Processor User Guide Land Instruments International Dronfield, S18 1DJ England Telephone: (01246) 417691 Facsimile: (01246) 410585 Email: infrared.sales@landinst.com Internet: www.landinst.com Land Instruments International 10 Friends Lane Newtown PA 18940-1804 U.S.A. Telephone: (215) 504 8000 Facsimile: (215) 504 0879 Email: irsales@landinstruments.net Internet: www.landinst.com Land Instruments International, 2003 Publication Nº: LSPP Issue: A 05/03
ABC abcdefg The Quality Management System of Land Instruments International Ltd. is approved to BS EN ISO9001:2000 for the design and manufacture, stockholding, in-house repair and site servicing of non contact temperature measuring instrumentation. Associated software designed and developed in accordance with TickIT. Calibration certificates are available from our UKAS accredited Calibration Laboratory No. 0034. The Land calibration laboratory complies with the requirements of the international standard BS EN/IEC 17025. This product complies with current European directives relating to electromagnetic compatibility and safety (EMC directive 89/336/EEC; Low voltage directive 73/23/EEC). All packaging material used for this product is 100% recyclable. Quality Assurance
SAFETY INFORMATION SYMBOL PUBLICATION DESCRIPTION IEC 417, No.5031 Direct Current 3 IEC 417, No.5032 IEC 417, No.5033 IEC 617-2, No.02-02-06 IEC 417, No.5017 Alternating Current Both direct and alternating current Three-phase alternating Current Earth (ground) terminal IEC 417, No.5019 Protective conductor terminal IEC 417, No.5020 Frame or chassis terminal IEC 417, No.5021 Equipotentiality IEC 417, No.5007 On (supply) IEC 417, No.5008 Off (supply) IEC 417, No.5172 Equipment protected throughout by double insulation or reinforced insulation (equivalent to Class II of IEC 536) Safety Information
SAFETY INFORMATION (Continued) SYMBOL PUBLICATION DESCRIPTION ISO 3864, No. B.3.6 WARNING Risk of electric shock ISO 3864, No. B.3.1 Caution BS EN 100015 Observe precautions for handling electrostatic discharge sensitive devices BS EN 60825-1 WARNING Laser Radiation Refer to the operating instructions Note Safety Information
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CONTENTS QUALITY ASSURANCE SAFETY INFORMATION CONTENTS (This Page) PREFACE 1.0 INTRODUCTION 1 2.0 SYSTEM OVERVIEW 2 2.1 LSP Processor 2.2 Configuration Software 3.0 PROCESSOR HARDWARE INSTALLATION 4 3.1 LSP Processor Dimensions 4.0 SYSTEM CABLE CONNECTIONS 5 4.1 LSP Processor Front Panel 4.2 LSP Processor Base Panel 4.3 Mains Power (X1) 4.4 System Alarm (X2) 4.5 Auxiliary Input Connection (X3) 4.6 Scan Valid Output (X4) 4.7 Remote Laser Control Output (X5) 4.8 LSP Linescanning Thermometer Connection (X6) 4.9 External Communications - Ethernet (X7) 4.10 External Communications - Serial RS232 (X8) 4.11 RS232 Terminal Connector 5.0 SYSTEM DISPLAY 11 5.1 System Display LED's 5.2 System Display Events 6.0 ETHERNET CONFIGURATION 13 Contents
CONTENTS (Continued) 7.0 QUICK-START GUIDE 14 7.1 Select the Ethernet ID Setting 7.2 Applying Power to the Processor 7.3 Display System Status 7.4 Connection of the Processor to the Personal / Laptop Computer 7.5 Communicating with the Processor 7.6 Temperature Data Capture 8.0 DIGITAL AND ANALOG INPUT/OUTPUT (DAIO) CARD 18 8.1 Card Programming 8.2 Analog Input Link Positions Appendix A - SYSTEM FAULT DIAGNOSIS CHART 19 Appendix B - START-UP MODE DIAGNOSIS CHART 20 Contents
PREFACE 242001 Fig. A - LSP Processor These instructions should be used in conjunction with the information detailed within the LSP Processor Installation Guide. Any instructions undertaken must be carried out by suitably trained personnel. Preface
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1.0 INTRODUCTION This guide provides a system overview describing the hardware installation and introduces the processor Configuration Software for interrogation, setup and modification of the system's operating parameters. A more comprehensive User Guide accompanies the Configuration Software which describes the configuration of the software in detail and provides information about the processing operations. Page 1
! R S23 2 TE RMIN AL XXX.XXX.XXX.XX IP ADDRESS User Guide 2.0 SYSTEM OVERVIEW The Landscan LSP Processor provides a dedicated data input, mathematical processing facility for use with LANDSCAN sensor heads for process control applications. The processor provides external communications interfaces for system configuration and for the transmission of scan line information to host computers. This can be achieved using RS232C or an Ethernet connection when the transmission of large quantities of data at high speed is required. The processor has been designed to function automatically and continuously with in-built self-analysis of system events, plus comprehensive diagnostic information accessible through the configuration software and front panel display. The processor supports up to two simultaneous Ethernet connections. In addition, the processor captures data from any of the Landscan heads and manipulates the information into a zone model. The system can be considered to consist of two distinct components, the Control Processor and the Configuration Software which runs on a portable PC and is used to configure the processor parameters. PROCESS MONITORING PROCESS CONTROL Optional Software Landscan NT Ethernet 5 4 3 2 1 Ethernet Switch RS232 Serial Comms LSP SYSTEM Interconnection Cable Temporary Link Portable PC RS232 LSP Linescanning Thermometer LSP Processor Configuration Software 242002 Fig. 1 - Typical LSP System Overview Page 2
2.1 LSP Processor The LSP Processor is a wall mounted unit, that will sample 1000 data points per scan line, at scan speeds between 10Hz and 100Hz. The processor can partition the scanner temperature profile into a maximum of 14 discrete regions or zones which can overlap if required. Within these zones a processing function can be applied to yield peak, average and minimum measurements. An analog 4 to 20mA output is provided that allows for remote control of the Landscan sensor head's emissivity settings. An additional alarm relay output is available to alert the user to conditions which may result in the data captured being invalid. (e.g. power loss at the Landscan sensor head) The product edges can be detected by identifying where in the scan line the temperature rises above a preset threshold level. This is achieved automatically by analysing the peak product temperature in relation to the environmental background temperature. The system uses the edge detection information to align the zone positions, allowing the zones to track a target which may be moving erratically within the sensor s field of view. If the target moves, grows or shrinks within the sensor s field of view, the zone model follows these movements. The processor provides an RS232 serial communication connection located on the front panel, which allows a laptop personal computer or similar to be connected temporarily to allow modifications to the system configuration. A second RS232 serial communications connection can be used for permanent monitoring. Ethernet communication is also provided on the processor to allow the connection of third party computer systems and also the Landscan NT software. Calibrated temperature data and zone processed data are available in real time for the purposes of analysis and database storage by remote computer systems. Configuration of the processor is fully supported by the Ethernet communications, with the configuration software capable of setting up the processor for an appropriate network setting. When the user has satisfactorily configured the system for a particular application, the parameters essential for operation are secured against power loss inside the system. The processor will continuously operate without interruption, utilising these settings until parameter changes are requested by the user. 2.2 Configuration Software The Configuration Software enables the user to communicate with the processor for initial setting up of the operating parameters and provides limited process monitoring capability. All operating parameters are securely retained in the non-volatile memory of the processor. The Configuration Software features; Configuration of: Scanner Type Processor Ethernet Zones and Alarms Displays: Profile Zone and Alarm Status Scanner Status Zone Profile (Professional version only) 2D Map (Professional version only) Configuration Load and Save Processor Diagnostics Context Help Temporary communications are through an RS232 terminal on the front panel of the processor. Permanent process monitoring may be achieved via a second RS232 link to the processor base panel connection. For further information, see the LSP Configuration Software User Guide. Page 3
3.0 PROCESSOR HARDWARE INSTALLATION 3.1 LSP Processor Dimensions 203 / 8.0 120 / 4.7! RS 232 TE RMI NA L XXX.XXX.XXX.XX IP ADDRE SS 306 / 12.0 4 holes dia. 6 / 0.2 193 / 7.6 181 / 7.1 280 / 11.0 326 / 12.8 All dimensions in mm / in 242003 Fig. 2 - LSP Processor Dimensions Page 4 280 / 11.0
4.0 SYSTEM CABLE CONNECTIONS 4.1 LSP Processor Front Panel! RS232 Diagnostics LED's TERMINAL XXX.XXX. XXX.XX IP ADDRESS Ethernet Configuration Switch RS232 Terminal. Connection to remote PC running configuration software 242004 Fig. 3 - LSP Processor Front Panel The front panel of the LSP Processor is shown in Fig. 3, illustrating:- System Diagnostics LED's Ethernet Configuration Switch RS232 Terminal Connector for use with a PC or Laptop, running Configuration Software Page 5
4.2 LSP Processor Base Panel Mains Power Alarm Contacts X1 X2 NO NC C sv X3 1 2 SCR X4 1 2 X5 1 2 X6 S1 S2 E1 E2 AT1 AT2 SV1 SV2 FT1 FT2 V1 V2 SCR X7 X8 Scan Valid Output Remote Laser Control Ethernet Connection RS232 Connection Scanner Connections 242005 Fig. 4 - LSP Processor Base Panel The base panel of the LSP Processor is shown in Fig. 4, illustrating:- Mains Power (X1) System Alarm Contacts (X2) Scan Valid Output (X4) Remote Laser Control Connections (X5) LSP Linescanner Connections (X6) External Communications - Ethernet Connection (X7) External Communications - RS232 Connection (X8) Page 6
4.3 Mains Power (X1) The processor requires a three-wire a.c.supply, that includes an earth ground connection. Warning RISK OF ELECTRIC SHOCK The a.c. supply and associated wiring must conform to local regulations for voltage and power rating. Failure to provide an earth ground connection can cause electric shock and improper operation of the equipment. Ensure that the earth ground wire has a current carrying capacity equal to, or greater than the largest power conductor. Ensure that the a.c. supply to this equipment is connected through an accessible isolator switch. The power consumption of the LSP Processor is approximately 60W and the unit must be fused independently with a 5amp fuse. Earth Live Neutral 242006 Fig. 5 - IEC Mains Socket Wiring Diagram 4.4 System Alarm (X2) The processor provides a system alarm relay output that indicates system event warnings eg. scanner head faults. Three contacts are provided; [NO] 'Normally open', [NC] 'Normally Closed' and [C] 'Common'. The relay rating is 2A @ 30V d.c. maximum. X2 NO NC C 242007 Fig. 6 - System Alarm Contacts Page 7
4.5 Auxiliary Input Connection (X3) This facility has not been implemented at present. 4.6 Scan Valid Output (X4) The processor provides a scanning head scan valid output. This signal can be used to synchronise the process to the scanner head data acquisition rate. 80 Scan 1 scanner revolution 1 1 'Scan valid' timing signal, valid when 'High' (+5V) 2 2 'Fast temperature output' signal (4 to 20mA) 242008 Fig. 7 - Scan Valid Timing Diagram sv X4 1 2 Pin 1 : +5V TTL Output Pin 2 : 0V 242009 Fig. 8 - Scan Valid Contacts 4.7 Remote Laser Control Input (X5) The remote laser control input allows the scanner head laser to be remotely operated. The laser contacts can be operated by utilising an external switch or relay contacts (closed contacts activate the scanner head laser and open contacts make the scanner head laser inactive). X5 1 2 242010 Fig. 9 - Remote Laser Control Contacts Page 8
4.8 LSP Linescanning Thermometer Connection (X6) This connector allows the LSP Linescanning Thermometer to be interfaced to the LSP Processor unit. X6 S1 S2 E1 E2 AT1 AT2 SV1 SV2 FT1 FT2 V1 V2 SCR 242011 Fig. 10 - LSP Linescanning Thermometer Connection Contacts 4.9 External Communications - Ethernet (X7) The ethernet connection provides a high-speed communications interface. The user is able to request live data and remotely configure the processor from the user's own PC. To make use of the external communications, customers must send commands to the processor using the LAND specified format. Full details of the LAND messaging interface are given in the Processor Configuration Software User Guide. The processor provides a connection for a 10BASE-T RJ45 Shielded Twisted Pair (STP) connector of CAT5 specification. The general cable recommendation is to use shielded 10BASE-T LSOH Category 5 / Level 5 STP cable.this provides protection from electromagnetic interference in industrial environments. The use of unshielded 10BASE-T LSOH Category 5 / Level 5 UTP is only recommended for area's that are guaranteed to be free from severe electromagnetic interference. The maximum cable length allowed is 100m / 328ft, which can be extended to 457m / 1499ft by utilising external network repeaters. X7 242012 Fig. 11 - Ethernet Connection Page 9
4.10 External Communications - Serial RS232 (X8) The serial connection provides the means by which a user can request statistical data and remotely configure the processor from the user's own PC. To make use of the external communications, customers must send commands to the processor using the LAND specified format. Full details of the LAND messaging interface are given in the Processor Configuration Software User Guide. The general recommendation for cable is 3-core with overall screen. X8 Pin 2 : Receive (Rx) Pin 3 : Transmit (Tx) Pin 5 : Ground (GND) 242013 Fig. 12 - Serial (RS232) Connection 4.11 RS232 Terminal Connector The front panel RS232 terminal connector is intended to be used in conjunction with a laptop PC running the Processor Configuration Software. A serial cable is supplied with the the LSP Processor for this purpose. If for any reason the RS232 cable supplied is not suitable for your type of portable computer, then an alternative can be supplied (upon request), or can be wired up as shown below: LSP Processor front panel 25-way serial communications terminal connection Portable computer Serial Port (COM)1 GND Rx 7 Tx 3 2 242017 Fig. 13 - Wiring Diagram for Processor to PC Connection Cable Consult your portable computer User Guide for pin connections to the serial port (COM1). Page 10
5.0 SYSTEM DISPLAY The LSP Processor has six LED's located on the front panel, which are used to indicate system events and system status. The LED's provide immediate diagnosis of the current status of the unit and allow detailed fault finding.! RS232 TERMINAL XXX.XXX.XXX.XX IP ADDRESS 242014 Fig. 14 - Front Panel LED's 5.1 System Display LED's Each of the display LED's has a number of possible states which can be used to diagnose the current status of the system. Symbol Description LED Constant On LED Flashing On LED Off Power - This indicates that power has been applied to the unit Power OK Fault Fault System Running - This indicates that the software is running and acts as a visual watchdog System Start-up Mode Running OK Software watchdog Fault Scanner - This is an indication of the status of the scanner Hardware OK Stabilising Scan Valid Hardware OK Receiving valid data Fault Ethernet Comms - This is an indication of the status of the Ethernet network adapter and network activity Ethernet Adapter OK Network not active Ethernet Adapter OK Network activity Fault Temperature Alarm - This indicates the processor and scanner internal ambient temperature sensor status High Temp trip Highest Temp trip Temp OK System Alarm - This is an indication of the status of the system alarm Fault System Alarm active System OK It is possible to diagnose the system to individual hardware and software components using the display and the 'System Fault Diagnosis Chart' found in Appendix A. Page 11
5.2 System Display Events The display is also used to indicate various software events. These events override the usual functions of the indicators allowing the user to confirm events performed by the software. The following events are indicated: Start-up Progress - On power-up, the unit runs through a sequence of the LED's to indicate the stage of the unit start-up procedure. Each LED is switched on at various stages to indicate progress. The sequence used is: Power System Running Ethernet Comms Scanner Temperature Alarm System Alarm Following this sequence, the unit beeps to indicate a successful start-up and the 'System Running' LED starts to flash. (Refer to Appendix B for 'Start-up Mode Diagnostics Chart', detailing information about each stage of progress) System Exit to Flash Upgrade Mode - If an LSP Processor is connected to a laptop using the serial port and a request is received to enter the Flash Upgrade Mode, the LED's run through the start-up sequence once, to indicate that the software is entering Upgrade Mode. Page 12
6.0 ETHERNET CONFIGURATION The Ethernet network is configured using the Ethernet ID switch located on the processor front panel. 9 XXX.XXX.XXX.XX IP ADDRESS 242015 Fig. 15 - Ethernet ID Switch The rotating switch on the front panel allows the user to set a unique number for each unit. This number is the lowest digit of the IP address stored in the unit. XXX.XXX.XXX.XX_ On power-up, the unit then reads the switch and creates the unit's IP address from the base address plus the switch setting. For example, if the base address of the unit was 10.1.10.100 and the switch setting was 5 the actual IP address used by the unit would be 10.1.10.105. This allows for all units on the network to be configured with the same base address and have a unique switch setting. Using this system allows units to be moved around the network without the need to use configuration software to change network settings. The base address of the unit can be changed using the Configuration Software, details of which are explained in the Configuration Software 'User Guide'. Note The switch is only read on power-up of the unit and any changes to the switch position following this, does not change the network IP address. It is therefore necessary when applying power to the unit, to ensure that the IP switch setting is in the relevant position. Page 13
7.0 QUICK-START GUIDE This section describes a sequence of actions which confirm that the system is functioning correctly. In the event of verification failure, refer to the Processor Configuration Software User Guide. If any further problems are encountered, contact Land Instruments International for assistance. 7.1 Select the Ethernet ID Setting Before the unit is powered-up, it is necessary to ensure that the Ethernet switch, located on the front panel of the processor, is set to the required value. Refer to Section 6.0 for details of network configuration and Ethernet ID selection. 7.2 Applying Power to the Processor When power has been applied to the processor unit, the display runs through the start-up procedure to indicate start-up progress. Refer to Section 5.0 for details of the display start-up sequence. 7.3 Display System Status After the start-up procedure has ended, the display begins to indicate the current system status. This depends on the connections made to the unit at this point. The 'System Running' LED should be flashing to indicate that the unit is running correctly. Refer to Section 5.0 for details of display status indication. 7.4 Connection of the Processor to the Personal / Laptop Computer Connect the supplied RS232C Serial Comms lead to the 25-way terminal on the front panel of the processor and to the 9-way COM 1 serial port of the portable computer. LSP PROCESSOR FRONT PANEL RS232 TERMINAL XXX.XXX.XXX.XX IP A DDRESS 25 - WAY CONNECTOR PORTABLE COMPUTER REAR PANEL COM 1 SERIAL POWER RS 232C SERIAL COMMS CABLE (SUPPLIED) 9 - W AY CO NNECTOR 242016 Fig. 16 - Processor to PC Connection Page 14
7.5 Communicating with the Processor The following section describes how to communicate with the processor for the purposes of system configuration and how to monitor data acquisition of the processor. Ensure that the Processor Configuration Software has been fully installed. Start the 'Processor Configuration Software' by selecting the desktop icon or the program menu option. The configuration software starts immediately and attempts to communicate with the processor. Following successful communications with the processor, the user is prompted to perform an upload of the current processor configuration. Confirm the upload. The following upload progress dialog box is then displayed. 242018 Fig. 17 - Upload Dialog Box Following a successful processor configuration upload, the current processor configuration is displayed in the main window of the software. Page 15
242019 Fig. 18 - Main Window Dialog Box The status bar located at the bottom of the main window should indicate that the system is running correctly ('System OK') and the configuration status box should indicate that this is a live configuration ('Live Configuration'). The processor is now operating correctly and communicating with the Processor Configuration Software. The Processor Configuration Software indicates system faults by turning the 'Main Window' status bar to red. A description of the fault will be indicated on the status bar. Further diagnosis is possible from the processor diagnostics window. Refer to the Processor Configuration Software User Guide for further details. Page 16
7.6 Temperature Data Capture The following section assumes that a target temperature is available for verification. After completing the steps detailed in the previous section, select the 'Configuration' dialog box and select the specific system parameters including 'Scanner Type' and 'Units of Measurement'. Select the 'Processor Download' option from the toolbar and confirm the action. A 'Download Progress' dialog box will be displayed, indicating the successful download of the new configuration. 242020 Fig. 19 - Download Dialog Box Select the 'Profile Display' option from the Processor Configuration Software toolbar. The 'Scanner Profile Display' window will be displayed, indicating the 'Target Temperature Profile'. Fig. 20 - Temperature Profile Display Confirm that the data displayed is as expected for the current temperature and that the temperature range shown on the display matches the system scanner type. The Processor Configuration Software is now monitoring the correct operation of the system. 242021 Page 17
8.0 DIGITAL/ANALOG INPUT AND OUTPUT CARD (DAIO) The Digital/Analog Input and Output Card (DAIO) provides the following inputs and outputs: INPUTS OUTPUTS No. OF CHANNELS SPECIFICATION Digital 4 TTL compatible, active high Analog 4 Differential, milliamp or voltage - link selectable. 0 to 1/2/5/10V range, scaling span and offset - independently software selectable Digital 4 TTL compatible, active high Analog 4 0 to 20mA / 4 to 20mA, - independently software selectable 242022 Fig. 21 - DAIO Card Inputs and Outputs The status of each channel is updated once per scan line. 8.1 Card Programming When used with the LSP Processor, the DAIO card must be set to CARD#1. This is done by fitting the 3 jumper links on the headers at position "I/OCARD#1" (see Fig. 23). 8.2 Analog Input Link Positions The analog inputs can accept either voltage (V) or current (ma) signals. Each of the four channels may be independently set using jumper links. For voltage input: Set the appropriate link to "V" (see Fig. 24) Select the required voltage input range in the LPU config or Landscan software For current input: Set the appropriate link to "I" (see Fig. 24) Select the voltage input range in the software to 0 to 5V. Page 18
37-WAY 'D' CONNECTOR PIN NO. FUNCTION CHANNEL 1 Digital Input Ch1 2 Digital Input 0V 3 Digital Input Ch2 4 Digital Input 0V 5 Digital Input Ch3 6 Digital Input 0V 7 Digital Input Ch4 8 Digital Input 0V 9 No Connection - 10 No Connection - 11 No Connection - 12 Analog Output Ch1_drive 13 Analog Output Ch1_return 14 Analog Output Ch2_drive 15 Analog Output Ch2_return 16 Analog Output Ch3_drive 17 Analog Output Ch3_return 18 Analog Output Ch4_drive 19 Analog Output Ch4_return 20 Digital Output Ch1 21 Digital Output 0V 22 Digital Output Ch2 23 Digital Output 0V 24 Digital Output Ch3 25 Digital Output 0V 26 Digital Output Ch4 27 Digital Output 0V 28 No Connection - 29 No Connection - 30 Analog Input Ch1+ 31 Analog Input Ch1-32 Analog Input Ch2+ 33 Analog Input Ch2-34 Analog Input Ch3+ 35 Analog Input Ch3-36 Analog Input Ch4+ 37 Analog Input Ch4-242023 Fig. 22 - Pin Configuration for DAIO 37-Way 'D' Connector Page 19
Jump Links Fitted JM 3 JM 2 JM 1 JM 6 JM 5 JM 4 JM 9 JM 8 JM 7 I/O CARD #3 I/O CARD #2 I/O CARD #1 242024 Fig. 23 - DAIO Card Programming AI1 AI2 V I V I V I V I LK1 LK2 LK3 LK4 VOLTAGE INPUT CURRENT INPUT (ma) 242025 Fig. 24 - Analog Input Link Positions Page 20
Appendix A SYSTEM FAULT DIAGNOSIS CHART Power LED OFF Faulty Power Supply ON Unit In Start-up Faulty Mode. Check Processor Diagnostics Chart Card B.2 ON Run LED OFF Faulty Processor Card Flashing Unit In Run Mode Scanner LED OFF Ethernet LED OFF OFF Temp LED OFF System Alarm ON No Faulty Scan Valid Processor Signal Card ON Comms Faulty Processor Driver Problem Card Ambient Faulty Temperature Processor Card OK ON System Faulty Processor OK Card ON LED Flashing? NO NO NO NO No Faulty Valid Processor Data Available Card LED Flashing? Comms Faulty OK Not Processor Active Card Temperature Faulty Processor Warning >55 C Card LED Flashing? Faulty Processor Fault Card LED Flashing? YES YES YES YES Receiving Faulty Valid Processor Data Card Comms Faulty OK Processor Active Card Temperature Faulty Processor >60 C Alarm Card System Faulty Alarm Processor Active Card Page 21
Appendix B START-UP MODE DIAGNOSIS CHART Load OS & Drivers System Running LED On Ethernet Driver Fault OFF Ethernet LED ON Unit in Start-up Mode OS & Drivers Loaded OK Start Application Software Faulty I/O Card OFF Scanner LED ON I/O Card Identified Fault With TCP/IP Kernal OFF Temp Alarm LED ON Ethernet Configured Fault With I/O Card Configuration OFF System Alarm LED ON I/O Configured System Start-up Completed Page 22