rather simple solution can be implemented by using a tube with flange plates welded at the ends and thus creating a fixed floor mount Fig 14 Mounting example of the SND40 Pos 23 Komponente n allgeme in Lee rseite 0 mod_1165223317234_501 docx 2343 1 ...

Page 34: ...ubes Cans and Drums Mounting B0059001 Rev 2 3 34 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 24 Kapitelübersicht 04 Elektrische Installation 0 mod_1121421905234_501 docx 509 1 1 ...

Page 35: ...er supply cable and signal cable towards the control unit In order to reduce interferences laying out the SND40 cables within separate EMC cable channels might be required All cables must be professionally laid out Bending radii see suppliers data sheets must be kept to Damages due to wearing buckling must be avoided by circumspective installing Note Care for sufficient strain relief Damaged cable...

Page 36: ...5VV5 F Lapp Oilflex 140 3x1 0 1 5mm or equivalent better is suitable For usage under severe interferences a shielded mains connection cable must be used such as one of the type H05VVC4V5 K Lapp Oilflex 140CY The shielding must then be grounded at the feeding side The cable needs to led in via special EMC cable entries or EMC bulkhead screw fitting Alternatively the shielding can also be connected ...

Page 37: ...25 IN7 26 PLC UPowerOut 13 30V DC 0 5A Ext 24 V supply common connection of all outputs sourcing output 27 Ext 24 V supply 28 Low Uout 4 V Rload 1 2 kOhm High Uout UPowerOut 2 V DC Iout 50 mA Sourcing output OUT0 Function see chart of outputs 29 OUT1 30 OUT2 31 OUT3 32 OUT4 33 OUT5 34 OUT6 35 OUT7 36 Roland CECM18S G green max 20 Vss unloaded Output a Eddy current transmitter 37 yellow Output b Ed...

Page 38: ...AND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 4 3 2 View at terminals Fig 17 SND40 View at terminals Fig 18 Numeration of terminals Pos 28 Schweissnaht Geräte SND40 5 Elektrische Installation Rundkörper Betriebsart Rundkörpe r 0 mod_1143443021421_501 docx 1953 3 1 ...

Page 39: ...ram no M1 M2 M4 M8 M16 1 1 0 0 0 0 2 0 1 0 0 0 3 1 1 0 0 0 31 1 1 1 1 1 Program 0 does not exist Selecting this program will cause an error message Outputs SND40 PLC OUT 0 1 2 3 4 5 6 7 Terminal Function Measurement Start active Test job Start active Ready for operation Teach In active Slippage Fault general Reduced detection capability Motor Function on Program selection Program selection active ...

Page 40: ...ata At the sensor side those cables are equipped with a round plug The other side is prepared with splice ferrules The wires need to be connected to the assigned cable terminals For doing so the terminal strips can be detached Pos 30 Schweissnaht Sensoren Elektrische Installation Sonde nanschluss 0 mod_1143119592375_501 docx 1947 23 1 4 5 Connecting of probe The eddy current probe has a connecting...

Page 41: ...tern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 41 4 5 1 Connecting scheme for eddy current probes Description 1 SND40 control unit 2 Sensor Connection Box SCB EC S 3 Eddy current probe Fig 20 Connecting scheme for eddy current probes Pos 31 Schweissnaht Geräte SND40 5 Elektrische Installation Anschlussplan Streuflussse nsoren 0 mod_1129193874250_501 docx 806 2 1 ...

Page 42: ... 21 Connection schedule for Leakage Flux Sensors Note For cables delivered starting Nov 2014 following applies Contact No 8 might be connected with the cable shield A brown wire might be connected parallel together with a blue wire This will not affect the proper functionality of the cable the sensor or the control unit Pos 32 Schweissnaht Geräte SND40 5 Elektrische Installation Rundkörper Anschlu...

Page 43: ...ors Fig 22 Connection schedule Combination sensors Note For cables delivered starting Nov 2014 following applies Contact Nr 8 might be connected with the cable shield A brown wire might be connected parallel together with a blue wire This will not affect the proper functionality of the cable the sensor or the control unit Pos 33 Schweissnaht Geräte SND40 5 Elektrische Installation Anschlussplan Wi...

Page 44: ...Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 4 8 Connection schedule Eddy current sensors and Encircling coil systems Fig 23 Connection schedule for eddy current sensors and encircling coil systems Pos 34 Schweissnaht Geräte SND40 5 Elektrische Installation Anschlussplan Wirbe lstromsonden 0 mod_1131639945750_501 docx 933 2 1 ...

Page 45: ...ND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 45 4 9 Connection schedule Eddy current probes Fig 24 Connection schedule for eddy current probes Pos 35 Schweissnaht Geräte SND40 5 Elektrische Installation Profibus DP Anschluss 0 mod_1144917172046_501 docx 2051 3 1 ...

Page 46: ...40 EC MF PR Mainboard SND40 View of the Profibus DP module type Anybus S Supplier HMS Industrial Networks For further details about Profibus interface please read chapter Technical data Fig 25 Mainboard Profibus module Connection to the Profibus may only be done by an electrician Note For use as Profibus cable the type Unitronic BUS FD P L2 FIP 1 x 2 x0 64 mm supplier Lapp or an equivalent better ...

Page 47: ...t be switched on View of module with connected cable Allocation of the Profibus plug Color of wire D SUB Name red Pin 3 P B Line green Pin 8 N A Line Shield Enclosure Fig 26 Profibus module cable Factory setting on Profibus module 1 Bus termination downward ON upward OFF 2 Slave address 00 Both turn switches in pos 0 00 means the slave address is determined by the system configuration Fig 27 SND40...

Page 48: ...dule Connection to the ProfiNet bus may only be done by an electrician Note For use as ProfiNet IO cable a commonly used RJ45 Ethernet cable Cat 5e is suitable For usage in severely interference loaded environs a separate shielding might be required View of module with connected cable Allocation of ProfiNet IO socket RJ45 socket on the p c b View Plug side Pin 1 TD Pin 2 TD Pin 3 RD Pin 6 RD Pins ...

Page 49: ...Connection to the CC Link bus may only be done by an electrician View of module with connected cable Allocation of CC Link socket Pin Signal 1 Communication line DA 2 Communication line DB 3 Digital GND DG 4 Shield 5 Frame Ground FG PE Addressing the CC Link module The station number and the baud rate are set in the system parameter of the SND40 Rotary switches on the module are set to 9 by Roland...

Page 50: ...s and Drums Electrical installation B0059001 Rev 2 3 50 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 39 Kapitelübersicht 05 Kommunikation mit der SPS 0 mod_1121421968312_501 docx 510 1 1 ...

Page 51: ...rror messages can also be read 5 1 1 Signal overview Inputs sinking inputs Terminal parallel Byte Bit Fieldbus Name Comment IN0 BIN0 0 Measurement start test job start IN1 BIN0 1 Program selection IN2 M1 only possible via parallel interface Activate by program selection If the program selection is not set the function mentioned without brackets can be activated IN3 M2 IN4 M4 IN5 Reset fault 2 M8 I...

Page 52: ...BOUT0 3 Set up active M2 OUT 4 BOUT0 4 Slippage weld seam detected duration M4 OUT 5 BOUT0 5 General fault M8 OUT 6 BOUT0 6 Reduced detection capability M16 OUT 7 BOUT0 7 Motor Weld seam detected pulse The output OUT4 Weld seam detected permanent is only activated in the system configuration at acknowledge mode Terminal parallel Byte Bit Fieldbus Name Comment BOUT1 0 Ready BOUT1 1 1 7 Not used Ter...

Page 53: ... in the program operating status Automatic Ready and Set up Edit 5 1 3 Input Program selection Via the PLC interface the programs 1 to 31 can be selected binary coded In addition the signals M1 to M16 are used Pattern for the binary coding Program 0 Signals M1 M16 not set this combination is not permitted Program 1 M1 set Program 2 M2 set Program 3 M1 M2 set Program 31 M1 M2 M4 M8 M16 set control ...

Page 54: ...nt start active Indicates that a measurement is active For this purpose the signal measurement start has to be applied at the input An exception is the set up operation Two cases have to be distinguished 1 Control test job PLC Therefore the system parameter testjob control mode must be adjusted to PLC The operator can request the measurement in the set up routine by pushbutton Therefore the keys t...

Page 55: ...uration The output OUT4 Weld seam detected permanent is only activated in the system configuration at acknowledge mode Meaning in the round specimen mode slippage During the measurement slippage was detected Meaning in the flat specimen mode weld seam detected duration A weld seam was detected but not yet acknowledged This takes place via the input weld seam acknowledge 5 1 11 Output General fault...

Page 56: ...r each transmission direction 4 bytes are reserved Master Data direction Input SND40 Byte BIN0 Process channel Byte BIN1 Byte BIN2 Byte BIN3 Master Data direction Output SND40 Byte BOUT0 Process channel Byte BOUT 1 Byte BOUT 2 Byte BOUT 3 Note When configuring the data format attention must be paid to provide consistent data transmission from the PLC Note For CC Link assignment see also chapter 4 ...

Page 57: ...0 Bus Offline Overview of bus messages Message Explanation Boundary condition Without Fieldbus interface In the system configuration the parameter Fieldbus is set to OFF INIT Phase during the start up of the control unit the interface is prepared for operation Parameter Fieldbus is ON and Slave address is valid Bus offline The Fieldbus interface is in a fault condition or out of order or no Fieldb...

Page 58: ...d baud rate Depending on the type of fieldbus the valid range of values is different Note The range of values is not checked by the SND40 during the input Example with Fieldbus interface in the Profibus DP version Fieldbus address 1 here the address 1 is entered Addressing the ProfiNet module The MAC ID is hardware preset and cannot be set changed It will be displayed in the hardware info of the S...

Page 59: ...us master supply the tools for integrating the GSD file into the Profibus network For example the Siemens step 7 Tools are suitable for this ROLAND ELECTRONIC does not supply such tools since they must be orientated according to the interface conception of the masters The GSD file is supplied on a CD or can be downloaded from the ROLAND ELECTRONIC homepage 5 2 6 GSD file for ProfiNet IO The GSD fi...

Page 60: ...s off the Data in the user area are not valid Word data area 2 Word Word number Roland Byte Function RWr0 RWr0 0 7 BIN1 RWr0 8 F BIN0 Ready Not used General Control RWr1 RWr1 0 7 BIN3 RWr1 8 F BIN2 Fault identification Active Program number Link Output RWwn PLC Roland R1000 Bit Data area not used System area not used Word data area 2 Word Word number Roland Byte Function RWw0 RWw100 0 7 BOUT1 RWw1...

Page 61: ...ient Time the SND40 must have switched the output OUT7 Motor to LOW If not a fault condition exists Sequence plan for measuring 1 Prepare the tube for measuring 2 Check if signal OUT2 Ready for measuring is HIGH If YES continue If NO the unit is not ready for measuring e g during Teach In 3 Switch the signal IN0 Measuring Start to HIGH and start the tube turn 4 Check if signal OUT7 Motor is HIGH w...

Page 62: ...ev 2 3 62 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Fig 35 Flow chart for tube measurement Pos 42 Komponente n allgeme in Lee rseite 0 mod_1165223317234_501 docx 2343 1 Pos 43 Kapitelübersicht 06 Inbetriebnahme 0 mod_1121421999890_501 docx 511 1 1 ...

Page 63: ...al Tube drive and tube feeder is functional SND40 is mounted Power supply for SND40 is connected and checked for function Sensor cable is laid out connected and checked PLC interface is connected and checked for function LEDs PLC is programmed Setup and Auto operation and checked for function Tube drive is running slip free in Auto mode as well as in Setup mode Suitable tubes in sufficient quantit...

Page 64: ...01 Rev 2 3 64 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 6 2 Menu tree Fig 36 SND40Menu tree Pos 46 Schweissnaht Geräte SND40 7 Inbetriebnahme Rundkörpe r Grundeinstellungen Standardwerte 0 mod_1165994743734_501 docx 2427 233 1 ...

Page 65: ...n 0 X Rotation rate rpm Speed mm s 100 X X Analysis Slip rate 3 0 X X Weld seam width 3 X X Samples per cm 30 X Sensor signal Eddy current X Filter type Flank Extreme SAF7 Absolute X X Detection grade good X X Group Correlation factor Eddy current parameters Low pass Hz Auto High pass Hz Auto Frequency kHz 50 0 X X Phase 0 X Signal type Y component Amount X Input gain dB 20 X Output AC voltage V 2...

Page 66: ...00 X X Analysis Slip rate 3 0 X X Weld seam width 5 X X Samples per cm 30 X Sensor signal Leak flux X Filter type Flank Extreme SAF8 Flank Standard X X Detection grade good X X Group Correlation factor Eddy current parameters Low pass Hz Auto High pass Hz Auto Frequency kHz 50 0 X X Phase 0 X X Signal type Y Component Amount X Input gain dB 20 X Output AC voltage V 20 X DC voltage offset mV X Y st...

Page 67: ...tion rate rpm 300 06 300 06 Min rotation rate rpm 5 00 5 00 Max speed mm s 3000 3000 Min speed mm s 10 10 Angular resolution 1 0 1 0 Interval forming Time Time Time interval 500 ms 500 ms Path interval 500 mm 500 mm Path resolution mm 1000 1000 Fieldbus off off Fieldbus address 1 1 Fieldbus baud rate 115 115 Inputs to logics 255 255 Outputs from logics 255 255 Selection test job KM PLC KM PLC Conf...

Page 68: ...D40 for Tubes Cans and Drums Start up B0059001 Rev 2 3 68 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 48 Kapitelübersicht 09 Betrieb 0 mod_1121422024046_501 docx 512 1 1 ...

Page 69: ...en automatically be loaded This procedure can require up to 30 seconds While the operating software becomes loaded the system will check the voltages cables and sensors If a fault condition is detected here the system will show respective messages Has the operating software been loaded the system automatically switches over to the measurement mode and loads the last used measurement program If ano...

Page 70: ...37 Measuring operation Changes over to the program selection Prints out the signal visualization and a list of the program parameters Changes over to the system parameter selection No key function in this mode Changes over to the statistics function Selects the parameters from the list No key function in this mode Note The result of the weld seam detection is stated in dB signal amplitude within t...

Page 71: ...ist Sets up a new program at the empty program space on which the cursor is just placed Therefor the unit switches over to the mode setup operation No key function in this mode The unit switches over to the mode setup operation Selects the parameters from the list Deletes the program on which the cursor is just placed No key function in this mode Copies the program on which the cursor is just plac...

Page 72: ...test job with test job PLC or test job KM Prints out the signal visualization and the program list Changes on signal type Eddy current to the mode Setup X Y diagnosis Inserts the screen keyboard Stores the settings and returns to the mode Setup Program selection Enters the parameter Starts measuring the turn speed Signals see chapter 11 1 timing diagram speed measurement with test job PLC or test ...

Page 73: ...channel and parameters for controlling the X Y visualization Fig 40 Setup X Y diagnosis Starts the continuous measuring operation Signals see chapter 11 1 timing diagram x y with test job PLC or test job KM Prints out the signal visualization and the eddy current parameters Stops the continuous measuring operation No key function in this mode Changes over to the setup operation mode Selects the pa...

Page 74: ...ccumulation of events since the last reset Fig 41 Statistics function Resets the event table Prints out the signal progression and the parameter list Exits the statistics function No key function in this mode No key function in this mode No key function in this mode Setting the Statistics system parameter to on activates the statistics function Setting the Create SN file system parameter to on act...

Page 75: ... day After 14 days the oldest file will automatically be deleted Statement of signal noise ratio from SND version 1 17 Here all messages are stored which are shown in the status bar Example Weld seam detection good 14dB 10 04 07 09 47 Weld seam detection good 12dB 10 04 07 09 48 PM AC overdrive 10 04 07 09 48 Weld seam detection not possible 0 9dB 10 04 07 09 49 3 Signal1 log Shows the digital val...

Page 76: ...rs Fig 42 System parameters Changes the current parameter settings Prints out the signal progression and al list of the eddy current parameters Shows the hardware parameters No key function in this mode Stores the data of the last measurements signal1 log Selects the parameters from the list Returns to the measuring mode No key function in this mode Pos 57 Schweissnaht Geräte SND40 8 Betrieb Ände ...

Page 77: ...7 8 Creating and editing of measuring programs In the measuring programs the parameters for detecting and positioning the weld seam are stored We recommend to create product specific tool specific measuring programs in order to consider all variables material wall thickness width of weld seam etc which are important for optimal detection For creating editing a measuring program first insert a samp...

Page 78: ...tion 15 With the Activate program key the created measuring program will be activated Pos 59 Schweissnaht Geräte SND40 8 Betrieb Optim ierung der Schweißnahtpositionierung 0 mod_1129107581046_501 docx 783 2 1 7 9 Optimizing the positioning of the Weld seam If no satisfying results can be achieved with the default settings the changing of certain parameters can often cause improvements For more det...

Page 79: ...page Determines the max permissible slip rate variation of turn speed If the unit reports too large slip rates the turn drive system should be inspected first If a larger slip rate must be accepted the resulting worse positioning accuracy must be considered Standard value 3 Value range 0 1 Parameter Filter type In the SND40 the sensor signal becomes digitally filtered The result serves for seam de...

Page 80: ...e interior surface of the material e g jutting out of seam at inside Changing the frequency normally requires adaptation of the parameters Phase and Input gain For most applications a value of 25 100 kHz is optimal Standard value 50 KHz Value range 1 800 kHz Parameter Phase Changing the value turns the eddy current signal at the X Y level it is used for optimizing the signal on use of the signal t...

Page 81: ...ax 49 0 7236 9392 33 81 7 13 Setup Test operation X Y Fig 44 Setup the test operation The function X Y serves for checking and optimizing the program parameter settings on signal type eddy current In this mode the signal is shown two dimensionally At the signal type Y Component only the vertical signal share is considered X share of signal yellow line Y share of signal green line ...

Page 82: ...se differently The noise signal which does not belong to the weld seam becomes horizontally oriented Though now not the full amplitude of the weld seam signal becomes evaluated the signal to noise ratio is remarkably better and thus the positioning is more safely With the following parameters the X Y indication and the X Y gains can be controlled Parameter Scan sections This parameter sets the sto...

Page 83: ... stored Error in Flash Change KM hardware System configuration was not loaded Error in the system file Re enter system parameters or change KM hardware Unable to copy program File already existing insufficient memory space or error in Flash Delete unused files check name Unable to store program File already existing insufficient memory space or error in Flash Delete unused files check name No acti...

Page 84: ...gnized Apply 24 V replace PM hardware PM Sensor cable error 13 Sensor not connected sensor cable defective Connect sensor SPS Selected program number 0 is invalid 14 Program no 0 selected Select valid program PM transmit buffer overflow 95 Communication module does not react or is too slow Check RS232 connection Hardware error PM AC overdrive 16 AC gain is too large Adjust gain Reduce output volta...

Page 85: ...bility of Weld Seams and chapter 13 1 Checklist 8 2 Creation of a sample tube We recommend creating a sample tube for better delimitation of possible occurring problems Archive each type of tube an label it as follows Tube Type Program number Detection result dB ________ dB Date If the detection quality becomes in the course of operation significantly bad i e the number of outputs critical detecti...

Page 86: ... and Drums Fault messages causes and remedies B0059001 Rev 2 3 86 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 67 Kapitelübersicht 02 Te chnische Daten 0 mod_1121421119875_501 docx 506 1 1 ...

Page 87: ... 40 C operation Further characteristics Embedded PC with Windows CE operating system for user interface Real time computer ARM7 for detection and positioning Programming and operation via 10 Touchscreen 31 programs selectable via parallel interface field bus interface 8 potential free optocoupler inputs 24 V DC with common ground potential sinking inputs Specification min switching voltage HIGH 13...

Page 88: ... e g HP Deskjet HP5650 hp5652 hp6540 other models must be registered in the operating system for USB stick for software updating and backup of the program data not until distribution with PC assembly NetDCU5 2 approx April 2006 10 Mbit Ethernet interface internal for general system access via TCP IP telnet IP address for Telnet 192 168 100 107 Subnet 255 255 255 000 on delivery IP address for remo...

Page 89: ...nly with the magnetic leakage flux principle The combined unit EC MF represents with its combined sensors the future proof solution for sophisticated Weld Seam Detection The combination sensors are designed for both eddy current and magnetic flux leakage The other two versions EC and MF are for special cases only The matching sensors support only the respective principle A specimen examination in ...

Page 90: ...etizing current for the leakage flux and combination sensors In addition a sensor check signal with current exit 0 20mA can be attached This module is only present with SND40 devices with the numbers MF in the designation 5 without representation Motherboard on which the modules are attached 6 EC The eddy current module is the front end electronics to the eddy current sensor This module is only pr...

Page 91: ... ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 91 9 2 Mechanical drawing control unit SND40 All dimensions are in mm Fig 46 SND40 Mechanical drawing of the unit until 2016 May 380 300 305 12 70 82 4 x 7 4 0 92 5 116 116 33 5 212 5 420 232 5 190 7 340 50 98 25 ...

Page 92: ... 9392 0 Fax 49 0 7236 9392 33 All dimensions are in mm Fig 47 SND40 Mechanical drawing of the unit from 2016 May Pos 72 Schweissnaht Sensoren Sensorbeze ichnung Sensorbe zeichnunge n 0 mod_1129638259156_501 docx 865 2 1 380 12 70 8 2 4 x 7 92 5 116 116 33 5 190 Flanschbohrung oben und unten eine mit Abdeckung Flange holes on top and bottom one with cover 12 240 214 221 99 432 300 ...

Page 93: ...8mm length 80mm Measuring principle 1 NS Seam sensor Standard meas principle leakage flux Measuring principle 2 EC Eddy current Recommended frequency range 10 100 from 10 KHz to 100 KHz Eddy current probe T T type F F type Connection S Plug connection Type of enclosure 9 type 9 12 type 12 Application Round specimen C Coil flat specimen EC9 8x60NT10 100 SC Material of enclosure N Aluminium nickel p...

Page 94: ... 3 0 75 mm is permissible range Pos 77 Schweissnaht Sensoren NS9 NS9 EC8x 60NT10 100 S Technische Daten 0 mod_1121265905687_501 docx 568 2 1 9 5 Combination sensor NS9 EC8x60NT10 100 S Technical data Application Round material ferrous non ferrous tubes Diameter of tube 10 250 mm Wall thickness Up to 3 mm depending on material Measuring principle Magnetical leakage flux eddy current Width of measur...

Page 95: ...aired see also chapter 10 Maintenance Air gap between sensor element and tube surface 0 6 0 65 mm in new condition 0 3 0 75 mm is permissible range Pos 79 Schweissnaht Sensoren NS9 NS9 GMR S Technische Daten 1 mod_1237299036468_501 docx 8288 2 1 9 7 Leak flux sensor NS9 GMR S Special feature GMR sensor element high magnetic resolution for precision steel tubes Technical data Application Round mate...

Page 96: ...DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 9 7 1 Technical drawing NS9 Note When using the supplied rubber mounts the total width extends for 50 mm 25 mm per rubber mount from 165 mm to 215 mm Fig 48 NS9 technical drawing Pos 81 Schweissnaht Sensoren NS9 NS9 EC5x 30NT10 100 S Technische Daten 1 mod_1237298782468_501 docx 8283 2 1 ...

Page 97: ...ux Eddy current high resolution only for non ferrous material relative magnetic Flux 0 Width of measuring patch 2 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP53 Weight 6 6 kg 14 5 lbs Material of enclosure Aluminum nickel plated Sensor cable KNS9S leak flux CECM18S G eddy current Air gap between pole boots and tube surface 0 2 0 25 mm in new condition 0 1 0 35 mm is per...

Page 98: ...v 2 3 98 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Note When using the supplied rubber mounts the total width of 165mm increases by 50mm 25mm per mount to 215mm Fig 49 Dimensional drawing NS9 EC5x30NT10 100 S NS9 EC5x30NF10 100 S_eng wmf ...

Page 99: ... Diameter of tube 10 250 mm Wall thickness Up to 1 5 mm Measuring principle Eddy current with pre magnetization Width of measuring patch 4 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP53 Weight 6 6 kg 14 5 lbs Material of enclosure Aluminum nickel plated Sensor cable KNS9S electro magnet CECM18S G eddy current Air gap between pole boots and tube surface 0 2 0 25 mm in ne...

Page 100: ...3 100 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Note When using the supplied rubber mounts the total width of 165 mm increases by 50 mm 25 mm per mount to 215 mm Fig 50 Dimensional drawing NS9NH EC8x18NT10 100S NS9NH EC8x18NT10 100 S_eng wmf ...

Page 101: ...ide the permissible range the sensor needs to be repaired see also chapter 10 Maintenance Air gap between sensor element and tube surface 0 6 0 65 mm in new condition 0 3 0 75 mm is permissible range Pos 84 Schweissnaht Sensoren NS9 EC9 8x60NF10 100 S Technische Daten 0 mod_1129553399437_501 docx 823 2 1 9 11 Eddy current sensor EC9 8x60NF10 100 S Technical data Application Round material non ferr...

Page 102: ...ew condition 0 3 0 75 mm is permissible range Pos 86 Schweissnaht Sensoren NS12 NS12 EC8x80NF10 100 S Te chnische Daten 0 mod_1128418556515_501 docx 683 2 1 9 13 Combination sensor NS12 EC8x80NF10 100 S Technical data Application Round material ferrous non ferrous tubes Diameter of tube 12 250 mm Wall thickness Up to 4 mm depending on material Measuring principle Magnetical leakage flux eddy curre...

Page 103: ...condition 0 3 0 75 mm is permissible range Pos 88 Schweissnaht Sensoren NS12 NS12NH EC 8x80NT10 100 S Te chnische Daten 1 mod_1237297744421_501 docx 8273 2 1 9 15 Combination sensor NS12NH EC8x80NT10 100 S Special feature extra large width of measuring patch for tubes with rough surface or heterogeneous weld seam Technical data Application Round material ferrous non ferrous tubes Diameter of tube ...

Page 104: ...24 EC18x 185NT10 100 S Te chnische Daten 0 mod_1186991521906_501 docx 4535 2 1 115 33 165 92 175 30 132 5 99 88 35 17 5 26 The fixing screws should NO T be screwed deeper than 10 mminto the plate Otherwise the sensor function could be destroyed Attention Attention Attention b M6 x 10 87 5 c These two screws must not be used or removed A B a Sensor element Magnetic poles d 8 pcs SKF ball bearing 9x...

Page 105: ...ature 10 40 C 50 104 F during operation Class of protection IP54 Weight 63 kg 139 lbs Material of enclosure Aluminum nickel plated Sensor cable KNS9S and CECM18S G Air gap between pole boots and tube surface 0 5 0 55mm in new condition 0 3 0 7mm is permissible range The air gaps must be within the permissible range If the value gets due to wearing outside the permissible range the sensor needs to ...

Page 106: ...or 90 mm 45 mm per mount from 257 mm to 347 mm Description 1 Thread holes M12 for mounting the sensor Do not screw in the mounting screws in for more than 15 mm since otherwise the internal components will be damaged Fig 52 NS24 EC18x185 NT10 100 S Technical drawing NS24 EC18x185 NT10 100 S wmf Pos 92 Schweissnaht Sensoren NS24 NS24 EC30x 185NT10 100 S Te chnische Daten 0 mod_1188219837453_501 doc...

Page 107: ...ition 1 0 2 5mm is permissible range Number of rubber mounts 8 9 18 Cooling water for NS24 EC30 sensors Connections at sensor Connecting material Copper tube Diameter 10mm outer Ø 8mm inner Ø The cooling water for the NS24 EC30 sensors must meet the following specifications TEMPERATURE PRESSURE THROUGHPUT Temperature min 5 C max 30 C at incoming connection Pressure max 2bar Throughput min 5l min H...

Page 108: ...the total width extends for 90 mm 45 mm per mount from 257 mm to 347 mm Description 1 Thread holes M12 for mounting the sensor Do not screw in the mounting screws for more than 15 mm since otherwise the internal components will be damaged Abb 53 NS24 EC30x185 NT10 100 S Technical drawing NS24 EC30x185 NT10 100 S wmf Pos 94 Schweissnaht Sensoren Zubehör Netzteil NT NS S NT NS S 0 mod_1187332877328_...

Page 109: ...rgy it will be controlled by the SND40 system Supply voltage 90 260V AC 50 60Hz Output 60 90 VDC 240 W set to 75 V Fuse protection 3 15 A medium blow 5 20 mm in connecting terminal for mains voltage Startup current 14 A Triggering Opto coupler input for enabling the output voltage Relay input for the selection of magnetizing current valid from serial number C1211 Ambient temperature 0 40 C during ...

Page 110: ... 1 Output for supplying the sensor 2 Input for controlling by the SND40 3 Connecting terminals for the supply voltage mains voltage with built in fuse 3 15 A medium blow Brown L blue N green yellow PE ground Always connect the safety lead PE 4 Adjuster for output voltage behind screw 5 Cable infeed fitting for supply voltage 6 Control connection assignment valid from serial number C1211 Fig 55 Con...

Page 111: ...rds sensor HAN8 Pin 1 15 V bridged Pin 1 15 V Pin 2 15 V bridged Pin 2 15 V Pin 3 AGND bridged Pin 3 AGND Pin 4 Measurement signal bridged Pin 4 Measurement signal Pin 5 Measurement signal bridged Pin 5 Measurement signal Pin 6 coil ENABLE Power supply Pin 6 coil 60 V 90 V DC Pin 7 coil ENABLE Power supply Pin 7 coil 60 V 90 V DC Pin 8 Shield for sensor cable Pin 8 NC Operation For operating the p...

Page 112: ...terial Flat material Diameter of tube unlimited Wall thickness Depending on material Measuring principle Eddy current Arrangement axial Width of track 4 mm Width of measuring patch 6 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 15 kg 0 33 lbs Material of enclosure Stainless steel Sensor cable CECM18S G Sensor Connection Box SCB EC S Description 1 View active ...

Page 113: ...aterial Diameter of tube unlimited Wall thickness Depending on material Measuring principle Eddy current Arrangement axial Width of track 10 mm Width of measuring patch 13 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 2 kg 0 44 lbs Material of enclosure Stainless steel Sensor cable SM18CECM18S GG Sensor Connection Box SCB EC S Description 1 View active area 2 ...

Page 114: ... material Measuring principle Eddy current Arrangement axial Width of track 16 mm Width of measuring patch 20 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 3 kg 0 66 lbs Material of enclosure Stainless steel Sensor cable SM18CECM18S GG Sensor Connection Box SCB EC S Description 1 View active area 2 Direction of material flow 3 Cable plug order no 2277704 1 Vie...

Page 115: ...nt Arrangement radial Width of track 3 mm Width of measuring patch 4 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 15 kg 0 33 lbs Material of enclosure Stainless steel Sensor cable SM18CECM18S GG Sensor Connection Box SCB EC S Description 1 Direction of material flow 2 Sleeve Ø 12 x 1 5 made of INOX 3 View active area 4 Cable plug order no 2277704 All dimensio...

Page 116: ...resolution Arrangement radial Width of track 1 mm Width of measuring patch 1 5 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 15 kg 0 33 lbs Material of enclosure Stainless steel Sensor cable CECM18S G Sensor Connection Box SCB EC S Description 1 View active area 2 Direction of material flow 3 Marking 4 Sleeve Ø 5 x 0 5 made of INOX 5 Cable plug Order no 227770...

Page 117: ...olution Arrangement axial Width of track 1 5 mm Width of measuring patch 2 mm Ambient temperature 10 40 C 50 104 F operation Class of protection IP65 Weight 0 15 kg 0 33 lbs Material of enclosure Stainless steel Sensor cable CECM18S G Sensor Connection Box SCB EC S Description 1 View active area 2 Direction of material flow 3 Marking 4 Sleeve Ø 5 x 0 5 made of Stainless steel 5 Cable plug order no...

Page 118: ...e control unit The cable has a cable socket at the sensor side and open end wires with wire end ferrules at the control unit side Versions of cable KNS9S G straight cable socket at sensor side KNS9S W angled cable socket at sensor side Cable socket at sensor side Harting HAN8 1 white 12 V 2 green 12 V 3 Brown blue AGND 4 yellow Meas signal 1 5 red Meas signal 2 6 grey coil 7 pink coil 8 blank shie...

Page 119: ...must be specified 1 white 12 V 1 white 12 V 2 green 12 V 2 green 12 V 3 brown blue AGND 3 brown blue AGND 4 yellow Meas 4 yellow Meas signal 1 signal 1 5 red Meas 5 red Meas signal 2 signal 2 6 grey coil 6 grey coil 7 pink coil 7 pink coil 8 blank shield 8 blank shield Control unit side Sensor side cable plug 8 7 6 6 7 8 cable socket Harting HAN8 2 1 5 5 1 2 Harting HAN8 3 4 4 3 Fig 65 SKNS8S Cabl...

Page 120: ...IDY TP Bending radius 57 mm laid fixed 150 mm laid flexible Pos 105 Schweissnaht Kabel SM18CECM18S GG 1 mod_1218117114734_501 docx 7253 2 1 9 28 Sensor cable SM18CECM18S GG Usage Connecting the Eddy current sensors as well as the combosensors and the encircling coils to the sensor switch box For using Eddy current probes the Sensor Connection Box SCB EC S must be used in addition The cable has a c...

Page 121: ... sensor and task the PLC must perform an additional program switching on the SND40 This must be considered on planning the arrangement A 24V input serves for controlling the switch over function The sensor cables are connected at corresponding flange sockets The allocated cables SKNS8S and SM18CECM18S GG need to be ordered separately The PLC control cable is connected to a M12 flange socket The co...

Page 122: ...ng scheme Description 1 SPS SND40 SSB SND40 Supply connection 2 KNS9S Cable leakage flux 3 CECM18S G Cable eddy current 4 SM18CECM18S GG Sensor cable eddy current 5 SKNS8S Sensor cable leakage flux Fig 69 SSB SND40 connecting scheme 9 29 3 PLC supply control connection scheme Fig 70 PLC supply control connection scheme SND40 Sensor 1 NS S NS EC8 EC9 Sensor 2 NS S NS EC8 EC9 4 5 SSB SND40 4 5 1 1 2...

Page 123: ...nnection Box SCB EC S This box contains the protective resistor for limiting the transmitter current For the larger combination sensors eddy current sensors and encircling coil sensors the box is not needed The sensor is connected to the box with the cable belonging to the sensor For connecting the box to the control unit sensor switch box the cable CECM18S G is required Fig 71 SCB EC S Pos 108 Sc...

Page 124: ... zinc plated and chromated Hardness 45 5 Shore A All dimensions in mm Fig 72 Rubber mounts Further properties Spring rate compression 180 N mm 1000 lbs in Max compression travel 1 5 mm 0 06 in Max compression force 270 N 60 lbs Spring rate shearing 28 N mm 160 lbs in Max shear travel 3 8 mm 0 15 in Max shear force 110 N 25 lbs Description 1 Compression 2 Shearing Fig 73 Rubber mounts Pos 109 Schwe...

Page 125: ...il Butadien Metal parts zinc plated and chromated Weight approx 0 4 kg 0 88 lbs Hardness 55 5 Shore A All dimensions in mm Fig 74 Rubber mounts Further properties Spring rate compression 600 N mm 3500 lbs in Max compression travel 4 5 mm 0 18 in Max compression force 2900 N 600 lbs Spring rate shearing 120 N mm 700 lbs in Max shear travel 10 mm 0 39 in Max shear force 1200 N 250 lbs Description 1 ...

Page 126: ...or Tubes Cans and Drums Technical data B0059001 Rev 2 3 126 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 110 Kapite lübe rsicht 12 Wartung 0 mod_1121422080015_501 docx 514 1 1 ...

Page 127: ...g or uneven weld seams If pole shoes show visible wearing marks the air gap between pole shoe and tube surface can increase to an inadmissible size Check whether this air gap is within the permissible range Larger air gaps reduce the magnetic flux and can drastically limit the detecting capability of the sensor If the air gap exceeds the permissible range the pole shoes need to be renovated The va...

Page 128: ...ng values because they depend on the mechanical conditions The case when increased wear is existing depends considerably on the individual conditions of application Increased wear Comment Reduced wear Sensor is mounted wrongly or unfavourably Sensor is not correctly aligned The sensor can no longer move suspended in the bracket or runs unevenly on the material The rubber mounts might break The rol...

Page 129: ...nge via PLC The operator can use the keys Print Statistics Program or System Active A detecting job was started by the PLC This operational condition will be automatically terminated as soon as the positioning procedure has been performed When no error condition is existing the condition changes over to Ready Program change A program change was started by the PLC This operational condition will be...

Page 130: ...USB stick and spare fuse inside of unit SND40_USB Stick_und_Sicherung JPG The program replaces the previous backup program of the SND40 device SND40_10Store exe and its English version SND40_10StoreENU exe The programs mentioned above are among others no longer able to backup and restore advanced system configuration and programs with numbers higher than 31 10 5 1 Definitions Term Explanation SND4...

Page 131: ...he buttons for function selection as well as on the right side a brief description of the function in English 10 5 2 Function description The program contains 3 different functionalities which are described in detail below 1 Backup of all system and program configuration files Actually following files are included System cfg SystemEx cfg Program1 cfg Program255 cfg if available 2 Restore the syste...

Page 132: ... SND40StoreV2 is implemented as a stand alone program but can be started directly from the SND40 application without the need to exit it as of version A5 V2 15 of SND40_10 exe Note For all functions the corresponding backup USB stick should already be connected before selecting a function this facilitates the subsequent functional sequence Fig 78 To start the program press the Backup button from t...

Page 133: ...It is also possible to connect the USB stick after starting the function but then it is necessary to wait a few seconds so that the operating system can recognize the USB stick properly After confirming the message the program checks if the USB stick is present If the result is negative you will receive a corresponding error message and the function will be aborted If the USB stick is identified a...

Page 134: ...Geometry According to the parameter PRODGEOM in the file System cfg the suffix Round is used for Geometry in measurement mode Round or Flat in measurement mode Flat This makes it possible to back up from different dates and or systems on a USB stick In case the copy procedure has been successful a message window appears and the numbers of copied files are displayed in the status bar 10 5 3 2 Funct...

Page 135: ...er recovery may still be possible Since the system files usually already exist in the SND40 program directory they are initially renamed to System cfg old or SystemEx cfg old before being restored from the backup directory In case that the copy process has been successful the SND40 device must be restarted to permit the changed files to become active A message dialog window pops up and the number ...

Page 136: ...40 device and saved program files 10 5 3 4 Button Exit By pressing this button the backup program is terminated and the main menu of the SND40 application appears without restarting of the SND40 device Pos 118 Schweissnaht Geräte SND40 10 Wartung Einstelle n der System zeit Datum 2 mod_1322649945826_501 docx 10293 2 1 10 6 Setting the System Time Date The system time date is a component of the Win...

Page 137: ... 0 7236 9392 0 Fax 49 0 7236 9392 33 137 In the Start menu choose under Settings the Control Panel In the Control Panel press or click on the Date Time icon Change the system time date as for any other Windows PC Clicking on the Apply key validates the changes Go back to the Windows Desktop and choose in the Start menu under Programs the Command Prompt Enter ndcucfg ...

Page 138: ...rtung Kalibrieren des Touchscreens 2 mod_1322655735011_501 docx 10299 2 1 10 7 Calibrating the touchscreen Method 1 Calibration via Remote connection Note Establishing a Remote connection is described in this manual section Service function Remote Desktop Establishing a Telnet connection is also described in this manual section Data backup via network item 1 2 At the PC establish Remote connection...

Page 139: ...hone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 139 In the Start menu under Settings choose the Control Panel In the Control Panel press resp click on the Stylus icon Click on the Calibration tab Operate the Recalibrate key Calibrate the display according to the instructions After the calibration process close the calibration window and return to the start screen ...

Page 140: ...ern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Establish a Telnet connection Enter ndcucfg Type the following commands and confirm each by pressing Enter reg save quit The changes are now saved Restart the application Start application SND40_10 1 Open the Windows Explorer by double click the icon My Device Start application SND40_10 2 Please execute FFSDISK ...

Page 141: ...t PC connection but with a external USB keyboard Connect a USB keyboard Terminate SND40 program ESC key The procedure in calibration without PC is almost identical No Telnet connection is required So proceed with the calibration as described in method 1 Instead of a USB keyboard you may also use a USB mouse Finally when you return to the start screen make the taskbar visible Press Run and execute ...

Page 142: ...es Cans and Drums Maintenance B0059001 Rev 2 3 142 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank page Pos 120 Kapite lübe rsicht 11 Technische Unte rlagen 0 mod_1121422102859_501 docx 515 1 1 ...

Page 143: ...age Waiting for PLC start is generated by the SND40 The PLC prepares a tube for detection and gives the signal start test job to the SND40 Key Start Test job Parallel Data Inputs1 IN0 Start Test job Parallel Data Outputs1 OUT2 Ready for measuring OUT5 General fault OUT7 Motor t1 100 ms t2 Time which the PLC needs to prepare a tube for parameter programming Putting on the tube t3 30 ms t4 The durat...

Page 144: ... for PLC start is generated by the SND40 The PLC prepares a tube for detection and gives the signal start test job to the SND40 Key Start Key Stop Parallel Data Inputs1 IN0 Start test job Parallel Data Outputs1 OUT2 Ready for measuring OUT5 General fault OUT7 Motor t1 100 ms t2 Time which the PLC needs to prepare a tube for parameter programming Putting on the tube t3 30 ms t4 The user will termin...

Page 145: ...dy have the tube prepared for rotation The PLC must then accordingly output the signal motor to rotate the tube Key Start test job Parallel Data Outputs1 OUT2 Ready for measuring OUT5 General fault OUT7 Motor t1 100 ms t2 The duration of the test procedure speed measurement is depending on tube diameter and tube rotation rate t3 0 ms The duration of parameter optimization test job speed measuremen...

Page 146: ...D40 key 3 X Y operation started terminated by key operation 4 The PLC must already have the tube prepared for rotation The PLC must then accordingly output the signal motor to rotate the tube Key Start Key Stop Parallel Data Outputs1 OUT2 Ready for measuring OUT5 General fault OUT7 Motor t1 100 ms t2 The user will end the X Y operation with the Stop key t3 System parameter time t4 0 ms The total d...

Page 147: ...asuring with IN0 a valid program must be selected externally or via keyboard and the unit must be in Automatic Ready condition Parallel Data Inputs1 IN0 Measuring Start Parallel Data Outputs1 OUT2 Ready for measuring OUT5 General fault OUT7 Motor t1 20 ms t2 30 ms t3 Depending on tube diameter t4 0 ms t5 30 ms 1 Not mentioned inputs outputs of the interface are not required for measuring 2 A HIGH ...

Page 148: ...y value 8 IN6 Binary value 16 IN7 Parallel Data Outputs1 OUT0 Meas Start active OUT1 Programm active OUT2 Binary value 1 Ready for measuring OUT3 Binary value 2 OUT4 Binary value 4 OUT5 Binary value 8 OUT6 Binary value 16 OUT7 Motor IN0 and IN1 are flank triggered interrupt inputs In the standard configuration the positive flank is active Both inputs must not be activated simultaneously The min ti...

Page 149: ...ata Inputs1 IN0 Start test job Parallel Data Outputs1 OUT0 Start Test job active OUT2 Ready for measuring OUT3 Setup active OUT4 Slippage OUT5 General fault OUT6 Reduced detecting capability OUT7 Motor t1 100 ms t2 Time which the PLC needs to prepare a tube for parameter programming Putting on the tube t3 30 ms t4 Duration of test procedure locating of rotation rate is according to tube diameter a...

Page 150: ...40 The PLC prepares a tube for detection and gives the signal start test job to the SND40 Key Start Key Stop Parallel Data Inputs1 IN0 Start test job Parallel Data Outputs1 OUT0 Start Test job active OUT2 Ready for measuring OUT3 Setup active OUT5 General fault OUT7 Motor t1 100 ms t2 Time which the PLC needs to prepare a tube for parameter programming Putting on the tube t3 30 ms t4 The user term...

Page 151: ... must then accordingly output the signal motor to rotate the tube Key Start test job Parallel Data Outputs1 OUT0 Start Test job active OUT2 Ready for measuring OUT3 Setup active OUT4 Slippage OUT5 General fault OUT6 Reduced detecting capability OUT7 Motor 1 100 ms t2 Duration of test procedure speed measurement depending on tube diameter and tube rotation rate t3 0 ms t4 30 ms The duration of para...

Page 152: ...d terminated by key operation 4 The PLC must already have the tube prepared for rotation The PLC must then accordingly output the signal motor to rotate the tube Key Start Key Stop Parallel Data Outputs1 OUT0 Start Test job active OUT2 Ready for measuring OUT3 Setup active OUT5 General fault OUT7 Motor t1 100 ms t2 The user will terminate the X Y operation with the Stop key t3 System parameter tim...

Page 153: ...upt inputs In the standard configuration the positive flank is active Both inputs must not be activated simultaneously The min time between 2 commands must be 20 ms IN1 is the strobe input for the data inputs IN2 to IN6 The output signals OUT2 to OUT6 have two different functions On externally activating the command Program selection IN1 the input data IN2 to IN6 are mirrored at the outputs OUT2 t...

Page 154: ... 344 1 Entering the tube parameters is tube magnetic set sensor signal to leakage flux check if signal gets better with less magnetization yes yes no no Signal gain 1 magnetic flux 100 1 diameter of tube 2 speed resp 3 rotation rate 4 settling time 5 slippage 6 width of weld seam 7 sort out threshold magnetic flux 100 can weld seam signal easily be evaluated no set sensor signal to eddy current te...

Page 155: ... can be used as these devices Auto MDI X are capable and accept the crossing of the wires The connection is made inside the unit 1 RJ45 socket Fig 80 Remote Desktop connection Further prerequisites 1 On the Host PC the permanent IPV4 address 192 168 100 222 with the sub net mask 255 255 255 0 must be allocated This can also be found in the registry of the SND40 If it should be necessary to set ano...

Page 156: ...ould be visible in the rhost window then the SND 40 software can be remote operated via mouse Script for easy establishing a connection On the Roland website https roland electronic com en service software there is a script to download which starts the connection by double click on the unzipped file 11 2 2 1 Allow rhost exe in the Windows Firewall When starting rhost exe for the first time this me...

Page 157: ...ND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 157 Fig 82 Activate the Telnet Client The activation of the Telnet Client must be performed here Fig 83 Activate the Windows function Telnet Client step1 Fig 84 Activate the Windows function Telnet Client step 2 ...

Page 158: ...m to folder ffsdisk on the SND40 Copy files from the SND40 to the Host PC Enter cd ffsdisk and confirm with ENTER Enter copy cfg Host PC name netdcu and confirm with ENTER this will copy the program files and the system settings Enter copy statistics log Host PC name netdcu and confirm with ENTER this will copy the Log files Now all files should be reported as copied For verification enter dir and...

Page 159: ...sconnect the unit from mains net before performing works on the unit Discharge yourself to ground before touching electronic components Otherwise components could be damaged due to electrostatic charges Typical delivery condition of a SND40 combination unit 1 Leakage flux module 2 Processor module 3 Eddy current module Fig 85 Delivery condition Required tools and material Mid size screw driver Scr...

Page 160: ...g the processor module Change of components 1 Processor module Fig 86 Exchanging the processor module Remove the module carefully Grab the module with both hands index finger and middle finger and carefully lift the module off its socket Insert the new module with the same orientation The pin strip always points towards the unit floor Before inserting the module into the socket take care that on b...

Page 161: ... flux module Loosen all cable plugs and the 4 fixing screws Every screw connection consists of an M3 screw a toothed washer and a flat washer Do not lose any parts danger of short circuit Carefully pull the module at the upper and lower side in order to loosen it from its socket Insert the modified leakage flux module with the same orientation into the socket If the module has been correctly inser...

Page 162: ...sher Do not lose any parts danger of short circuit Note Older units are equipped with a flat plug at the lower right screw joint Do not forget this when mounting the driver module Replace every screw by one of the provided spacer bolt Plug on the cable driver module Take care that every connector at the module gets into the corresponding contact on the eddy current module Fasten the module with th...

Page 163: ... V1 18 13 07 2007 Change Signal noise ratio extended to 40dB resp 40dB Only in combination with PM V14 or later KM V1 19 30 07 2007 Change SnlogFile extended to 14 days Change Storing fault messages of PM in SNLogFile KM V1 20 27 10 2007 Introduction New language Portuguese new MUI file SND40 exe 0416 mui Introduction New SND40Store software KM V1 21 09 01 2008 Introduction New language Spanish ne...

Page 164: ...ratio extended to 40dB resp 40dB PM V15 20 10 2008 Introduction Profinet errors PM V18 01 05 2009 Introduction Profinet error free PM V19 28 01 2010 Works well with new leakage flux module and with old module for NETDCU 10 too PM V20 15 04 2011 Same as V19 Error magnetic field on start up fixed PM V21 08 09 2011 Error message Fan defect error fixe on old leakage flux module PM V22 24 04 2012 New P...

Page 165: ...12 KM version 1 15 very good 18dB 8 1 24dB 16 1 good 12dB 4 1 18dB 8 1 satisfactory 3 5dB 1 5 1 9 5dB 3 1 not possible 3 5dB 1 5 1 9 5dB 3 1 Detection grade for round material Automatic mode Detection grade Signal to noise ratio ultra 18dB 8 1 extra 12dB 4 1 very good 6dB 2 1 good 2 5dB 1 33 1 satisfactory 1 1dB 1 14 1 Typical gain values for NS9 12 EC NT10 100 S sensors Frequency AC gain 6kHz 44d...

Page 166: ... Seam Detection System R4000 SND40 for Tubes Cans and Drums Technical records B0059001 Rev 2 3 166 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 Blank Page ...

Page 167: ...O interface SND40 EC MF CC Unit for Eddy current sensors Eddy current probes Encircling coil systems Leakage flux sensors Combination sensors Controlling via CC Link interface Pos 130 Schweissnaht Geräte SND40 12 Be stelldaten Rundkörpe r Se nsoren 0 mod_1143531082781_501 docx 1977 233333 1 12 2 Sensors 12 2 1 Leakage flux sensors Order designation Comment NS9S Sensor incl 4 pcs rubber mount for F...

Page 168: ...ubehör 0 mod_1143532386031_501 docx 1981 2 1 12 3 Cables Accessories Order designation Comment KNS9S G Cable for connecting the combo and leakage flux sensors to the control unit with straight cable socket standard length 5 m max 25 m KNS9S W Cable for connecting the combo and leakage flux sensors to the control unit with angular cable socket standard length 5 m max 25 m CECM18S G Cable for connec...

Page 169: ...en modified with parameters not fitting to this tube No of non detected weld seams too high Wrong weld seam position with permanently changing positioning 7 Velocity or rotational speed differs from the settings in the program Check this with function Speed Measurement 8 Velocity or rotational speed is not constant due to problems with drive control bad transmission of power from drive to tube red...

Page 170: ... ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 If you are still unable to locate the reason of your problem and you need the support of the manufacturer please send the filled out checklist together with the information on the next page to Roland Electronic ...

Page 171: ...___________________________ Your name __________________________________ Your telephone no __________________________________ Your e mail __________________________________ Manufacturer of machine where SND40 is integrated __________________________________ Please add any comment that may help to identify the error e g since when does error occur how often under which situation new tube coil mater...

Page 172: ...or Tubes Cans and Drums Appendix B0059001 Rev 2 3 172 ROLAND ELECTRONIC GmbH Otto Maurer Str 17 DE 75210 Keltern Phone 49 0 7236 9392 0 Fax 49 0 7236 9392 33 End of Document Pos 135 Komponenten allgemein Leerseite 0 mod_1165223317234_501 docx 2343 1 ...

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Roland R4000, Manual

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