USYS 2100 Monitoring, Data Control, Acquisition and Display for Single and Multi Sensor Applications. New user friendly design Operator interface with choice of languages New menu driven, context sensitive software keys New faster and more efficient software platform Status of your line at a glance Intelligent SIGMA EXPERT control and Cpk pilot Rugged and reliable combination of proven and innovative technology Bright high resolution color TFT LCD screen Unlimited number of product recipes Strip chart, SPC data and graphics Reel Report, Session Report, Data Log CE compliant
USYS 2100 The Universal Processor, Operators Will Love The operator friendly USYS 2100 is an updated version of the USYS 2000 which has been proven in numerous applications. Its flexible configuration, with CPU, I/O PCBs and process-specific intelligence from the extensive Zumbach software library, provides optimal adaptability to suit the process and production line. A complete status display of the parameters informs continuously on the performance of the production line. This makes the USYS 2100 an ideal solution for diameter, wall thickness, capacitance, concentricity/eccentricity and fault control. Multifunctional USYS 2100 manages and monitors quality and production costs by simultaneously carrying out all the following functions (multitasking): 1. Continuous measurement and display 2. Monitoring of the limit values 3. Diameter, wall thickness, concentricity/ eccentricity, capacitance control 4. Material savings 5. Recipe management 6. Statistics and data logging, SPC control charts 7. Communication with a computer Can Be Used With Any Zumbach Gauge Up to 2 sensors may be connected for dimensions. It is also possible to connect KW fault detectors, spark testers and a length detector. All faults can be logged and identified. Typical sensors which can be connected to the USYS 2100 processor: ODAC for diameter Spark Tester for cable insulations ODEX 10 for concentricity/ eccentricity and diameter CAPAC for capacitance KW for lump and neckdown Diameter and Thickness Control Every USYS 2100 includes 1 SIGMA EXPERT controller with Static Regulating Device (SRD) or relay output. The SIGMA EXPERT controller is self-optimizing. It does not require further parameter optimization and even provide dynamic regulation of the process during start-up. Recipe Memory Unlimited product recipes can be stored in the memory and are constantly accessable. Any amount of products can be managed by an external PC connected to the serial or the Ethernet interface. The statistics for the quality of every reel as well as of the entire production are calculated by USYS and are available to the host computer. Communication and Networking ZUMBACH offers a variety of interface units and USYS software to satisfy almost any need to communicate with other computers or networks. USYS Web Server This optional software enables the display of information from USYS processor at remote terminals. Whilst the USYS processor is working it is also possible to edit the product table from one or several terminals. Communicates via LAN. Viewing with Internet Explorer or other browser. Applications Different configurations are possible, depending on the user's needs and requirements: Centralizing the Information Distributing the Information Managing the USYS processor from different remote locations Multi Terminal / Multi User System USYS 8100 and/or USYS 2100 LAN Intranet Production manager USYS Data Log Windows based software for easy data collection from one or several processors and for saving the data in text or Excel files. Windows and Excel are trademarks of Microsoft Corporation Forward departement Production planning Quality control 2
USYS 2100 In the Wire, Cable, Plastics, Rubber and Other Industries A Selection of Typical Application Configurations: Diameter and Eccentricity Measurement, Spark Tester and Lump Detector/Neckdown Full cold end product information with automatic control of diameter through capstan speed or extruder screw rpm. Hot and Cold Diameter & Eccentricity, Spark Tester and Lump Detector/Neckdown For quick control based on the hot end diameter measurement taking into account the shrinkage as the product cools. Capacitance or Diameter Control & Eccentricity, Spark Tester and Lump Detector/Neckdown Select capacitance or diameter as the most important parameter to control, depending on the product specification. USYS 2100 In the Steel and Metal Industry USYS 2100 is available with dedicated software for products such as rods, bars, sleeves, tubes, profiles, bolts and others in milling and forming processes. The special software features a selectable end suppression for the start and end of a product, so that end deformations do not figure in the statistical data and do not cause unintended corrective action. Alarms and pre-alarm limits can be set to control the production process and to warn the operator before product tolerance limits are reached. User friendly screens allow process status recognition "at a glance". Trend information is also shown which immediately informs the operator about the product variability. The menu driven software allows the user to specify the parameters for statistical evaluation and the statistical acquisition periods as required. Typical Processes QC Stations (Non-destructive testing) In-line measurement at QC stations integrated into the production line or at the end. A typical check of outside dimensions is achieved with ODAC measuring heads. Typical Display Configurations Peeling The instruments are arranged according to customer request or at the end of the production line for measurement of the finished product. Cold Rolling Wire or profiles are rolled to a final, more precise tolerance. ODAC diameter gauges measure the final product. Grinding Centerless grinding as well as grinding between centers for in-process and post-process applications. Polishing ODAC diameter gauges, mostly single axis, measure the bright finished bar. Cold Drawing In-line measurement allows the user to monitor die wear, die breaks, scratches or any other defects or diameter variations. 3
Typical Screens Concentricity display (With ODEX measuring system) Diameter and eccentricity information (With ODAC and ODEX measuring units) Bar rolling: Mean diameter information (With 2 ODAC gauges) Bar rolling: Mean diameter, statistics summary, characteristic strip chart information etc. Capacitance value (With CAPAC measuring system) Statistics, showing full graphical SPC pages: Histogram or X-Bar/Range Application Limits 1 or 2 ODAC Dimensional sensors or 1 or 2 CAPAC Capacitance sensors, 1 ODEX Concentricity/eccentricity and diameter gauge, 2 Event inputs (KW, Spark Tester), 1 Controlled Parameter. SIGMA EXPERT Controller and Cpk Pilot Intelligent and self-adjusting systems for dynamic control even during start-up. By means of the Cpk Pilot, the nominal value is automatically adjusted to the lower limit given by statistical computations. This means important material savings! HOT/COLD Control (Dual Loop) Patents: GB 2 145 852 B and others As a result of using 2 measuring gauges and a SIGMA EXPERT controller, dynamically optimal control is obtained with respect to the cold value. Material savings 4
USYS 2100 Front Panel Features 8.4" TFT LCD color screen with antireflective protection glass Context specific function keys Navigation and cursor keypads Numeric keypad USB port Power on/off switch Direct access function keys Mode key Switch between operator mode and configuration mode System information key Alphanumeric keyboard connector (PS/2 connector) Example of Main Screen Extrusion line with 2 diameter gauges, 1 eccenctricity and diameter measuring system, 1 fault detector and 1 spark tester Navigate with the cursor to view the Max, Min, Average etc. of controlled parameter Value of parameter being monitored/controlled "Trend charting" of controlled parameter Select the number on the numeric keypad or navigate with the cursor keys to display information specific to the device identified on the line layout. Relevant parameter status and value displayed in these windows Direct access key labels Depiction of the line layout (user configurable) Display TFT LCD display. Modern graphic user interface context sensitive software keys, direct access function keys and menu. Line and system configuration Measured values Status of measured values (in or out of tolerance) Alarms Error messages Strip chart, trend analysis SPC data and graphics Product table for unlimited product recipes 5 Software "Real Time" multitasking operating system 2 Function modes: Operator mode Configuration mode 5 context sensitive software function keys System security in case of mains power failure Simple software updates with flash disk or USB memory stick
USYS 2100 Rear Panel Features RS-232 COM 1, COM 2 Label / tag printer reel end summary printed onto self-adhesive labels or tags (contents configurable by user). Host computer / PLC up/download Connector for external keyboard or Ethernet Multi-port PCB RS-422 Included at "E" software versions (ODEX) Option for "A" software versions ISA Bus slots for system expansion Measuring head connector(s) Amphenol connectors for the connection of any digital ODAC J or CAPAC J-type sensor. USB ports Connector for parallel screen System printer (desktop or rack mount) data logging with length and time data reel end and session end reports "SRD" Static Regulating Device (or motorized potentiometer). Control of line speed/ extruder screw r.p.m. MPK1-10T Motorized potentiometer with servo valve for control of internal air support pressure. Line speed/footage counter input Proximity detector/wg2-/ti 069 Centronics LPT 1 Mouse PS/2 Mains connector Integrated connector with mains filter. Ground connection 2 Motorola I/O channel slots supporting an array of input/output PCBs needed to interface the system to the "outside world". Alarm/analog outputs expansion features tolerance pre-alarm and SPC trend alarm Event inputs (lumps, neckdowns, spark failures etc.) Chart recorder analog Specifications Power 90... 135 / 180... 265 VAC (auto-select), 47... 63 Hz Operating temperature 0... 50 C (32... 120 F) Weight Approx. 17.2 kg (38 lbs.) Dimensions Basic configuration Industrial PC (1 Ethernet, 3 USB 1.x, 2 RS-232, 1 Centronics, 8.4" TFT LCD, 32 MB flash disk). 1 CP.311 for one ODAC sensor, 1 IO.012 for input/ output, controller, alarm, 1 SRD (Static Regulating Device). USYS 2100 meets the current CE standards regarding overall performance and EMC (Electro Magnetic Compatibility). Inputs / Outputs The use of one additional board allows many different combinations. According the type, number and combination, the number of inputs and outputs change. Description Type of boards N6.IO.003 N6.IO.005 N6.IO.011 N6.IO.012 Digital inputs 8 5 8 7 Analog inputs 4 Digital outputs 4 5 Analog outputs 1 4 2 Relay outputs 8 5 3 210 (8.23) 177 (7) 1) 4 HU 2) 500 (19.7) 403 (15.8) 1) 1) without case 2) 1 HU = Height Unit = 44.45 mm (1.75 in.) 510 (20.1) 483 (19.0) 1) Technical specifications are subject to change without notice Dimensions in mm (in.) Switzerland: Zumbach Electronic AG, P. O. Box, CH-2552 Orpund, Phone +41 (0)32 356 04 00, Fax +41 (0)32 356 04 30, E-mail: sales@zumbach.ch USA: Zumbach Electronics Corp., 140 Kisco Avenue, Mount Kisco, NY 10549-1407, Phone +1 914 241 7080, Fax +1 914 241 7096, E-mail: sales@zumbach.com Other ZUMBACH companies in Argentina, Belgium, Brazil, China, France, Germany, India, Italy, Spain, Taiwan and UK plus agents and service in more than 40 countries. www.zumbach.com 6 USYS.004.5006.E MAY.2008