BK MIKRO 7 Control System for Tool, Object and Free Space Monitoring Operating Instructions Issue 2.01 dated 5.2.2007 MSC Tuttlingen GmbH Rudolf-Diesel-Straße 17 78532 Tuttlingen Germany Tel. +49 7461 925-276 Fax +49 7461 925-268 E-Mail sales-tut@msc.de www.msc-tuttlingen.
OI: BK MIKRO 7 General Notice General Notice Safety guidelines These operating instructions contain notices which you should observe to ensure your own personal safety, as well as to protect the product and connected equipment. These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger: Immediate danger to life and limb of personnel and others. Non-compliance may cause death or serious (crippling) injury.
General Notice OI: BK MIKRO 7 Qualification of personnel Only qualified personnel may carry out the following activities on the control system: installation, commissioning, operation, maintenance. Qualified persons in accordance with the safety guidelines are defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and systems in accordance with established safety practices and standards.
OI: BK MIKRO 7 Contents Contents 1 2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.2 2.2.1 2.2.2 2.2.3 2.3 3 3.1 3.2 3.3 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.3 4.2.4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.3 6 7 7.1 7.2 7.3 8 8.1 8.2 8.3 9 Characteristics ...........................................................................................................................3 System Components .................................................................................................................
Table of Figures OI: BK MIKRO 7 Table of Figures Fig. 2-1: Control unit – Connections ............................................................................................................4 Fig. 2-2: Control unit – Dimensions .............................................................................................................5 Fig. 2-3: Control unit – Light-emitting diodes ...............................................................................................8 Fig.
OI: BK MIKRO 7 1 Characteristics Characteristics BK MIKRO 7 is a control system suitable for tool as well as for object and free space monitoring applications. The complete BK MIKRO 7 system comprises a control unit, a sensor (scanner), a connection cable.
System Components OI: BK MIKRO 7 2 System Components 2.1 Control unit 2.1.1 Characteristic properties The control unit is available in three models preconfigured for different supply voltages. The relevant version will be marked on the rating plate: 24 VDC, 120 VAC, 230 VAC. On its front panel, the control unit is fitted with plug-in screw terminals to connect all machine inputs and outputs, supply voltage, and the scanner. The screw terminals have been arranged on two plug-in terminal blocks.
OI: BK MIKRO 7 2.1.2 System Components Technical data Housing Protection type Dimensions (W x H x D) Case mountings Power supply voltage (depending on model) Power consumption Control voltage (int./ext.) Inputs – Input current – Pulse duration Switched outputs Making/breaking capacity Operational life of relay Connections Climatological conditions Ambient temperature Storage temperature Insulating material housing, protection class II, built-in unit IP 20 45 mm x 75 mm x 107.
System Components 2.1.3 OI: BK MIKRO 7 Connections Power supply "24 VDC" model: "+" 24 VDC terminal Supply voltage input 24 VDC "–" 24 VDC terminal Reference potential of 24 VDC supply voltage 2) "120 VAC" and "230 VAC" models : "L1" terminal Supply voltage input, depending on model: 120 VAC or 230 VAC "N" terminal Supply voltage input, depending on model: 120 VAC or 230 VAC "+" 24 VDC terminal Control voltage for "Start" and "Teach" controlling inputs 24 VDC unregulated, output current 0.
OI: BK MIKRO 7 System Components Selection inputs "S1" terminal "S2" terminal "S3" terminal The input signal (static) of +24 VDC relative to "Com" terminal must be stable during 10 ms min. before "Teach" or "Start". The input S3 must be connected at a wand length of 250 mm. Concerning shorter wands, S3 remains unconnected. By connecting S3, the wand is slower and therefore it oscillates less.
System Components OI: BK MIKRO 7 Relay outputs The terminals have been designed as dry relay contacts. By switch selection, they may be configured as either normally open or normally closed. The contacts have been designed for 250 VAC and, by additional internal circuits, protected against inductive switch-off peaks of up to 19 W (2 ms). "K.O." relay terminals These two terminals are used to indicate a fault message (K.O.). "O.K.
OI: BK MIKRO 7 2.1.5 System Components Rotary switches The two rotary switches P1 and P2 on the control unit front panel are used to select the scanning mode ("Teach" or "Switch"). set the angular positions of the ranges, noted in degrees, that are controlled by object monitoring or free space monitoring. The position settings are possible in steps of 22.5°. P1 P2 0 270 0 90 180 90 180 Fig. 2-4: Control unit – Rotary switches The figure shows the setup on delivery.
System Components 2.1.6 OI: BK MIKRO 7 Toggle switches Using the six toggle switches arranged next to each other on the control unit front panel, the following functions may be set. High scanning intensity Low scanning intensity Relay N.C. (as normally closed contact) Relay N.O. (as normally open contact) Free space monitoring F O Object monitoring Counter-clockwise travel L R Clockwise travel Large range of tolerance Low range of tolerance Scanner TK7RL Scanner TK7A Fig.
OI: BK MIKRO 7 System Components "Clockwise / Counter-clockwise" switch (CW/CCW) Direction of rotation, i.e. direction to which scanner moves starting from stop position. Clockwise = When rotating to the right Scanner viewed from behind (the connection side), looking up length of scanner. Fig. 2-6: Definition of the rotation direction Note: Switch position may be changed by selection inputs S1, S2 and S3 (see table in section "Selection inputs"). "Tolerance range" switch Range of tolerance for "O.K.
System Components OI: BK MIKRO 7 2.2 Scanner 2.2.1 Characteristic properties The scanner housing is cylindrical and smooth, thus permitting easy installation (e.g. by using the mounting bracket). The scanner is designed for easy access for servicing and changing the wand. Aligning the scanner is easy and requires no additional instruments or aids. We offer two types of scanners for the different applications.
OI: BK MIKRO 7 Technical data Anodized aluminum IP 67 165 mm (standard), exchangeable wand 270° max. (scanner with mechanical backstop) 360° max. (scanner without mechanical backstop) Small circular connector, M12x1, 8 pin 0 ºC to +80 ºC –25 ºC to +85 ºC > 5 million at minimum scanning intensity ø1.2 circ. 150 Scanning wand Wand holder Housing Connector RO BK RO BK RO BK RO BK 26.5 angled, 8 pin Connection cable max. 114 standard length 165 mm 42.5 Protective cap ø20 9.
System Components 2.3 OI: BK MIKRO 7 Connection cable Control unit and scanner are connected by a 8-wire PUR-cable: 6 pin small circular connector to DIN 45322 at the control unit end. 8 pin molded plug at the scanner end. Length 5 m, can be extended to a maximum length of approximately 25 m with extension cables.
OI: BK MIKRO 7 3 Mode of Operation Mode of Operation BK MIKRO 7 can be operated in different ways: Scanning in one direction Scanning in both directions Monitoring with learning function (Teach mode) Monitoring with setting scanning range (Switch mode) Monitoring as object monitoring or free space monitoring All modes allow return travel monitoring. 3.1 Scanning process Applying a pulse to "Start" or "Teach" terminal will trigger a scanning cycle.
Mode of Operation 3.2 OI: BK MIKRO 7 Output of results Fault message (K.O.) A fault message will be output immediately on detection. The scanner will return to its stop position. Good cycle message (O.K.) without return travel monitoring: Results will be indicated on reaching the scanner's stop position. Note: Its return travel will not influence scanning results. – with return travel monitoring: On reaching the stop position, scanning process results will be indicated.
OI: BK MIKRO 7 4 BK MIKRO 7 with scanner TK7A – Scanning in one direction BK MIKRO 7 with scanner TK7A – Scanning in one direction Note: "Scanner" toggle switch set to "TK7A" = Switch P1=0 ? Scanner TK7A yes no no Error yes Switch P2=0 ? Switch „Object“ ? no Error yes no Switch P1 P2 ? yes no Error Switch P2 270 ? yes Switch mode Teach mode Fig.
BK MIKRO 7 with scanner TK7A – Scanning in one direction 4.1 OI: BK MIKRO 7 Teach mode = monitoring with learning function Requirement: Rotary switches P1=0 and P2=0 The scanning range will be determined by a learning cycle (external control signal). This mode of operation is the typical mode for tool detection applications: The system will check for the presence of the tool at the learned position 4.1.
OI: BK MIKRO 7 4.2 BK MIKRO 7 with scanner TK7A – Scanning in one direction Switch mode = monitoring with setting scanning range Requirement: Rotary switches 0 P1 P2 270 Rotary switch P1 and P2 settings will define the scanning range.
BK MIKRO 7 with scanner TK7A – Scanning in one direction 4.2.3 OI: BK MIKRO 7 Deflection of wand Rotation angles will be detected by scanner encoder pulses. These pulses are derived from the rotation of the motor. For scanning, a metal needle (wand) is used which, depending on the scanning force, can be deflected. As the scanner motor is still turning when the end of this wand has already come to a stop, differences between the set and actual rotation ranges will result.
OI: BK MIKRO 7 5 BK MIKRO 7 with scanner TK7RL – Scanning in both directions BK MIKRO 7 with scanner TK7RL – Scanning in both directions Note: "Scanner" toggle switch set to "TK7RL" = Only object monitoring, no free space monitoring! Special cases make possible scanning in one direction! Switch „Object“ ? Scanner TK7RL no Special modus specific wiring or relay usually not employed yes Switch P1=0 ? yes no yes Error yes Switch P2=0 ? Stop position exists ? yes no S1/S2= 00 or 11 ? no Erro
BK MIKRO 7 with scanner TK7RL – Scanning in both directions 5.1 OI: BK MIKRO 7 Teach mode = monitoring with learning function Requirement: Rotary switches P1=0 and P2=0 The scanning ranges will be determined by a learning cycle (external control signal). This mode of operation is the typical mode for tool detection applications: The system will check for the presence of the tools at the learned positions. 5.1.
OI: BK MIKRO 7 5.1.2 BK MIKRO 7 with scanner TK7RL – Scanning in both directions "Start", the real scanning process The scanner will travel to the previously "learned" positions of the objects to check for their presence. In so doing, the wand will first move in the preset direction, then in opposite direction. If the tools are within the monitoring ranges, the "O.K." relay will be activated. • If one of the two tools is not detected, (i.e.
BK MIKRO 7 with scanner TK7RL – Scanning in both directions 5.2 OI: BK MIKRO 7 Switch mode = monitoring with setting scanning ranges Requirement: Rotary switches 0 < P1 < 360 and 0 < P2 < 360 Rotary switch P1 and P2 settings will define two scanning ranges. In this mode of operation, BK MIKRO 7 allows only object monitoring: Two rotary switches are used to define two scanning ranges which are to be monitored before each working cycle. Note: A Pulse on the "Teach" terminal do not take effect. 5.2.
OI: BK MIKRO 7 5.2.2 BK MIKRO 7 with scanner TK7RL – Scanning in both directions Control operation "Object monitoring" The second "Start" pulse starts the real scanning process of object monitoring within two ranges. The control unit will change into an "O.K." state, i.e. it will issue a good message, if during a scanning cycle the operation sequence described below is followed: The scanner leaves its stop position. Both objects are detected within the rotation ranges P1 and P2.
Cycle Times 6 OI: BK MIKRO 7 Cycle Times Scanning times The following cycle times hold for systems with scanner TK7A or TK7RL: "Intensity" Switch TK7A – Scanning in one direction Angle "Teach" "Start" TK7RL – Scanning in both direction Angle "Teach" "Start" 15° 210 ms 150 ms ±15° 320 ms 260 ms 15° 170 ms 120 ms ±15° 210 ms 190 ms 90° 580 ms 280 ms ±45° 720 ms 370 ms 90° 330 ms 250 ms ±45° 360 ms 300 ms 180° 1000 ms 390 ms ±90° 1200 ms 470 ms 180° 520 ms 370 ms ±90°
OI: BK MIKRO 7 7 Status Indication 7.1 Yellow LED Status Indication Fast flashing = Self-test After power-up, the system will carry out a self-test indicated by fast flashing of this yellow LED. Steady illumination = Ready to operate Following its self-test, the system is ready to operate. The LED stops flashing and remains steady. Slow flashing = Scanner fault The system has detected a scanner fault: Scanner is missing or has motor fault. Control cable is not correctly connected, e.g.
Status Indication 7.3 OI: BK MIKRO 7 Error messages – Flashing red and green LED Check the following settings to remove the error messages. "Scanner" toggle switch (TK7A/TK7RL) "Object monitoring / Free space monitoring" toggle switch (O/F) Rotary switches P1 and P2 Selection inputs S1 and S2 The error messages are distinguished by connected scanner with corresponding setting of toggle switch to "TK7A" or "TK7RL".
OI: BK MIKRO 7 Installation Notes 8 Installation Notes 8.1 Control voltage connection Power supply and Control voltage GND Power supply 24 VDC GND Control voltage GND 24 VDC 24 VDC Start Teach-in + – 24 V DC Com Start Teach S1 AC IN N L1 k.o. C NO/NC Start Teach-in S3 + – 24 V DC Com Start Teach S1 o.k. C NO/NC AC IN N L1 k.o. C NO/NC S2 BK MIKRO 7 24 VDC common power and control voltage supply S2 S3 o.k. C NO/NC BK MIKRO 7 24 VDC separate control voltage Control voltage ext.
Installation Notes 8.2 OI: BK MIKRO 7 Mounting bracket The delivering program offers a mounting bracket for the scanner as accessories. Article no. 61 07 165 contains the following parts: Designation Material Part no. Mounting bracket AlCuMgPb, F 38, thickness 8, naturally anodized 2 cheese head screws with hexagonal hole M3x40 8.8 zinced 3 2 self-securing nuts M3 8 zinced 4 1, 2 General tolerances ISO 2768 – mK burred edges Fig. 8-2: Mounting bracket 8.
OI: BK MIKRO 7 9 Ordering Information Ordering Information Control unit Article no. BK MIKRO 7 24 VDC 63 04 220 BK MIKRO 7 120 VAC 63 04 222 BK MIKRO 7 230 VAC 63 04 221 Scanner Article no. TK7A (scanner with mechanical backstop) 63 04 234 TK7RL (scanner without mechanical backstop) 63 04 235 Connection BK MIKRO 7: Control unit – Scanner Length Article no.
Ordering Information Page 32 of 32 OI: BK MIKRO 7 Rev. 2.01 dated 05.02.
