STS400™ Installation Manual
Datalogic Automation S.r.l. Via Lavino, 265 40050 - Monte S. Pietro Bologna - Italy STS400™ Installation Manual Ed.: 03/2013 © 2013 Datalogic Automation S.r.l. ALL RIGHTS RESERVED. Protected to the fullest extent under U.S. and international laws. Copying, or altering of this document is prohibited without express written consent from Datalogic Automation S.r.l. Datalogic and the Datalogic logo are registered trademarks of Datalogic S.p.A. in many countries, including the U.S.A. and the E.U.
CONTENTS REFERENCES .............................................................................................................v Conventions.................................................................................................................. v Reference Documentation ............................................................................................ v Support Through The Website...................................................................................... v Patents...........
3.5.2 3.6 3.7 3.7.1 3.7.2 3.8 3.8.1 3.8.2 RS485 Full-Duplex Interface.......................................................................................34 Auxiliary RS232 Interface ...........................................................................................35 Digital Inputs ...............................................................................................................36 Presence Sensor Input Connections .....................................................................
REFERENCES CONVENTIONS This manual uses the following conventions: "User" refers to anyone using an STS400™ array. "Reader" refers to the Matrix 410™ ATS reader mounted on the STS400™ array. "You" refers to the System Administrator or Technical Support person using this manual to install, configure, operate, maintain or troubleshoot an STS400™ station.
COMPLIANCE For installation, use and maintenance it is not necessary to open the readers. Only connect Ethernet and dataport connections to a network which has routing only within the plant or building and no routing outside the plant or building.
HANDLING The STS400™ is designed to be used in an industrial environment and is built to withstand vibration and shock when correctly installed, however it is also a precision product and therefore before and during installation it must be handled correctly to avoid damage. avoid that the array is dropped. do not fine tune the positioning by striking the array. NO NO do not weld the array into position which can cause electrostatic, heat or reading window damage.
GENERAL VIEW STS400™ 1 2 5 3 4 3 Figure A - STS400-0x8 1 2 3 5 4 3 Figure B - STS400-108 1 2 3 5 4 3 Figure C - STS400-205, STS400-305 viii 1 ID-NET™ Master 3 Mounting Slots (4) 2 ID-NET™ Slaves 4 Positioning Slot 5 Reading Windows
INTRODUCTION 1 1 INTRODUCTION 1.1 STS400™ - SOLUTION FOR TIRES SORTING STS400™, which means Solution for Tires Sorting, is a solution designed to be easily integrated into a sorting system for reading barcodes on the tires. STS400-005 Reading Station Tire Sorting Station The solution, made up of an array of Matrix 410™ ATS readers has been studied to be a premounted, pre-configured system entirely validated at the factory, in order to be quickly and easily installed by any technician.
STS400™ INSTALLATION MANUAL 1 1.2 TERMINOLOGY The manual will refer to some technical terms when explaining how to choose and install the STS400™. The following table will list the most used. Code Resolution Code Resolution is the width of the narrowest module (element) in a barcode, usually expressed in millimeters. It is also commonly expressed in mils, (thousandths of an inch). DOF DOF stands for Depth Of Field and it indicates the range (distance from the reader) where the barcode can be read.
INTRODUCTION 1 1.3 STS400™ FEASIBILITY REQUIREMENTS In order to make the best STS400™ solution choice which fits the application needs, some basic information is required. Highest Application Code Resolution: this data is fundamental for choosing the STS400™ model. This information must be the minimum barcode module among all the barcodes to be read in the application. STS400™ is supplied for two nominal resolutions: High Resolution, resolution between 0.25 mm (10 mils) and 0.
STS400™ INSTALLATION MANUAL 1 Conveyor Operating Width: This is the effective operative width where the tires can run: Operating Width Maximum Application FOV: This data is the maximum reading width where a barcode can be found by the STS400™. Because the barcode is located on or next to the Bead of the tire, the barcode will never be found at the edges of the Conveyor Operating Width.
INTRODUCTION 1.3.1 1 Extracting Tire Size From Tire Sidewall Markings The best way to find out your tire size is to actually look at the tire sidewall. As you can see in the figure below, there is generally a lot of different information on the tire; however, for our purpose, we just need 3 pieces of information: 1. Tire Width: the “215” designation states the Width of the tire in millimeters at the widest point from sidewall to sidewall when mounted on the correct wheel. 2.
STS400™ INSTALLATION MANUAL 1 1.4 STS400™ MODEL DESCRIPTIONS Once the main specifications have been collected, it’s possible to choose the STS400™ model which best fits the application according to the following rules: Highest Application Code Resolution STS400™ Nominal Code Resolution Maximum Application DOF STS400™ Nominal DOF Maximum Application FOV STS400™ Nominal Horizontal FOV The models differ by Application Type, Code Resolution, and number of readers.
INTRODUCTION 1 DC Supply Current Max @ 24 V ± 10% Model Peak Supply Current Max @ 24 V ± 10% Suggested Power Supply: PWR-120 or PG-120-K0x Bottom Reading Solution STS400-205 STS400-206 1.03 A 1.23 A 5.4 A for 2.8 ms 5.4 A for 2.8 ms 1.06 A 1.27 A 5.4 A for 3.1 ms 5.4 A for 3.1 ms Hook Chain (Side) Reading Solution STS400-305 STS400-306 Suggested Power Supply: PWR-240 Top Reading Passenger Car/Light Truck Solution STS400-0X5 STS400-0X6 STS400-0X7 STS400-0X8 1.13 A 1.35 A 1.58 A 1.80 A 5.
STS400™ INSTALLATION MANUAL 2 2 INSTALLATION 2.1 STS400™ SUPPORTING FRAME STS400™ has been optimized to be mounted on aluminum profiles. A frame made up of aluminum profiles allows the easiest and fastest mounting, and in most cases is the best choice. However, STS400™ can also be mounted on different supports like a fixed column.
INSTALLATION 2.1.1 2 Frame Width The frame Width has to be calculated according to the distances shown in the following figure: STS Main Plate Dimensions STS Main Plate Max Side Room Max Side Room STS400-xx7 and -xx8 = 1065 mm (41.9 in) STS400-xx5 and -xx6 = 785 mm (30.9 in) Safe Conveyor Width Safe W The Safe clearance between the frame and the conveyor sides has to be chosen according to the Maximum Side Room available. It is suggested to always keep at least of 200 mm of Safe clearance.
STS400™ INSTALLATION MANUAL 2 2.1.3 Frame Height This is the dimension most influenced by the STS400™ model.
INSTALLATION 2 Finally the frame Height (H) can be calculated by the following formula: H = Conveyor Height + Wmin + Max Reading Distance + STS400 Width + Safe Length - Foot Where: Safe Length is an extra length of 50 to 100 mm on the top of the frame, used for fine adjustment at installation time (if needed); Foot is usually considered to be roughly 50 mm: 50 mm 2.1.4 Frame Bill Of Materials We suggest using Bosch aluminum profiles; although any other brand can fully satisfy this purpose.
STS400™ INSTALLATION MANUAL 2 2.2 MECHANICAL DIMENSIONS STS400-005, STS400-205, STS400-305 392.5 [15.45] 140 [5.51] Ø65.0 [Ø2.54] 68.6 [2.70] 20 [0.79] 223 [8.78] 9 [0.35] 32.25 [1.27] 44.75 [1.76] 112.5 [4.43] 89 [3.50] 149 [5.87] 30 [1.18] 785 [30.91] STS400-015 392.5 [15.45] Ø65.0 [Ø2.54] 110 [4.33] 20 [0.79] 223 [8.78] 9 [0.35] 44.75 [1.76] 172.5 [6.79] 55 [2.17] 12 149 [5.87] 89 [3.50] 30 [1.18] 785 [30.
INSTALLATION 2 STS400-105 140 [5.51] 68.6 [2.70] Ø100.0 [Ø3.94] 20 [0.79] 9 [0.35] 223 [8.78] 241 [9.48] 44.75 [1.76] 112.5 [4.43] 32.25 [1.27] 392.5 [15.45] 89 [3.50] 176 [6.93] 30 [1.18] 785 [30.91] STS400-006, STS400-206, STS400-306 392.5 [15.45] 140 [5.51] Ø65.0 [Ø2.54] 20 [0.79] 223 [8.78] 9 [0.35] 32.25 [1.27] 44.75 [1.76] 42.5 [1.67] 149 [5.87] 89 [3.50] 30 [1.18] 785 [30.
STS400™ INSTALLATION MANUAL 2 STS400-016 392.5 [15.45] Ø65.0 [Ø2.54] 110 [4.33] 20 [0.79] 223 [8.78] 9 [0.35] 44.75 [1.76] 117.5 [4.63] 89 [3.50] 149 [5.85] 30 [1.18] 785 [30.91] STS400-106 140 [5.51] Ø100.0 [Ø3.94] 20 [0.79] 9 [0.35] 223 [8.78] 241 [9.48] 44.75 [1.76] 42.5 [1.67] 32.25 [1.27] 392.5 [15.45] 785 [30.91] 800 [31.
INSTALLATION 2 Ø65 [Ø2.54] 140 [5.51] 20 [0.79] 9 [0.35] 223 [8.78] 182.5 [7.18] 70 [2.76] 44.7 [1.76] 532.5 [20.96] 32.2 [1.27] STS400-007 89 [3.50] 149 [5.87] 30 [1.18] 1065 [41.93] Ø65 [Ø2.54] 110 [4.33] 20 [0.79] 9 [0.35] 223 [8.78] 257.5 [10.14] 55 [2.17] 44.75 [1.76] 532.5 [20.96] 32.25 [1.27] STS400-017 1065 [41.
STS400™ INSTALLATION MANUAL 2 Ø100 [Ø3.94] 20 [0.79] 9 [0.35] 140 [5.51] 223 [8.78] 241 [9.48] 182.5 [7.19] 70 [2.76] 44.75 [1.76] 532.5 [20.96] 32.25 [1.27] STS400-107 1065 [41.93] 89 [3.50] 176 [6.93] 30 [1.18] 1072 [42.22] Ø65 [Ø2.54] 9 [0.35] 20 [0.79] 44.75 [1.76] 532.5 [20.96] 140 [5.51] 223 [8.78] 42.5 [1.67] 32.25 [1.27] STS400-008 16 149 [5.87] 89 [3.50] 30 [1.18] 1065 [41.
INSTALLATION 2 147.5 [5.81] Ø65 [Ø2.54] 20 [0.79] 9 [0.35] 223 [8.78] 110 [4.33] 44.75 [1.76] 532.5 [20.96] 32.25 [1.27] STS400-018 1065 [41.94] 20 [0.79] 44.75 [1.76] Ø100 [Ø3.94] 9 [0.35] 140 [5.51] 532.5 [20.96] 223 [8.78] 241 [9.48] 42.5 [1.67] 32.25 [1.27] STS400-108 1065 [41.93] 176 [6.93] 89 [3.50] 30 [1.18] 1080 [42.
STS400™ INSTALLATION MANUAL 2 2.3 MOUNTING DISTANCE (DOF) 2.3.1 STS400-005, STS400-006, STS400-007, STS400-008 890 mm (35 in) Largest Tire Max. 250 mm (9.8 in) Smallest Tire Conveyor 2.3.2 STS400-015, STS400-016, STS400-017, STS400-018 710 mm (28 in) Largest Tire Max. 200 mm (7.
INSTALLATION 2.3.3 2 STS400-105, STS400-106, STS400-107, STS400-108 880 mm (34.6 in) Largest Tire Max. 400 mm (15.7 in) Smallest Tire Conveyor 2.3.4 STS400-205, STS400-206 Conveyor 317 mm (12.5 in) min nominal DOF DOF range = 317 mm (12.
20 Hook Chain Max. 155 mm Max. (6.1 in) 2.3.5 Smallest Tire Largest Tire 405 mm (15.
INSTALLATION 2 2.4 SUPPORTING PROFILE HEIGHT ADJUSTMENT The frame profile supporting the STS400™ must be positioned at the correct height in order to completely overlap the STS400™ nominal DOF to the application DOF. Note: The application DOF is the difference between the maximum tire width and the minimum tire width.
STS400™ INSTALLATION MANUAL 2 2.5 STS400™ MAIN PLATE MOUNTING Once the supporting profile has been positioned at the correct height we can proceed with the STS400™ mechanical mounting.
INSTALLATION 2 Finally the STS400™ can be mounted onto the station frame. The STS400™ has to be installed onto the station frame in the conveyor direction so that the main plate slot (reader side) is aligned with the plate support assembly. Output Side Rear of Frame Conveyor Direction Slide the main plate slot between the plate support assembly and the supporting profile until it reaches the end. The plate support assembly can fully support the STS400™ weight without human help.
STS400™ INSTALLATION MANUAL 2 Fix the STS400™ using 4 T-bolts and nuts (not supplied) to the supporting profile. When the main plate slot is fully inserted onto the plate support assembly, the 4 mounting slots are aligned with the supporting profile groove: Fixing Slots to Frame Also screw the locknut onto the plate support assembly and tighten it. 2.5.
INSTALLATION 2 = = = = STS400-xx7 centered over conveyor It’s clear that the plate support assembly must have a positional offset from the center.
STS400™ INSTALLATION MANUAL 2 2.6 PRESENCE SENSOR POSITIONING The STS400™ system comes with a pair of photocells that can be used to detect the presence of the tire on the conveyor and trigger the beginning and the end of the reading phase. When used, they must be positioned and mounted at the conveyor belt level depending on the size of the tires that must be handled. Position the presence sensors according to the following procedure: 1.
INSTALLATION 2 In some cases the system can work with only one photocell.
STS400™ INSTALLATION MANUAL 2 Hmin = minimum tire height (lowest profile tire) PS1 = Reading Phase ON/OFF Photocell Tire Height Tire Width Hmin PS1 FOVv @ inst dist Bottom Reading Station with Single Presence Sensor For Bottom Reading Stations installed at the minimum nominal DOF of 317 mm (12.5 in), the Vertical FOV is 145 mm (5.7 in). If allowed by the application, it is suggested to use this value for the conveyor gap in order to maximize the reading area.
ELECTRICAL CONNECTIONS 3 3 ELECTRICAL CONNECTIONS 3.1 STS400™ WIRING DIAGRAM CABLE IN STS400™ KIT CABLE FROM CUSTOMER SIDE PRE-MOUNTED CABLE ON STS400™ Sensor 2 Sensor 1 (optional) CAB-ETH M05 CBX500 ATS-001 M Ethernet Host (RJ45) S S S S S CAB-MS03 CBL-1480-02 24Vdc Serial Host: RS232 Outputs: RS485 (optional) RS422 OUT1 OUT2 Figure 3 - STS400™ Array Wiring CBL-1480-02 to CBX500 ATS-001 CAB-LP-05 to 24 Vdc STS400-1xx models Figure 4 - STS400-1xx Additional Wiring See par. 3.3.
STS400™ INSTALLATION MANUAL 3 3.2 CBX CONNECTION BOX PINOUT The STS400™s all connect to the CBX500 ATS-001 as shown in the previous diagram. The table below gives the pinout of the CBX terminal block connectors.
ELECTRICAL CONNECTIONS 3 3.3 POWER SUPPLY Power is supplied through the CBX500 ATS spring clamp terminal pins as shown in Figure 5: Power Supply VGND V+ in Earth Ground Figure 5 - Power Supply Connections For all STS400™ models the power must be 24 Vdc only. See par. 1.5 for recommended power supplies. It is recommended to connect the array CHASSIS to earth ground (Earth) by setting the appropriate jumper in the CBX connection box. See the CBX Installation Manual for details. 3.3.
STS400™ INSTALLATION MANUAL 3 3.5 MAIN SERIAL INTERFACE CAUTION Do not connect to the Main Interface spring clamp terminals if using Host Interface Modules (Fieldbus) with the CBX500. The signals relative to the following serial interface types are available on the CBX spring clamp terminal blocks. The main serial interface type and its parameters (baud rate, data bits, etc.) can be defined by the user via VisiSet™ software.
ELECTRICAL CONNECTIONS 3.5.1 3 RS232 Interface The RS232 interface can be used for Point-to-Point connections. When it is connected to the host computer it allows both transmission of code data and reader configuration by VisiSet™. The following pins are used for RS232 interface connection: CBX500 ATS TX RX RTS CTS SGND Function Transmit Data Receive Data Request To Send Clear To Send Signal Ground It is always advisable to use shielded cables.
STS400™ INSTALLATION MANUAL 3 3.5.2 RS485 Full-Duplex Interface The RS485 full-duplex (5 wires + shield) interface is used for non-polled communication protocols in point-to-point connections over longer distances (max 1200 m / 3940 ft) than those acceptable for RS232 communications or in electrically noisy environments.
ELECTRICAL CONNECTIONS 3 3.6 AUXILIARY RS232 INTERFACE The RS232 auxiliary interface is available for Point-to-Point connections. When it is connected to the host computer it allows both transmission of code data and reader configuration by VisiSet™. The parameters relative to the aux interface (baud rate, data bits, etc.) as well as particular communication modes such as LOCAL ECHO can be defined through the Communication folder of the VisiSet™ utility program.
STS400™ INSTALLATION MANUAL 3 3.
ELECTRICAL CONNECTIONS 3.7.1 3 Presence Sensor Input Connections CAUTION Power is available directly to the Input Device, independently from the Power Supply Switch inside the CBX. The sensors included in the STS400™ have a standard pinout (brown = +Vdc; blue = GND; black = switched) and can be connected to the Trigger and Input 2 as shown in the figures below.
STS400™ INSTALLATION MANUAL 3 3.7.2 Input Connections From PLC Alternatively, the reading system can be controlled by a digital output of a PLC. For this purpose, connect the switched signal and the appropriate reference level as shown in the figures below.
ELECTRICAL CONNECTIONS 3 3.8 DIGITAL OUTPUTS Two optocoupled general purpose outputs are available. The meaning of the two outputs Output 1 and Output 2 can be defined by the user. They are typically used to signal the data collection result. They are also available to the Host (either serial or Fieldbus) to be driven independently. The electrical features of the two outputs are the following: VCE = 30 Vdc max. ICE = 40 mA continuous max.; 130 mA pulsed max. VCE saturation = 1 Vdc max.
STS400™ INSTALLATION MANUAL 3 Output Device Power to Output device Output device Reference Output Signal Figure 18 - Open Collector Output Using STS400™ Power 3.8.2 Output Connections to External Digital Inputs Alternatively, the reading system's digital outputs can be used to control a digital input of another device such as a PLC. For this purpose, connect the switched signal and the appropriate reference level as shown in the figures below.
DISPLAY MENUS 4 4 DISPLAY MENUS NOTE While working on the display the complete reading station is offline. The Offline state means that no readings are performed, no data is transmitted to the PLC and any connection to WebSentinel will be lost. The display menus allow you to: change the messages on the display (View), perform backup and restore, and reset the counters. If the reading station is turned on and the system is ready, the master-reader shows the most important values on the display.
STS400™ INSTALLATION MANUAL 4 4.1 MAIN MENU To enter the Menu press the Up and Down buttons simultaneously. The menu structure is shown below.
DISPLAY MENUS 4.2.1 4 Standard In this standard view the following content will be shown on the display: Row 1: Reading Result Rows 2 and 3: Code Content Row 4: Number of digits in code and Angle of code in image Good Read Good 1234567890 0010 Dgt 351 Deg No Read No Read Reading ... Reading Active 4.2.2 Network State In this view the state of the slave readers, connected to the ID-NET™ network, can be checked. Below the address number the status of the reader is displayed as a symbol.
STS400™ INSTALLATION MANUAL 4 4.2.3 Reading Mask In VisiSet™, if the Array Layout Monitor parameter in the Display folder is enabled, it changes the appearance of the reading mask. Array Layout Monitor Enabled If the Array Layout Monitor parameter is enabled, on row one, the display shows the result of the reading phase: code content, or read event message. Row two shows the reading phase counter and read rate counting from the last restart of the system.
DISPLAY MENUS 4 Row 1: Last Reading Result Row 2:Statistics Rows 3 and 4: Reading Mask Good Read Master and Slave 1 1234567890 G99% N01% M00% P00% 110000000000000 000000000000000 Good Read Slave 3 and Slave 4 1234567890 G99% N01% M00% P00% 000110000000000 000000000000000 No Read No Read G99% N01% M00% P00% 000000000000000 000000000000000 4.2.4 Init Counters This menu item is only visible if the connected reader is set as master and the Array Layout Monitor parameter is enabled.
STS400™ INSTALLATION MANUAL 5 5 READING FEATURES 5.1 DOF AND FOV DATA 5.1.1 Passenger Car/Light Truck Solutions PN Description Readers Code Resolution Focus Distance qty mm (mils) mm (in) Min Reading Distance mm (in) Max Reading Distance mm (in) Vertical FOV Horizontal FOV @ min distance @ min distance mm (in) mm (in) 937401023 STS400-005 5 937401024 STS400-006 6 937401025 STS400-007 7 937401026 STS400-008 8 1225 (48.
SOFTWARE CONFIGURATION 6 6 SOFTWARE CONFIGURATION 6.1 DEFAULT CONFIGURATION The factory default configuration for the STS400™ is given here for reference: MASTER READER CONFIGURATION The following gives an excerpt of the relevant configuration parameters READING SYSTEM LAYOUT: Device Network Setting = Alone o ID-NET Topology Role = Master (synchronized) Expected Slave Device = xx Link Failure Timeout (ms) = 10000 OPERATING MODES: Operating Mode = Phase Mode Reading Phase ON = Ext.
STS400™ INSTALLATION MANUAL 6 SLAVE READERS CONFIGURATION Same configuration as master except for the following: READING SYSTEM LAYOUT: Device Network Setting = Alone o ID-NET Topology Role = Slave (synchronized) Slave Address = 1,2,3, … OPERATING MODES Acquisition Trigger Delay for SLAVES 1,3, 5,… (odd nodes) Status = Enabled Delay Time (x100us) = 20 Acquisition Trigger Delay for SLAVES 2,4,… (even nodes) Status = Disabled 1D CODES: Code search priority = 45 Degrees (odd nodes) Horizo
SOFTWARE CONFIGURATION 6 Backup Procedure 1. Make sure the Write Protection switch (inside the CBX500 ATS) on the BM100 is unlocked. 2. While VisiSet™ is connected to the Master reader, select the Backup item from the Device Menu in confirm by clicking the Yes button. 3. During the procedure, messages appear on the VisiSet™ terminal window showing the progress and at the end the final results. 4. Set the Write Protection switch on the BM100 to locked. Restore Procedure 1.
STS400™ INSTALLATION MANUAL 7 7 MAINTENANCE 7.1 STS400™: WHAT YOU CAN AND CANNOT DO The STS400™ comes pre-assembled, configured, calibrated and tested. Very few changes may be needed (and are allowed) to adapt the system to the plant operating conditions. Several changes are not permitted and if they are carried out the warranty is automatically void. If necessary, the readers’ configuration can be altered, but this should be done only according to the indications in chapter 6.
TROUBLESHOOTING 8 8 TROUBLESHOOTING 8.1 GENERAL GUIDELINES When wiring the device, pay careful attention to the signal name (acronym) on the CBX100/500 spring clamp connectors (chp. 3). If you need information about a certain reader parameter you can refer to the VisiSet program help files; either connect the device and select the parameter you’re interested in by pressing the F1 key, or select Help>Paramters Help from the command menu.
STS400™ INSTALLATION MANUAL 9 9 TECHNICAL FEATURES ELECTRICAL FEATURES Power Supply Voltage Consumption Communication Interfaces Main - RS232 - RS485 full-duplex Auxiliary - RS232 ID-NET™ Ethernet Inputs Input 1(External Trigger) and Input 2 Max. Voltage Max. Input Current Outputs Output 1 and Output 2 VOut (ILoad = 0 mA) Max. VOut (ILoad = 10 mA) Max. PD = VOut ILoad Max.
TECHNICAL FEATURES PHYSICAL FEATURES Dimensions: STS400-0x5, -0x6 STS400-105 STS400-106 STS400-0x7, -0x8 STS400-107 STS400-108 Weight: Mounting Plate Reader + Bracket Pre-mounted Cables ID-NET Cables and Terminator QLs 9 785 x 223 x 149 mm (30.91 x 8.78 x 5.87 in.) 785 x 241 x 176 mm (30.91 x 9.49 x 6.93 in.) 800 x 241 x 176 mm (31.50 x 9.49 x 6.93 in.) 1065 x 223 x 149 mm (41.93 x 8.78 x 5.87 in.) 1072 x 241 x 176 mm (42.20 x 9.49 x 6.93 in.) 1080 x 241 x 176 mm (42.52 x 9.49 x 6.93 in.
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