BINAR PRODUCTION SYSTEMS FLC Tool CAMERA ASSEMBLY VERIFICATION USER MANUAL 2 FLC Tool User manual 2021-03-23 eng 1.00 Binar Solutions AB Box 2001 SE-461 11 TROLLHTTAN Sweden tel +46 (0)520 47 32 00 e-mail info@binar.se website www.binarsolutions.com 2021-03-23 eng 1.00 Contents 3 1 System overview ..................................................................................... 4 2 Operating the system Step-by-step ....................................................... 5 3 The FLC tool ............................................................................................ 6 3.1 Overview .................................................................................................... 6 3.2 LED symbols used throughout the manual ............................................... 6 3.3 Pairing ........................................................................................................ 7 3.1 How to apply and remove the FLC tool ..................................................... 8 3.2 Operation the verification sequence ...................................................... 9 3.3 Offline mode .............................................................................................10 3.3.1 Entering Offline mode ......................................................................10 3.3.2 Offline mode operation ....................................................................10 3.3.3 Leaving Offline mode .......................................................................10 3.4 Error/Warning cases ................................................................................. 11 3.5 Batteries ................................................................................................... 12 3.5.1 Battery LOW warning ....................................................................... 12 3.5.2 Replacing batteries .......................................................................... 12 Inductive plug-in-sensors ......................................................................... 13 3.6.1 Replacing the inductive sensors ...................................................... 13 3.7 Mechanical dimensions ............................................................................ 15 3.6 4 IIoT-Gateway LP304 ............................................................................... 16 4.1 Power supply ............................................................................................ 16 4.2 Connecting the I/O signals ....................................................................... 17 4.2.1 Timing diagram ................................................................................18 4.3 BiDisp3 (optional) ..................................................................................... 19 4.4 Mechanical dimensions and mounting .................................................... 19 4.5 User Interface .......................................................................................... 20 4.5.1 Home page ...................................................................................... 20 4.5.2 Pairing ............................................................................................. 20 4.5.3 Lamp test ........................................................................................ 20 4.5.4 Battery status .................................................................................. 21 4.5.5 System status .................................................................................. 21 4.5.6 Local settings ................................................................................... 21 5 Technical Data ........................................................................................ 22 6 Parts and accessories ............................................................................. 23 7 Troubleshooting .................................................................................... 24 The symbols in this manual are references to other manual sections.
( 3.2) for example, refers to section 3.2. If the manual is read as a pdf file, the references are clickable and link to the designated section. 2021-03-23 eng 1.00 4 1 System overview FLC, developed for Volvo Cars, is a special tool used for verifying that a front window camera has been mounted correctly. FLC uses wireless communication to receive job orders and report results back. Two inductive sen-
sors are used to verify the assembly and two RGY LEDs provide process information to the oper-
ator during operation. There is also an internal WiFi module available for future use/options. 3.1 FLC communicates with the IIoT (Industrial Internet of Things) Gateway LP304 (referred to as LP304 in this manual) through which job orders/results are transferred. LP304 has a touch screen interface and digital I/Os for communicating system control and operator information. There is also a Gigabit Ethernet port for future optional uses. 4 Camera unit assembly to verify FLC verification tool 3.1 Input (from PLC): Job Request 4.2 Output (to PLC): Job Completed 4.2 Pairing button (optional) System status 4 e.g. a Status lamp. A B Splitter cable for digital I/Os 4.2 Antenna for wireless communication with FLC Tool 2 Digital inputs 2 Digital outputs Power supply 24VDC, max 4A 4.1 IIoT-Gateway LP304 4
(referred to as LP304 in this manual) Option:
BiDisp3 multi-color LED display for showing more extensive user information. 2021-03-23 eng 1.00 5 2 Operating the system Step-by-step After all the hardware are mounted and all wiring is done:
Power ON LP304. Wait for appr. 45 seconds for LP304 to start up. The default screen will show on LP304. If no FLC tool has been paired yet, then perform the pairing operation 3.3. Wait for a Job Request and then perform the verification 3.2 (3.1). 2021-03-23 eng 1.00 6 3 The FLC tool 3.1 Overview Battery compartment
(beneath the end cap) Trigger button Status/Sequence indicator LEDs Pairing button Inductive plug-in-sensors Guide pin 3.2 LED symbols used throughout the manual Status/Sequence LED symbols used in this manual Style Steady Slow blink 1/sec (1Hz) Fast blink 5/sec (5Hz) Red/Yellow Color Green Yellow Red 2021-03-23 eng 1.00 3.3 Pairing 7 For the FLC tool to able to receive and perform jobs, it must first be paired with its base station (the IIoT-Gateway LP304). Make sure that the FLC tool is within range of the base station while performing the pairing operation. 1 Press (and hold) the Pairing button 2 Push the Trigger button
(no need to keep pressed). 3 4 The LEDs will do 3 fast green blinks per second, while seeking contact with the base station (LP304). Set the Base station (LP304) ready for pairing as well (this may be done prior to step 1-3 if one wish). Either press (and keep pressing) the Pairing button of the base station 4.5.2 or click the Pairing button at the LP304 touch screen interface. Note LP304 has a 180 sec pairing timeout. 5 When the FLC tool makes contact and pairs with the base station this is indicated by 5 fast green blinks followed by a few seconds of steady green light. Important!
The Pairing button has to be pressed throughout the whole Pairing operation. 2021-03-23 eng 1.00 8 3.1 How to apply and remove the FLC tool Here is the way to apply and remove the FLC tool. APPLYING With the tool at a slight angle insert the front guide pin into its corre-
sponding hole [1] and turn the tool downwards
[2] into place [3]. If the camera unit is not mounted correctly at the side to verify, the tool will not be able to come all the way down. However, if the camera unit is just a tiny bit out of place, the tool itself is meant to push the unit into place. REMOVING To remove the tool after verification, angle it backwards [4], the oppo-
site way it was applied, as shown in the images to the right. To remove the tool this way is important for avoiding unnecessary wear to the sensor sur-
faces. 2 2 1 3 4 4 2021-03-23 eng 1.00 9 3.2 Operation the verification sequence 2 Both LEDs will blink fast yellow for a short moment while the inductive sensors are being calibrated. 3 After that both LEDs will blink slowly yellow
(steady yellow if in Offline mode 3.3.) The FLC tool is now ready for operation. 1 Push the Trigger button to start. Note -
The Trigger button may be pressed throughout the operation but does not have to be. Note 30 sec timeout:
Verification must be completed within 30 seconds, otherwise the operation must be restarted (by pushing the FLC trigger button again). 4 5 Position the FLC tool at the first side to verify (left or right side doesnt matter). If the assembly was done correctly the yellow blinking LED closest to the camera unit will turn steady green. If not, the assemblage has to be corrected. Then position the FLC tool at the other side. If this side is also mounted correctly the other yellow blinking LED will turn green. After a few seconds both green LEDs will turn off, indicating a successful verification. 2021-03-23 eng 1.00 The offline mode makes it possible to perform a verification sequence totally independent of the supervisory system. This may be useful for e.g. post adjustments or for testing the tool itself. 10 3.3 Offline mode 3.3.1 Entering Offline mode 1 Push and hold the Trigger button. 2 3 The LEDs will show steady yellow light for 3 seconds indicating that the Offline mode is enabled. While still pressing the Trigger button, press the Pairing button 5 times in a row (max 1 sec between each time). x5 3.3.2 Offline mode operation The Offline operation is performed exactly as the online operation (3.2). The only difference is that instead of the LEDs blinking slowly yellow during the operation, they will show a steady yel-
low light. 3.3.3 Leaving Offline mode To return to normal operation just pair to the LP304 gateway again 3.3. 2021-03-23 eng 1.00 11 3.4 Error/Warning cases When activating the FLC tool by pressing the trigger button the following Error/Warning indications may occur. Fast blinking RED Inductive sensor fault. Slow blinking RED Steady RED No contact with the base station (LP304). No active job order exists. Possible reasons/solutions:
- Base station is out of range (operation range is up to 10 m (line-of-sight)).
- Base station is shut down or broken.
- No Pairing has been performed. Solution:
Wait for a job order. Reason:
The sensor at the side of the blinking LED may be faulty. Solution:
Replace the sensor 3.6.1. If that doesnt solve the problem replace the FLC tool. Fast blinking RED/YELLOW Pairing no longer valid. Reason:
Another FLC tool has been paired to the same station (LP304) as this tool, and therefore the pairing is no longer valid. Solution:
Perform the pairing operation again 3.3 2021-03-23 eng 1.00 12 3.5 Batteries The FLC tool is powered by two 1.5V AA Lithium batteries
(Energizer, type Ultimate Lithium 12-2039). 3.5.1 Battery LOW warning The estimated battery life is appr. 100.000 verification operations. When the battery capacity starts to run low, the operator is warned by e.g. a lamp connected to the Out2 digital output signal or (optional) by a message shown on a BiDisp display 4.2. 3.5.2 Replacing batteries Start by pulling of the end cap to expose the battery lid.
To open the battery compartment, turn the lid 90 counter clockwise. Batteries are inserted with the positive (+) pole facing outwards. Beware! Because the battery lid is spring loaded, it can easily fly away when you loosen it. 2021-03-23 eng 1.00 13 3.6 Inductive plug-in-sensors The FLC tool has two inductive plug-in-sensors, one at each side. The sensors can be replaced in case of malfunction or wear. There is a left hand and a right hand variant of the sensors. The left hand sensor will not fit the right side and vice versa. The letters L and R inprinted in the housing and the sensor units will tell which sensor to use at which side. 3.6.1 Replacing the inductive sensors Note that the FLC tool contains ESD-sensitive electronics (sensitive to electro-
static discharge). When replacing sensors the inside electronics will be some-
what exposed. Avoid touching the electronics and be sure to be well grounded. 1 Start by carefully pulling of the front cap to expose the plug-in-sensors. Be careful not to damage the thin walls at the bottom. 2021-03-23 eng 1.00 14 Remove the screws holding the sensor to be replaced. 2 3 4 Gently pull the sensor straight upwards. It can be a little tough but do not try to pry it up, just gently work it upwards. Put the replacement sensor in place by gently pushing it straight downwards. Then apply the screws. Be sure not to tighten them to hard that will damage the housing threads. Finally mount the the front cap back again, the opposite way it was dismounted. 2021-03-23 eng 1.00 15 3.7 Mechanical dimensions 2021-03-23 eng 1.00 Tool holder, wall mounted. Part no 53014 Tool holder, desk mounted. Part no 53018 16 4 IIoT-Gateway LP304 FLC communicates with LP304 through which job orders/results are transferred. LP304 has a touch screen interface and digital I/Os for communicating system control and operator infor-
mation. Input (from PLC): Job Request 4.2 Output (to PLC): Job Completed 4.2 System Status signal e.g. a Lamp indicator Steady On System OK Slow blinking FLC battery low Off System Error or FLC battery critical low 3 fast blink/second Pairing in progress Antenna for wireless communication with FLC Tool Pairing button (optional) 4.2 System status 4.2 e.g. connected to a Status lamp. 2 Digital inputs 2 Digital outputs 4.2 1 7 6 2 3 4 8 5 IIoT-Gateway LP304 A B Splitter cable for digital I/Os 4.2 Power supply 24VDC, max 4A 4.1 Option:
BiDisp3 multi-color LED display for showing more extensive user information. 4.1 Power supply LP304 is powered by 24VDC, max 4A, connected to the PWR connector (4-pole M12, male, T-coded). A suitable power supply is LP-PW14 from Binar Solutions AB (part no 51336). 1 2 3 4
+24V (20-30VDC) NC 0V NC M12 4-pole Male T-coded 1 3 4 2 LP-PW14 Power supply Part no. 51336 2021-03-23 eng 1.00 17 4.2 Connecting the I/O signals The I/O signals needed for the FLC system to work are connected to the 8-pole M12 connector I/O at the front of the LP304 by means of a splitter cable dividing the I/O signals into two 5-
pole M12 connectors, A and B (se section below). To the A connector there is an adapter cable con-
nected as well. I/O 8-pole M12 Male A-coded Connected to I/O at LP304 I/O 1 2 3 4 5 6 7 8
+24V OUT1
+24V 0V OUT4 IN2 0V IN3 I/O splitter cable Part no 54405 1 1 Adapter cable Part no 50137 A B A2 4-pole M12 Male A-coded 2 3 1 4 A3 4-pole M12 Male A-coded 5-pole M12 Female A-coded 1 4 5 2 3 Splitter cable Adapter cable A3 1 2 3 4 Signal Function Job Request 0V OUT1 Job Completed NC IN2 0V NC A2 1 2 3 4 A 1 2 3 4 5 B 1 2 3 4 5 Signal Function
+24V
+24V OUT4 System Status Pairing button 0V 0V IN3 NC Digital Inputs Type Signal levels Digital Outputs Type High level voltage
+24VDC Positive logic Logical 0 < +5VDC; Logical 1 > +15VDC
+24VDC Positive logic High level voltage = Supply voltage Output current Max 2A / output Short circuit protected Yes 2021-03-23 eng 1.00 18 4.2.1 Timing diagram Normal verification sequence:
Job Request IN1 Job Completed OUT1 Wireless To FLC Wireless From FLC d c 1 sec timeout b e FLC Timeout counter 30 sec timeout or Job finished a Job Request from PLC FLC Trigger button Verification finished The FLC tool in use. a Verification must be completed within 30 seconds (the timeout period), otherwise the operation must be restarted (by pushing the FLC trigger button again). b Job Completed (OUT1) goes low either when Job Request (IN1) goes low or after a 1 sec timeout. c d e Message:
Request to start + battery status. Message:
OK to start Message:
Verification done + battery status. 2021-03-23 eng 1.00 4.3 BiDisp3 (optional) To provide the operator with more comprehensive and clearer process information an optional BiDisp3 multi-color LED display may be connected to the X2 connector at LP304 (CAN bus). 19 4.4 Mechanical dimensions and mounting LP304 comes with mounting brackets attached and mounting is done by means of four screws, size M5 to M6 (see dimensions below). Mounting is preferably done in line of sight of the FLC tool, with the display at least at operators eye level, preferably a bit higher. DO NOT place LP304 in a metal enclosure as that would block the wireless communication. 2021-03-23 eng 1.00 20 4.5 User Interface 4.5.1 Home page B The status row [A] will show current system status The main menu [B]
There is no current job order. Waiting for job New job waiting A new job is ordered and waits to be done. The FLC tool is activated and verification Do perform job is to be performed. The job is completed. The FLC tool is activated when there is no job ordered. Battery low (and no active job). Pairing is in progress. Pairing is completed. Battery low Pairing Paired Job done No active job Home Status Return to Home page Show System status page 4.5.4 Not used for this application Network Local settings Show Local Settings page 4.5.2 Pairing The full pairing sequence is described in section 3.3. The base station can be set for pairing by pressing the PAIR NEW TOOL button. The pairing process can be aborted by pressing the STOP PAIRING button. 4.5.3 Lamp test To start Lamp test press button START LAMP TEST. This will make a lamp or other indicator driven by the System status signal (Out4 4.2) blink slowly (1Hz). To stop Lamp test press button STOP LAMP TEST. 2021-03-23 eng 1.00 A 4.5.4 Battery status 21 Note that the battery status of the FLC tool is only communicated to the system when the FLC tool is activated and there is a job waiting. The screen therefore reflects the status that applied at last job performed. The battery symbol to the right shows the battery status. When battery is low the symbol turns yellow. When battery is critical low the symbol turns red. Unknown battery status. This is shown in case LP304 hasnt received battery status from FLC, e.g. at start-up or after pairing. Section I/O Section CAN Section BWS Shows the I/O signal status. Shows status for the CAN bus
(connectors X1 and X2) Not used for this application. DO NOT press the START PAIRING button. Sets the application language Language None of the other functions at this page are used for this application. 4.5.5 System status 4.5.6 Local settings 2021-03-23 eng 1.00 22 5 Technical Data FLC TOOL Part no. CE-marked Enclosure class LP304 Part no. CE-marked Enclosure class Weight Dimensions Recommended batteries 2 pcs. Make: Energizer; Type: Ultimate Lithium 12-2039 Ambient temperature 0 40C (non-condensing) 35935 Yes IP42 55000 Dimensions L248.9 x w45 x h95.5 mm Operation range Up to 10 meters (line-of-sight) Power supply 20-30VDC (24VDC nom.) Max input current 4A Power connector M12, 4-pole Male, T-coded Ambient temperature 0 40C (non-condensing) Yes IP42 0.7 kg (incl bracket) w154.2 x d104 x h56 mm (excl connectors, antenna, and brackets) 2021-03-23 eng 1.00 23 6 Parts and accessories FLC tool PART NO PART DESCRIPTION 35935 FLC tool Complete with plug-in-sensors, end/front cover and batteries. 5 53019 Plug-in-sensor kit Left and Right plug-in-sensor 35939 End cover 35940 Front cover 36022 Battery lid 53020 FLC Toolbelt 31782 Battery (1 pcs) Energizer, Ultimate Lithium 12-2039 53014 FLC Tool holder Cup, wall mounted 53018 FLC Tool holder Cup, desk mounted LP304 IIoT Gateway PART NO PART DESCRIPTION 55000 LP304 IIoT Gateway 5 35851 LP304 Antenna 51329 LP-PW13 Power supply 24VDC, 8,0A. M12, 4-pole female, T-coded Cabling PART NO PART DESCRIPTION 50138 I/O splitter cable M12 8-p female to 2x M12 5-p female. A-coded. Length 39 cm. 50137 I/O adaptor cable M12 4-p male to M12 4-p male. A-coded. Length 22 cm. 50132 LP132 I/O cable 10 m M12 4-p male to M12 4-p female. A-coded. 50233 LP233 CAN cable 10 m M12 5-p male to M12 5-p female. A-coded. 50239 LP239 Bus termination M12 5-p female. A-coded. Miscellaneous PART NO PART DESCRIPTION 51113 LP113 Push button Green LED lamp. M12 I/O connections. 54405 Bidisp3/128/C display 128 x 16 px, 2 x CAN, 1 x RS232. 2021-03-23 eng 1.00 24 7 Troubleshooting FLC Tool Also see section 11 Error/Warning cases Situation Possible cause Cause/Solution Fast blinking red LED (one or both)*
Inductive sensor fault. The sensor at the side of the blinking LED may be faulty. Slow blinking red LEDs*
No contact with the base station
(LP304). Steady red LEDs*
No active job order exists. Wait for a job order. Fast blinking alter-
nately red/yellow LEDs*
Pairing no longer valid. Replace the sensor 3.6.1. If that doesnt solve the problem, replace the FLC tool.
- Base station is out of range (operation range is up to 10 m (line-of-sight)).
- Base station is shut down or broken.
- No Pairing has been performed. Another FLC tool has been paired to the same station (LP304) as this tool, and therefore the pairing is no longer valid. Perform the pairing operation all over again 3.3 None of the LEDs will light up*
No batteries mounted or mounted in wrong direction. Check/replace batteries. If that doesnt solve the problem, replace the FLC tool. Batteries need to be replaced. Hardware failure. Hardware failure Replace the FLC tool. Hardware failure Replace the FLC tool. One of the LEDs will not light up*
Pairing button doesnt respond
* When pressing the Trigger button LP304 Gateway Status lamp* slow blinking Status lamp* off Situation Possible cause Cause/Solution FLC battery low. Replace FLC batteries. FLC battery critical low or System error Replace FLC batteries. If that doesnt solve the problem contact the system administrator. Power supply malfunction. Check the power supply. LP304 screen is black/System show no life signs Hardware failure Operation range too short Antenna broken. Hardware failure. Receiving no job orders. Cabling faulty/malfunction
* Or other indicator driven by the System status signal (Out4) 4.2 If that doesnt solve the problem, contact the system administrator. Check/replace the antenna. If that doesnt solve the problem, contact the system administrator. Check I/O status at LP304 Status page 4.5.5. Verify the cabling. 2021-03-23 eng 1.00 25 2021-03-23 eng 1.00 Binar Solutions AB Box 2001 SE-461 11 TROLLHTTAN Sweden tel +46 (0)520 47 32 00 e-mail info@binar.se website www.binarelektronik.se 2021-03-23 eng 1.00 FCC Warning This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Any Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
-Reorient or relocate the receiving antenna.
-Increase the separation between the equipment and receiver.
-Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
-Consult the dealer or an experienced radio/TV technician for help.