technical description -...

Technical Description

LJU Automatisierungstechnik GmbH

PLA-140 PLA-140 TF PLA-140-SSI

Positioning Code Light Barrier

TNB_0016_PLA-140_en

© LJU Automatisierungstechnik GmbH

Am Schlahn 1

14476 Potsdam

Germany

Tel.: +49 (0) 33201 / 414-0

Fax: +49 (0) 33201 / 414-19

E-mail: [email protected]

Internet: www.ljuonline.de | www.grenzebach.com

The standard names, trade names, product names etc. used in this technical description may also be

brand names even when not specially indicated and as such subject to the statutory stipulations.

Translation of the original document

November 2016

Technical Description PLA-140

Table of contents

TNB_0016_PLA-140_en 3

Table of contents

1 General and safety ...................................................................................................................... 5

1.1 Information about the technical description ........................................................................ 5

1.2 Symbols in the documentation ............................................................................................ 6

1.3 Limitation of liability ............................................................................................................. 7

1.4 Copyright ............................................................................................................................. 7

1.5 Conformity ........................................................................................................................... 7

1.6 Proper use ........................................................................................................................... 8

1.7 Spare parts and repair ........................................................................................................ 8

1.8 Disposal instructions / environmental specifications ........................................................... 9

1.9 Warranty .............................................................................................................................. 9

1.10 Customer service ................................................................................................................ 9

1.11 Modifications and alterations ............................................................................................ 10

1.12 Personnel and qualification ............................................................................................... 10

2 Properties ................................................................................................................................... 11

3 Design, function, displays ........................................................................................................ 13

3.1 Design ............................................................................................................................... 13

3.2 Function ............................................................................................................................ 14

3.3 Control-LEDs ..................................................................................................................... 14

4 Interface description ................................................................................................................. 15

4.1 Serial RS-485 LJU-Bus (PLA-140 / PLA-140 TF) ............................................................. 15

4.2 SSI 32 Bits (PLA-140-SSI) ................................................................................................ 15

5 Installation of the PLA-140 ....................................................................................................... 16

5.1 Installation notes ............................................................................................................... 16

5.2 Mounting and electrical connection .................................................................................. 17

6 Cleaning of the PLA-140 ........................................................................................................... 18

7 Data sheet PLA-140 ................................................................................................................... 19

7.1 Technical data ................................................................................................................... 19

7.2 Connections and pin assignment ...................................................................................... 20

7.3 Device drawing.................................................................................................................. 20

TNB_0016_PLA-140_en 4


General and safety

TNB_0016_PLA-140_en 5

1 General and safety

1.1 Information about the technical description

This technical description contains technical information about the Positioning Code Light Barrier of

the type:

PLA-140

PLA-140 TF

PLA-140-SSI

It gives important notes on the device.

Read this technical description carefully before you use the device!

It will ensure smooth operation and prevention of errors, defects and damage to the system. Moreo-

ver, the universal safety and accident prevention specifications have to be implemented at the site

where the devices are used.

The technical description includes important notes on the operation and safety; it is part of the product

and must be kept at hand close to the device, so that it is accessible to the personnel at all times.

Every person who is assigned to work on or with the device must have read and understood this tech-

nical description before working with the device. This is mandatory even if the concerned person has

already worked with such a device or the like, or has been trained by the manufacturer.


General and safety

TNB_0016_PLA-140_en 6

1.2 Symbols in the documentation

There are warning notes and symbols in this technical description. It is absolutely mandatory to com-

ply with these and follow them. These are operating instructions and warn you of possible damage to

property and personnel. Always follow these instructions. Moreover, always follow the universal safety

specifications and accident prevention specifications.

Warning!

This symbol along with the signal word “Warning” refers to a potentially dangerous

situation that can lead to serious injuries or fatality if it is not avoided.

Caution!

This symbol along with the signal word “Caution” refers to a potentially dangerous

situation that can lead to minor injuries and damage to property if it is not avoided.

Note!

This symbol indicates that there are additional and important information and tips on

the relevant topic.

See also!

This symbol indicates that other detailed descriptions on the particular topic are avail-

able or provides references to other sections in this documentation.


General and safety

TNB_0016_PLA-140_en 7

1.3 Limitation of liability

All data and notes in this technical description have been compiled, taking into consideration, the ap-

plicable norms and specifications, the state-of-the-art technology and our knowledge and experience

gained over the years.

The LJU Automatisierungstechnik GmbH is not liable for any damage or operational disorders arising

due to:

Non-compliance of the technical description

Improper use

Employment of untrained personnel

Independent remodeling and modification of the device

Moreover, non-compliance of the technical description absolves LJU Automatisierungstechnik GmbH

of the warranty obligation.

1.4 Copyright

The contents of this technical description should be treated as confidential. It is meant solely for the

persons working with the device. Handing over this technical document to third parties without written

permission of the manufacturer is not allowed.

Note!

The content details, texts, drawings, images and other illustrations of the technical

description are protected by copyright and are subject to the industrial property rights.

Any improper utilization is punishable by law.

1.5 Conformity

Devices made by LJU Automatisierungstechnik GmbH have been designed to comply with EU direc-

tives.

Please contact LJU Automatisierungstechnik GmbH if you wish to obtain a copy of these EU declara-

tions of conformity.


General and safety

TNB_0016_PLA-140_en 8

1.6 Proper use

The PLA is a device for industrial and commercial plants for position reading in transportation sys-

tems.

Warning!

Danger due to improper use!

Any improper use and/or different use of the PLA can lead to dangerous situations.

Therefore:

- Only use the PLA in a proper manner.

- Under all circumstances, comply with all technical data and permissible conditions

at the site of operation.

- Do not operate the PLA in environments with hazardous oils, acids, gases, va-

pors, dust, radiation, etc.

1.7 Spare parts and repair

Warning!

Risk of injury due to spurious spare parts and incorrect repair!

Spurious or faulty spare parts and repair can lead to damage, malfunctions or total

failure and can impair safety.

Therefore:

- Use only original spare parts of the manufacturer.

- Replace defective devices immediately and send them for repair.

When ordering a spare part, specify the plant number WNR

of the component and send it to the address given on the inner

side of the covering sheet (page 2). The plant number is given

on the type plate of the individual components.

(see figure)

Send in the defective device for repair with a short description of the error scenario, to the address

given on the inner side of the covering sheet (page 2).


General and safety

TNB_0016_PLA-140_en 9

1.8 Disposal instructions / environmental specifications

Provided no agreement for take-back or disposal has been made, the individual components of the

device, after appropriate dismantling, have to be segregated and disposed of or recycled, according to

the current stipulations.

Materials marked with the recycling symbol or green dot have to be

disposed of using the relevant recycling method.

1.9 Warranty

The warranty covers only production defects and component defects.

The manufacturer is in no way responsible for damage occurring during transit or unpacking.

In no case and under no circumstances shall the manufacturer be liable under warranty for defects or

damage caused by improper use, incorrect installation or impermissible operating conditions, or due to

dust or aggressive substances.

Consequential and accidental damage are excluded from the warranty.

The warranty is valid for 12 months from the commencement of operation or 24 months after delivery,

whichever is earlier.

Resellers or distributors may negotiate different warranty periods in accordance with their terms and

conditions of sale and delivery.

If you have further questions relating to the warranty, please contact your supplier.

1.10 Customer service

Our service is available for technical information.

Information about the responsible contact persons is available via telephone, fax, email or the internet

see contacts on the inner side of the covering sheet (page 2).


General and safety

TNB_0016_PLA-140_en 10

1.11 Modifications and alterations

To avoid danger and to ensure optimal performance, no modifications, remodeling or add-ons are al-

lowed on the device, unless expressly approved by LJU Automatisierungstechnik GmbH.

Warning!

Risk of injury due to design modification!

Unauthorized technical modifications can lead to considerable damage to persons and

property.

Therefore:

- Replace the defective device!

- Replace it with an LJU device of the same model.

1.12 Personnel and qualification

Warning!

Risk of injury due to inadequate qualification!

Inappropriate handling can lead to considerable personal and property damage.

Therefore:

- The installation, operation and maintenance of the device must be carried out by

trained and instructed personnel.


Properties

TNB_0016_PLA-140_en 11

2 Properties

The absolute-value coded, contactless positioning light barrier PLA is an intelligent device for speed

and distance regulation and for self-positioning of vehicles in automated electrified monorails (EMS).

Notes!

- For distance regulation, radio control or data transfer over contact lines etc., fur-

ther LJU-components are necessary.

- For applications other than automated electrified monorails special conditions may

apply.

Absolute value measurements required in order to carry out certain functions in production processes

are fundamentally subject to special requirements such as:

1. Only checked results from measurement devices may be passed as such to the controller.

2. Results which cannot be checked must be flagged.

3. After every data sequence a self-test must take place.

How the PLA fulfills these requirements is shown in the following:

After a traveled distance, normally of 40-50 mm but at the furthest of 128 mm, all light barriers

of the PLA are checked once for transmitted light. If all of the PLA's light barriers are error

free, then it is certain that all transmitted-light obstructions and shadows are caused by the

code rail.

In the LJU code rail system only the defined hole sizes are permitted, holes of deviating size

cause a flag to be set which allows no function other than 'travel'. Should deviating values be

measured, then the last correctly read value continues to be valid and further operation is lim-

ited to path counting operations – marked with the flag bit – the values of which are only re-

turned together with the flag.

A region not defined by code rail hole size (breaks in rails and lifters) may equal a maximum of

200 mm (recommend 25-35 mm). After the undefined region the PLA must have read a new

valid value. If the PLA does not read a valid code then the vehicle is stopped.

Upwards and downwards sequential code reads are monitored for plausibility. If no plausibility

is recognized then this also results in stopping the vehicle and an error message is produced.

The PLA reads permanently installed track reference marks from absolute-value coded data rails of a

length of up to 2096 meters with a resolution of 1.27 mm and at speeds up to Vmax 200 m/min. This

allows the highest precision regulation of speed and positioning.


Properties

TNB_0016_PLA-140_en 12

The track reference read-in (actual position) is transmitted over the interface.

If a voltage interruption occurs here, then after voltage return the processor rereads the slot. After con-

tinued vehicle travel a new absolute value must have been read after 200 mm, otherwise a code-read

error is generated.

No loss of information results from voltage interruptions and movement of the vehicle in a no-voltage

state, since with voltage return the actual position is immediately recognized and transmitted over the

interface.

Function of the light barriers is monitored and the status indicated with 2 LEDs.


Design, function, displays

TNB_0016_PLA-140_en 13

3 Design, function, displays

3.1 Design

The PLA is a microprocessor controlled module consisting of the following components. The compo-

nents are arranged in the U-shaped housing at an angle to each other, conforming to the housing's

form.

2x Status-LED (2x back)

Housing with CPU board, infrared-transmitter board and infrared-receiver board

The connection for data and power supply is led out of the housing to M12-plug

Fastening points (4x top)


Design, function, displays

TNB_0016_PLA-140_en 14

3.2 Function

Using the absolute value coding of the data rail read by the light barrier (infrared scanner), a micropro-

cessor constantly calculates the current position of the vehicle with a resolution of 1.27 mm.

The calculated position data is cyclically requested by the vehicle controller over the interface and is

thus available as a way reference for regulating speed, distance regulation, positioning etc.

The data rail required for use of the PLA is produced in number-coded segments (7 segments per

code rail) with a usable length of 896 mm.

Code direction

Syncbit

1. Bit

2^1314. Bit

2^0

123

By installing the code rail with ascending absolute values, continuous coding allowing a length of up to

2096 meters without code repetition. In the Bus master system it is possible to coding a route up to

15000 m.

See also!

Notes on code rail and code rail installation are given in the separate description of

the code rail installation for the PLA-14 and PLA-140.

3.3 Control-LEDs

The status of the PLA is displayed with two LEDs on the back of the

PLA.

Messages:

green - power supply 24 V DC ok

red - valid code read


Interface description

TNB_0016_PLA-140_en 15

4 Interface description

4.1 Serial RS-485 LJU-Bus (PLA-140 / PLA-140 TF)

internal LJU-Bus-Protocol

4.2 SSI 32 Bits (PLA-140-SSI)

The PLA works as slave with SSI data communication.

The master generates and sends the low-active tact signals to the PLA.

The PLA responds with the high-active actual data packet.

In idle state the master tact signal is on high level. As long as there are no data available the PLA

data channel is in high state, too.

As soon as there has been generated a data packet by the PLA the data channel will be set to low

state to indicate request availability. (The MSB bit of the 32 bit packet will be set now)

By sending of 32 low active tact pulses the master can now acquire the data packet.

On raising edge of the 32nd pulse the data channel remains in static high state. The master has to

wait again for the next change of the data channel to low state to get next ready for request infor-

mation.

Ready state should be back after latest 10 ms. The SSI master has to monitor this cycle by a

watchdog timer.

If this watchdog has been activated it is required to read out the slave data and discard them.

The transferred data packet is coded as follows:

X101-010E LLLP-PPPP PPPP-PPPP PPPP-PPPP

X Low-Startbit;

(ready for request)

101-100 Shift control bits to recognize

possible shift faults

E Fault bit;

1 = Fault on act. position

(Last position preserved)

LLL Always 0

P-PPPP PPPP-PPPP PPPP-PPPP 21 bit position

Note!

The poll rate should be between 200-500 kHz.


Installation of the PLA-140

TNB_0016_PLA-140_en 16

5 Installation of the PLA-140

5.1 Installation notes

Caution!

To avoid destructions at the PLA and to guarantee a faultless function of the PLA, for

all works on the PLA, disconnect the power from the PLA.

Caution!

The PLA has optical devices used for distinct positioning.

To ensure error-free functioning, it is essential that the inner sides of the PLA are

kept shielded from the effects of direct external light. Light intensity levels of the

environment there are substantially higher than average, such as direct sunlight, ex-

ternal IR light or industrial radiator, can lead to reading errors.

Therefore, please make sure there is a suitable mounting or shielding/covering!

Note!

To ensure smooth operation in contamination-endangered installations, the PLA-140

light barrier should be cleaned after every cycle using soft, anti-static brushes!

Note also the information in chapter 6!


Installation of the PLA-140

TNB_0016_PLA-140_en 17

5.2 Mounting and electrical connection

Fasten the PLA only at the fastening points provided for it and fit it to the vehicle with suitable

holders (e.g. mounting panels).

The fastening points are given in the device drawing.

Assembling the PLA that the PLA runs preferentially over the code rails. Opening of the PLA

down.

Note the drive direction! (Travel Direction is given at the type plate, M12 connector in drive direc-

tion/in code direction of the code rails)

Alignment

- Align the markings on the PLA centered above the code

- Align the PLA parallel to the code rail

- Code rails runs centered through the PLA

Electrical connection: connecting the PLA with the vehicle controller by a 5pole or 8pole M12 ca-

ble (depending on interface).

The connection of the PLA at the vehicle controller is given in the connection plan

of the vehicle controller!


Cleaning of the PLA-140

TNB_0016_PLA-140_en 18

6 Cleaning of the PLA-140

Caution!

To avoid destructions at the PLA and to guarantee a faultless function of the PLA, for

all works on the PLA, disconnect the power from the PLA.

The amount of staining in some mounting positions of the PLA-140 (e.g. vertical installation) can be

higher and requests additional actions for ensuring trouble-free operation.

Note!

Errors such as 88d, 102d in the DC, or the overshooting of the stopping positions indi-

cate that the PLA is dirty. Clean the PLA!

The light barrier areas in the reading unit shall be cleaned at least once each quarter-year.

Cleaning:

1. If possible flip open the PLA respectively demount the PLA.

2. Clean the light barrier fields at the left and at the right side in the PLA with a soft, antistatic

cloth or with a moistened piece of leather.

Do not use any cleaning fluids such as alcohol solutions or other cleaning agents!

3. Mounting the PLA. (see chapter Installation)


Data sheet PLA-140

TNB_0016_PLA-140_en 19

7 Data sheet PLA-140

7.1 Technical data

General

Type PLA-140 PLA-140 TF PLA-140-SSI

Interface serial

RS-485 LJU Bus

serial

RS-485 LJU Bus

SSI

32 Bits

Housing ABS

Color Grey

Dimensions H x L x W 88 mm x 170 mm x 84 mm

Weight 520 g

IP protection class IP 54

Status 2 x LED

Minimum cornering radius 1000 mm

Minimum climbing radius 2000 mm

Electrical data

Power supply 24 V DC

Power consumption approx. 50 mA

Light barriers

Type PLA-14B-Empfänger-1 (receiver)

PLA-14B-Sender-1 (transmitter)

Number of light barriers 112

Resolution 1.27 mm

Max. scanning speed 200 m/min

Ambient conditions

Operating temperature + 10 °C to + 50 °C

Storage temperature - 10 °C to + 50 °C

Relative humidity < 80% non-condensing

tropicalized - -

We reserve the right to make technical changes!


Data sheet PLA-140

TNB_0016_PLA-140_en 20

7.2 Connections and pin assignment

Connections PLA-140 / PLA-140 TF [ RS-485 LJU Bus / 24 V DC ]

X1

[M12 5pole male]

Pin 1 - L+

Pin 2 - Bus A

Pin 3 - L-

Pin 4 - Bus B

Pin 5 - free

Connections PLA-140-SSI [ SSI / 24 V DC ]

X1

[M12 8pole male]

Pin 1 - L-

Pin 2 - L+

Pin 3 - Clock+

Pin 4 - Clock-

Pin 5 - Data+

Pin 6 - Data-

Pin 7 - PE

Pin 8 - PE

7.3 Device drawing

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