G0017_002_0028

MANUAL ENGLISH VERSION TECHNICAL DOCUMENTATION Thermo Protection Cooling Case TPCC / DM TPCC / T / DM www.psi-technics.com Company Headquarters PSI Technics GmbH Rudolf-Diesel-Str. 21a D-56220 Urmitz, Germany Phone +49 2630 91590 - 0 Fax +49 2630 91590 - 99 info@psi-technics.com www.psi-technics.com/EN/ Copyright and Trademarks c 2007-2016 , PSI Technics GmbH All rights reserved. Copyright All trademarks are the property of their respective owners. Release Notice This is the April 2016 release (Version 3.3) of the TPCC User Manual. It applies to the TPCC/DM, T/DM, CLV and LMS models of PSI Technics’ Thermo Protection Cooling Case (TPCC). The following limited warranties give you specific legal rights. You may have others, which vary from state/jurisdiction to state/jurisdiction. Hardware Limited Warranty: PSI Technics warrants that this TPCC hardware product (the ‘Product’) shall be free from defects in materials and workmanship and will substantially conform to PSI Technics’ applicable published product specifications for a period of one (1) year, starting from the date of purchase. This limited warranty does not apply to software or firmware products. Warranty Remedies PSI Technics’ sole liability and your exclusive remedy under the warranties set forth above shall be, at PSI Technics’ option, to repair or replace any Product that fails to conform to such warranty (‘Nonconforming Product’), or refund the purchase price paid by you for any such Nonconforming Product, upon your return of any Nonconforming Product to PSI Technics, together with a copy of the original proof of purchase, a full description of the application the product is used for as well as a description of the problem. The product must be packaged for safe transportation. PSI Technics GmbH Rudolf-Diesel-Str. 21a D-56070 Urmitz, Germany Phone +49 2630 91590 - 0 Fax +49 2630 91590 - 99 support@psi-technics.com www.psi-technics.com/EN/ Warranty Exclusions and Disclaimer These warranties shall apply only in the event and to the extent that: (i) the Product is properly and correctly installed, configured, interfaced, stored, handled, operated, serviced and maintained in accordance with PSI Technics’ relevant user manual(s) and product specifications, and; (ii) the Product is not modified or misused. The preceding warranties shall not apply to, and PSI Technics shall not be responsible for: defects or performance problems resulting from (i) the combination or utilization of the Product with products, information, data, systems or devices not made, supplied or specified by PSI Technics; (ii) the operation of the Product under any specification other than, or in addition to, PSI Technics’ standard specifications for its products; (iii) the unauthorized modification or use of the Product; (iv) the removal of the product’s serial numbers or the altering, defacing or removal of any other markings or parts of the Product; (v) damage caused by accident, lightning or other electrical discharge, excessive current/voltage or temperature, fresh or salt water immersion or spray; or (vi) normal wear and tear on consumable parts (e.g., batteries). PSI Technics GmbH does not warrant and cannot be held liable for the results resulting from the use of this product. The warranties above state the entire liability of PSI Technics GmbH and your exclusive remedies relating to the performance of the product. Except as otherwise expressly provided herein, the product and accompanying documentation and materials are provided AS-IS and without express or implied warranties of any kind by either PSI Technics or anyone who has been involved in its creation, production, installation or distribution, including but not limited to, the implied warranties of merchantability and fitness for a particular purpose, title and non-infringement. The stated express warranties are in lieu of all obligations or liabilities on the part of PSI Technics arising out of, or in connection with, any products or software. Some states and jurisdictions do not allow limitations on duration or the exclusion of an implied warranty, so the above limitation may not apply to you. Limitation of Liability The entire liability of PSI Technics GmbH under any provision herein shall be limited to the amount that was paid by you for the product. To the maximum extent permitted by applicable law, in no event shall PSI Technics GmbH or its suppliers be liable for any indirect, special, incidental or consequential damages whatsoever, under any circumstances or legal theory relating in any way to the use, quality or performance of products, software and accompanying documentation and materials, (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or any other pecuniary loss, and any claims of third parties), regardless of whether PSI Technics has been advised of any such loss and regardless of the course of dealings which develops between you and PSI Technics. Because some states and jurisdictions do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you. Regardless of the above, if you purchased this product in the European Union, the aforementioned warranty provisions may not apply to you. Please contact PSI Technics GmbH to obtain applicable warranty information. PSI Technics GmbH Rudolf-Diesel-Str. 21a D-56070 Urmitz, Germany Phone +49 2630 91590 - 0 Fax +49 2630 91590 - 99 support@psi-technics.com www.psi-technics.com/EN/ TPCC Professional - User Manual Changes and Revisions Ver. 1.09 1.10 2.00 2.01 2.02 2.03 2.04 3.00 3.10 3.20 3.21 3.22 3.3 Date 02/23/2011 05/09/2011 07/30/2012 08/28/2012 12/28/2012 05/10/2013 06/29/2013 12/11/2013 09/16/2014 11/06/2014 10/21/2015 03/03/2016 04/06/2016 04/06/2016 Table 1: Changes Author J. Geukes A. Neumann M. Speich M. Speich J. Geukes J. Geukes J. Geukes M. Henn G. Holzbach G. Holzbach G. Holzbach G. Holzbach G. Holzbach and Revisions Changes Modification Modification New Version Modification Modification Modification Cable Feed Update Combined version Board Update Error Monitoring Update Modification Modification New Company Structure Version 3.3 Revision J. Geukes J. Geukes M. Niecking J. Geukes J. Geukes J. Geukes J. Geukes J. Geukes J. Geukes J. Geukes J. Geukes G. Holzbach G. Holzbach IV TPCC Professional - User Manual Preface Welcome to PSI Technics Thank you for choosing the PSI Technics Thermo Protection Cooling Case (TPCC). The TPCC Professional is a thermal protection system specifically designed for protecting sensors that are used in high-temperature environments. It was designed for use with a variety of sensors that are used in industrial applications, such as laser distance meters and data light barriers. The TPCC is made of state-of-the-art materials and equipped with temperature controls. It is an extremely powerful system, based on state-of-the-art technology with thermoelectric components. Industrial environments are often subject to very harsh conditions, such as dust, humidity or extreme temperatures. These conditions, however, are rarely considered during the development of sensors and structural components. Excessive temperatures can cause electronic components and sensors to malfunction. Most often, these components and sensors play a critical role in production processes and failures or malfunctions can result in extremely costly outages. PSI Technics addressed this problem by developing the TPCC product family. The TPCC product range comprises powerful solutions that prevent temperature-induced sensor failures. 04/06/2016 Version 3.3 V TPCC Professional - User Manual Table of Contents Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . Preface VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII 1 Introduction 1.1 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TPCC Professional 2.1 2.2 2.3 1 2 General Description . . . . . . . . . . . . . . . . . . . . . . . . 2 2.1.1 Package Contents . . . . . . . . . . . . . . . . . . . . . . 4 2.1.2 Product Specifications . . . . . . . . . . . . . . . . . . . 6 2.1.3 TPCC Front . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1.4 Top View . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1.5 Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.6 TPCC Dimensions . . . . . . . . . . . . . . . . . . . . . 13 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.1 Safety Overview . . . . . . . . . . . . . . . . . . . . . . 15 2.2.2 Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.2.4 TPCC Glass Pane . . . . . . . . . . . . . . . . . . . . . 16 2.2.5 Environmental Specifications . . . . . . . . . . . . . . . 16 2.2.6 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 16 2.2.7 Electromagnetic Interference (EMI) . . . . . . . . . . . 16 2.2.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 17 Mechanical Installation and Alignment . . . . . . . . . . . . . . 18 2.3.1 Mounting the TPCC Using Threaded Holes . . . . . . . 18 2.3.2 Mounting the TPCC Using Clearance Holes . . . . . . . 19 2.3.3 Installing the Upper Housing . . . . . . . . . . . . . . . 20 2.3.4 Aligning the TPCC for Use with Optical Sensors . . . . 20 04/06/2016 Version 3.3 VI TPCC Professional - User Manual 2.4 2.5 2.6 2.7 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.4.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 23 2.4.3 Cable Connections . . . . . . . . . . . . . . . . . . . . . 23 2.4.4 Cable Feeds . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.4.5 Connecting the Cables . . . . . . . . . . . . . . . . . . . 26 2.4.6 Pin Allocation . . . . . . . . . . . . . . . . . . . . . . . 27 2.4.7 Error Monitoring (optional) . . . . . . . . . . . . . . . . 28 2.4.8 Connecting the Solid-state Relay . . . . . . . . . . . . . 29 2.4.9 Installing the Solid-state Relay . . . . . . . . . . . . . . 30 Operating the TPCC . . . . . . . . . . . . . . . . . . . . . . . . 31 2.5.1 SICK DME3000/4000/5000 Distance Meters . . . . . . 32 2.5.2 SICK DS/DT500 Distance Meters . . . . . . . . . . . . 32 2.5.3 SICK DMT-DML Distance Meters . . . . . . . . . . . . 32 2.5.4 SICK DL100/DL100 Hi Distance Meters . . . . . . . . . 32 2.5.5 SICK CLV631/690 Bar Code Scanners . . . . . . . . . . 32 2.5.6 SICK LMS400 Distance Meters . . . . . . . . . . . . . . 32 2.5.7 SICK WL12G Reflex Sensor . . . . . . . . . . . . . . . . 33 2.5.8 SICK Lector 620 Professional / ICR620 Bar Code Reader 33 2.5.9 SICK DT20 Hi . . . . . . . . . . . . . . . . . . . . . . . 33 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.6.1 Troubleshooting the TPCC . . . . . . . . . . . . . . . . 34 Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2 . . . . . . . . . . . . . . . 35 2 . . . . . . . . . . . . . . . 36 Recommended Connectors . . . . . . . . . . . . . . . . . . . . . 37 2.7.1 2.7.2 2.8 R Cable Cross-Section 1.5mm Cable Cross-Section 2.5mm 3 Reader Comment Form 40 4 Notes 42 04/06/2016 Version 3.3 VII TPCC Professional - User Manual 5 Support 43 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5.2 Service and Support . . . . . . . . . . . . . . . . . . . . . . . . 43 6 List of Figures, List of Tables and Appendix 44 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 A Appendix 48 A.1 Appendix - Mounting Instructions (Adapter Plate) . . . . . . . 04/06/2016 Version 3.3 48 VIII TPCC Professional - User Manual 1 1 INTRODUCTION Introduction This user manual describes different models of PSI Technics’ “Thermo Protection Cooling Case” with thermostatic control. Although a variety of sensors can be used with the TPCC, this manual focuses on the use of SICK DMT-DML, DME3000/4000/5000 DL100/100 Hi, DS/DT500, WL12G, R Lector 620/ICR620, CLV631/CLV609, LMS400 and DT20 Hi sensors. 1.1 Overview This technical documentation is an important tool for installing and using PSI Technics’ TPCC Professional System. It is designed for technically trained staff and is aimed at facilitating the installation and use of the system. Warning - A warning indicates situations that could lead to potential damage. Read this information carefully to prevent damage, errors or malfunctions. Prior to installing and using the TPCC, PSI Technics recommends analyzing the environmental conditions at the operating site. To support this process, PSI Technics offers a thermal imaging spot analysis using a thermal imaging camera as well as a long-term temperature analysis that lasts over a period of several days. NOTE - Inspect each shipment immediately upon receipt and report any damages to PSI Technics. 04/06/2016 Version 3.3 1 TPCC Professional - User Manual 2 2.1 TPCC Professional General Description The TPCC Professional System consists of the Thermo Protection Cooling Case. It extends the sensors’ application range to an environmental temperature of 176◦F (+80◦C). The sensor is mounted on adapter plates that are specific to the sensor (as shown in the Appendix, Figures 25-35) and must be installed inside the TPCC Professional housing. The compact form of the TPCC allows for easy installation on site. When the TPCC is operated within the admissible ambient temperature range, the sensor will be kept at a permissible operating temperature at all times. Different models of the TPCC Professional System are available (see Table 2). The appropriate version depends on the type of sensor you are using. The TPCC/T/DM model is used for SICK DMT/DML distance meters. The differentiating feature of the ’T’ model is the front pane that is mounted inside the tube and is tilted along the beam axis. This construction ensures a smooth operation of SICK DMT/DML sensors. The bottom of the tube has a small outlet hole that allows condensation to escape. The tube is integrated into the upper part of the ’T’ model housing. Table 2 below contains an overview of the TPCC models that can be used for the different sensors described in this manual. The glass panel for the sensor assembly is located either at the front or at the top of the corresponding TPCC model housing. 04/06/2016 Version 3.3 2 TPCC Professional - User Manual Table 2: Overview of Sensors and Corresponding TPCC Models Sensor SICK DMT-DML SICK DME3000 / DME4000/DME5000 SICK DL 100/100 Hi SICK DS/DT500 SICK WLG12 R SICK Lector 620 Professional / ICR 620 SICK CLV631/CLV690 SICK LMS400 SICK DT20 Hi 04/06/2016 DM X X T/DM X CLV LMS X X X X X X X Version 3.3 3 TPCC Professional - User Manual 2.1.1 Package Contents The TPCC includes the following standard components: • Lower housing with cooling unit • Sensor-specific upper housing • Adapter plate for mounting the sensor • Sensor mounting screws for adapter plate • Solid state relay (SSR) for wear-free cooling control • Dessicant bag • Different types of cable feeds (4 types) – 1 40 x 40 mm cable feed with large feed-through – 2 20 x 20 mm cable feeds with large feed-through – 1 20 x 20 mm cable feed with small feed-through – 3 20 x 20 mm cable feeds without feed-through NOTE - Please note that the mounting screws for installing the TPCC in the customer’s facility are NOT part of the delivery, since the mounting screws depend on the installation and may vary. However, the TPCC can generally be mounted on the clamping and alignment bracket using three M10 screws (see Figure 9 in section 2.3). 04/06/2016 Version 3.3 4 TPCC Professional - User Manual In addition, the following components can be ordered for a particular sensor: • 24VDC/20 power supply • Circuit breaker • TPCC cable (YSLYCY 7 x 1.5 mm2 ) • Sensor cable • Sensor connectors • Installation kit (includes all required components for operating the TPCC) – Power supply – Fuse – Terminal board – Single-core cable – Grounding bar with mount – Shielding terminal NOTE - If a particular item that you would like to order is not listed in the specifications section or on the fax order form, please send an email to info@psi-technics.com, we will provide the corresponding order details. 04/06/2016 Version 3.3 5 TPCC Professional - User Manual 2.1.2 Product Specifications TPCC Specifications: The protective case for industrial use is made of lightweight material (Polyamide-6) that provides excellent damping and insulation properties. The TPCC provides: • Easy installation and alignment of the Y/Z axes • 24V power supply • Automatic deactivation at excessive temperatures (over-temperature shutdown) • Operating temperature range: -4◦F to 176◦F (-20◦C to +80◦C) R • SKINTOP CUBE Screw-type terminal block cable feeds • Designed for industrial applications • Thermostatic Control • Weight: 15.43 lbs (7 kg) • IP protection: IPX5 when mounted horizontally Available as an option: • Error message in case of over-temperature shutdown, isolated switching contact • Error message when one or both fans are failing, isolated switching contact 04/06/2016 Version 3.3 6 TPCC Professional - User Manual 2.1.3 TPCC Front The main feature at the front of the TPCC/DM is the centered protective glass panel (or the tube mounted in the TPCC/T/DM). The TPCC/CLV, and TPCC/LMS models have a closed front and the glass panel is located at the top of the TPCC housing. The protective glass panel is the opening the sensor uses for data collection and for calculating distances or reading data. The glass panel should be cleaned on a regular basis to avoid measurement errors or error messages. In addition, the sensor’s working range must be taken into account when mounting the TPCC. NOTE - Inspect each shipment immediately upon receipt and report any damages to PSI Technics. 04/06/2016 Version 3.3 7 TPCC Professional - User Manual Warning - During transport, the glass panel of the TPCC/DM, TPCC/CLV and TPCC/LMS models is protected by a cover. This cover must be removed prior to installing the TPCC Professional System. The TPCC/T/DM version does not require a separate protective cover as the housing design provides adequate protection for the glass panel during transport. The air supply holes shown in Figure 5 and the air vent holes shown in Figures 1, 2 and 4 must be kept clean and free of obstructions at all times during operation. Warning - During operation, a laser beam is emitted through the glass panel. To prevent potential eye injuries, never look directly at the glass panel or through it while the device is running. 04/06/2016 Version 3.3 8 TPCC Professional - User Manual Figure 1: TPCC/DM Front Figure 2: TPCC/T/DM Front 04/06/2016 Version 3.3 9 TPCC Professional - User Manual Figure 3: TPCC/CLV & TPCC/LMS Front 04/06/2016 Version 3.3 10 TPCC Professional - User Manual 2.1.4 Top View Figure 4: TPCC/CLV & TPCC/LMS Top View 04/06/2016 Version 3.3 11 TPCC Professional - User Manual 2.1.5 Back Figure 5: TPCC Back - All Models R The SKINTOP CUBE screw-type terminal block cable feeds that supply power to the TPCC and the enclosed sensor are located at the back of the R TPCC housing. The SKINTOP CUBE cable feed system can be customized depending on the number of required cable feeds. Unused terminal blocks must be protected with a blind cap (see Section 2.4.4). The air vent and air supply holes are located underneath the terminal blocks. Warning - The air vent and air supply holes must be kept clean and free of obstructions. Do not place any objects inside these holes. 04/06/2016 Version 3.3 12 TPCC Professional - User Manual 2.1.6 TPCC Dimensions Figure 6: TPCC Back View - All Models Figure 7: TPCC/DM and CLV Models - Side View 04/06/2016 Version 3.3 13 TPCC Professional - User Manual Figure 8: TPCC/T/DM with Tube - Side View An aperture (’A’) in the TPCC/T/DM model with a diameter of 5 mm at the bottom of the tube in front of the glass pane permits condensation to escape, as shown in Figure 8. Warning - Aperture (’A’) should be checked on a regular basis and kept free of obstructions. 04/06/2016 Version 3.3 14 TPCC Professional - User Manual 2.2 2.2.1 Safety Safety Overview Warning - For your own safety, please read the following warnings carefully before using the system. Always keep this manual at hand for easy reference. To prevent personal injuries and property damage, strictly follow all instructions and procedures described in this manual. The system is an electromechanical device and may malfunction. To prevent potential malfunctions, appropriate safety measures must be taken prior to installing and operating the TPCC. This is especially important for systems that are critical for production. Warning - The internal components are sensitive to static electricity. Never modify, disassemble or repair the system yourself. All modifications must be performed by authorized service personnel. Warning - The system must be correctly installed, mounted and connected prior to initial operation. 2.2.2 Cabling Warning - Always turn off the TPCC before connecting or removing any feeds or cables to avoid potential damage. 2.2.3 Transport Warning - Only transport the TPCC inside the specially designed cover. Use the sturdy cardboard cover to transport the TPCC. Proper packaging ensures that the TPCC is protected from damage during transport. 04/06/2016 Version 3.3 15 TPCC Professional - User Manual 2.2.4 TPCC Glass Pane Warning - All TPCC models (except the TPCC/T/DM) have a protective film on both sides of the glass pane. Remove the protective films prior to operating the TPCC. The glass pane of the TPCC/T/DM does not require a protective film as the integrated tube provides sufficient protection. 2.2.5 Environmental Specifications • Operating temperature: -4◦F to 176◦F (-20◦C to +80◦C) • Operating temperature with integrated heating: -40◦F to 176◦F (-40◦C to +80◦C) • Storage temperature: -22◦F to 122◦F (-30◦C to +50◦C) 2.2.6 Power Supply • Rated voltage: 24 VDC • Operating current: 11 A maximum 2.2.7 Electromagnetic Interference (EMI) Electric Welding Warning - Electric welding creates an electromagnetic field. This electromagnetic field induces a strong electromagnetic noise. Remove all TPCC feeds and cable connections prior to performing electric welding close to the device. Warning - Always disconnect the power supply prior to performing any welding on the housing. 04/06/2016 Version 3.3 16 TPCC Professional - User Manual 2.2.8 Maintenance Depending on the operating conditions of the TPCC Professional, the TPCC’s cooling element should be inspected and cleaned every six months. A cooling element that is clogged with dirt can obstruct the airflow and affect the TPCC’s cooling performance. Use canned compressed air with a small air nozzle that can be inserted via the fan vent holes to clean the cooling element. This also ensures that the fans are protected against over-revving that could be caused by a compressed air blast. Warning - Disconnect the TPCC from the power supply prior to performing maintenance on the housing. Warning - Ensure that the fans are working properly after the cooling element has been cleaned. 04/06/2016 Version 3.3 17 TPCC Professional - User Manual 2.3 2.3.1 Mechanical Installation and Alignment Mounting the TPCC Using Threaded Holes 1. The clamping and alignment bracket is already attached to the TPCC. To mount the TPCC with the alignment bracket, drill 3 holes into the mounting surface (diameter (Ø) 8.5 mm) to hold the clamping and alignment bracket (shown in Figure 9). 2. Tap the three drill holes (M10). 3. Insert screws, washers and spring rings (not included) and lightly tighten the screws, as shown in Figure 9. 4. Align the TPCC. 5. After aligning the TPCC, securely tighten the screws with a torque wrench. Figure 9: Mounting the TPCC 04/06/2016 Version 3.3 18 TPCC Professional - User Manual 2.3.2 Mounting the TPCC Using Clearance Holes 1. The clamping and alignment bracket is already attached to the TPCC. To mount the TPCC with the alignment bracket, drill 3 holes into the mounting surface (Ø 10.5 mm) to hold the clamping and alignment bracket (shown in Figure 9). 2. Insert and lightly tighten the screws (1), washers (4), spring rings (5) and nuts (6), as shown in Figure 10 (2=Mounting area, 3=Clamping and alignment bracket). Please note that the mounting components are not included and must be ordered separately. 3. Align the TPCC. 4. After aligning the TPCC, securely tighten the screws with a torque wrench. Figure 10: Mounting the TPCC Using Clearance Holes 04/06/2016 Version 3.3 19 TPCC Professional - User Manual 2.3.3 Installing the Upper Housing After mounting the sensor inside the TPCC according to the mounting instructions provided in Appendix A, the TPCC’s upper housing must be mounted on the lower housing. The screws of the upper housing must first be hand-tightend and then tightened with a torque of 1N m using a torque wrench to ensure that the device is protected to IPX5. Warning - The TPCC is only protected to IPX5 when mounted horizontally. If the TPCC needs to be mounted in a different position an appropriate mechanical protection must be used to protect the air outlet from spray water. 2.3.4 Aligning the TPCC for Use with Optical Sensors Mount the TPCC so that the sensor beam always hits the center of the object or reflector, regardless of the distance from the TPCC. For additional information on aligning the sensor, please refer to the corresponding documentation of the sensor manufacturer. 04/06/2016 Version 3.3 20 TPCC Professional - User Manual 2.4 Wiring General All cables leading from the TPCC Professional system to the temperature controls must be installed safely and securely. Only cables that are appropriate for use with the TPCC Professional system should be connected to the device. Warning - The existing board has been replaced with a new version (Rev. 2). The schematics and wiring information on the following pages refer to this new board. It will be shipped as a default board with all TPCC models starting August 2014. The old and new board versions are shown in the pictures below. For TPCC models that were ordered prior to August 2014 and include an old board version, please use the wiring schematic for the old board in the manual version that was included in your shipment. Figure 11: New Board 04/06/2016 Figure 12: Old Board Version 3.3 21 04/06/2016 +A1 Modified electrical cabinet 0 Version 3.3 Date -SSR1 +3 -4 Name +2 -1 110V Power Supply by Customer / Signal1_+ 2 1 2 Signal2_+ g.holzbach jg Signal2_Output / Signal1_Output 21.10.2015 / / B16A -TPCC_F1 Review Orig. -X1 24V/20A -TPCC_V1 Edited L0 / Date L1 PE / / 1 6 PE Replaced by TPCC U 2 Replaced by SH 4 3 2 1 -X04 SH 6 5 4 3 PE 2 1 -X03 3 4 -TPCC1_W2 LiY - CY 4x0,75 -TPCC1_W1 YSLYCY 7x1,5 -TPCC1 -X1 1 2 +24VDC Terminal Board 6 GND 3 -X3 TPCC wiring EN + Fehlerüberwachung Thermo Protection Cooling Case 5 GND 4 SSR1:+3 5 7 not used P28 1 -Q1 2 max. 100mA over temperatur TPCC1_NC_6 TPCC1_NC_5 SSR1:-1 -X2 8 + = -X2 10 Page Page max. 100mA 11 -Q2 fan error 9 10 9 10 TPCC Professional - User Manual Figure 13 contains a schematic representation of the TPCC Professional wiring. Figure 13: TPCC Professional Wiring 22 TPCC Professional - User Manual 2.4.1 Cables 2.4.2 Power Supply Feed the power supply cable through the cable screw located at the bottom of the back housing. • Recommended cable: YSLYCY 7 x 1.5 mm2 Ensure that the +24 VDC feed has the right polarity to avoid damaging the components. Cable length is limited to 82 ft (25 m). 2.4.3 Cable Connections 1. To connect the cables, remove the top of the TPCC housing. 2. Feed the cables through the screw-type cable feed connections and connect them to the terminal block. For additional information, please refer to sections 2.4.4, 2.4.5, 2.4.6 and 2.4.8 in this manual. 04/06/2016 Version 3.3 23 TPCC Professional - User Manual 2.4.4 Cable Feeds Figure 14: Cable Feeds at the Back of the TPCC Housing R The TPCC models have a modular SKINTOP CUBE cable feed. The 40x40mm gasket must be used for the power supply cable feed. Several gasket inserts for the sensor cable feeds are included in the delivery. Unused feeds must be protected with corresponding blind caps to ensure that the device is protected to IPX5. 04/06/2016 Version 3.3 24 TPCC Professional - User Manual Figure 15: Cable Feeds and Frame Installation Overview R SKINTOP CUBE screw-type terminal block cable feeds consist of two parts (clip modules) that are positioned around the cable and pushed together until the parts click into place. The cable feeds are positioned inside the corresponding frame and secured to the frame with the clamping brackets. To remove the cables, proceed in reverse order. To remove the clip modules from the cable, the holding clips of the clip modules must first be unlatched, then the clip modules must be pulled apart. 04/06/2016 Version 3.3 25 TPCC Professional - User Manual 2.4.5 Connecting the Cables Connecting the Cables to the Terminal Board The terminal board contains the connections for the +24VDC power supply, the GND connector and the switch contact for the solid-state relay (X1, see Figure 16). It also contains the connections for the cooling elements, fans and temperature monitoring (X2, see Figure 16), the optional error outputs, a protective circuit that protects the sensor from transient interference such as surges or bursts, and a separate ground connection (X3, see Figure 16). Figure 16: Terminal Board 04/06/2016 Version 3.3 26 TPCC Professional - User Manual 2.4.6 Pin Allocation Figure 17 shows the terminal board pin allocation. Figure 17: Terminal Board Pin Allocation +24VDC, GND and PE on terminal -X1 are the power supply connections of the TPCC Professional and must be connected according to the diagram shown in Figure 17. Except for the optional error monitoring described in section 2.4.7 the pins on terminal -X2 are connected by PSI Technics. Terminal -X3 is used to ground the TPCC’s aluminum profile. It is connected with the adapter plate mounting screws and does not have to be connected separately. Please note that the labels SSR1, SSR2, and SSR3 refer to the terminal for the solid-state relay. 04/06/2016 Version 3.3 27 TPCC Professional - User Manual 2.4.7 Error Monitoring (optional) The TPCC enables integrated error monitoring for the fans and the overtemperature set point. Potential errors can be read from an isolated switching contact on terminal block X2. In addition, the board has two red indicator LEDs that indicate a fault status. The different switching states are described in the table below. Table 3: Error Monitoring Switching States Error Fan 2 defective Fan 1 defective Fans 1 and 2 defective Over-temperature Output 1 Switched Switched Switched Locked Output 2 Locked Locked Locked Switched LED1 ON ON ON OFF LED2 OFF OFF OFF ON • Error output 1 (terminal X2:11 - X2:10) transmits an over-temperature error. • Error output 2 (terminal X2:2 - X2:1) transmits a failure of one or both fans. If these signals should be monitored by a PLC, please use the connection diagram in Figure 17. 04/06/2016 Version 3.3 28 TPCC Professional - User Manual 2.4.8 Connecting the Solid-state Relay Connect the solid-state relay (SSR) as shown in the following Figure. The SSR LED indicates the SSR operating state. When the LED lights up the SSR output is connected and the TPCC is operating in cooling mode. When the LED is not illuminated the interior temperature of the TPCC is either below the minimum threshold of 86◦F (+30◦C) or above the maximum threshold of 122◦F (+50◦C). The minimum threshold protects the laser distance meter from being cooled down too much; the maximum threshold protects the laser distance meter from overheating. Figure 18: Connecting the Solid-state Relay 04/06/2016 Version 3.3 29 TPCC Professional - User Manual 2.4.9 Installing the Solid-state Relay The solid-state relay should be installed in a freely accessible location within the control cabinet. Use the mounting holes shown in Figure 19 to install the solid-state relay inside the cabinet. Figure 19: Installing the Solid-state Relay 04/06/2016 Version 3.3 30 TPCC Professional - User Manual 2.5 Operating the TPCC The system can be operated once the installation is complete. To guarantee a smooth operation of the TPCC Professional System, the system should be commissioned by authorized service personnel or by specifically trained personnel. Warning - The TPCC models are only protected to IPX5 when mounted horizontally. If the TPCC needs to be mounted in a different position an appropriate mechanical protection must be used to protect the air outlet from spray water. Warning - Prior to operating the TPCC, ensure that all cables are properly connected as shown in the connection diagrams in section 2.4.5. After all of the connections have been checked and are properly connected, the system can be switched on. Warning - To ensure that the device is protected to IPX5 the screws that secure the upper housing to the lower housing must be tightened with a torque of 1N m using a torque wrench. 04/06/2016 Version 3.3 31 TPCC Professional - User Manual 2.5.1 SICK DME3000/4000/5000 Distance Meters When using SICK DME3000/4000/5000 sensors, ensure that the lateral guide plates of the TPCC mount lie flat against the sensor. Mount the sensor according to the instructions in Appendix A, Figures 26 and 25. 2.5.2 SICK DS/DT500 Distance Meters For mounting SICK DS/DT500 sensors, please refer to the instructions in Appendix A, Figure 27. 2.5.3 SICK DMT-DML Distance Meters When using a SICK DMT-DML sensor, blanking should be enabled. Blanking is used to ignore objects that are located directly in front of the sensor to avoid measurement errors that can be caused by dirt on the glass pane and to ensure accurate readings even when the glass pane is slightly dirty. When blanking is enabled, the specified sensor data will be collected at a minimum range of 2.0 m. Mount the sensor according to the instructions in Appendix A, Figure 28. 2.5.4 SICK DL100/DL100 Hi Distance Meters When using a SICK DL100 or 100 Hi distance meter a 90-degree angle connector must be used to connect the sensor. Mount the sensor according to the instructions in Appendix A, Figure 29. 2.5.5 SICK CLV631/690 Bar Code Scanners When using SICK CLV631/690 sensors, ensure that the lateral guide plates of the TPCC mount lie flat against the sensor. Mount the sensor according to the instructions in Appendix A, Figures 30 and 31. 2.5.6 SICK LMS400 Distance Meters When using a SICK LMS400 sensor, ensure that the lateral guide plates of the TPCC mount lie flat against the sensor. Mount the sensor according to the instructions in Appendix A, Figure 32. 04/06/2016 Version 3.3 32 TPCC Professional - User Manual 2.5.7 SICK WL12G Reflex Sensor When using a SICK WL12G reflex sensor, the sensor’s transmission power must be adjusted using the sensor potentiometer. The sensor has a switching threshold at a measurement signal damping of 8%. The TPCC’s glass panel has a transmission percentage of 98% at the corresponding signal wavelength range. Mount the sensor according to the instructions in Appendix A, Figure 33. 2.5.8 R 620 Professional / ICR620 Bar Code SICK Lector Reader When using a SICK ICR620 sensor the internal sensor light must be adjusted to prevent it from reflecting on the TPCC’s glass panel. It may be necessary to disable the internal sensor light and use an external light instead. Mount the sensor according to the instructions in Appendix A, Figure 34. 2.5.9 SICK DT20 Hi When using a SICK DT20 Hi sensor, ensure that the lateral cooling plates located on the inside are mounted first. After the inner plates have been mounted, mount the outer cooling plates. The outer cooling plates must be lightly pressed against the sensors when mounted on the adapter plate to ensure optimum cooling. Mount the sensor according to the instructions in Appendix A, Figure 35. 04/06/2016 Version 3.3 33 TPCC Professional - User Manual 2.6 2.6.1 Troubleshooting Troubleshooting the TPCC If problems occur during the operation of the TPCC Professional System, please check the following and provide PSI Technics support (support@psitechnics.de) with a detailed description of the problem: 1. Ensure that the correct voltage is used • Check the power supply unit • Ensure that the +24 VDC feed is connected to TPCC terminals X1.1 - X1.2. 2. Check the environmental temperature • If the environmental temperature exceeds the maximum threshold, the TPCC’s internal temperature is too high and the system will shut down automatically. • The system will restart once the temperature is within the specified temperature thresholds. 3. Error Monitoring • The optional error monitoring errors can be read from an isolated switching contact on terminal block X2. In addition, the board has two red indicator LEDs that indicate a fault status. The different switching states are described in the table 3 in chapter 2.4.7. 4. Visually check the fans • If the optional failure output is not available on the TPCC the proper function of the fans must checked manually. the If one of the fans is no longer working, the system must be shut down. 04/06/2016 Version 3.3 34 TPCC Professional - User Manual 2.7 Cable Length Cable Cross-Section 1.5mm2 2.7.1 Power Supply Unit Value Setting [U] = V 30,00 28,00 26,00 24,00 0 5 10 15 20 25 Distance [s] = m Figure 20: Line Drop, 1.5mm2 Cable Cross-Section PSI Technics recommends a maximum cable length of 82 ft (25 m). When using the maximum cable length the power supply needs to be adjusted as shown in Figure 20. 04/06/2016 Version 3.3 35 TPCC Professional - User Manual 2.7.2 Cable Cross-Section 2.5mm2 Figure 21: Line Drop, 2.5mm2 Cable Cross-Section PSI Technics recommends a maximum cable length of 82 ft (25 m). When using the maximum cable length the power supply needs to be adjusted as shown in Figure 21. 04/06/2016 Version 3.3 36 TPCC Professional - User Manual 2.8 Recommended Connectors The recommended connectors depend on the sensor you are using. All connectors and cables are available from PSI Technics. Connectors can be ordered using the fax order form at the end of this manual or by visiting http://www.psi-technics.com/EN/Contact.php. SICK DME5000 When using a SICK DME5000 Profibus-type distance meter, PSI Technics recommends using a Profibus BUS IN connector (see Figure 22) and a Profibus BUS OUT connector (see Figure 23) the part numbers are listed below. BUS IN: BUS OUT: Part No. KT 1436 Part No. KT 1437 Figure 22: BUS IN 04/06/2016 Figure 23: BUS OUT Version 3.3 37 TPCC Professional - User Manual SICK DMT/DML For SICK DMT/DML distance meters with RS232/RS422 interfaces, PSI Technics recommends using the following connector due to the sensor construction: Part No. KT 1440 The following 45-degree and 90-degree angle connectors are recommended for use with the Profibus version of SICK DMT/DML distance meters: Part No. Part No. KT 1438 (45-degree) KT 1436 (90-degree) SICK DL100 Hi For SICK DL100 Hi distance meters the following connectors must be used due to the sensor construction. Part No. Ethernet connector 10391 (90-degree) Part No. SSI 10341 (90-degree) Part No. Power DC 10741 (90-degree) Figure 24: 90-Degree Ethernet Connector In addition, an angled cable socket must be used for the 8-pin SSI interface. For the SSI interface the same angled connector can be used as for SICK DMT/DML sensors (Part number KT 1436 (90-degree)). Prefabricated cables in various lengths are available. Adapter cables for replacing 04/06/2016 Version 3.3 38 TPCC Professional - User Manual DME3000/4000/5000 sensors with DL100 Hi distance meters are also available from PSI Technics. R SICK Lector 620 Professional / ICR620 For SICK ICR620 sensors cables with straight connectors must be used. NOTE - All connectors and cables are available from PSI Technics. Connectors can be ordered using the fax order form at the end of this manual or by visiting: http://www.psi-technics.com/EN/Contact.php. 04/06/2016 Version 3.3 39 TPCC Professional - User Manual 3 Reader Comment Form TPCC Technical Documentation - TPCC (DM, T/DM, CLV, LMS Models) April 2016 / Version 3.3 We appreciate your comments and suggestions for improving this publication. Which PSI Technics product do you use? What are you using the PSI Technics product for? Please circle a response for each of the statements below: 1 = Strongly agree 2 = Agree 3 = Neutral; 4 = Disagree; 5 = Strongly disagree The manual is well organized I can find the information I need The information in the manual is accurate The instructions are easy to understand The manual contains sufficient examples The examples are appropriate and helpful The layout and format are attractive and useful The illustrations are clear and helpful 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 Please answer the following questions: Which sections do you use the most? What do you like most about the manual? What could be improved? 04/06/2016 Version 3.3 40 TPCC Professional - User Manual Reader Comment Form We appreciate your feedback. Your feedback about the supporting documentation helps us to improve it with each revision. Please use one of the following methods to send us your comments or suggestions: • Email your feedback to support@psi-technics.com • Fill in the Reader Comment Form and mail it to the address listed on the bottom of the form If this manual does not include a Reader Comment Form, please send your feedback to the address listed at the beginning of this manual. Please use the following subject line: Subject: TPCC/DM, T/DM, CLV and LMS Reader Comment Form Please send us your feedback using one of the following methods: Mail to: PSI Technics Subject: TPCC Rudolf-Diesel-Str. 21a D-56220 Urmitz Germany Fax to: +49 2630 91590 - 99 Subject: TPCC Email to: support@psi-technics.com Subject: TPCC All comments and suggestions become the property of PSI Technics. 04/06/2016 Version 3.3 41 TPCC Professional - User Manual 4 Notes 04/06/2016 Version 3.3 42 TPCC Professional - User Manual 5 Support 5.1 General Technical Support If you have a problem and cannot find the information you need in the product documentation, contact your local PSI Technics office or PSI Technics support. You can also request support: • Via the PSI Technics website www.psi-technics.com/EN/ • By sending a support request email to: support@psi-technics.com 5.2 Service and Support German Headquarters PSI Technics GmbH Rudolf-Diesel-Str. 21a D-56070 Urmitz, Germany Phone +49 2630 91590 - 0 Fax +49 2630 91590 - 99 04/06/2016 US Office P.O. Box 23761 Pleasant Hill, CA 94523 U.S.A. tom.anderson@psi-technics.com Phone: +1 925-287-0904 Version 3.3 43 TPCC Professional - User Manual 6 List of Figures, List of Tables and Appendix Contents List of Figures . . . . . . . . . . . . . . . . . . . . 45 List of Tables . . . . . . . . . . . . . . . . . . . . . 47 04/06/2016 Version 3.3 44 TPCC Professional - User Manual LIST OF FIGURES List of Figures 1 TPCC/DM Front . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 TPCC/T/DM Front . . . . . . . . . . . . . . . . . . . . . . . . 9 3 TPCC/CLV & TPCC/LMS Front . . . . . . . . . . . . . . . . 10 4 TPCC/CLV & TPCC/LMS Top View . . . . . . . . . . . . . . 11 5 TPCC Back - All Models . . . . . . . . . . . . . . . . . . . . . 12 6 TPCC Back View - All Models . . . . . . . . . . . . . . . . . . 13 7 TPCC/DM and CLV Models - Side View . . . . . . . . . . . . 13 8 TPCC/T/DM with Tube - Side View . . . . . . . . . . . . . . 14 9 Mounting the TPCC . . . . . . . . . . . . . . . . . . . . . . . . 18 10 Mounting the TPCC Using Clearance Holes . . . . . . . . . . . 19 11 New Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 12 Old Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 13 TPCC Professional Wiring . . . . . . . . . . . . . . . . . . . . 22 14 Cable Feeds at the Back of the TPCC Housing . . . . . . . . . 24 15 Cable Feeds and Frame Installation Overview . . . . . . . . . . 25 16 Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 17 Terminal Board Pin Allocation . . . . . . . . . . . . . . . . . . 27 18 Connecting the Solid-state Relay . . . . . . . . . . . . . . . . . 29 19 Installing the Solid-state Relay . . . . . . . . . . . . . . . . . . 30 20 2 35 2 Line Drop, 1.5mm Cable Cross-Section . . . . . . . . . . . . . 21 Line Drop, 2.5mm Cable Cross-Section . . . . . . . . . . . . . 36 22 BUS IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 23 BUS OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 24 90-Degree Ethernet Connector . . . . . . . . . . . . . . . . . . 38 25 SICK DME3000 Mounting Instructions . . . . . . . . . . . . . . 49 26 SICK DME4000/DME5000 Mounting Instructions . . . . . . . 50 27 SICK DS/DT500 Mounting Instructions . . . . . . . . . . . . . 51 04/06/2016 Version 3.3 45 TPCC Professional - User Manual 28 SICK DMT/DML Mounting Instructions . . . . . . . . . . . . 52 29 SICK DL100/DL100 Hi Mounting Instructions . . . . . . . . . 53 30 SICK CLV631 Mounting Instructions . . . . . . . . . . . . . . . 54 31 SICK CLV690 Mounting Instructions . . . . . . . . . . . . . . . 55 32 SICK LMS400 Mounting Instructions . . . . . . . . . . . . . . 56 33 SICK WL12G Mounting Instructions . . . . . . . . . . . . . . . 57 R 34 SICK Lector 620 Professional / ICR620 Mounting Instructions 58 35 SICK DT20 Hi Mounting Instructions . . . . . . . . . . . . . . 59 04/06/2016 Version 3.3 46 TPCC Professional - User Manual LIST OF TABLES List of Tables 1 Changes and Revisions . . . . . . . . . . . . . . . . . . . . . . . 2 Overview of Sensors and Corresponding TPCC Models . . . . . 3 3 Error Monitoring Switching States . . . . . . . . . . . . . . . . 28 04/06/2016 Version 3.3 VI 47 TPCC Professional - User Manual A Appendix Contents A.1 Appendix - Mounting Instructions (Adapter Plate) . . . . . . . . . . . . . . . . 04/06/2016 Version 3.3 48 48 TPCC Professional - User Manual A APPENDIX Figure 25: SICK DME3000 Mounting Instructions 04/06/2016 Version 3.3 49 TPCC Professional - User Manual Figure 26: SICK DME4000/DME5000 Mounting Instructions 04/06/2016 Version 3.3 50 TPCC Professional - User Manual A APPENDIX Figure 27: SICK DS/DT500 Mounting Instructions 04/06/2016 Version 3.3 51 TPCC Professional - User Manual Figure 28: SICK DMT/DML Mounting Instructions 04/06/2016 Version 3.3 52 TPCC Professional - User Manual A APPENDIX Figure 29: SICK DL100/DL100 Hi Mounting Instructions 04/06/2016 Version 3.3 53 TPCC Professional - User Manual Figure 30: SICK CLV631 Mounting Instructions 04/06/2016 Version 3.3 54 TPCC Professional - User Manual A APPENDIX Figure 31: SICK CLV690 Mounting Instructions 04/06/2016 Version 3.3 55 TPCC Professional - User Manual Figure 32: SICK LMS400 Mounting Instructions 04/06/2016 Version 3.3 56 TPCC Professional - User Manual A APPENDIX Figure 33: SICK WL12G Mounting Instructions 04/06/2016 Version 3.3 57 TPCC Professional - User Manual R Figure 34: SICK Lector 620 Professional / ICR620 Mounting Instructions 04/06/2016 Version 3.3 58 TPCC Professional - User Manual A APPENDIX Figure 35: SICK DT20 Hi Mounting Instructions 04/06/2016 Version 3.3 59 Fax Order Form Fax-Nr. +49 2630 91590 - 99 US customers: Please send this order form via email to sales@psi-technics.com Billing Address Company: Street: ZIP/City: Country: Phone: Fax: Customer ID No. VAT ID No.: Shipping Address (if different) Company: Street: ZIP/City: Country: Shipping Method: Contact: Phone: Fax: Quantity Part No. G0009 002 0028 G0001 002 0028 G0005 002 0028 G0007 002 0028 G0017 002 0028 G0021-002-0028 G0026-002-0028 G0013-002-0028 G0029 002 0028 G0027-002-0028 10856 10465 10195 KT 1436 KT 1437 KT 1438 KT 1440 10391 10341 10734 KT 0800 000 0001 Date PSI Technics GmbH Rudolf-Diesel-Str. 21a D-56220 Urmitz, Germany Description TPCC / DME 3000 TPCC / DME 4000/5000 TPCC / DS/DT-500 TPCC / DMT-DML TPCC / DL 100/100Hi TPCC / CLV 631-0000 TPCC / CLV 690-0000 TPCC / LMS 400 TPCC / WL12G-3B2531 TPCC / ICR620S-T11503 TPCC / DT20 Hi TPCC Installation Accessory Kit TPCC Power Supply Unit 230VAC/24VDC; 20A BUS IN Profibus Connector 90-degree DME5000 BUS OUT Profibus Connector 90-degree DME5000 Profibus Connector for SICK DMT/DML 45degree RS232/422 Connector for SICK DMT/ DML Ethernet Connector DL100 (4-pin) 90-degree SSI Connector DL100 (8-pin) 90-degree Power DC Connector DL100 90-degree Solid State Relay Stamp/Signature Phone: +49 2630 91590 - 0 Fax +49 2630 91590 - 99 Email: info@psi-technics.com http://www.psi-technics.com 61 Managing Director: Karl-Heinz F¨ orderer