Usys20 Usys.050.0020.en

PROCESSOR UNIT
HARDWARE / SOFTWARE
USYS 20
Document INSTRUCTION MANUAL

identification >>> USYS.050.0020.EN
The translation of the original instruction manual

This document, its contents, and the technology described are strictly confidential. It is provided
for assistance to ZUMBACH customers only. It may not be copied, reproduced or passed on to
third parties without express, written permission from ZUMBACH Electronics.
Registration, or Update Date of this Manual 23.04.2019
USYS 20 11 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, France, Germany, 1/146
USYS.050.0020.EN_20190423 India, Italy, Spain, Taiwan, UK and USA, plus agents and service in more than 40 countries.
About this Manual
The instruction manual contains all the information on installation, operation, maintenance, repair
and safety precautions for the USYS 20.
The content of this page describes in abbreviated form the chapters within this manual.
Read the chapters 2, 3 and 4 before starting the installation.
Chapter
1 Introduction
Generalities to be considered on receiving the Goods, Guarantee cases,
Addresses of the ZUMBACH Group, EU Declaration of conformity.
2 Safety
General and specific Safety precautions.
3 Technical description
System overview, delivery, technical data, drawings.
4A Hardware – Description
4B Hardware – Installation
5 Operating instructions (Software)
6 Statistics
7 List of select-codes
8 Host Interface
9 Maintenance
10 Repairing
Return for repairs, spare parts.
11 Decommissioning / Disposal
12 Protocols of communication
13 Appendix
14 ZUMNET
15 Index
2/146 11 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, France, Germany, USYS 20
20190423_USYS.050.0020.EN
India, Italy, Spain, Taiwan, UK and USA, plus agents and service in more than 40 countries.
Contents
1 INTRODUCTION 10
1.1 DEAR CUSTOMER.................................................................................................. 10
1.1.1 Risks and transportation......................................................................... 10
1.1.2 Inspection of goods upon arrival............................................................ 10
1.1.3 Warranty.................................................................................................... 10
1.2 ADRESSES – THE ZUMBACH-GROUP................................................................. 11
1.3 ZUMBACH PRODUCT OVERVIEW........................................................................ 12
1.4 SYMBOLS................................................................................................................ 14
1.5 EU DECLARATION OF CONFORMITY (Copy)...................................................... 15
2 SAFETY 16
2.1 SAFETY................................................................................................................... 16
2.2 GENERAL PRECAUTIONS..................................................................................... 16
2.3 INTENDED USE....................................................................................................... 17
2.4 INADMISSIBLE USE............................................................................................... 17
2.5 CARE AT HANDLING.............................................................................................. 17
2.6 MODIFICATIONS AT THE SYSTEM....................................................................... 17
3 TECHNICAL DESCRIPTION 18
3.1 SYSTEM OVERVIEW USYS 20.............................................................................. 18
3.2 DELIVERY EXTEND OF THE STANDARD EXECUTION....................................... 18
3.3 DIMENSIONS........................................................................................................... 19
3.3.1 Version as table top................................................................................. 19
3.3.1.1 Wall mounting............................................................................... 19
3.3.2 Version as 19" rack.................................................................................. 19
3.3.2.1 In 19" rack............................................................................... 19
3.3.2.2 Only 19" rack.......................................................................... 19
3.3.3 Wall mounting........................................................................................... 20
3.3.4 Table top.................................................................................................... 20
3.4 TECHNICAL DATA.................................................................................................. 21
4A DESCRIPTION OF THE HARDWARE 22

4A.1 PROCESSOR BOARD N6.CP.305.......................................................................... 23
4a.1.1 General description.................................................................................. 23
4A.1.2 Technical data........................................................................................... 23
4A.2 N6.IA.165 MULTIFUNCTION I/O BOARD............................................................... 24
4A.3 OPTION: DDC/SRD CONTROL MODULE B.USY.002.8010 (N6.IA.173.A)........... 24
4a.3.1 General description ................................................................................. 24
4A.4 OPTION: RTC USYS 20 – USY.9401.00100 (M 1093.A2)...................................... 25
4A.4.2 Technical data........................................................................................... 25
4B INSTALLATION / COMMISSIONING 26
4B.1 OPERATING PRECAUTIONS................................................................................. 26
4B.2 CHECK THE POWER SUPPLY VOLTAGE............................................................. 26
4B.3 COMPONENTS OF THE PROCESSOR UNIT USYS 20........................................ 27
4B.3.1 Front panel................................................................................................ 27
4B.3.2 Rear panel................................................................................................. 28
4B.3.3 "Port 1" and "Port 2" Serial ports........................................................... 29
4B.3.4 "Port 3" Ethernet connection.................................................................. 30
4B.4 CONNECTION TO MAINS....................................................................................... 30
4B.5 GAUGE.................................................................................................................... 30
4B.6 LENGTH DETECTOR.............................................................................................. 31
4B.6.1 Installation................................................................................................ 31
4B.6.2 Connection (2-Wire NAMUR)................................................................... 32
4B.6.3 Configuration and operational check....................................................... 32
4B.7 CONTROL OF THE STATISTICS............................................................................ 33
4B.8 ANALOG OUTPUT.................................................................................................. 33
4B.9 RELAY OUTPUTS................................................................................................... 33
4B.10 CONTROL WITH MOTOR POTENTIOMETER (DDC-CONTROLLING)................ 34
4B.10.1 Actuation by relays................................................................................... 34
4B.10.2 Correction effects..................................................................................... 34
4B.10.3 Control key "Controller ON/OFF"............................................................ 34
4B.10.4 Configuration of the controller parameters........................................... 34
4B.11 STATIC CONTROL SRD (OPTION)........................................................................ 35
4B.11.1 Trim mode.................................................................................................. 35
4B.11.2 Connecting the SRD Static Regulating Unit........................................... 36
4B.11.3 Polarity of the SRD input voltage............................................................ 36
4B.11.4 Power-On relay.......................................................................................... 36
4B.11.5 Control key "Controller ON/OFF" ........................................................... 36
4B.11.6 Configuration of the controller parameters............................................ 37
4B.12 "ST2": DIGITAL AND ANALOG IN- AND OUTPUTS............................................. 37
4B.12.1 Pin assignment "ST2".............................................................................. 37
4B.12.2 Wiring references for "ST2"..................................................................... 37
4B.12.3 "DIN1" and "DIN2" Counter inputs......................................................... 38
4B.12.3.1 Equivalent circuit..................................................................... 38
4B.12.3.2 Allocation.................................................................................. 38
4B.12.3.3 Interferences at the digital counter inputs USYS xx............ 38
4B.12.3.4 Configuration........................................................................... 39
4B.12.3.5 Electrical specifications:
"DIN1" and "DIN2" counter inputs.......................................................... 40
4B.12.4 Digital inputs "DIN3" to "DIN7"............................................................... 40
4B.12.4.1 Equivalent Circuit.................................................................... 40
4B.12.4.2 Configuration........................................................................... 40
4B.12.4.3 Allocation of the digital inputs
"DIN3" to "DIN7" in the "sinking" mode:............................................... 41
20190423_USYS.050.0020.EN
4B.12.4.4 Allocation of the digital inputs
"DIN3" to "DIN7" in the "sourcing" mode:............................................. 41
4B.12.4.5 Electrical specifications: counter inputs "DIN3" to "DIN7".41
4B.12.5 Digital outputs "DOUT1" to "DOUT5"..................................................... 42
4B.12.5.1 Equivalent Circuit.................................................................... 42
4B.12.5.2 Configuration........................................................................... 42
4B.12.5.3 Allocation of the digital outputs............................................. 43
4B.12.5.4 Electrical specification of digital outputs.............................. 43
4B.12.6 Output similar........................................................................................... 43
4B.12.7 Analogue output SRD (optionally).......................................................... 43
4B.12.8 Analogue input SRD (optionally)............................................................. 43
4B.13 "ST1" RELAY OF OUTPUTS.................................................................................. 44
5 OPERATING MANUAL 45
5.1 FUNCTIONAL DESCRIPTION................................................................................ 45
5.2 PRINTOUTS AND PARAMETER DEFINITIONS..................................................... 46
5.3 FUNCTION OF FRONT PANEL ELEMENTS.......................................................... 47
5.3.1 LCD Display.............................................................................................. 47
5.3.1.1 Window title............................................................................ 47
5.3.1.2 Measured value display........................................................ 48
5.3.1.3 Information Line..................................................................... 48
5.3.2 Entry field.................................................................................................. 49
5.3.2.1 Key "+/-" ................................................................................. 49
5.3.2.2 Key " " .................................................................................. 49
5.3.2.3 Key "Esc"............................................................................... 49
5.3.2.4 Key "Enter"............................................................................. 49
5.3.2.5 Key "Select"........................................................................... 49
5.3.3 Function keys........................................................................................... 50
5.3.4 Alarm lamps.............................................................................................. 50
5.3.5 Control key "Controller ON/OFF"........................................................... 50
5.4 FUNCTION KEYS – PARAMETER ENTRY............................................................ 51
5.4.1 Function key "Nominal"........................................................................... 51
5.4.2 Function key "Tolerance"........................................................................ 52
5.4.3 Function key "Statistic"........................................................................... 53
5.4.4 Function key "User"................................................................................. 54
5.5 KEY "SELECT" – CONFIGURATION MODE....................................................... 55
5.5.1 Key "Select".............................................................................................. 55
5.5.2 Display field.............................................................................................. 56
5.5.3 Parameter identification.......................................................................... 56
5.5.4 Parameter entry........................................................................................ 56
5.5.5 Navigation................................................................................................. 58
5.5.6 Protected entry......................................................................................... 58
5.5.7 Exit from configuration mode................................................................. 59
5.5.8 System configuration printout................................................................ 59
5.5.9 Security code............................................................................................ 59
5.5.10 Changing the security code.................................................................... 60
5.6 TOLERANCE MONITORING AND FAULT DETECTION........................................ 60
5.6.1 Select Code 400: Output rate of tolerances........................................... 60
5.6.2 Select Code 403: Tolerance in empty measuring field......................... 60
5.6.3 Select Code 404: Absolute or relative tolerance limits......................... 60
5.6.4 Select Code 405: Mode of tolerance monitoring................................... 61
5.6.5 Select Code 406: Extended tolerance monitoring................................. 61
5.6.6 Select Code 407: Tolerance monitoring of the ovality.......................... 61
5.6.7 Select Code 408: Fault detection............................................................ 62
5.6.8 Select Code 409: Acquisition period for KW function.......................... 62
5.6.9 Alarm lamps.............................................................................................. 62
5.6.10 Relays and digital outputs....................................................................... 63
5.7 PRINTER INTERFACE............................................................................................ 63
5.7.1 Printer initialization string....................................................................... 63
5.7.2 Text format................................................................................................ 63
5.7.3 Operation.................................................................................................. 63
5.7.4 Report layout............................................................................................ 63
5.7.5 Formatted Output of the reports............................................................. 64
5.7.6 System configuration printout................................................................ 65
5.8 CONTROLLER (OPTION)....................................................................................... 65
5.8.1 Control key "Controller ON/OFF"........................................................... 65
5.8.2 Display of the correction factor.............................................................. 65
5.8.3 Entry of controller settings..................................................................... 66
5.8.4 Inner Diameter.......................................................................................... 66
5.8.5 Select Code 200: Dead band................................................................... 66
5.8.6 Select Code 201: Control limits.............................................................. 66
5.8.7 Select Code 202: Averaging.................................................................... 67
5.8.8 Select Code 203: Deadtime..................................................................... 67
5.8.9 Select Code 204: Correction factor........................................................ 68
5.8.10 Select Code 205: Selection of the control value................................... 68
5.8.11 Select Code 210: Entry mode of the dead band.................................... 68
5.8.12 Select Code 211: Control action............................................................. 68
5.8.13 Select Code 212: Length-based or time-based control........................ 68
5.8.14 Select Code 213: Controller type and control polarity......................... 69
5.8.15 Select Code 214: Actuator constant....................................................... 69
5.8.16 Select Code 220: Manual reset of the static controller......................... 70
5.8.17 Factory settings........................................................................................ 70
5.9 LED ADDITIONAL DISPLAY................................................................................... 70
5.9.1 Mains connection..................................................................................... 70
5.9.2 Connection to the USYS 20 processor unit........................................... 70
5.9.3 Setting the device address...................................................................... 71
5.9.4 Character format...................................................................................... 71
5.9.5 Functional description............................................................................. 72
20190423_USYS.050.0020.EN
5.10 OPTIMIZING MEASUREMENT ACQUISITION....................................................... 72
5.10.1 Select Code 910: Relative fault monitoring........................................... 72
5.10.2 Select Code 911: Absolute monitoring................................................... 73
5.10.3 Select Code 912: Position monitoring.................................................... 73
5.10.4 Select Code 913: Error suppression...................................................... 73
5.10.5 Select Code 918: Acquisition interval of internal preprocessing........ 73
5.11 CYCLICAL OUTPUT OF THE ACTUAL VALUES.................................................. 73
5.12 ERROR MESSAGES............................................................................................... 74
5.13 PENETRATION DEPTH MEASUREMENT OR HEIGHT MEASUREMENT........... 75
5.13.1 Penetration depth measurement principle............................................ 75
5.13.2 Select Code 922: "Zeroing" a ground penetration depth..................... 75
5.13.3 Select Code 922: Resetting the ground penetration depth.................. 76
5.14 DUAL-MEASURING HEADS WITH ....................................................................... 76
SYNCHROBOX CI-1JS/1J "LARGE DIAMETER".................................................. 76
5.14.1 "Large Diameter" Calibration of dual ODAC JSxK with ...................... 77
synchrobox CI-1JS/1J.............................................................................. 77
5.15 OPTION: REAL-TIME CLOCK................................................................................ 78
5.15.1 Display of date and time.......................................................................... 78
5.15.2 Select Code 080: Selection of date format............................................. 78
5.15.3 Select Code 081: Selection of time format............................................. 78
5.15.4 Entering date and time............................................................................. 78
5.15.5 Configuration of statistics and reports.................................................. 78
6 STATISTICS 79
6.1 COMPUTATION OF THE STATISTICAL VALUES.................................................. 79
6.2 ACQUISITION OF ADDITIONAL PARAMETERS................................................... 80
6.3 FUNCTIONAL DESCRIPTION................................................................................ 80
6.3.1 Delay of actual values and events.......................................................... 80
6.3.2 "Start/Stop" Evaluation period................................................................ 80
6.3.3 Pause function "Pause"........................................................................... 81
6.3.4 Period number.......................................................................................... 81
6.3.5 Length counter......................................................................................... 81
6.3.6 Text fields.................................................................................................. 81
6.3.7 Additional values...................................................................................... 81
7 LIST OF SELECT-CODES FOR PARAMETER INPUT 82

7.1 GROUP 0XX: MEASUREMENT AND DISPLAY..................................................... 82
7.2 GROUP 1XX: DISTANCES AND LENGTH DETECTOR........................................ 84
7.3 GROUP 2XX: CONTROLLER................................................................................. 84
7.4 GROUP 3XX: ANALOG OUTPUT........................................................................... 86
7.5 GROUP 4XX: TOLERANCE CONTROL................................................................. 86
7.6 GROUP 5XX: DIGITAL AND RELAY OUTPUTS – DIGITAL INPUTS.................... 87
7.7 GROUP 6XX: SERIAL COMMUNICATION ............................................................ 89
7.8 GROUP 7XX: STATISTICS AND REPORTS ................................................................ 92
7.9 GROUP 9XX: SYSTEM PARAMETERS AND MEASURING HEAD....................... 93
8 HOST INTERFACE: LIST OF DATA AND PARAMETERS 96
8.1 GROUP A: SYSTEM PARAMETERS...................................................................... 96
8.2 GROUP B: LINE AND CONTROL PARAMETERS................................................. 98
8.3 GROUP C: PRODUCT PARAMETERS................................................................... 99
8.4 GROUP D: MEASUREMENTS AND RESULTS.................................................... 100
8.5 GROUP E: ALARM MESSAGES AND DEVICE STATUS.................................... 101
8.6 GROUP F: CONTROL FUNCTIONS..................................................................... 102
8.7 GROUP G: MEASURING HEAD INPUT VALUES................................................ 103
9 MAINTENANCE 104
9.1 REGULAR MAINTENANCE.................................................................................. 104
9.2 DIAMETER CALIBRATION................................................................................... 104
9.2.1 Select Code 901: Head type.................................................................. 104
9.2.2 Select Code 900: Measurement unit..................................................... 105
9.2.3 Select Code 001: Measurement resolution.......................................... 105
9.2.4 Select Code 902: Head calibration........................................................ 105
9.3 INITIALISATION OF THE INSTRUMENT.............................................................. 106
10 REPAIRING 107
10.1 RETURN FOR REPAIRS....................................................................................... 107
10.2 CONDITIONS APPLYING TO SPARE PARTS...................................................... 107
10.3 HOW TO MOUNT THE HOOD OF THE TABLETOP MODEL.............................. 108
10.4 LIST OF SPARE PARTS FOR............................................................................... 108
10.5 CHECK LIST BEFORE CONTACTING THE SERVICE........................................ 110
11 DECOMMISSIONING / DISPOSAL 111

11.1 DECOMMISSIONING.............................................................................................111
11.2 GENERAL DISPOSAL...........................................................................................111
12 PROTOCOLS OF COMMUNICATION 112

12.1 OVERVIEW............................................................................................................ 112
12.1.1 ASCII protocol........................................................................................ 112
12.1.2 Multidrop protocol.................................................................................. 112
12.2 COMMUNICATION SYNTAX................................................................................. 113
12.3 GENERAL DEFINITIONS...................................................................................... 113
12.3.1 Communication errors........................................................................... 114
12.3.2 Data and parameter access................................................................... 115
12.4 ZUMBACH ASCII PROTOCOL ............................................................................ 115
12.4.1 Upload..................................................................................................... 115
12.4.2 Download................................................................................................ 116
20190423_USYS.050.0020.EN
12.5 ANSI X3.28-2.5-A4 STANDARD PROTOCOL...................................................... 116
12.5.1 Upload..................................................................................................... 116
12.5.2 Download................................................................................................ 118
12.6 EXAMPLES: UPLOAD/DOWNLOAD WITH IBM COMPATIBLE PC................... 119
12.6.1 Example with ZUMBACH ASCII protocol............................................. 119
12.6.2 Example with ANSI X3.28-2.5-A4 protocol........................................... 121
12.7 ANNEX: CONNECTING AN IBM COMPATIBLE PC............................................ 125
13 TECHNICAL APPENDIX 126

13.1 WIRING DIAGRAM USYS 20 (LEMO) STANDARD............................................. 126
13.2 WIRING DIAGRAM USYS 20 (LEMO) STANDARD 19"...................................... 127
13.3 WIRING DIAGRAM USYS 20 (AMPHENOL) STANDARD................................... 128
13.4 WIRING DIAGRAM USYS 20 (AMPHENOL) STANDARD 19"............................ 129
13.5 SN6.CP.305.A3 1/2................................................................................................ 130
13.6 SN6.CP.305.A3 2/2................................................................................................ 131
13.7 SCHEMATIC DIAGRAM SN6.CP.305.3................................................................ 132
13.8 INTERFACE PCB SN6.IA.165.A1......................................................................... 133
13.9 SCHEMATIC DIAGRAM SN6.IA.165.2................................................................. 134
13.10 SRD INTERFACE PCB SN6.IA.173.A3................................................................. 135
13.11 SCHEMATIC DIAGRAM SN6.IA.173.3................................................................. 136
13.12 INTERFACE FOR KEYBOARD AND DISPLAY SN6.IA.175.A2........................... 137
13.13 SCHEMATIC DIAGRAM N6.IA.175.3.................................................................... 138
14.1 GENERAL DESCRIPTION.................................................................................... 139
14 ZUMNET 139
14.2 CABLING............................................................................................................... 139
14.3 SHIELD / GROUND............................................................................................... 139
14.4 ELECTRICAL STANDARD.................................................................................... 139
14.5 FAIL-SAFE INTERFACE....................................................................................... 139
14.6 ZUMNET APPLICATION EXAMPLE..................................................................... 140
15 INDEX 141
1 INTRODUCTION
1.1 DEAR CUSTOMER

Thank you for giving us and our products your trust. Kindly read the operating instructions
carefully. This is a prerequisite to achieve faultless initial operation and functioning of
the unit. The safety precautions must be observed during all phases of installation,
operation, maintenance, repair and decommissioning.
► The commercial terms and conditions of the document "General terms and
conditions of sale" (ZUMB.540.0003.E) are binding.
1.1.1 Risks and transportation

The moment the equipment is shipped from our plant, Buyer assumes all risks
regarding it, in particular but not limited to the risk for damage, loss, theft, attachment
or confiscation.
1.1.2 Inspection of goods upon arrival

• Remove packing material carefully.
• Keep it for possible storing or return of the unit.
• Check the equipment for possible damage due to transportation.
• In case of damage, inform immediately both the forwarder and the carrier.
• Examine the equipment within a reasonable period of time and notify us
immediately in writing of any defects, or missing parts.
1.1.3 Warranty
As far as practically possible and in our opinion deemed necessary, each part of the
equipment is tested for its proper working condition prior to shipment.
The general warranty regulations can found in our “General sales and delivery terms”
(ZUMB.540.0003.E).
Certified Quality
In addition to conforming to ISO 9001:2015, Zumbach's quality standards
guarantee a highly precise, robust and reliable product. The goal of the
ZUMBACH group is to offer industry the most complete line of measuring and
monitoring instruments of the highest quality and technology. Worldwide support
by competent advisors and reliable service is provided by 11 ZUMBACH owned
enterprises and by over 40 agencies, we are committed to Total Customer
Satisfaction. ISO 9001:2015
20190423_USYS.050.0020.EN
1.2 ADRESSES – THE ZUMBACH-GROUP
Switzerland Zumbach Electronic AG India Zumbach Electronic India Pvt. Ltd.
(H.Q.) P.O. Box S No: 106/2/1, 2nd lane, "Daffodils" Society
CH-2552 Orpund Row House No: 7, Near Karnataka Bank,
Phone +41 (0)32 356 04 00 Behind D mart, Baner Mahalunge Road,
Fax: +41 (0)32 356 04 30 Baner, Pune - 411045
E-mail: sales@zumbach.ch Maharashtra
Mobile +91 9890 100 813
Benelux Zumbach Electronic AG E-mail: sales@zumbachindia.com
P.O. Box
CH-2552 Orpund Italia Zumbach Electronic Srl
Tel. +32 (0)52 31 18 81 Via Adua, 19
Fax +41 (0)32 356 04 30 IT-21045 Gazzada Schianno (VA)
E-mail: sales@zumbach.be Tel. +39 0332 870 102
Fax +39 0332 464 605
China Zumbach Electronic (Shanghai) Co., Ltd. E-mail: zumit@zumbach.it
2F, Building 18
No. 481 Guiping Road Taiwan Zumbach Electronics Far East
200233 Shanghai, P.R. China 4F., No. 262, Sec. 6
Tel. +86 (0)21 542 60 443 Ming-Chuan E. Road
Fax +86 (0)21 542 61 151 Taipei
E-mail: sales@zumbach.com.cn Taiwan R.O.C.
Tel. +886 2 2630 5530
Deutschland Zumbach Electronic GmbH Fax +886 2 2630 5529
Kesselsgasse 2 E-mail: info@zumbach.tw
DE-50259 Pulheim
Tel. +49 (0)2238 8099-0 UK Zumbach Electronics Ltd.
Fax +49 (0)2238 8099-49 Registered Office Address:
E-mail: verkauf@zumbach.de 22 Cromwell Business Centre
Howard Way, Newport Pagnell
Büro in Gera:
Milton Keynes, MK16 9QS.
Robert-Leube-Weg 3
Phone: +44 (0)870 774 3301
DE-07548 Gera
Fax: +44 (0)870 774 3302
Tel. +49 (0)365 8320265
E-mail: sales@zumbach.co.uk
Fax +49 (0)365 8320268
Company Registered in England
Mobil +49 (0)172 9318525
Company Registration Number: 1233358
E-mail: wohlfeld@zumbach.de
USA Zumbach Electronics Corp.
España Zumbach Electrónica S.L.
140 Kisco Avenue
Avinguda de Cornellà, 144, 3o, 3a
Mount Kisco, NY 10549-1407
ES-08950 Esplugues de Llobregat
Phone: +1 914 241 7080
(Barcelona)
Fax: +1 914 241 7096
Tel. +34 93 666 93 61
E-mail: sales@zumbach.com
E-mail: gestion@zumbach.es
France ZUMBACH Bureau France

(vente) 6 rue de l'Avenir
FR-77760 La Chapelle La Reine
Tél. +33 (0)1 64 24 46 31
Fax +33 (0)1 64 24 46 26
E-mail: ventes@zumbach.com.fr
Service ZUMELEC Sarl
après-vente: 6 rue de l'Avenir
FR-77760 La Chapelle La Reine
Tél. +33 (0)1 64 24 42 69
Fax +33 (0)1 64 24 46 26
E-mail: service@zumbach.com.fr
www.zumbach.com
20180611 blog.zumbach.com
1.3 ZUMBACH PRODUCT OVERVIEW
ZUMBACH Measuring and Control Systems for On-line and Off-line Use in the Wire
and Cable Industry, Plastics and Rubber Industry, Steel and Metal Industry, for Medical
and Laboratory Applications and more.
ODAC® 1, 2 and 3 axis Laser

Diameter Scanners for
non-contact dimensional
measurement
MSD Diameter and Ovality

measuring heads for
non-contact dimensional
measurement with "Linear
Sensor Technology"
ODEX® Non-contact Eccentricity,

Diameter and Ovality
Measuring System
USYS Multitasking Data

Acquisition and Control
Systems
RAYEX® X-Ray Measuring System

for CV lines (Continuous
Vulcanization)
CELLMASTER® Foam and Foam Skin

Measuring and Control
System
CAPAC® Capacitance Measuring

and Control Systems
20190423_USYS.050.0020.EN
UMAC® Ultrasonic Eccentricity
and Wall Thickness
Measuring and Control
Systems
KW
Lump and Neckdown
Fault Detectors
PROFILEMASTER® In-Line Profile

Measurement using
"Light Section" Principle
and Machine Vision
SIMAC® Surface Quality

Inspection Systems
LSV Speed and Length

Measuring System
WST TEMPMASTER Conductor Preheaters
AST L
AST H 15A Spark Testers
DST 28A
CALIBRATOR SP Spark Tester Calibrator

for all Spark Tester
Models
1.4 SYMBOLS
Warning, possibility of electrical shock!
General warning sign!

See further instructions in this manual.
Disposal of old devices: This symbol indicates that this product

must not be disposed together with regular household waste.
Collect old devices separately and deliver them to the designated
collection point for recycling of electrical devices and electronic
accessories according to WEEE (waste electrical and electronic
equipment) directives.
CAUTION Safety warning: A note with the heading CAUTION indicates

a danger which could possibly lead to damage or loss of data.
Only continue the process if you have fully understood the note
and can adhere to it.
WARNING Safety warning: A warning with the heading WARNING indicates

a danger which could possibly lead to injury or death. Only
continue the process if you have fully understood the note and
can adhere to it.
20190423_USYS.050.0020.EN
1.5 EU DECLARATION OF CONFORMITY (Copy)
The following EU declaration of conformity is a content report of the original document
only, which is kept and available at Zumbach Electronic AG. The document has no
serial number or signing.
2 SAFETY
2.1 SAFETY
The USYS 20 fulfills the requirements of European directives for low voltage and EMC.
This instruction manual provides information on existing residual risks and

avoidance of dangers. Inform persons who are handling the USYS 20 regarding
proper use and avoidance of dangerous situations.
Installation, operation, maintenance and repairing as well as decommissioning

must be done only by qualified personnel.

Follow the instructions in the corresponding chapters to avoid hazards.
Attention: Hazardous voltages inside the unit. Observe the safety instructions
given in the instruction manual and the general precautions for working with
hazardous live voltages.
Be sure to disconnect the device from the power supply before working inside
the device: Pull the power plug! It is the responsibility of qualified electricians
to recognise the resulting dangers and to take appropriate safety measures.
2.2 GENERAL PRECAUTIONS

• The USYS 20 should be operated by qualified personnel only.
• Standard precautionary measures when dealing with laser are to be observed.
• Follow the procedure described in chapter 4 to avoid dangerous situations when
working with the USYS 20.
• For care and service study carefully chapter 10 in this instruction manual.
It contains information about avoiding dangerous situations.
• Service work is to be carried out by authorized technical personnel. If no other
agreement has been made, the service is to be carried out by the Zumbach
organisation.
► Further, specific safety aspects are listed in the corresponding chapters.
20190423_USYS.050.0020.EN
2.3 INTENDED USE
The USYS 20 is exclusively for the below listed applications determined. Other applications,
of which we have no knowledge, extinguishes all warranty claims.

• The USYS processor serves to process, display, monitor and to log the measured
data from the connected ZUMBACH sensor(s).
• The front panel and the back plate and also the connectors must be kept free from
water or other liquids.
2.4 INADMISSIBLE USE

Any use of the device not intended for its destination can be hazardous to the operator or
result in damage and voids all warranty claims.

WARNING
Following applications are forbidden:
• using the USYS 20 in a medium other than air
• using the USYS 20 in environment with a great explosion risk
• using the USYS 20 at temperature, humidity or altitude zones others than the
described in technical data
• operating the USYS 20 differently than by dedicated Zumbach data acquisition
system

► The above list does not pretend to be complete
In case of doubt, please contact an authorized ZUMBACH service centre or
the head quarter in Orpund, Switzerland.
2.5 CARE AT HANDLING
Avoid inappropriate handling!
The USYS 20 need no extraordinary care at handling. Appropriate operation, considering all,
in this instruction manual mentioned caution-and safety-measures is sufficient to guarantee
a long longevity and operation security.
2.6 MODIFICATIONS AT THE SYSTEM

In order to obtain the latest technical stand of this instrument, in case of system modifications
or expansions, it is recommended to consult an authorized Zumbach service station or to take
contact with the main office.
► The addresses are listed in chapter 1.2.
Following points are to be considered:
– Attach a short description of the application
– Attach the type designation and serial number of the USYS 20 as well as a list
of other sensors and options which are connected
3 TECHNICAL DESCRIPTION
3.1 SYSTEM OVERVIEW USYS 20

USYS 20 is a new and modern processor unit designed for both wire drawing and
cable extrusion applications. ZUMBACH provides low-cost measuring, monitoring and
logging systems for the diameter, the ovality, the capacitance, broken wires, etc. They
are equipped with a diameter gauge from the ODAC® series or with a capacitance
measuring system type CAPAC HS-J.
All important parameters can be evaluated statistically and printed. It is of course

easy to establish a connection with a supervisory computer. If the internal controller
(available as an option) is used, the processor automatically controls the production
line based on the nominal value.
Terminal/Host
Relay Outputs
Alarms
Events, for example:
- Faults
- Alarms
Printer
Length detector
MPK 10 or
Closed static controller (SRD)
Loop
Control
Cooling Trough
Extruder ODAC® Capstan
3.2 DELIVERY EXTEND OF THE STANDARD EXECUTION

– Processor unit USYS 20
– 1 Mains connector
– 2 Sub-Min-D connector 25 P.m., "Port 1" and "Port 2"
– 1 Sub-Min-D connector 7 P.m. "ST1"
– 2 Sub-Min-D connector 15 P.m. "ST2"
– 1 Instruction manual
20190423_USYS.050.0020.EN
3.3 DIMENSIONS
3.3.1 Version as table top
3.3.1.1 Wall mounting 5
323 (12.72)
510 (20.08) 300 (11.81)
176 (6.93)
3.3.2 Version as 19" rack

3.3.2.1 In 19" rack 524 (20.63) 323 (12.72)
510 (20.08) 300 (11.81)
176 (6.93)
524 (20.63)
3.3.2.2 Only 19" rack

483 (19.02)
337 (13.27)
4 x Ø6.5 (.25)
(1.5)
38
3 HU*
(5.22)
132.5
(2.22)
56.5
(1.5)
38
9 (.35) 483(18.31)
465 (19.02) 280 (11.02) 40 (1.57)
9 (.35) 337 (13.27)
4 x Ø6.5 (.25)
* HU = Height Unit (1 HU = 44.45 mm / 1.75 inch)
(1.5)
38
(5.22)
132.5
(2.22)
56.5
3.3.3 Wall mounting
3.3.4 Table top
Projection
• Subject to modifications
• Dimensions in mm (inch)
20190423_USYS.050.0020.EN
3.4 TECHNICAL DATA
Energy supply
Electrical power supply 100...240 V
Mains voltage 85...265 VAC
Mains frequency 47...63 Hz
Power 50 VA max.
Environmental conditions
Temperature range +5 ... +50 °C (41 ... 122° F)
keine Betauung oder Reifbildung
keine direkte Sonneneinstrahlung
Transport / storage -20 ... +50 ° C (-4 ... 122° F)
Atmospheric humidity max. 80% (non condensing)
Environmental protection IP 51
Altitude 0 ... 3000 m (0 ... 9843 ft.) over sea level
Weight and dimensions
Table top version 3.4 kg (7.5 lbs)
240 x 101 x 266 mm (9.45 x 3.98 x 10.47 inch)
19" version 11.5 kg (25.4 lbs)
483 x 132 x 280 mm (19.01 x 5.19 x 11.02 inch)
Unit functions
Display LCD 4.2", monochrome, 240 x 128 pixels
7 LED for operating state and alarms
Input Membrane keypad with 21 keys, grouped as:
– Function keys (6)
– Numerical keys (10)
– Navigation (5)
Inputs 1 measuring gauge input (J signal) for ODAC or CAPAC
1 counter input (e.g. line speed)
4 digital inputs (max. 30 VDC)
Outputs 5 digital outputs (max. 30 VDC)
3 relay outputs (max. 30 VDC/VAC, 4A)
Communication 1 serial interface RS232/RS422 for printer
(max. 115 kbits/s)
1 serial interface RS232/RS422 for data communication
with Host computer (max. 115 kbits/s)
1 interface Ethernet with TCP/IP protocol for data
communication with Host computer
Software main functions – Menu-driven system configuration
– Measurement and display
– Limit monitoring with signalling
– Statistics with printer output
– Communication with Host computer
– DDC controller (option: SRD control module)
• Specifications are subject to change without notice
4A DESCRIPTION OF THE HARDWARE
The USYS 20 processor unit is a powerful measurement, display and control system
equipped with a 4.2" LCD screen. The instrument is equipped with a compact ZUMBACH
processor board type N6.CP.305. This processor board offers various I/O interfaces
such as two serial interfaces, Ethernet and an internal parallel communication interface.
It also provides an interface for connecting the external gauge. The instrument also
contains a ZUMBACH I/O multifunction board type N6.IA.165 especially developed
for the USYS 20.
LCD
Front panel
Keypad
RS
Ethernet
N6.CP.305 RS-232/-422
RS-232/-422
J-Input
ZUMBUS
Relay (3)
Multi I/O Digital Out (5)
N6.IA.165
Digital In (4 + 2)
Length Counter
SRD In/Out (Option)
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4A.1 PROCESSOR BOARD N6.CP.305
4A.1.1 General description
The processor board is the central processing unit of the USYS 20. It receives data
from the connected gauge, the N6.IA.165 multifunction I/O board, the front panel
and external control elements such as a host computer or a PLC. Based on these
inputs, the processor board computes the data needed for process control, statistical
evaluation, display, menu control, etc.
The processor board provides the connection interface with the sensor type ODAC or
CAPAC. It processes signals from the J interface and computes the measured values
and results needed by the system.
This board also carries out the communication with the ZUMBACH multifunction I/O
board. The required data transfer takes place through ZUMBACH's ZUMBUS own
parallel data bus.
N6.CP.305.A N6.ME.013.A
The application software for USYS 20 is stored in a swappable module type N6.ME.013
(flash memory). This makes it extremely easy to carry out the necessary software
updates/upgrades. The shape of the connector renders it inversion-proof.
4A.1.2 Technical data

CPU Coldfire 32-bit microcontroller
Data memory SDRAM 64Mbit, EEPROM 256kbit
Program memory Module FLASH 32Mbit (N6.ME.013)
Watchdog Software
Parallel interface (internally) ZUMBUS 8 bit
Serial interfaces 2 x RS232/422/485 (1 x galvanically separated)
1 x RS422 (internally)
Ethernet Fast Ethernet Controller 100Mbps
4A.2 N6.IA.165 MULTIFUNCTION I/O BOARD

This board connects the USYS 20 control unit to external devices, warning lamps,
signal transmitters, control elements, etc.
A DDC/SRD control module can also be connected as an option.
The board provides the following outputs:
– 1 scaleable 16-bit analogue output, +/-10 Volt or 0...10V, galvanically separated
– 5 opto-isolated digital outputs (sourcing, sinking or TTL mode)
– 1 relay with changeover contact
– 2 relays with make contact

The board provides the following inputs:
– 4 opto-isolated digital inputs (sourcing or sinking mode)
– 1 opto-isolated fast counter input (16-bit counter)
4A.3 OPTION: DDC/SRD CONTROL MODULE B.USY.002.8010 (N6.IA.173.A)

This board, available as an option, provides the USYS 20 control unit with a closed-loop
controller. The control function can be carried out with relay contacts (DDC control) or
galvanically separated analogue I/O (SRD control).
This option is very easy to retrofit. The USYS 20 software automatically adapts to the
new hardware configuration (Plug and Play) and the controller-specific menus and
functions are placed at the user’s disposal.
The board is equipped with the following I/Os:
– 1 16-bit analogue input, galvanically separated, -10...0 V or 0...+10 V
– 1 16-bit analogue output, galvanically separated, same voltage as analogue input
– 2 opto-isolated digital inputs (sourcing or sinking mode)
B.USY.002.8010
(N6.IA.173.A)
20190423_USYS.050.0020.EN
4A.4 OPTION: RTC USYS 20 – USY.9401.00100 (M 1093.A2)

This board, available as an option, provides the USYS 20 control unit with a real-time
clock.
The real-time clock supplements the collected statistical data and results with time
and date. Different time and date formats are available.
This option is very easy to retrofit. The USYS 20 software automatically adapts to the
new hardware configuration (Plug and Play) and the menus and functions related to
the real-time clock are placed at the user’s disposal.
4A.4.2 Technical data

RTC Quartz-controlled timebase
Time format Hours and minutes (HH:MM) in 12 or 24 hour format
Date Format Day, Month, Year (DD.MM.YY) or month, day, year (MM.DD.YY)
Battery Lithium cell, 3V, type CR2430
USY.9401.00100
(M 1093.A2)
4B INSTALLATION / COMMISSIONING
Installation activities must be carried out only by qualified personnels.
The installation must be carried out in a way that ensures the safety of operators
without specific electrical know-how.
Warning: Dangerous voltages inside. Be sure to disconnect the device from the
power supply before working inside the device: Pull the power plug! It is the
responsibility of qualified electricians to recognise the resulting dangers and
to take appropriate safety measures.
– Follow the indications in this chapter for the installation and initial operation of the
USYS 20.
– If the unit is opened for repair or for installing an optional expansion PCB,
it is important to note the following point about the reassembly!
The hood can only be properly set up if one first lightly

adjusts the three front screws [1] and only then the
two rear screws [2]. Otherwise, the hood is submitted
to too great a stress and cannot be placed into
the correct position.
4B.1 OPERATING PRECAUTIONS

Following the instructions will enable high performance of the operations and
ensure many long years of use. Adhere to following suggestions:
• Handling the AC and other cables
When connecting and disconnecting the cables, take hold of the plug section and
not the cord. Pulling the cord may cause damage to the cable and create
hazards.
• Preventing electric shock and fire hazards

If the cable is broken or damaged, or if the wire is exposed, have it replaced!
4B.2 CHECK THE POWER SUPPLY VOLTAGE

Before switching on the unit, check whether the operating voltage indicated on the
name plate 16 matches the mains voltage. The name plate is located on the right side
of the housing (see chapter 4B.3.2) or on the back plate on the 19" version.
20190423_USYS.050.0020.EN
4B.3 COMPONENTS OF THE PROCESSOR UNIT USYS 20
4B.3.1 Front panel
6 5 4 3 2 1
Pos. Description
1 "Power" Mains switch
2 Mains control lamp
3 "Control" display LED
Indicates that the imbedded controller is active
4 "Controller ON/OFF" control key
Enables the manual ON/OFF of the internal controller
5 Function keys
Provide direct access to the main functions of the instrument, e.g.
display of measurements and deviations, input of product settings,
display of statistical values
6 Alarm lamps
Light up as soon as a pre-programmed limit has been exceeded
7 Numeric keypad and navigation keys
8 Display LCD
4B.3.2 Rear panel
Amphenol
(old)
10 9 10 11 12 13 14 15 16
Pos. Description
9 "N L" connection. Mains inlet with protective ground.
Mains voltage 110...240 VAC (auto-select "auto range"), 47...63 Hz
10 "INPUT HEAD" connection (Lemo)
Connector for a ZUMBACH ODAC® or CAPAC® J scanner.
Note: For customers who still have older cables with "Amphenol"
connector, an adapter cable "Lemo-Amphenol", order number
ODAC.9173.30010, is available.
11 "Port 3" Ethernet connection socket
For integrating the equipment into a local Ethernet network.
12 "Port 1" and "Port 2" connections
RS232/422/485 serial ports for connecting various peripherals
such as printer, remote display or host computer
13 "ST 1" Connection
Relay outputs
14 "ST 2" Connection
Digital in- and outputs, analog output
15 Nameplate on the rear panel elements
16 Nameplate (on device page and/or on device lower surface)
Type, article no. and connection data
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4B.3.3 "Port 1" and "Port 2" Serial ports
USYS 20 provides two serial ports. They can be used as RS-232, RS-422 full
duplex or RS-485 half duplex according to need. The serial ports follow the RS-232/
RS-422/RS-485 standard. The transmission parameters such as baud rate, parity
check, etc. are configured in the software configuration menu. In addition, the "Port
2" interface is galvanically separated.
Pin allocation RS-232/RS-422/RS-485, 25 Pol/m Sub D plug:

Pin Signal Description
1 GND GND
2 TxD RS-232 Data transmit
3 RxD RS-232 Data receive
7 GND GND
8 T- (R-) RS-422 Data transmit (RS-485 Data transmit and receive)
17 R+ RS-422 Data receive
18 R- RS-422 Data receive
20 T+ (R+) RS-422 Data transmit (RS-485 Data transmit and receive)
All the pins that are not connected are not described either.
When using RS-422/RS-485, it is necessary to terminate internally the lines of

both interfaces with 120 ohms resistors. This is necessary either with point-to-point
connections or with networks in which the termination resistors must be mounted at
the origin (Master) and at the location of the last participant (Slave). None of the other
network stations needs termination resistors. Reflections in the network caused by
incorrectly terminated lines could totally prevent data communication.
The "Port 2" interface is already equipped with a resistor. It can be switched ON and
OFF with switch S1.
S1 (OFF)
4B.3.4 "Port 3" Ethernet connection
The integrated Ethernet controller (type 10/100baseTxEthernet) allows integrating the
equipment into a local network with the TCP/IP protocol. The required settings for the
operation of the Ethernet connection such as IP address, subnet mask and Gateway,
can be set in the software configuration menu.
The Ethernet port number is 2020. This number is fix programmed by the user and
can not be changed.
4B.4 CONNECTION TO MAINS

The USYS 20 processor unit must be connected to an interference-free and with
protective earth protected mains. Before connecting to mains, check weather the
operating voltage indicated on the name plate corresponds to the mains voltage. The
name plate is located on the right side of the housing (see chapter 4B.3.2) or on the
back plate on the 19" version.
Use a power cord that meets the requirements of IEC 60227 or IEC 60245, i.e. rated
voltage at least 300 Vac, three wires with cross section at least 1 mm2 and conductors
coloured brown, blue and green-and-yellow, operating temperature at least 70 °C.
The brown conductor must be connected to the phase, the blue conductor to neutral
and the green-and-yellow conductor to protective earth. When the local applicable
regulations are different, then these local regulations must be applied.
The power cable must be equipped with a C13 cable connector, and the conductors
must be wired as indicated on the back of the USYS 20.
To safely disconnect the USYS 20 from the power supply, the cable connector must
be unplugged. If the cable connector is not accessible, an equivalent disconnecting
device must be installed.
4B.5 GAUGE
The cable included in the delivery must be used for connecting the gauge to the "Head
Input" Lemo connector 10 situated on the rear part of processor unit USYS 20.
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4B.6 LENGTH DETECTOR
The processor unit USYS 20 is equipped with one built-in lengths counter which can
be controlled through an external length detector (impulse generator, proximity switch).

It is not always essential to connect the length detectors to this system but it is always
preferable. The connection of at least one length counter is however necessary, if the
following functions are required:
– The production facility has to be automatically controlled on the basis of the
produced length.
– It is necessary to include the length in the log of the statistical evaluation.
– The processor unit connected with the USYS Data Log software from
Zumbach, operating based on the length.
Various devices can be used as length detector. Which length detectors can be used
depends on the speed of the line, the dimensions of the product and the installation
possibilities:
– Proximity switch according to DIN 19234 (NAMUR standard)
– Proximity switch 3-wire PNP
Warning!
The length detector must still generate at least two pulses a minute at the lowest
possible transient line speed. The error message "Err 400" is displayed if less two
pulses per minute are generated.
The highest counting frequency of 2.5 kHz must not be exceeded when the line is
running at its highest speed! (See chapter: Electrical Specification: "DIN1" Counter
Input).
The formula for computing the smallest distance between two pulses, taking into
account the line speed, is:
Line speed (m/min) 1000

Min. distance (mm) = x
2500 Hz 60
4B.6.1 Installation
Line drive
Line
30.2 mm
Rotating steel can coupled

to the line drive
10.8 mm
15 mm
blue brown
31.2 mm or yellow or white
Proximity detector
(–) (+)
NJ.11.N201 Signal Supply
Aluminium shell
Max. distance approx. 2.0 mm
4B.6.2 Connection (2-Wire NAMUR)
The connection cables of the proximity detector exist in two versions:
• Type A: (+) Supply = brown PROXIMITY-SWITCH
(-) Signal = blue NAMUR
• Type B: (+) Supply = white + -
(-) Signal = yellow 16 17 18 30
Connection to "ST2" connector, upper terminal row
Connector ST2 – Upper terminal row

1 15
Note: See chapters: Counter inputs "DIN1", if other types are used
by proximity switch (2 - or 3-wire not NAMUR).
4B.6.3 Configuration and operational check

It remains to configure the length detector in the software after it has been successfully
connected. It is also necessary to carry out an operational check to ascertain that the
computed pulse length or line speed is correct.
The configuration of the length detector can be carried out as follows:

– Switch on the USYS 20 processor unit.
– Switch to the configuration mode using the "Select" key.
– Set select code 100 "Length detector ON/OFF" to 1 and select the desired
measurement unit Meter (0) or Feet (1) under select code 110 "Length unit".
– The distance in meters or feet between two length detector pulses can be
entered with Select code 111 "Length per pulse".

The operational check can be carried out as follows:
– Select the "Current line speed" as display value (selection 13) under
select code 012.
– Exit the configuration mode by pressing the key "Actual".
– It is now possible to read on the main screen the line speed computed from the
length pulses. If this value does not exactly match the real speed, it can be
fine tuned by varying the distance between pulses (select code 111).
20190423_USYS.050.0020.EN
4B.7 CONTROL OF THE STATISTICS
Several digital inputs are available for controlling the statistical evaluation. They are:
"Start/Stop": Connector "ST 2", upper terminal row, connection 24
"Pause": Connector "ST 2", upper terminal row, connection 25
"Event": Connector "ST 2", upper terminal row, connection 26
Ex-factory, digital inputs are predefined as "sinking" inputs (see section "Digital Inputs
DIN3 to DIN 7" in these instructions). This means that, to trigger the desired function,
it is necessary to apply a control voltage to the appropriate input port (terminals 23 or
27) from 5 VDC up to 30 VDC (1 = active) relative to GND.

If an external control voltage isn’t available, the input ports can also be reconfigured
as "Sourcing". To this end, the JP1 jumper on the N6.IA.165 PCB must be plugged
in accordingly (see section "Digital Inputs DIN3 to DIN7" in these instructions). In this
configuration, the desired function is triggered as soon as the corresponding input
(terminals 23 or 27) is connected to the ground "GND" (0 = active). In this case, it
might be advisable to invert the "Logical Polarity" of the inputs by Select Code 530.
Note: Logical Polarity

Irrespective of JP1's position, USYS interprets a high-level voltage at the digital inputs
(DINx) as "Active" and 0 volt as "Inactive". If the opposite polarity is needed, it can be
inverted in the software by Select Code 530.
Chapter "Statistics" of the present manual provides a complete description of the way
these digital inputs operate.
4B.8 ANALOG OUTPUT

The analog output is located on connector "ST 2", lower terminal row, connections 11
(Signal) and 12 (GND).
The output can be either a deviation signal with a voltage range from -10 V to +10 V
or an absolute signal with a voltage range from 0 V to +10 V. The deviation output
value is given by the difference between actual value and setpoint. The absolute
output value is a voltage proportional to the actual value. The operating mode can be
selected with select code 301. The sensitivity can be entered with select code 302.
4B.9 RELAY OUTPUTS

The contacts of the integrated relays are available on connector "ST 1".
"Relay 1": Connector "ST 1", make contact,
connections 1 (On) and 2 (Common)
"Relay 2": Connector "ST 1", make contact,
connections 3 (On) and 4 (Common)
"Relay 3": Connector "ST 1", changeover contact,
connections 5 (On), 6 (Common) and 7 (Off)
The relays can be used for miscellaneous control functions. The selection is carried
out in the software with select code 500 (Relay 1), 501 (Relay 2) and 502 (Relay 3).
Chapter "SELECT CODE" in this manual provides a complete description of the

output selection possibilities.
4B.10 CONTROL WITH MOTOR POTENTIOMETER (DDC-CONTROLLING)
The automatic control of the line by varying the capstan speed or the number of
revolutions of the extruder can be implemented by connecting the ZUMBACH motorised
potentiometer of type MPK1-10T as regulating unit to Relay 1 (Impulse +) and Relay
2 (Impulse -) of the connector "ST1". If the relays are used for another purpose (e.g.
for tolerance alarms), the motorised potentiometer can be connected to digital outputs
1 and 2 with connector "ST2" (lower terminal row).
Caution!
When connecting and using the motor potentiometer must be absolutely kept nominal
dates of the multi-functions I/O card N6.IA.165.
1 2 3 4 5 6 7
4B.10.1 Actuation by relays
– ZUMBACH Motorized Potentiometer
(Mot Pot) MPK1-10T
The mot pot can be directly connected
7 8 9
("ST 1" connector) to relay 1 (impulse +) Control Control
and 2 (impulse -). The necessary control pulse + pulse -
voltage is supplied by the motorized MPK1-10T
potentiometer.
1 2 3 4 5 6 7
– Customer Side of Motorised
Potentiometer
The motor potentiometer is V-ext.
connected to relays 1 and 2
("ST 1" connector). Control Control
pulse + pulse -
The necessary control voltage
(V-ext.) is supplied by the customer. MOTOR-POTENTIOMETER
4B.10.2 Correction effects

According to which way control operates, by correcting the number of revolutions of
the extruder or the speed of the line, the action of the control pulses "Impulse +" (Relay
1) and "Impulse" - (Relay 2) changes as follows:
Deviation Correction on capstan Correction on extruder

Pulse + + slower faster
Pulse - - faster slower
4B.10.3 Control key "Controller ON/OFF" 4

Used for switching the internal controller on and off. The corresponding green status
light "Control" 3 indicates the current state. Any error message in the controller
causes this status light to blink. The triggering fault is also displayed as a number (e.g.
"ERROR 401") in the information line of the LCD display.
4B.10.4 Configuration of the controller parameters

To complete the commissioning of the controller, it is still necessary to check and
change if necessary every controller parameter by means of the software
configuration menu.
A detailed description of all configuration possibilities is to be found in Chapter
"5.8 CONTROLLER" of this instruction manual.
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4B.11 STATIC CONTROL SRD (Option)
The automatic control of the line by varying the capstan speed or the number of
revolutions of the extruder can be implemented by connecting the optional
ZUMBACH static actuator.

"SRD Input" and "SRD Output" on "ST2" connector (upper terminal row) provide the
necessary connections to the analogue outputs and inputs.
The static actuator behaves like an electronic potentiometer. The voltage available
at the output depends upon some percentage of the input voltage determined by the
position of the potentiometer (setting potentiometer for capstan or extruder). The ratio
between both voltages is called "SRD (Static Regulating Device) Factor". This factor
is continuously adjusted by the controller during production in order to maintain the
product at the set nominal value "Nominal".
When the production line is started, the ratio between the two voltages must be set
to 1. This can be achieved with Select Code 220, through an external contact or the
host interface. When the input voltage changes, e.g. if the main potentiometer is
adjusted by the machine operator, the output voltage is automatically adapted to the
input voltage. The voltage applied to the static actuator must not exceed 10 VDC. If
this however occurs, the error message "ERROR 402" is displayed.
In trim mode, the voltage ratio can vary between 0.1 and 2. If the voltage ratio computed
by the controller exceeds these limits, the corresponding error message "ERROR 404"
is displayed.
The output voltage of the static actuator (input x ratio) must not exceed 10 VDC. If this
limit is however reached, the error message "ERROR 403" is displayed.
The "SRD" static actuator is driven in so-called "trim mode". In other words, it is part
of the connection between the available setting potentiometer and the motor drive of
the extruder or capstan.
Main potentiometer
Adjustment potentiometer
for extrusion or capstan Solid state
regulating device
USYS 20 Motor drive
Diagram "Solid state regulating device in trim mode" Ovality, SRD Factor
The "SRD factor" (voltage ratio) computed by the controller can be displayed on the
LCD display as a bar graph. This allows the user to monitor easily and reliably the
behaviour of the control. To do that, it is necessary to set Select Code 020 "Value
displayed on bar graph" to 12.
4B.11.1 Trim mode

The SRD static regulating unit is connected between the Ratio Pot for capstan speed
or revolution number of the extruder and its motor drive.

Connection of plug "ST2":
Master Pot.
16 30
Extruder
Trim Pot.
M
1 13 14 15
4B.11.2 Connecting the SRD Static Regulating Unit

The connection is performed through connector "ST2".
The following connections must be performed:

– The nominal voltage of the extruder or of the capstan must be connected to "SRD
Input" of the static regulating unit. The connection has to be made with 14 (Signal)
and 15 (GND).
– The corrected "SRD Output Voltage" is available on 13 (Signal) and 15 (GND).
– An external resetting of the static control member requires an appropriate signal,
e.g. on digital input "DIN 6", clamp 28.
– The same function can also be activated with Select Code 220 in the configuration
menu.
– External "freezing" of the automatic controller, requires a signal, e.g. on digital input
"DIN 7" clamp 29.
4B.11.3 Polarity of the SRD input voltage

The SRD input voltage polarity can be positive (0 ... +10 VDC) or negative (0 ... -10
VDC). The output voltage polarity of the static regulating unit is always identical to the
polarity of the input voltage.
4B.11.4 Power-On relay

A relay on the N6.IA.173 I/O board can be used for connecting the output of the SRD
static regulating device to the input or the ground whenever the USYS 20 processor
unit has been switched off. If the input and output are connected to each other, it is
possible to start the line with the USYS 20 switched off, provided the operating mode
TRIM has been selected.
The operating mode of the power-on relay can be selected on the N6.IA.173 I/O PCB
with jumper JP1.
N6.IA.173.A
The output of the static regulating device corresponds to zero
(GND)
JP1
Basic setup.
The input of the static regulating device is connected to the output
4B.11.5 Control key "Controller ON/OFF" 4

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4B.11.6 Configuration of the controller parameters
To complete the commissioning of the controller, it is still necessary to check and
change if necessary every controller parameter by means of the software configuration
menu.
► A detailed description of all configuration possibilities is to be found

in Chapter "5.8 CONTROLLER" of this instruction manual.
4B.12 "ST2": DIGITAL AND ANALOG IN- AND OUTPUTS

16 30
4B.12.1 Pin assignment "ST2"
1 15
PIN NAME DESCRIPTION PIN NAME DESCRIPTION

1 DOUT1+ Digital Output 1 (High) 16 +12V Supply +12V (OUT)
2 DOUT1- Digital Output 1 (Low) 17 V_NAMUR1 Supply for NAMUR (OUT)
3 DOUT2+ Digital Output 2 (High) 18 DIN1 Digital Input 1 (Counter 1,
Encoder Signal A
4 DOUT2- Digital Output 2 (Low) 19 GND GND
5 DOUT3+ Digital Output 3 (High) 20 +12V Supply +12V (OUT)
6 DOUT3- Digital Output 3 (Low) 21 V_NAMUR2 Supply for NAMUR (OUT)
7 DOUT4+ Digital Output 4 (High) 22 DIN2 Digital Input 2 (Counter 2,
Encoder Signal B)
8 DOUT4- Digital Output 4 (Low) 23 GND GND
9 DOUT5+ Digital Output 5 (High) 24 DIN3 Digital Input 3
10 DOUT5- Digital Output 5 (Low) 25 DIN4 Digital Input 4
11 AOUT Analog Output 26 DIN5 Digital Input 5
12 GND GND (for Analog) 27 GND GND
13 SRD OUT OPTIONAL: SRD Output 28 DIN6 OPTIONAL: Digital
Input 6 (SRD)
14 SRD IN OPTIONAL: SRD Input 29 DIN7 OPTIONAL: Digital
Input 7 (SRD)
15 SRD GND OPTIONAL: SRD GND 30 GND GND
4B.12.2 Wiring references for "ST2"

POS 4
POS 1: Wire section max. 1.5 mm2 (flexible)

POS 2: Use screwdriver "0"
POS 3: Interconnect the connections with
jumpers if necessary
POS 4: Fasten the cable with a strain release
device. With thin cables, reverse the
strain release device or use packing
POS 1 POS 2 POS 3

4B.12.3 "DIN1" and "DIN2" Counter inputs
The DIN1 and DIN2 inputs are intended for connecting NAMUR proximity switches or
fast digital signals.
+12 V
Multifuse
4B.12.3.1 Equivalent circuit V_NAMUR JP 8/9
Protection
DIN circuit
3k3
900E
GND
4B.12.3.2 Allocation
Signal source: TTL output Signal source: Switch
+5V B
V_NAMUR
USYS xx
USYS xx
Out DIN
GND GND DIN

A
Signal source: 2-wire proximity Signal source: 2-wire proximity

switch (NAMUR) switch (not NAMUR)
V_NAMUR +12V
+ +
USYS xx
USYS xx
- DIN - DIN
470
Signal source: 3-wire proximity Signal source: PLC output

switch (PNP) (sourcing)
VCC +12V
USYS xx
USYS xx
Out 24VDC Out

DIN DIN
GND
GND
GND PLC
GND
4B.12.3.3
Interferences at the digital counter inputs USYS xx
Prevention of electromagnetic interferences at the counter inputs "DIN1", "DIN2"
and the digital inputs "DIN3" until "DIN7".

Strong electromagnetic fields can cause interferences at the digital inputs, that are
processed by the USYS as pulses. The reason is often due to the inconvenient laying
of the cables of the digital inputs. In order to prevent such interferences, following
directions should be considered:
1. The connection cables to the digital inputs should be as short as possible.
2. Lay the cables as far as possible away from strong electromagnetic fields.
3. The connection cables within a cable channel should only be layed together
with common signal cables but never together with control cables!
4. Should still appear interferences or if the above mentioned measures
are not possible, it is recommended to use a shielded connection cable.
Zumbach offers different shielded cables.
20190423_USYS.050.0020.EN
Description Zumbach Part number Type
Shielded two-core Flex cable A13 220 0202 2 x 0.25 mm2 color leads
Shielded three-core Flex cable A13 220 0302 3 x 0.25 mm2 color leads
Shielded four-core Flex cable A13 220 0402 4 x 0.25 mm2 color leads
Shielded five-core Flex cable A13 220 0502 5 x 0.25 mm2 color leads
Shielded eight-core Flex cable A13 220 0802 8 x 0.25 mm2 color leads
Shielded ten-core Flex cable A13 220 1002 10 x 0.25 mm2 color leads
Shielded sixteen-core Flex cable A13 220 1602 16 x 0.25 mm2 color leads
Pin assignment with shielded connection cable
Signal source: 2-lead proximity switch (NAMUR)
Connection cables with shielding
Signal source: 3-lead proximity switch (PNP)
Connection cables with shielding
Caution! The shielding can only be connected on the USYS side.
4B.12.3.4 Configuration
Thanks to the series resistors, it is possible to connect up to 30 V at the digital
inputs DIN1 and DIN2, without an additional, external resistor.
For the NAMUR proximity switch, the corresponding input resistor must be with a
jumper (JP8/JP9) on the N6.IA.165 board (from version .A5):
Not NAMUR NAMUR ST2

ST1
JP9 JP8
DIN1 JP 8 open JP 8 closed JP1
DIN2 JP 9 open JP 9 closed JP2
Input voltage max. 30 V max. 12 V
4B.12.3.5 Electrical specifications: "DIN1" and "DIN2" counter inputs
The counter inputs are equipped with a bridgeable 4.2 kohms resistor. It allows
the input voltage to reach up to 30 V. Without this resistor (bridged with a jumper),
the maximal voltage reaches 12 V. This is used with NAMUR and 3-wire proximity
detectors (PNP).
Counter inputs
Voltage on terminals max. 30 V1) (12 V 2))
Input resistance 4.2 kOhm (900 Ohm 2))
Upper switching threshold Typical value 2.2 V
Lower switching threshold Typical value 1.4 V
Max. input frequency 2.5 kHz
Protective circuit Overvoltage
Power supply +12 V Iout (max) = 140 mA
1)
It is necessary to install a protective resistor at the DIN input end if the voltage of the signal source is higher.
2)
Up to the N6.IA.165.A4 version without 4.2 kOhms series resistor:, or if jumper is closed
max. voltage on terminals 12 V (up to 30 V with a 1 Kohm protective resistor)
Input resistance 900 ohms.
4B.12.4 Digital inputs "DIN3" to "DIN7"
4B.12.4.1 Equivalent Circuit
+5V
10k
Protection
DIN
circuit
GND
4B.12.4.2 Configuration
Digital inputs "DIN3" to "DIN7" can be configured as "sourcing" inputs or as "sinking"
inputs. The selection of the suitable operating mode is performed for all inputs together
by means of jumper JP1 on the N6.IA.165 PCB.
JP1 Position: + JP1 Position:

Sourcing Inputs Sinking Inputs
(Work attitude)
Note: Logical polarity

Irrespective of JP1's position, USYS interprets a high-level
voltage at the digital inputs (DINx) as ACTIVATED and 0 volt
as DEACTIVATED. If the opposite polarity is needed, it can be
inverted in the software with the Select-code 530!
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4B.12.4.3 Allocation of the digital inputs "DIN3" to "DIN7" in the "sinking" mode:

+5V B
+12V
USYS xx
USYS xx
Out DIN
GND GND A DIN
Signal source: 2-wire proximity Signal source: 3-wire proximity

switch (not NAMUR) switch (PNP)
VCC +12V
+12V
+
USYS xx
USYS xx
Out
DIN
- DIN GND
GND
470
Signal source: PLC output

(sourcing)
USYS xx
24VDC Out
DIN
GND
GND
PLC
4B.12.4.4 Allocation of the digital inputs "DIN3" to "DIN7" in the "sourcing" mode:

+5V B
DIN
USYS xx
USYS xx
Out DIN
GND GND A GND
Signal source: PLC output

(sinking) PLC
Out
USYS xx
DIN
GND
GND
4B.12.4.5 Electrical specifications: counter inputs "DIN3" to "DIN7"
Voltage on terminals max. 30 V

Input resistance 10 kohms
Upper switching threshold typical value 1.8 V
Lower switching threshold typical value 1.1 V
Max. input frequency 20 Hz
Protective circuit Overvoltage
4B.12.5 Digital outputs "DOUT1" to "DOUT5"
4B.12.5.1 Equivalent Circuit Isolation barrier

4k7 Jumper
+5V
DOUT+
Protection
circuit
DOUT-
Solder-jumper
4B.12.5.2 Configuration ST2

ST1
JP1
5
4
3
2
DOUT 1
JP2
Solder-jumper
(Darlington)
JP2
The digital outputs "DOUT1" to "DOUT5" can be operated in 3 modes:
Mode digital input Jumper JP2 Polarity Output Output

Condition voltage
TTL-Activ-Output closed actively 5V
(work attitude) deactivated 0V
Output "Sourcing" open actively 0V
deactivated Vext
Output "Sinking" open actively Vext
deactivated 0V
Note: Logical polarity

The output transistor is OPEN if a USYS output is ACTIVATED (see equivalent connection
diagram). The output transistor is CLOSED if a USYS output is DEACTIVATED. If the
opposite polarity is needed, it can be inverted in the software!
Darlington outputs:
A Darlington transistor can be connected for each output when higher output currents
are required in special applications. Scratching off the corresponding solder bridge
will activate the Darlington transistor.
To deactivate again the Darlington transistor, close the previously opened solder bridge
with a soldering iron.
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4B.12.5.3 Allocation of the digital outputs
TTL input General load
+5V DOUT+
USYS xx
USYS xx
DOUT+
DOUT- Vext
Load
DOUT-
PLC input (sinking) PLC input (sourcing)

PLC
DOUT+
USYS xx
USYS xx
DOUT-
Vext DOUT+ Vext
DOUT-
PLC
4B.12.5.4 Electrical specification of digital outputs
Standard execution
Terminal voltage max. 30 V
Termnal current
Without Darlington output1) max. 20 mA
With Darlington output 100 mA
Case of tension
Without Darlington output1) max. 0.6 V by 20 mA
With Darlington output max. 1.2 V by 100 mA
Protective circuit Relay spark arresting
1)
Work attitude
4B.12.6 Output similar

Voltage range -10 V...+10 V
Output current (max.) 4 mA
Dissolution 16 Bit
Protective circuit Overvoltage; EMV
4B.12.7 Analogue output SRD (optionally)

Output current (max.) 4 mA
Dissolution 16 Bit
4B.12.8 Analogue input SRD (optionally)

Critical frequency 1.6 kHz
Dissolution 16 Bit
4B.13 "ST1" RELAY OF OUTPUTS
1 2 3 4 5 6 7
1 3 5
2 4 6
7
RELAIS 1 RELAIS 2 RELAIS 3
(Relay in the inactive condition)
Maximum load of the contacts:

48 VDC, 0.5A
30 VDC, 4A
50 VAC, 4A @ AC-1
AC-1: Utilization category according to IEC / EN 60947:
Non-inductive or light inductive loads.
Caution!
The specifications refer to resistive loads. Other types of loads may cause the switching
contacts to be damaged by arcing.
In such cases, the load at the contacts has to be reduced to prevent arcing.
Inductive loads such as circuit breakers, transformers, etc. must be equipped with
spark killer diodes, RC modules or varistors. The transient current of incandescent
lamps and capacitive loads must be limited, e.g. with protective resistors.
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5 OPERATING MANUAL
• Familiarize yourself with all aspects of the operation. Pay particular

attention to safety instructions
• The personnel operating the USYS 20 processor unit as well as the
connected peripherals and options must be suitably instructed to avoid
dangerous situations.
5.1 FUNCTIONAL DESCRIPTION

For the functioning of the internal controller it is necessary to connect an external
length detector to compute the running time of the product. It is also necessary to
connect a length detector if the produced length has to be recorded in the statistical
evaluation or if the processor unit is connected to PCLink from ZUMBACH.
1. The following quantities are is determined or computed from the actual values
with the "Correction Value" taken into account
– Deviation between the "Actual" value and the set "Nominal" value
– If a dual-axes gauge is used, the ovality is computed from the X and Y values
(absolute value of the X - Y difference). The smallest and largest values are
determined from XY. The three XYZ-axes are taken into account when a
three-axes gauge is used.
– During the statistical evaluating period, values such as minimum, maximum,
arithmetic average, min- max range, standard deviation.
2.
The following quantities are computed from the signa of the length detector:
– Actual length a swell as total length during the statistical evaluation
– Line speed of the product for the internal controller
3.
The manufacturing plant can be automatically controlled by the number of extruder's
revolutions or by the line speed when the internal controller (available as an option)
is used. Relays and a static regulating device are available for this purpose.
4. The Minimum, Maximum, arithmetical average, Max - Min range, standard deviation
and CpK values are determined during the statistical evaluation period. The produced
length can also be logged.
5.
An external "Start/Stop" signal (for example when changing the reel) is required to
conclude the running statistical period and to compute the corresponding values. A
new evaluation period begins immediately.
6.
An external "Pause" signal (for example standstill of the line) stops the statistical
evaluation.
7.
An external "Input" signal allows you to count the events (for example sparks of a
spark tester) during the running statistical period.
8.
Off-tolerance states, events such as lumps and neckdowns, General Alarm or other
status messages can be transmitted by relays or digital outputs.
9.
Following data transmission can be realised through two serial interfaces
– Data transmission between USYS and a host computer (Up/Download)
– Output of statistical values on a serial printer or terminal
– Output of actual values to be displayed on digital auxiliary display units
– Connection with the external data acquisition module ZUMBACH USYS
Data Log
10.
An analog output is also available whose output voltage corresponds to the absolute
value or to the deviation of the actual value from the nominal value.
5.2 PRINTOUTS AND PARAMETER DEFINITIONS
– Measured value (Diameter)

The measured diameter (or, generally speaking, value) is the value recorded by the
gauge during one rotation of the mirror system. A dual-axes gauge provides two values,
one along the X-axis and the other one along the Y-axis. An ODAC TRIO provides three
values. The measured position of the object in the measuring field is also available.
– Actual value "Actual"

The arithmetic mean is computed from the values provided by the gauge during the
set averaging time. This occurs independently for every measuring axis of multi-axes
gauges. The values obtained in this way are adjusted with the "Offset" correction
value and displayed. The USYS operation is based on this so-called corrected actual
value. For the sake of simplicity, we will however keep writing about the actual value,
irrespective of the presence or absence of a correction.
If a gauge with several axes is connected, the arithmetic mean, the quadratic mean
and the ovality are computed from the individual measuring axes. The user can choose
each of these results as actual value.
– Deviation
This value, continually updated, corresponds to the difference between the computed
actual value and the set nominal value. The deviation can be positive or negative and
can either be displayed on the LCD display or output through the Analog Output.
– Nominal value "Nominal"

The nominal value is the ideal value to be reached during manufacturing. It is the
reference for computing the deviation, driving the display, supplying the analog output
and driving the internal controller.
– Correction value "Offset"

This value can be given as an absolute value, i.e. in mm (or inch). It corrects the
displayed actual value in order to compensate the changes occurring in the final
product (e.g. shrinkage after cooling, foaming).
– Tolerance limits + and - "Tolerance"

The tolerance limits can be entered separately for plus and minus. They determine by
how much the final product can deviate from the set nominal value. The limits can be
entered as absolute values or as relative values with respect to the "Nominal" setpoint.
The monitoring of two pre-alarm limits can be enabled if necessary. They are again
entered separately, i.e. for plus and minus.
The ovality can also be monitored for tolerances exceeded.
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5.3 FUNCTION OF FRONT PANEL ELEMENTS
6 5 4 3 2 1
5.3.1 LCD Display 8

The visualisation of the measured actual values, operating modes, as well as of
information and alarm messages is the main function of the LCD display.
The screen has been partitioned into different, predefined regions to provide a better
overview.
Window title
Measured Value Display
Information line
5.3.1.1 Window title

The title indicates in which mode the display currently is. The text corresponds to the
name of the activated function key 5 or, if a switch has been performed with the
"Select" key, the text "Select" is displayed instead.
5.3.1.2 Measured value display
The measured value display can be freely configured. It can show up to three different
measured values. It is also possible to display other values such as speed or other
information, should special applications require it.
If needed, a bar graph can be added in the lower part of the measured value display.
This diagram can represent the deviation (left fig.) or the absolute value (right fig.).
The values and resolution of the bar graph can be freely defined and entered by the
user.
5.3.1.3 Information Line

For displaying both error messages and normal operating state messages. The
information line is displayed in the same way on all the display pages. The functionality
of the information line remains also the same on all pages.
Error messages can in general be identified by the text "ERROR" followed by a three-
digit number. Let us for instance mention the error messages "ERROR 300" related
to the diameter gauge, and "ERROR 401" that hints to a problem with the automatic
control of the line.
Chapter "5.12 Error messages" in this manual contains a complete list of existing
error messages.
Operating state messages can vary widely. They are described in detail in several
chapters of this manual. For instance the message "PULSE +" indicates that the
internal controller has output a positive correction pulse.
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5.3.2 Entry field 7
The entry field contains numerical entry keys as well as special characters and
navigation keys.
5.3.2.1 Key "+/-"

This key toggles the sign of certain inputs such as the "Offset" correction value.
Output value: Operating "+/-":
5.3.2.2 Key " "

Shifts the cursor down to the next entry field.
5.3.2.3 Key "Esc"

For cancelling an entry and resetting the current entry field to its initial value.
Output value: Entry:
After "Esc":
5.3.2.4 Key "Enter"

To confirm the current entry. The validity of the entered value is checked. Should the
value be invalid, it is rejected with the error message "ERROR".
Entry: Range exceeded Error message
The value is accepted if the entry is valid, the entry field closes and, should another
parameter be present, the cursor jumps to the next entry field.
Entry: Valid value After "Enter"
5.3.2.5 Key "Select"

Switches the system to configuration mode. Further details on the configuration mode
are to be found in chapter 5.5 "Select Key – Configuration Mode" of this instruction
manual.
5.3.3 Function keys 5
The function keys provide a fast access to the main entry and display pages of the
system. The currently active function key is displayed in the window's title. An example
illustrating what follows when the "Nominal" key has been pressed:
To leave a displayed page involves pressing another function key or the "Select" key.
If no entry takes place during 3 minutes, the system automatically returns to the main
page "Actual".
5.3.4 Alarm lamps 6

The alarm lamps are chiefly used to display tolerance excess. With special applications
or functions, e.g. Fault Detection, these might also display other alarms or operating
states.
The alarm lamps (AL) are driven according to the settings of the corresponding Select
Codes in the table below:
Select Select Select - AL2 - AL1 + AL1 + AL2 AL3

Code Code Code
406 407 408
0 0 1 Tolerance - x x Tolerance + KW +/-
0 1 x 1)
Tolerance - x x Tolerance + Ovality
1 0 1 Tolerance - Low High Tolerance + KW +/-
Prealarm Pre-alarm
1 1 x 1) Tolerance - Low High Tolerance + Ovality
Prealarm Pre-alarm
x = No operation
x 1) = it is impossible to simultaneously display "Ovality" and "KW +/-".
5.3.5

Control key "Controller ON/OFF" 4
Please note: this key is only activated when the controller module available as an
option is present.
It switches the internal controller on and off. The corresponding green status light
"Control" 3 indicates the current state. Any error message in the controller causes
this status light to blink. The triggering fault is also displayed as a number (e.g.
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5.4 FUNCTION KEYS – PARAMETER ENTRY 5
5.4.1 Function key "Nominal"
Displays the setpoints and correction values of the product. The current entries can
be modified, then stored again.
The "Offset" correction value can be used to correct the actual value measured by
the gauge. It compensates the changes occurring in the final product (e.g. shrinkage
after cooling). The sign can be changed by pressing key "+/-".
This key toggles the sign of certain inputs such as the "Offset" correction value.
Output value: Operating "+/-":

The correction value "offset" can be protected against unwanted entry. The protection
can be activated by the select code 990 sets to 2. If one however tries to execute a
input with the active protection on, this will reply with the error "CODE".

If this protection is active, the offset value can be input by means of Select-Code 031.
If the protection is inactive, this select code is not displayed.
Systems with an integrated controller (option) also display the product's Inner Diameter.
The inner diameter is needed for computing the controller's gain and must be re-entered
for each product. This value must be set to zero when controlling solid products.
Please note:
In systems with integrated controller (option), the controller has to be switched off before
certain entries can be performed. Otherwise, any attempt to perform such entries will
be rejected with the error message "CTRL ON" or "CONTROLLER ON".
5.4.2 Function key "Tolerance" 5

Displays the tolerance limits of the product. The current entries can be modified, then
stored again.

If needed, the system can also monitor the measured product for prealarm limits and
ovality (absolute difference between X and Y).
The user can program to a large extent the kind and scope of tolerance monitoring.
This is described extensively in chapter 5.6 of this manual.
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5.4.3 Function key "Statistic" 5
Allows users to display statistical data.
The characteristics to be statistically acquired are selected with Select Code 700, 701
and 702. An error message is displayed if no selection has been carried out.
The statistical data to be displayed are those of the last statistical period terminated
by a "Start/Stop".
From the time the instrument has been switched on to the end of the first statistical
period, the period number "Zero" is displayed and all results remain zero.
All results are determined and displayed at the end of the statistical period.
The characteristics to be statistically acquired are selected with Select Code 700, 701
and 702.
The name of the selected characteristic and the number of the statistical period provide
the identification of the record currently displayed.
Characteristic Name Period Number
Up to three characteristics can be statistically acquired in parallel. The ">>>" symbol that
appears on the upper right corner of the display means that more than one characteristic
is selected. The display switches to the next record whenever the "Statistic" function
key is pressed.
First Characteristic "X" Second Characteristic "Y"
Select Code 711 is used if it is necessary to display additional information. It consists,
for instance, in the number of events and the number of lumps and neckdowns returned
by the lump detection function (provided this function has been activated with Select
Code 408).
Extra informations
5.4.4 Function key "User" 5

Allows users to display and enter application-specific parameters and data.
In the current software version, this page allows users to display and enter additional
information related to the statistics and the related logging.

Each line can contain up to 15 alphanumeric characters. The following characters are
available: [0-9] [A-Z] [# * - .]
Numbers are directly entered through the numerical keyboard:
Letters and extended character are entered with key "+/-". The character is replaced
by the next one every time the key is depressed:

[ Space ] [ # ] [ * ] [ - ] [ . ] [ A ] ..... [ Z ] .... etc.
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The displayed character is accepted when the "Select" key is pressed. The cursor
then jumps to the next position on the right.
The whole line is accepted with "Enter". It is then stored into the system and the cursor
jumps to the next line.
An entry can be interrupted with "Esc". The entered characters are discarded and the
cursor jumps back.
5.5 KEY "SELECT" – CONFIGURATION MODE
5.5.1 Key "Select" 7

Switches the system to configuration mode. The title line "Select" is displayed on
the top left corner of the display. All active system functions such as measurement,
statistics and control keep running undisturbed in the background. The information
line in the lower part of the display remains active and displays error messages as
well as normal operating state messages.
Information line
5.5.2 Display field
The screen has been partitioned into different, predefined regions to provide a better
overview of the displayed and entered configuration parameters.
Select Code number

Group name
Parameter name
Parameter value
5.5.3 Parameter identification

Every parameter available in the system includes an identification number, the "Select
Code number", with a value between 000 and 999. When the "Select" key is pressed,
the parameters will be displayed one at a time in the order of their identification number.
Each parameter has also a "Parameter Name". This text description should help users
to understand its function. It is therefore not necessary to refer to the instruction manual
for customising the system configuration.
To obtain a clear overview of all parameters, these have been divided into logical
function groups, so-called "Group Designation". This speeds up the search for a given
parameter in the Select Code list while making it above all much simpler. The current
software version supports the following "Group Designations":
Group Function Select Code numbers

0xx Measurement and Display 000 – 099
1xx Distances 100 – 199
2xx Controller 200 – 299
3xx Analog Output 300 – 399
4xx Tolerance Monitoring 400 – 499
5xx Assignment of all I/O 500 – 599
6xx Serial Interfaces 600 – 699
7xx Statistics and Reports 700 – 799
9xx System Parameters 900 – 999
Please note: Select Code numbers 800 – 899, not used in this software version, are
therefore not displayed in the configuration menu.
A complete list of all parameters available in this software version with their Select
Code numbers, parameter names, functional description and selection possibilities is
to be found in Chapter 7 "LIST OF THE SELECT CODES" of this manual.
5.5.4 Parameter entry

The Select Code number allows the user to find quickly a given parameter by directly
entering its number.
For instance, let us consider the "User Language", Select Code number 090. According
to the list in Chapter 7, this Select Code is defined and described as follows:
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Group 0xx: MEASUREMENT AND DISPLAY
090 User Language
Defines the language of the display texts
0 = English
1 = French
2 = German
"Select" Key. The first Select Code "000" The entries "090" and "Enter" are
of the list is displayed: displayed. current selection 2 =
German
The cursor is now positioned on the current selection. The unmodified entry can now be
confirmed by pressing "Enter". In this case, the cursor jumps to the next Select Code
in the list. In our example, this should be Select Code 091 "LCD – brightness".
To change the selection, it is enough to type in the new value of the parameter, then
confirm with "Enter". The entry is tested for correctness. The value is accepted if it is
correct. It is then stored into the system, and the cursor jumps to the next Select Code
in the list. In our example, this should be the Select Code 091 "LCD – brightness".
Should the entered value be invalid, it is rejected with the error message "ERROR".
The current selection of the same parameter is displayed again after approximately
2 seconds.
5.5.5 Navigation
There are several ways to navigate through the configuration menu. The "select" key
allows the user to display quickly the pages with the corresponding configurations.
Whenever the key is pressed, the display switches to the next Select Code of the list.
It shows the "Code Designation", the "Parameter Name" and the "Parameter Value"
of the code.
Key "Select":
The " " key can be used for switching from "Code" to "Value". The same applies to
switching from "Value" to "Code".
Key " ":
5.5.6 Protected entry

A security code can protect the "Select" key access to the configuration mode. This
can prevent an unintended change of the system configuration. If the protection has
been activated, pressing the "Select" key results in an error message "CODE". This
prompts the user to enter the safety code and to confirm with "Enter".
The system only switches to the

configuration mode after the correct
safety code has been entered.
Systems with Controller

In systems with integrated controller (option), the controller has to be switched off before
certain entries can be performed. Otherwise, any attempt to perform such entries will
be rejected with the error message "CTRL ON" or "CONTROLLER ON".
20190423_USYS.050.0020.EN
5.5.7 Exit from configuration mode
To leave the configuration menu, it is enough to press any function key at any time.
Please note:
If the system does not receive any entry for three minutes when in configuration mode,
it automatically returns to the main display "Actual".
5.5.8 System configuration printout

USYS 20 allows the user to print out the entire system configuration. The current
product parameters and all Select Code numbers in the system with their settings are
collected in a list to be printed.
The printing of the device configuration can be defined with Select Code 930 and also
started with "Enter". The entered number corresponds to the desired interface. The
available interfaces are "Port 1" (RS1), "Port 2" (RS2) or "Port 3" (Ethernet).
It is necessary to check first that the settings of the selected interface really correspond
to those of the connected printer.
0 = No operation
1 = Outputs the device configuration through the serial interface "Port 1"
2 = Outputs the device configuration through the serial interface "Port 2"
3 = Outputs the device configuration through the Ethernet interface "Port 3"
The entered parameter is automatically reset to zero at the end of a successful printout.
If needed, this operation can be repeated as many times as needed by using the same
procedure. All active system functions such as measurement, statistics and control
keep running undisturbed in the background.
The printed image depends on the software being used and looks like the following:
Configuration ZUMBACH USYS 20
Program U20S1005
Nominal 123.456
Tolerance + 123.456
Tolerance - 123.456

Parameter Group 0xx
000 0.8
001 6
010 1
..... etc. ...
The list that follows contains all available Select-Code numbers and their settings.
5.5.9 Security code

If necessary, the system and product parameters entry can be protected with a security
code. The entry protection can be configured with Select Code 990.
The security code set at the factory is: 954 728
5.5.10 Changing the security code
The security code 954 728 set at the
factory can be modified and reprogrammed
at will. It must however lie in the range
000'000 and 999'999. It can be entered
with Select Code 991.
Warning!
When a new code is entered, it replaces the standard one. The standard code is
therefore no longer valid! The new code must be stored at a safe place from which it
can be retrieved when needed.
5.6 TOLERANCE MONITORING AND FAULT DETECTION

Tolerance monitoring can be adapted to a large extent to user requirements. Select Code
numbers in group "4xx: TOLERANCE MONITORING" are available for this purpose.

A list of all Select Code numbers is to be found in Chapter 7 "LISTE OF THE SELECT-
CODES" of this manual.
5.6.1 Select Code 400: Output rate of tolerances

0 = Normal. Monitoring taking place at the end of each specified
averaging time interval (see Select Code 000)
1 = Fast monitoring (10 values/s or 1 value/mirror rotation according
to the setting of Select Code 918)
It provides the user with the choice between monitoring tolerances at the end of each
specified averaging time (see Select Code 000) or relatively to faster single values.
If "Fast" is selected, monitoring is performed every 0.1 s (average of all the mirror
rotations) or once per mirror revolution (see also Select Code 918).
The output of off-tolerance states with relays or through digital outputs is also performed
at this increased rate.
5.6.2 Select Code 403: Tolerance in empty measuring field

0 = Tolerance monitoring is not carried out if the measuring field is empty
1 = The tolerance is also monitored if the measuring field is empty
Defines if tolerance monitoring must be active or not if the measuring field is empty,
i.e. the diameter is zero.
5.6.3 Select Code 404: Absolute or relative tolerance limits

0 = Absolute
1 = Entry relative to the set "Nominal" value
Defines the entry mode of the tolerance limits. These can be either absolute values
or relative ones with respect to the "Nominal" value.
Example:
Nominal: 12.000 mm, tolerance +: 12.150 mm, tolerance -: 11.900 mm
Entered as absolute value: Entered as relative value:
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5.6.4 Select Code 405: Mode of tolerance monitoring
0 = The average is monitored (root mean square of XY or XYZ)
1 = The values of each axis are separately monitored with regard to the set
tolerance value (main alarm and/or prealarm)
This code allows the user to specify if tolerance monitoring must check the average
of all measurement axes or each axis separately for an off-limit condition.
This setting concerns both the main alarm limits and the prealarm limits.
Example:
X Value: 12.150 mm, Y Value: 11.950 mm, RMS: 12.001, Tolerance +: 12.100 mm
If zero were selected, the tolerance alarm would not be triggered, since the root mean
square value 12.001 is not exceeded in our example. Tolerance monitoring would
however also be triggered in this case if the measurement axes were individually
monitored.
5.6.5 Select Code 406: Extended tolerance monitoring

0 = None (only both the + and - main tolerance limits are monitored)
1 = With additional monitoring of prealarm limits
Allows the user to set two additional alarm

limits, "Prealarm +" and "Prealarm –".
5.6.6 Select Code 407: Tolerance monitoring of the ovality

0 = None
1 = Monitoring of the ovality (difference between XY or XYZ)
The ovality of the measured product is also monitored when this function is active. In
the case of dual-axes measuring heads, the ovality is given by the absolute value of
the difference between the axes X and Y.
Example: X Value: 12.150 mm, Y value: 11.950 mm

Ovality: X - Y = 0.200 mm
In the case of three-axes measuring heads, the only axes used for computing the
ovality are the one with largest measured value and the one with the smallest measured
value.
Example: X Value: 12.150 mm, Y value: 11.950 mm, Z value: 11.850
Ovality: Largest - Smallest = X - Z = 0.300 mm
5.6.7 Select Code 408: Fault detection
0 = Disabled
1 = Function switched on
The special lump detection function (Fault Detection) detects very abrupt deviation from
the dimension such as lumps and neckdowns that might occur during the manufacturing
process.
The values being monitored are the extreme values, i.e. individual mirror values from
the connected measuring head. Each one of them can appear during the adjusted entry
duration (see Select Code 409). This provides a way to catch the smallest irregularities
without influencing the normal dimension measurement or any other function of the
system.
The lump detection function now tests if the acquired extreme values exceed the limit
values for lumps and neckdowns. If this occurs, it can be signalled on the front panel.
Internal counters, one for lumps and the other one for neckdowns are increased in
parallel.
The limits entered for the lump detection function are relative to the "Actual" value and
not, as in the case of tolerance limits, relative to the nominal value. In this way, one
ensures that the lump detection function functions independently of the set tolerance
limits and nominal value.
5.6.8 Select Code 409: Acquisition period for KW function

Number of measurements with moving average
Range: 1 – 99
Unit: Measurements
This parameter defines the number of measurements per second to be used to
compute the moving average for the KW function. The resulting average value is used
as actual value for monitoring. The value designated as “Measurement” may be either
the result of a mirror rotation or the average of such revolutions over a time of 0.1 s.
The selection is performed with Select Code 918.
5.6.9 Alarm lamps 6

The alarm lamps are chiefly used to display off-tolerance states. With special applications
or functions, e.g. Fault Detection, these might also display other alarms or operating
states.
The alarm lamps (AL) are driven according to the settings of the corresponding Select
Codes in the table below:
Select Select Select - AL2 - AL1 + AL1 + AL2 AL3

Code Code Code
406 407 408
0 0 1 Tolerance - x x Tolerance + KW +/-
0 1 x 1)
Tolerance - x x Tolerance + Ovality
1 0 1 Tolerance - Low High Tolerance + KW +/-
Prealarm Pre-alarm
1 1 x 1) Tolerance - Low High Tolerance + Ovality
Prealarm Pre-alarm
x = No operation
x 1) = It is impossible to simultaneously display "Ovality" and "KW +/-".
20190423_USYS.050.0020.EN
5.6.10 Relays and digital outputs
All alarm states described in this chapter can be made available on the outside
through relays or digital outputs. The configuration of these outputs is performed with
Select Code numbers from the group "5xx: RELAYS AND DIGITAL OUTPUTS".
5.7 PRINTER INTERFACE
5.7.1 Printer initialization string

The printer initialization string is made of up to six ASCII characters output at the start
of every printing cycle. It can e.g. be used, when printing labels, to position the printing
head at a specific output position before starting to print.
Every ASCII control characters in the printer initialization must be entered as a decimal
number. The Select Code numbers 611 to 616 are available for this purpose. The
characters are also output in this order. A character 000 is simply skipped.
Example: Form Feed, ASCII character [FF], decimal value 12

Select Code 611 input = 012
The characters are output in the order in which they are input. If the value of a character
is zero, it is simply skipped.
5.7.2 Text format

The text format is defined as 40 character per line (without the End Of Line character).
Each output line is terminated with the selected end of line character(s) carriage Return
[CR] or Carriage Return + Line Feed [CR][LF]. The format selected here allows the
user to either print on continuous forms or on labels.
When printing on labels or special paper, it might be necessary to define and enter a
printer initialisation string to configure the printer. This is done with Select Code 611
to 616.
5.7.3 Operation
The statistical data and any additional information selected are output through the
serial "Port 1" (RS 1) interface This occurs at the end of a statistical period triggered
by a corresponding "Start/Stop" signal.
5.7.4 Report layout

The user can define to a large extent the content of the printed reports. Select Code
numbers in group 7xx "STATISTICS AND REPORTS" are available for this purpose.
A list of all Select Code numbers is to be found in chapter 7 "LIST OF THE
SELECT CODES" of this manual.
Select-Code 710: Selection of the text fields to be printed

0 = Without text field
1 = Heading "ZUMBACH USYS 20" (can be modified through the host interface)
2 = Second title line (empty, but can be modified through the host interface)
4 = Lot number
8 = Product name
16 = Product number
32 = Operateur Code
This number provides a list of all additional text fields that can added to the report
printout. It is possible to perform a multiple selection by adding together the appropriate
selection numbers and by entering the obtained amount into the system.
Example: One would like to include "Lot number" and "Product number"
Lot number = 4, Product number = 16
Entry = 20 (4 + 16)
Select-Code 711: Selection of the additional values to be printed

0 = No additional values
1 = Reel number
2 = Length produced
4 = Number of events
8 = Number of lumps and neckdowns (Fault Detection)
16 = Cpk
This number provides a list of all additional values that can added to the report printout.
It is possible to perform a multiple selection by adding together the appropriate selection
numbers and by entering the obtained amount into the system.
Example: The "Length produced" and "CpK" should be selected

Length produced = 2, CpK = 16
Entry = 18 (2 + 16)
5.7.5 Formatted Output of the reports

The printout of statistical values looks the following way when all options are selected:
ZUMBACH USYS 20
Second title line ......................
Lot number 722-09-2009

Product name AW2-456-BJK
Product number 123-456
Operator code 712
Period number 12
Length produced 1734 m
Events 2
Lumps 3
Neckdowns 0
Stat 1 : RMS mean value

Average 12.005 mm
Maximum 12.023 mm
Minimum 11.989 mm
Standard deviation 0.027 mm
Max-Min range 0.034 mm
CpK 1.363
----------------------------------------––––
The "ZUMBACH USYS 20" and "Second title line" headings introduced above can be
entered or modified through the host interface. Both headings are made of a string
with up to 40 characters.
20190423_USYS.050.0020.EN
5.7.6 System configuration printout
USYS 20 allows the user to print out the entire system configuration. The current
product parameters and all Select Code numbers in the system with their settings are
collected in a list to be printed.
Setting the Select Code 930 to 1 and confirming with "Enter" starts the printing cycle.
This parameter is finally reset automatically to zero. If needed, this operation can be
repeated as many times as needed by using the same procedure. All active system
functions such as measurement, statistics and control keep running undisturbed in
the background.
The printing operation is performed through the serial interface "Port 1" (RS 1). It is
necessary to check first that the "Port 1" (RS 1) settings (Select Code 600 to 610)
really correspond to those of the connected printer.
The printed image depends on the software being used and looks like the following:
Configuration ZUMBACH USYS 20

Program U20S1005
Nominal 123.456
Tolerance + 123.456
Tolerance - 123.456

Parameter Group 0xx
000 0.8
001 6
010 1
..... etc. ...
The list that follows contains all available Select Code numbers and their settings.
5.8 CONTROLLER (OPTION)
5.8.1 Control key "Controller ON/OFF" 4

5.8.2 Display of the correction factor

The "SRD factor" (voltage ratio) computed by the controller can be displayed on the
LCD display as a bar graph. This allows the user to monitor easily and reliably the
behaviour of the control. To do that, it is necessary to set Select Code 020 "Value
displayed on bar graph" to 12.
5.8.3 Entry of controller settings
It is necessary to switch off the controller before entering all controller settings. Otherwise,
any attempt to perform such entries will be rejected with the error message "CTRL
ON" or "CONTROLLER ON".
5.8.4 Inner Diameter

The inner diameter is needed for computing the controller's gain and must be re-entered
for each product. This value must be zero when solid products are controlled.
The entry page is reached with the "Nominal" key.
5.8.5 Select Code 200: Dead band

Entry of the dead band in % of the insulation thickness or as absolute value
(see Select Code 210)
Format: x.xx
Range: 0 – 9.95 % or 0 – 9.95 mm
The dead band is a symmetrical band around the nominal value. Deviations inside this
band won't trigger any control pulse. This allows a certain degree of variation in the
product dimensions. The more stable the product dimensions, the narrower can be
this band. The control deadband can be entered as a percentage of the wall thickness
([nominal - inner diameter] / 2) or as an absolute value in mm. The choice between
the two modes is performed with Select Code 210.
Entering a percent value has the advantage that the resulting dead band changes
with the entered nominal value, i.e. with the size of the product. In most cases, it is
thus not necessary to re-enter it with every product change.
5.8.6 Select Code 201: Control limits

Entry of the control limits in % of the insulation thickness or as an absolute value
Format: xx.x
Range: 0.1 – 99.5 % or 0.1 – 99.5 mm
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The control limits form a symmetrical band around the nominal setpoint to limit the
action range of the controller. The error message "ERROR 401" is displayed if these
safety limits are exceeded. The control is then stopped and the General Alarm activated.
These safety limits prevent runaway situations that can be triggered by certain mishaps
on the extrusion line (extruder starvation, etc.). The control limit setting should be large
enough to allow for the wide dimensional fluctuations that may occur during start-up.
The control limit is expressed as a percentage of the wall thickness ([nominal - inner
diameter] / 2). It therefore varies with the nominal value, i.e. with the product size. In
most cases, it is thus not necessary to re-enter it with every product change (same
dimensional stability).
5.8.7 Select Code 202: Averaging

Shortest time if control is length-based OR averaging time in seconds if control is
time-based (see Select Code 212)
Format: xx.x
Range: 0.1 – 99.5 s
This parameter provides an efficient smoothing of the controller's signal when product
dimensions fluctuate.
If control is length-based (Select Code 212 on 0), this parameter specifies the shortest
time for computing the average of the actual values. This averaged value is then
compared to the nominal value and a suitable correction is applied. The entered time
only sets the minimal value, i.e. it define the lower limit of the variable. The upper limit
is computed by the system, based on the travel time of the product.
If control is time-based (Select Code 212 on 1), this parameter specifies the time in
seconds for computing the average of the actual values. This averaged value is then
compared to the nominal value and a suitable correction is applied.
5.8.8 Select Code 203: Deadtime

Shortest time if control is length-based OR averaging time in seconds if control is
time-based (see Select Code 212)
Format: xxx.x
Range: 0.1 – 999.5 s
This parameter specifies the time between two pulses of the controller.
If control is length-based (Select Code 212 on 0), this parameter specifies the shortest
deadtime between two control pulses. The entered time only sets the minimal value,
i.e. it define the lower limit of the deadtime. The upper limit is computed by the system,
based on the distances and the line speed. These distances are defined under "Distances
and length detector". In certain cases, the deadtime does not depend on the distances
and the line speed only. It also depends on slow-acting extrusion parameters such as
the extruder itself. The influence of these parameters can be included by adjusting
(increasing) the deadtime.
If control is time-based (Select Code 212 on 1), this parameter specifies the deadtime
between two pulses.
5.8.9 Select Code 204: Correction factor
Gain of the internal controller
Format: xxx
Range: 1 – 200 %
This parameter specifies the correction rate per control pulse. That is, the deviation
is corrected for each control pulse according to the entered percentage. If e.g. a
deviation of 0.2 mm occurs and if the correction factor is set to 70%, the first control
pulse corrects 0.14 mm of the error. The remaining error is still 0.06 mm, from which
the second pulse corrects 0.042 mm, etc.
5.8.10 Select Code 205: Selection of the control value

0 = Controller not operating
1 = RMS mean value: RMS average (X or average from XY or XYZ)
2 = Average: Arithmetic average (X or average from XY or XYZ)
3 = X
4 = Y
5 = Z
6 = Unavailable
7 = Greatest: greatest value from XY or XYZ
8 = Smallest: smallest value from XY or XYZ
This parameter allows the user to define the suitable control value.
5.8.11 Select Code 210: Entry mode of the dead band

0 = Dead band entered in % of the insulation thickness
1 = Dead band entered as an absolute value

The entry mode of the dead band specifies how the dead band is entered and used
by the controller. See Select Code 200.
5.8.12 Select Code 211: Control action

0 = The control is applied to the insulating section (e.g. sheath extrusion)
1 = The control is applied proportionally to the diameter
(e.g. centerless grinding)
This parameter specifies if the controller acts on the insulating section, e.g. sheath
extrusion, or in direct proportion to the diameter, e.g. centerless grinding. In the case
of control on the section with USYS 20, it is necessary to enter the internal diameter,
respectively the diameter before the extrusion.
5.8.13 Select Code 212: Length-based or time-based control

0 = Length-based control (a pulse generator must be connected)
1 = Time-based control. The deadtime and the controller's averaging
must be entered manually (see Select Code 202 and 203)
Length-based control requires an external pulse generator to be connected. It is then
necessary to configure the software according to the pulse generator. The Select Codes
available for this purpose are given below. They must be configured to fit the application:
Select Code 100: Length detector ON/OFF
Select Code 111: Distance between 2 pulses of the length detector
Select Code 112: Distance extruder to measuring head
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5.8.14 Select Code 213: Controller type and control polarity
0 = Static SRD controller
The output voltage increases when a positive fault signal is present
1 = Static SRD controller
The output voltage decreases when a positive fault signal is present
2 = Pulses: Control through internal relays
Select Code 213 on 0 or 1:

The control method, correcting the number of extruder revolutions, or correcting the
speed of the line through the capstan, determines the way Select Code 213 must be
set. When the static controller is used, it is necessary to adapt as follows the action
of the control on the output of the static actuator:
Correction Select Code Voltage change for a

on 213 positive diameter error
Capstan 0 Voltage increases
Extruder 1 Voltage decreases
Select Code 213 on 2:

Implementing the control method by correcting the number of revolutions of the extruder
or the capstan speed modifies the action of the control pulses "Pulse +" and "Pulse -"
according to the following table below:
Correction pulse Error signal Capstan correction Extruder correction

Impulse + + faster slower
Impulse - - slower faster
5.8.15 Select Code 214: Actuator constant

This value is only needed with a pulse-based control (e.g. motorised potentiometer)
Format: xx.x
Range: 0.2 – 99.5 %
This parameter allows the user to adapt the sensitivity of the connected actuator (e.g.
motorised potentiometer MPK1-10T) to the characteristics of the internal controller.
The sensitivity of the actuator is defined as the correction rate per second. This is
the percentage of the extrusion parameter to be modified (capstan speed, number
of revolutions of the extruder, etc.) that can be adjusted with a correction duration of
1 s (see technical data of the actuator). This percentage should not be understood as
absolute. It depends in fact on the position, i.e. it always refers to the current state of
the parameter to be modified.
Example: With a capstan speed of 14 m/s, the MPK1–10T actuator can generate a
decrease or an increase of 0.28 m/s in a second since its sensibility (actuator constant)
is equal to 2%. After one second (according to the parameter, already after a fraction
of a second), the actual speed has already changed and the 2% apply to the new
actual value. The application correction is therefore exponential (proportional to the
position) and not linear.
5.8.16 Select Code 220: Manual reset of the static controller
0 = No operation
1 = The voltage I/O ratio is set to 1
(Correction factor = 1)
This parameter allows the user to reset manually the static controller. Enter 1 and
confirm with "Enter" to trigger this function. The voltage I/O ratio of the static actuator
is set to 1. This corresponds to a correction of 1.
5.8.17 Factory settings

The factory setting of the controller parameters offers a good control in normal cases
without resorting to additional, more extensive adjustments.
Parameter Select Code Basic set-up

Deadband 200 0.1 % of wall
Control limits 201 50 % of wall
Minimum averaging 202 1.0 s
Minimum deadtime 203 0.1 s
Correction factor 204 70 %
Selection of the control value 205 1 RMS average
Entry mode of the deadband 210 0 %
Control Action 211 0 Section
Length-based or time-based control 212 0 Length
Controller type and polarity 213 0 SRD, positive
Actuator constant 214 2 %/s
5.9 LED ADDITIONAL DISPLAY
5.9.1 Mains connection

The additional displays are intended for a 230 VAC mains voltage. They are supplied
by the "PWR" connector on the rear side of the additional display.
Signal
C A B
PWR
L HI
O I I
M N N
N LO
P2
GND
5.9.2 Connection to the USYS 20 processor unit

The serial transmission is carried out with an RS-422 connection. If two or more
additional displays are connected, they can be coupled in parallel to the same interface
as shown below.
The transmission mode of the Serial Interface Select Code Setting

processor unit's serial interface must Port 1 (RS 1) 600 1 (RS422)
therefore be configured as RS-422. Port 2 (RS 2) 620 1 (RS422)
20190423_USYS.050.0020.EN
Additional display "1"
PWR
COM
A IN
B IN
L
N P2
USYS 20, Port 1 (RS 1) or Port 2 (RS 2)
Additional display "2" GND

1
14
2
15
3
16
4
17
5
18
PWR 6
19
COM
7 T+/R+ (RS485/RS422)
A IN
B IN
L T-/R- (RS485/RS422) 20
N P2 8
21
9
22
10
23
11
24
12
25
13
5.9.3 Setting the device address

Setting the device address of the two additional displays is performed with the DIL
switches on the front side of the display elements. Only switches "S1" to "S4" are used
to define the address. The remaining switches are configured at the factory and must
not be modified. It is necessary to remove carefully the front plate of the additional
display to reach the switch.
Device address "1" Device address "2" Device address "3"

1 8 1 8
ON ON ON ON ON ON ON ON ON ON ON ON ON ON
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
5.9.4 Character format

The format of each transmitted character is set in the additional displays as follows:
Number of Data bits = 7, Number of Stop bits = 1, Paritiy Control = even,
Baud Rate = 2400 Bits/sec.
The interface used for the additional display has to be configured according to these
values.
Parameter Select code "RS 1" Select code "RS 2" Value
Transmission mode = RS422 600 620 1
Baud Rate = 2400 601 621 4
Number of Data bits = 7 602 622 1
Number of Stop bits = 1 603 623 0
Parity Control = even 604 624 0
Use of the data 606 626 2
5.9.5 Functional description
Both serial interfaces can be used for two additional LED displays (Newport 6155 or
Zumbach display FA3).Switching on of the output function on takes place with select
code 606 = 2 for "Port 1" (RS 1) and Select-Code 626 = 2 for "Port 2" (RS 2).
At active function, a list of different values and results are output continuously via the
selected interface. The output rate corresponds to the averaging time set in the USYS
by means of select code 000.
The list of the output values is predefined and can Device Value
not be changed. The selection of the displayed address
values takes place by setting the corresponding 1 Root meas square value
device address in the auxiliary display. The following 2 Arithmetic mean value
values are available: 3 X
4 Y
5 Z
6 Ovality
7 Position X
8 Position Y
9 Position Z
10 Line speed
11 Current lengthen
5.10 OPTIMIZING MEASUREMENT ACQUISITION

This version of the instrument allows the user to set up and/or optimise specific
parameters for especially critical measurement acquisition conditions. These are
mainly parameters of the integrated measurement filter.
Individual parameters are set with Select Codes of group 9xx "SYSTEM AND
MEASURING HEAD PARAMETERS".
5.10.1 Select Code 910: Relative fault monitoring

0 = No monitoring
1 = +/- 50 %
2 = +/- 25 %
3 = +/- 12.5 %
4 = +/- 6.25 %
5 = +/- 3.13 %
6 = +/- 1.56 %
This parameter indicates the range of tolerated deviation as a percentage of the

nominal value. The error message "ERROR 304" is displayed if a measured value
is outside the range. The factory setting is 4. This gives a tolerated deviation of +/-
6.25%. It is necessary to choose a wider range if the object to be measured shows
large dimensional variations.
20190423_USYS.050.0020.EN
5.10.2 Select Code 911: Absolute monitoring
Entry in mm or inch according to the selected measurement unit and resolution.
Entering zero switches off monitoring.
This monitoring function checks if the measured values remain inside a definite absolute
range. The absolute deviation of raw data from the average of the previous data is
computed. The error message "ERROR 310" is displayed when too large deviations
occur. This filter masks e.g. droplets on the measured object. The factory setting is
"switched off".
5.10.3 Select Code 912: Position monitoring

Entering zero switches off monitoring.
This monitoring function checks if the position of the measured object changes from
scan to scan inside a definite absolute range. The error message "ERROR 303" is
displayed when too large deviations occur. This filter masks strong vibrations of the
measured object such as those occurring e.g. during wire drawing. The factory setting
is "switched off".
5.10.4 Select Code 913: Error suppression

Format: xx
Range: 0 - 99
This parameter indicates how many measurement errors are needed to display a
particular error message (of type ERROR xxx) on the LCD display. This damping can
prevent the confusing display of superfluous error messages when the measurement
conditions become unstable. The basic factory setting is 15.
5.10.5 Select Code 918: Acquisition interval of internal preprocessing

0 = Synchronous with mirror (1 measurement per mirror revolution)
1 = Default 0.1 s (10 measured values per second)
This parameter adapts the internal preprocessing to the external measurement conditions
or the measurement tasks. This set-up has an influence on all device functions switched
to "Fast". It therefore has an influence e.g. on the output period of the tolerances and
of the analog output or on the statistical evaluation. Furthermore, this parameter also
influences the acquisition period and thus the sensitivity of the KW function.
5.11 CYCLICAL OUTPUT OF THE ACTUAL VALUES

The "Port 2" (RS 2) serial interface can be used as a cyclical output of the actual values.
Switching on this cyclical output is done by setting select code 626 to 3.
The measured actual value is continuously outputted over the RS interface. The fastest
actual values of the connected measuring head, which were averaged over a fixed
time of 0.1 s, will be output. The actual value is defined as the diameter X of single-
axis measuring head and the root mean square of all measuring axes (XY or XYZ),
in case of measuring head with multiple measurement axes.
To be able to differentiate both possible values, the output is generated with an

identification code. The code g200 is assigned to the actual X value and the code
g210 to the RMS value. The outputted messages are as follows:
Actual value: g200[SP]xx.xxx[CR] or [CR][LF]
Actual value RMS: g210[SP]xx.xxx[CR][LF]
The format xx.xxx depends on the selected measuring unit and the resolution. The
final character [CR] or [CR][LF] can be set according Select-Code 627 to the user's
wish. If an error occurs with the USYS 10, then the outputed value xx.xxx is replaced
with ERRxxx how xxx for the current error number is.
Example measuring with fault "ERROR 304"
g210 6.003
g210 6.004
g210 ERR304
g210 ERR304
g210 6.008
g210 6.004
5.12 ERROR MESSAGES

When an alarm occurs, it appears on the LCD with the text "ERROR" followed by a
3-digit alarm number.
The internal General Alarm relay trips, provided that this function has been activated
in the configuration menu. See the description of Select Code 510, 511 and 512 in
chapter "7. SELECT CODE" of the present manual.
A list of all possible error messages is given below. The "ERROR 3xx" messages refer
to general problems with the measuring head or the measurement. The "ERROR 4xx"
messages, however, refer to the control or to the connected length detector.
Please note: It is also necessary to dispose of the sensor’s instruction manual when
troubleshooting malfunctions of type "ERROR 3xx".
Error Cause Elimination

Message
ERROR No diameter data from the Current supply for the sensor is missing,
300 measuring head possibly clean the measuring windows.
Replace laser or light source, check connection
cable to sensor.
ERROR Trouble in the edge of the Clean the measuring windows, check the
301 measuring field or wrong chopper signal, check if the measuring object
chopper signal is correctly placed in the measuring zone.
ERROR To many objects to be meas- Clean the measuring windows, possibly check
302 ured in the measuring field the video signals in the sensor.
ERROR Unstable measuring Improve the guidance of the measuring object
303
ERROR Big deviation of the measuring Improve the guidance of the measuring object,
304 value relative check surface of measuring object (water
drops, scale).
ERROR Big deviation of the measuring Check surface of measuring object (water
310 value absolute drops, scale), possibly improve guidance of
object.
ERROR Alarm "Clean windows" (Win- Clean windows as soon as possible
320 dow contamination indicator)
ERROR No impulse from length Check connection of length detector,
400 detector possibly faulty length detector.
ERROR Set control limit exceeded Optimise controller parameter, external regulat-
401 ing unit is faulty or incorrectly connected.
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5.13 PENETRATION DEPTH MEASUREMENT OR HEIGHT MEASUREMENT
The goal of this special measurement function is to measure objects that are not
completely inside the measurement field, that is, objects entering from above into
the measurement zone. The measurement mode needed for this purpose is called
"Penetration depth measurement". It can be activated by Select Code 921. The object
could also come into the measurement zone from below. In this case, one speaks of
"Height measurement".
Select Code 921: Measurement mode

0 = Diameter 1)
1 = Penetration depth measurement
2 = Height measurement
1)
The "Diameter" setup is used with penetration depth measurement and height
measurement to calibrate or recalibrate the device
5.13.1 Penetration depth measurement principle
Fig. 1 Fig. 2

Fig. 1
The distance measured here is the difference between the top edge of the measuring
field and the bottom edge of the object.
Fig. 2
How to display the thickness of a measured object guided over a roller? The penetration
depth of the roller without measuring object can be saved in the device as a reference
value so that this ground penetration depth is shown as zero.
5.13.2 Select Code 922: "Zeroing" a ground penetration depth

To "Zero" the display based on the ground penetration depth, proceed as follows:
1. Select the desired measurement mode by means of Select Code 921
and confirm with "Enter"
2. Bring the measuring head into the right position. There must not be any object
to measure on the roller
3. The "Zeroing" function for ground penetration depth is available under
Select Code 922. The current penetration depth is displayed on the right side.
The function is started by entering "1" followed by "Enter".

4. The completion of the function is signalled by an appropriate message and
zero is displayed on the right side. After three seconds, the system automatically
switches back to the Main screen "Actual". The instrument is ready to measure.

5.13.3 Select Code 922: Resetting the ground penetration depth

The stored ground penetration depth can be reset if necessary. The effective measured
penetration depth is shown again after this function has been executed. The function
is activated by entering "2" followed by "Enter".
5.14 DUAL-MEASURING HEADS WITH

SYNCHROBOX CI-1JS/1J "LARGE DIAMETER"
This execution is made of two measuring heads whose scanner motors are externally
synchronized. This configuration, consisting of two ODAC and a Synchrobox CI-2JS/1J,
provides a measurement system with a larger measuring field. The Synchrobox controls
both scanner motors and serially assembles both measurement signals. The evaluation
of the resulting large diameter is the same as in the normal USYS 20 execution.
20190423_USYS.050.0020.EN
5.14.1 "Large Diameter" Calibration of dual ODAC JSxK with
synchrobox CI-1JS/1J
The calibration of this type of measuring head combination requires three individual
steps. These can be performed either in the order described here or separately.
However, it is always recommended to go through the whole procedure.
1. Mount the calibration sample holder.

2. Check that the calibration sample is clean and insert it into the holder in
the center of the UPPER measuring field [a].
3. Calibrate USYS 20 according to the exact value of the calibration sample
Example:
Diameter of the calibration
standard = 75.007 mm
4. Insert the same calibration sample

into the holder in the middle of the
LOWER measuring field [b].
5. Calibrate USYS 20 according
to the exact value of the calibration
sample with Select Code 904.
6. Insert the large calibration sample into the holder in the middle of the ENTIRE
measuring field [c]. The size of the calibration sample is such that approximately
one half of both measuring fields is covered.
7. Calibrate USYS 20 according to the exact value of the calibration sample with
Select Code 905.
Example: Diameter of
the calibration standard = 142.21 mm

5.15 OPTION: REAL-TIME CLOCK
This PCB, available as an option, provides the USYS 20 control unit with a real-time
clock. The real-time clock supplements the collected statistical data and results with
time and date. Different time and date formats are available.
5.15.1 Display of date and time

The calibration of this type sensor combination requires three separate steps. These
can be both in the following order as performed separately.

If the option is available, the date and time are displayed in the relevant window title.
5.15.2 Select Code 080: Selection of date format

Using Select Code 80, the date format can be selected according to needs.

Select Code 080: Selection of Date Format
0 = DD.MM.YYYY (Day, Month, Year)
1 = MM.DD.YYYY (Month, Day, Year)
2 = YYYY.MM.DD (Year, Month, Day)
5.15.3 Select Code 081: Selection of time format

Using Select Code 81, the time format can be selected according to needs.

Select Code 081: Selection of Time Format
0 = HH:MM (Hours, Minutes)
1 = HH:MM:SS (Hours, Minutes, Seconds)
5.15.4 Entering date and time

Date and time are entered with Select Code 82 and 83. Data are entered in each case
according to the selected formats.
5.15.5 Configuration of statistics and reports

The statistical evaluation and the associated reports can acquire and print date and
time. The reports can be configured with selections 32 and 64 of Select Code 711.
Select Code 711: Selection of the additional values to be printed on the reel record
.....
32 = Date and time: End of the period
64 = Date and time: Beginning and end of the period
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6 STATISTICS
Statistical acquisition is very flexible and can meet practically all user requirements.
Select Code numbers in group "7xx : STATISTICS AND REPORTS" are available
for this purpose.

A list of all Select Code numbers is to be found in Chapter "7. LIST OF THE
6.1 COMPUTATION OF THE STATISTICAL VALUES

The statistical results are determined from the single measurements obtained during
an evaluation period. They can be results damped during the specified averaging
time. They can also be faster single values from the connected sensor that have been
averaged during a fixed time interval of 0.1 s. The selection of the acquisition mode
is performed with Select Code 720.
The internal statistical function can be used for up to three-dimensional evaluations. The
dimensions used for the statistics are selected with Select Code 700, 701 and 702.
The duration of the evaluation period is determined by the "Start/Stop" signal. This
signal can be sent through a digital input or through the serial host communication
interface.
The evaluation can be interrupted with a so-called "Pause" signal but without interrupting
the current period. With this function, it is also possible to specify if the internal length
counter should be disabled. The "Pause" function is automatically triggered by faulty
measurements or by line standstill.
Following values are collected or computed:
– Statistical average
This value represents the arithmetic average of all measured actual values during
the statistical period
– Statistical Maximum
This value represents the largest measured value during the statistical period
– Statistical Minimum
This value represents the smallest measured value during the statistical period
– Statistical Range
This value is a sum value and represents the difference between the smallest
(Minimum) and the largest (Maximum) value during the statistical period

– Statistical Standard Deviation
This value gives an information
1 1
about the regularity of the product
–––– [S Xi2 - –––– (S Xi)2]
during the statistical period.
n - 1 n
Following formula is used for
computation of the standard
n = Number of measurements
deviation:
Xi = Single measured value
– Statistical CpK-value
This value gives an information on the process capability and is calculated as
follows:
Upper tolerance limit - Average Lower tolerance limit - Average
a) b)
3 Sigma 3 Sigma
The valid CpK-value is always the smaller result of both the results of a) and b).
The maximum range for the CpK-value is set to 0.1 … 999.
6.2 ACQUISITION OF ADDITIONAL PARAMETERS

Statistical evaluation allows the user to acquire additional information or events and
to make then available at the end of the evaluation period.
– Length produced
The acquisition of the produced length requires the connection of an external
length detector. The length produced during an active "Pause" function can be
suppressed if needed (see Select Code 721).
– Event counter
This counter can be driven by a digital input. It counts the external events
occurring during a statistical period. The events generated during an active
"Pause" function can be suppressed if needed (see Select Code 721).
– Counter of the lump detection function
Two additional internal counters are available if the internal lump detection
function has been activated (see Select Code 408). They count the lumps and
neckdowns occurring during a statistical period. The lumps and neckdowns
produced during an active "Pause" function can be suppressed if needed (see
Select Code 721).
6.3 FUNCTIONAL DESCRIPTION
6.3.1 Delay of actual values and events

A delay can be applied to the actual value and the events of the statistical evaluation.
This is achieved with two shift registers for the distance to the take-up or cutting device.
This ensures that the information contained in each coil report really belongs to that
coil. The delay can be completely disabled by setting the relevant distances to zero.
Select Code 114: Distance between the measuring head and the end of the line
Select Code 115: Distance between the event gauge (e.g. sparker, lump
detector) and the end of the line
6.3.2 "Start/Stop" Evaluation period

The statistical evaluation period starts and stops with a "Start/Stop" signal. The
"Start/Stop" function can be controlled by the corresponding digital input of the "ST 2"
connector. A connected host computer can also supply the signal in parallel through
the serial communication interface.
20190423_USYS.050.0020.EN
As soon as a "Start/Stop" signal has been detected, all statistical values are computed
and stored for later use with the additional information and events. Statistical values
can be printed out and/or queried by a host computer.
Please note:
The recording of the measurements, of the length pulses and of the events in the new
statistical period remains disabled as long as this input is closed, i.e. is logical 0.
In the case of host communication, this is the case as long as the corresponding
parameter is set to "one".
6.3.3 Pause function "Pause"

The recording of the statistical values is suppressed as long as "Pause" is active. The
"Pause" function can be controlled by the corresponding digital input of the "ST 2"
connector. A connected host computer can also supply the signal in parallel through
the serial communication interface.
Please note:
The recording of the measurements, of the length pulses and of the events in the new
statistical period remains disabled as long as this input is closed, i.e. is logical 0.
In the case of host communication, this is the case as long as the corresponding
parameter is set to "one".
6.3.4 Period number

A number betwenn 1 and 9'999 is automatically attributed to each statistical period.
When switching on the unit, this number is automatically set to 1. After the period
number reaches 9'999 it automatically resets to 1. The current period number can be
set manually in the configuration menu. This allows the user to exclude for instance
a faulty coil from the statistics and to manufacture it again with the same number.
6.3.5 Length counter

To be able to log the produced length, it is necessary to connect a length detector. It
is also necessary to deﬁne the length between two pulses (Select Code 111) and the
count function must also be switched on (Select Code 100).
The length counter is reset automatically to zero after each "Start/Stop" signal.
The maximal detectable length that can be recorded, is 999'999 m. If this value is
exceeded, the length in the reel report will be identified as faulty by means of an
exclamation mark.
Period Number 12
Produced length ! 999999 m
Events 2
Lumps 3
Neckdowns 0
6.3.6 Text fields

If necessary, the coil report can contain additional text fields. These can be e.g. the
product name or the operator code. The selection of the desired text fields is performed
6.3.7 Additional values

If necessary, the coil report can contain additional values. These can be e.g. the number
of events or the Cpk value The selection of the desired additional values is performed
7 LIST OF SELECT-CODES FOR PARAMETER INPUT
7.1 GROUP 0XX: MEASUREMENT AND DISPLAY

000 Averaging time OR actual value recording time
(according to the selected measuring mode, Select-Code 920)
Format: xx.x
Range: 0.4 - 99.5 s
001 Resolution of measuring values
0 = 0.1 mm or 0.005 in.
1 = 0.05 mm 0.002 in.
2 = 0.02 mm 0.001 in.
3 = 0.01 mm 0.0005 in.
4 = 0.005 mm 0.0002 in.
5 = 0.002 mm 0.0001 in.
6 = 0.001 mm 0.00005 in.
7 = 0.0005 mm 0.00002 in.
8 = 0.0002 mm 0.00001 in.
9 = 0.0001 mm 0.000005 in.
Particularly for capacity measurement:
10 = 0.5 pF/m oder 0.2 pF/ft
11 = 0.2 pF/m 0.1 pF/ft
12 = 0.1 pF/m 0.05 pF/ft
13 = 0.05 pF/m 0.02 pF/ft
010 Displayed value no. 1
Selection of the value to be displayed on the main LCD display
0 = No display
1 = RMS: RMS average value (X or average of XY or XYZ)
2 = Average: arithmetic mean (X or average of XY or XYZ)
3 = X
4 = Y
5 = Z
6 = Ovality: absolute difference between the larger and smaller
value of XY or XYZ
7 = Larger: the larger value of XY or XYZ
8 = Smaller: the smaller value of XY or XYZ
9 = Position X: position of the measured object on the X axes
10 = Position Y: position of the measured object on the Y axes
11 = Position Z: position of the measured object on the Z axes
12 = not available
13 = Speed: actual line speed in m/min or feet/min
14 = Actual reel length in m or feet
15 = Deviation between RMS average value and nominal value
16 = Deviation between arithmetic mean and nominal value
17 = Deviation between X and nominal value
18 = Deviation between Y and nominal value
19 = Deviation between Z and nominal value
The selections are the same as for Select-Code 010
The selections are the same as for Select-Code 010
020 Value on the bar graph
Selection of the value to be displayed. The display shows the difference between
the selected value and the nominal value.
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There are 2 exceptions:
a) The position of the object is always related to the center of the
measuring field.
b) The ovality is always positive and is therefore displayed as an absolute value.
The zero is on the left side of the bar graph.
0 = No display
3 = X
4 = Y
5 = Z
6 = Ovality: absolute difference between the larger and smaller
value of XY or XYZ
12 = SRD factor: display of the correction factor, the ratio between
"Input and Output" of the SRD controller. The bar graph is
completely extinguished when the ratio is 1.
The display looks as followed:
Ratio between Input and Output

021 Range of the bar graph
Format according to the selected measuring unit and resolution
030 Display mode of the "offset" value
Choose whether the "Offset" value on page "Nominal" is to be displayed or not.
0 = No Display (-> "offset" value set to zero)
1 = Value displayed and ready for input
031 "Offset" correction value
Entering the desired value (corresponding to the "Offset" value on page "Nominal").
The sign can be changed by pressing the“+/-” key .
Entry in mm or inch according to which measurement unit and resolution are selected
Please note!
This parameter is available only if the input protection of the "Offset"
value is active (Select Code 990 = 2)
080 Selection of date format
0 = DD.MM.YYYY (Day, Month, Year)
1 = MM.DD.YYYY (Month, Day, Year)
2 = YYYY.MM.DD (Year, Month, Day)
081 Selection of time format
0 = HH:MM (Hours, Minutes)
1 = HH:MM:SS (Hours, Minutes, Seconds)
082 Input of the date
Input according to selected format (Select Code 080)
083 Input of the time
Input according to selected format (Select Code 081)
090 User language
Selection of the language for the user interface
0 = English
1 = French
2 = German
3 = not available
4 = Italian
091 LCD brightness

Format: xx
Range: 20 - 100 %
7.2 GROUP 1XX: DISTANCES AND LENGTH DETECTOR

100 Length detector function
To define if a length detector is used or not
0 = No external length detector
1 = With external length detector
110 Units for distances and length detection

0 = Meter (m)
1 = Feet (ft)
111 Distance between 2 pulses of the external length detector

Format : x.xxx
Range : 0.04 – 9.995 m or 0.1 – 9.995 ft
(according to select code 100)
112 Distance between extruder and measuring head
Format: xxx.xx
Range: 0.1 – 999.95 m or 0.5 – 999.95 ft
114 Distance between the measuring head and the line end
Format: xxx.xx
Range: 0.1 – 999.95 m or 0.5 – 999.95 ft
115 Distance between the event source (e.g. Sparktester, KW) and the line end
Format: xxx.xx
Range: 0.1 – 999.95 m or 0.5 – 999.95 ft
(according to Select code 100)
7.3 GROUP 2XX: CONTROLLER

Remark:
– These parameters are only available if the option
"Controller Interface USYS 20" (N6.IA.173) is installed
– All parameters can only be changed if the controller is turned Off
200 Dead band
Input in % of the wall thickness or as an absolute value
(according to select code 210).
Format: x.xx
Range: 0 – 9.95 % or 0 – 9.95 mm
201 Control limits
Input in % of the wall thickness or as an absolute value
(according to select code 210).
Format: xx.x
Range: 0.1 – 99.5 % or 0.1 – 99.5 mm
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202 Minimum averaging time OR averaging time
This value represents the minimum averaging time if the controller
is working on length base OR the averaging time if the controller is working
on time base (according to select code 212)
Format: xx.x
Range: 0.1 – 99.5 s
203 Minimum dead time OR dead time
This value represents the minimum dead time if the controller is working
on length base OR the dead time if the controller is working on time base
Format: xxx.x
Range: 0.1 – 999.5 s
204 Correction factor
Gain for the controller
Format: xxx
Range: 1 – 200 %
205 Selection of the controlled value
0 = No control
3 = X
4 = Y
5 = Z
6 = not available
210 Input mode of the controller dead band
0 = Controller dead band is entered in % of the wall thickness
1 = Controller dead band is entered as an absolute value
211 Effect of the controller
0 = The controller reacts on the wall thickness (e.g. jacketing)
1 = The controller reacts on the diameter
(e.g. Centerless grinding)
212 Controller mode Length or Time

0 = Length based control. Needs an external Length detector
1 = Time based control. Dead time and averaging time must
be set manually (see Select codes 202 and 203)
213 Controller operating mode and polarity in case of static SRD control
0 = Static SRD control: the output voltage increases
in case of a positive error
1 = Static SRD control: the output voltage decreases
in case of a positive error
2 = DDC control: control by relays
214 Correction factor of the regulating unit
This factor is only used in case of DDC control made trough a motorized
potentiometer (see Select code 213)
Format: xx.x
Range: 0.2 – 99.5 %
220 Manual Reset of the static SRD controller SRD

0 = No function
1 = The voltage proportion between input and output
is set to 1 (correction factor = 1)
7.4 GROUP 3XX: ANALOG OUTPUT
300 Update rate
0 = Normal. The output value is updated at the end
of the selected averaging time (select code 000)
1 = Fast output (10 values/s or 1 value/mirror rotation according
301 Operating mode
General remark: the position of the object is always related to the center
of the measuring field and is always a deviation from zero.
The ovality is always positive and is therefore outputted as an absolute
value.
0 = Deviation +/- 10 V, measured value "Actual" – nominal value "Nominal"
1 = Absolute value 0 - 10 V
302 Range for 10 V
Format in mm or inch according to the selected measuring unit and resolution
303 Output value

0 = No output
3 = X
4 = Y
5 = Z
6 = Ovality: absolute difference between the larger and
smaller value of XY or XYZ
9 = Position X: position of the measured object on the X axis
10 = Position Y: position of the measured object on the Y axis
11 = Position Z: position of the measured object on the Z axis
310 Output voltage at reset or error

Input of the desired voltage in volts at which should be output at a reset or
an error status.
Format: xx.xxx
Unit: V
Range: - 10.000 – + 10.000 V
7.5 GROUP 4XX: TOLERANCE CONTROL

400 Output clock tolerances
0 = Normal. The output value is updated at the end
of the selected averaging time (select code 000)
1 = Fast monitoring (10 values/s or 1 value/mirror rotation according
403 Tolerance alarm when measuring field is empty
0 = No tolerance monitoring
1 = The tolerance control is always active
404 Toleranzgrenzen absolute or relative1)

0 = Absolute
1 = Input is entered relative to the reference value "nominal"
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405 Mode of the tolerance monitoring1)
0 = Monitored is the average value of all axes
(X or square average value of XY or XYZ)
1 = The values of the individual axes are individually monitored
(main- and/or pre-alarms)
406 Extended tolerance control
0 = None (only the main tolerance
limits + and – are monitoring)
1 = Additional monitoring of the pre-alarms limits
2 = Separate monitoring of X and Y (profile measurement)
407 Tolerance control of ovality1)

0 = None
1 = Additional monitoring of the ovality (differenz between XY or XYZ)
408 Lump and Neckdown functions1)
0 = Out of operation
1 = Function is turned
409 Acquisition period for KW function1)
Number of measurements with moving average
Range: 1 – 99
Unit: Measurements/second
Remark:
1)
For the profile measurement, Select code 406 on 2, these choices have
no function. The settings are taken over: 404 = 0; 405 = 1; 407 = 0; 408 = 0
7.6 GROUP 5XX: DIGITAL AND RELAY OUTPUTS – DIGITAL INPUTS

500 General Alarm operating mode (selection of the alarm sources)
0 = No general alarm
1 = Measuring errors (ERROR 300 ... ERROR 309)
2 = Length detector error (ERROR 400)
4 = Controller errors (ERROR 401 ... ERROR 404)
8 = Tolerance limits
16 = Pre-alarm limits
32 = Alarm "Clean windows" (ERROR 320)
510 Use of relay no. 1 (Event active = Relay On)
a) Diameter measurement, with main alarms, pre-alarms and
ovality tolerance alarms (select code 406 on 0 or 1)
0 = No function
1 = Pre-alarm -
2 = Main tolerance limit -
3 = Pre-alarm +
4 = Main tolerance limit +
5 = Pre-alarms + and -
6 = Main tolerance limits + and -
7 = All pre-alarms and main tolerance limits
8 = Ovality tolerance alarm
9 = Control pulse -
10 = Control pulse +
11 = Fault detector +
12 = Fault detector –
13 = Fault detector + and -
14 = System alarm (function inverted: alarm = relay Off)
15 = Controller "On"
b) Profile measurement, alarms on X and Y (select code 406 on 2)
0 = No function
1 = Main tolerance limit X -
2 = Main tolerance limit Y -
3 = Main tolerance limit X +
4 = Main tolerance limit Y +
5 = Main tolerance limit X + and -
6 = Main tolerance limit Y + and -
7 = All main tolerance limits
8 = not available
9 = Control pulse -
11 = not available
12 = not available
13 = not available
511 Use of relay no. 2
The selections are the same as for Select code 510
512 Use of relay no. 3
520 Use of digital output no. 1 (event active = output active)
a) Diameter measurement, with main alarms, pre-alarms and
ovality tolerance alarms (Select code 406 on 0 or 1)
0 = No function
1 = Pre-alarm -
2 = Main tolerance limit -
3 = Pre-alarm +
4 = Main tolerance limit +
5 = Pre-alarms + and -
6 = Main tolerance limits + and -
7 = All pre-alarms and main tolerance limits
8 = Ovality tolerance alarm
9 = Control pulse -
11 = Fault detector +
12 = Fault detector –
13 = Fault detector + and -
b) Profile measurement, alarms on X and Y (Select code 406 on 2)
0 = No function
1 = Main tolerance limit X -
2 = Main tolerance limit Y -
3 = Main tolerance limit X +
4 = Main tolerance limit Y +
5 = Main tolerance limit X + and -
6 = Main tolerance limit Y + and -
7 = All main tolerance limits
8 = not available
9 = Control pulse -
11 = not available
12 = not available
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13 = not available
521 Use of digital output no. 2
530 Polarity of digital inputs
0 = Default : "1" = Input active
1 = Inverted: "0" = Input active
7.7 GROUP 6XX: SERIAL COMMUNICATION

Serial Interface RS 1:
600 RS1: Transmission mode
0 = RS-485, Half Duplex (multidrop), with RTS signal
1 = RS-422, Full Duplex (point to point), without RTS signal
601 RS1: Baud rate
3 = 1'200
4 = 2'400
5 = 4'800
6 = 9'600
7 = 19'200
8 = 38'400
9 = 57'600
10 = 115'200
602 RS1: Number of data bits
1 = 7
2 = 8
603 RS1: Number of stop bits
0 = 1
1 = 2
604 RS1: Parity control
0 = Even
1 = Odd
2 = Without control
606 RS1: Use of the data
0 = Interface is not used
1 = Output to printer: Reel report with statistical values (after "Start/Stop")
2 = Output for additional display: (FA3, NP6155)
3 = Output to printer: Configuration protocol USYS 20 (after "Start/Stop")
607 RS1: Line end character
0 = [CR] (carriage return)
1 = [CR] [LF] (carriage return and line feed)
608 RS1: Language for printouts
0 = English
1 = French
2 = German
3 = not available
4 = Italian
610 RS1: Number of additional line feeds [LF] after each printout
Format: xx
Range: 0 – 99
611 RS1: Printer initialisation character no. 1
Format: xxx
Range: 0 - 127
Format: xxx
Range: 0 - 127

Format: xxx
Range: 0 - 127
Format: xxx
Range: 0 - 127
Format: xxx
Range: 0 - 127
Format: xxx
Range: 0 - 127
Serial Interface RS 2:
620 RS2: Transmission mode of the serial interface
0 = RS-485, Half Duplex (multidrop), with RTS signal
621 RS2 : Baud rate
3 = 1'200
4 = 2'400
5 = 4'800
6 = 9'600
7 = 19'200
8 = 38'400
9 = 57'600
10 = 115'200
622 RS2: Number of data bits
1 = 7
2 = 8
623 RS2: Number of stop bits
0 = 1
1 = 2
624 RS2: Parity control
0 = Even
1 = Odd
2 = Without control
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626 RS2 : Use of the data
1 = Host-Computer, Up/Download
2 = Output for additional display: (FA3, NP6155)
3 = Cyclical output of actual values (10 values/s or 1 value/mirror
rotation, according to the setting of Select code 918)
5 = Host computer, upload/download with connection
to USYS Data Log1)
1)
Warning! The special communication functions for USYS Data Log can only
be activated for one of the two interfaces "Port 2" (serial RS-232/422) or "Port 3"
(Ethernet). If this function has been already activated on the other interface,
the error message "NOT ALLOWED" is displayed. In this case, kindly first change
the selection of the other interface. All already pre-programmed USYS Data Log
functions are reset.
627 RS2: Final character of a line
0 = [CR] (carriage return)
1 = [CR] [LF] (carriage return and line feed)
631 RS2: Selection of the HOST protocol (when select code 626 is set to 1)
0 = ZUMBACH-ASCII (RS-232, point to point)
1 = ANSI X3.28 (RS-485, multidrop protocol)
632 RS2: USYS 20 unit address for ANSI protocol (Select code 631 on 1)
Format: XX
Range: 0 - 99 (basic setting = 20)
Ethernet interface "Port 3":
640 Ethernet: IP address
IP address input into the local network
Format: xxx.xxx.xxx.xxx
Warning! Programming this parameter causes a software restart!
641 Ethernet: SubNet mask

SubNet mask input
642 Ethernet: Gateway address
Gateway address input
646 Ethernet: Use of the data
1 = Host-Computer, Up/Download
3 = Cyclical output of actual values (10 values/s or 1 value/mirror
5 = Host computer, upload/download with connection
to USYS Data Log1)
1)
Warning! The special communication functions for USYS Data Log can only
be activated for one of the two interfaces "Port 2" (serial RS-232/422) or "Port 3"
(Ethernet). If this function has been already activated on the other interface,
the error message "NOT ALLOWED" is displayed. In this case, kindly first change
the selection of the other interface. All already pre-programmed USYS Data Log
functions are reset.
647 Ethernet: Line termination character(s)
0 = [CR] (Carriage Return)
1 = [CR] [LF] (Carriage Return and Line Feed)
7.8 GROUP 7XX: STATISTICS AND REPORTS
700 Selection of the value for the statistic no. 1
Defines what value will be captured in the statistics
0 = No value
3 = X
4 = Y
5 = Z
6 = Ovality
7 = Biggest: the biggest value of XY or XYZ
8 = Smallest: the samllest value of XY or XYZ
The selections are the same as for select code 700
The selections are the same as for select code 700
705 Reel number

Input of a 3-digit number. With this input it is possible to set the number of the
current statistical period on an arbitrary number.
710 Choice of additional texts to be printed on the reel reports
0 = Without additional text
1 = Head line "ZUMBACH USYS 20"
(can be modified through the Host interface)
2 = Second line (empty, can be modified trough the Host interface)
4 = Order number
8 = Product name
16 = Product number
32 = Operator code
711 Choice of additional values to be printed on the reel reports
0 = Without additional value
1 = Reel number
2 = Total reel length
4 = Number of events
8 = Number of necks and lumps (KW function)
16 = Cpk
32 = Date and time: End of the period
64 = Date and time: Beginning and end of the period
720 Selection of the averaging time for the statistics
0 = Fast values. (10 values/s or 1 value/mirror
1 = Averaged values. Averaging time according
to Select code 000
721 Operating mode of the statistical "Pause" function
0 = The pause only interrupts the acquisition
of the measured values
1 = The pause interrupts the acquisition of the measured
values, length and event counters
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7.9 GROUP 9XX: SYSTEM PARAMETERS AND MEASURING HEAD
900 Measurement unit for the connected measuring head
0 = Metric (mm)
1 = Inch (in.)
2 = pF/m
3 = pF/ft

901 Type of measuring head
0 = ODAC 16
6 = ODAC 30
7 = ODAC 32 XY
13 = ODAC 15 XY J
15 = ODAC 82 J.DT
17 = CAPAC J
18 = ODAC 76 XY
19 = ODAC 151 J
21 = ODAC 152 XY
22 = 2 x ODAC 82 JS XY
25 = ODAC 18-34-64-110 XY
26 = ODAC 310
27 = 2 x ODAC 310 JS XY
29 = 2 x ODAC 151 JS XY
35 = ODAC 13-33-63-113 Trio
40 = ODAC 60 J.DT
41 = ODAC 100 J.DT
42 = 2 x ODAC 60 JS XY
43 = 2 x ODAC 60 JS
44 = 2 x ODAC 100 JS XY
45 = 2 x ODAC 100 JS
46 = ODAC 550
48 = ODAC 14 XY
50 = ODAC 160 J.DT
51 = 2 x ODAC 160 JS XY
52 = 2 x ODAC 160 JS
53 = ODAC 230
54 = 2 x ODAC 230 JS XY
55 = 2 x ODAC 230 JS
70 = MSD 25-50
71 = MSD 100-200
125 = ODAC 18-34-64-110 XY (CSS1) )
126 = ODAC 310 (CSS1) )
135 = ODAC 13-33-63-113 Trio (CSS1) )
140 = ODAC 60 J.DT (CSS1) )
141 = ODAC 100 J.DT (CSS1) )
146 = ODAC 550 (CSS1) )
148 = ODAC 14 XY (CSS1) )
150 = ODAC 160 J.DT (CSS1) )
153 = ODAC 230 (CSS1) )
170 = MSD 25-50 (CSS1) )
171 = MSD 100-200 (CSS1) )
225 = ODAC 18-34-64-110 XY – F (CSS1) )
235 = ODAC 13-33-63-113 Trio – F
240 = ODAC 60 J.DT – F(CSS1) )
241 = ODAC 100 J.DT – F(CSS1) )
250 = ODAC 160 J.DT – F(CSS1) )
1) CSS = Measuring heads with function "Calibrated Single Scan"

902 Calibration of measuring head
Please note: The measured capacitance value is in pF/m or pF/ft according
to which measurement unit and resolution are selected
903 Measuring head calibration in the UPPER measuring field
Warning! Especially for measuring heads type ODAC xxx JS connected
through an external Synchrobox
Value: Entry in mm or inch according to which measurement unit
and resolution are selected
904 Measuring head calibration in the LOWER measuring field
Value: Entry in mm or inch according to which measurement unit
and resolution are selected
905 Measuring head calibration in the WHOLE measuring field
Value: Entry in mm or inch according to which measurement unit and
resolution are selected
908 Offset calibration for capacitance measurement
0 = No operation
1 = Start of the offset calibration with an empty capacitance
measuring tube
910 Measuring filter: Relative control
0 = No control
1 = +/- 50 %
2 = +/- 25 %
3 = +/- 12.5 %
4 = +/- 6.25 %
5 = +/- 3.13 %
6 = +/- 1.56 %
911 Measuring filter: Absolute control

912 Measuring filter: Position control
913 Measuring filter: Error suppression (number suppressed before output)

Format: xx
Range: 0 – 99
914 Glass logic
0 = OFF
1 = ON
916 Alarm "Clean windows"

0 = Alarm OFF
1 = Alarm ON. Error message "ERROR 320" can be displayed.
918 Acquisition interval (internal preprocessing)
0 = Synchronous with mirror (1 measurement per mirror revolution)
1 = Default 0.1 s (10 measured values per second)
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920 Measuring mode
0 = The actual value is the average over the selected
averaging time (Select code 000)
1 = The actual value is the minimum during the set time
(Select code 000)
2 = The actual value is the maximum during the set time
(Select code 000)
921 Measurement mode

0 = Diameter1)
1) The "Diameter" setup is used with penetration depth measurement

and height measurement to calibrate the device
922 Zeroing of the measured penetration depth or height

0 = No operation
1 = The measured value is stored as a reference value.
The display then shows zero
2 = The stored reference value is reset. The measured
penetration depth or height is displayed again.
930 Prints the device configuration through the selected interface

Please note: This parameter is reset automatically to zero at the end
of the output procedure.
0 = No operation
1 = Outputs the device configuration through the serial interface
"Port 1"
2 = Outputs the device configuration through the serial interface
"Port 2"
3 = Outputs the device configuration through the Ethernet interface
"Port 3"
990 Parameter input protection

0 = No protection
1 = Access to the configuration mode is protected with the security code
2 = Accessing the configuration mode ("Select" key) and entering the offset
value ("nominal" page) are protected with the security code
991 Change the security code

Enter a 6-digit number in the range between 000'000 and 999'999
8 HOST INTERFACE: LIST OF DATA AND PARAMETERS
8.1 GROUP A: SYSTEM PARAMETERS

a040 Language for Printer
0 = English
1 = French (Français)
2 = German (Deutsch)
3 = not available
4 = Italian (Italiano)
a051 Resolution of measuring values
(the selection of the measuring units can be done with parameter a120)
0 = 0.1 mm or 0.005 in.
1 = 0.05 mm 0.002 in.
2 = 0.02 mm 0.001 in.
3 = 0.01 mm 0.0005 in.
4 = 0.005 mm 0.0002 in.
5 = 0.002 mm 0.0001 in.
6 = 0.001 mm 0.00005 in.
7 = 0.0005 mm 0.00002 in.
8 = 0.0002 mm 0.00001 in.
9 = 0.0001 mm 0.000005 in.
a060 Operating mode of analog output
Remark: the position of the object is always related to the center of
the measuring field and is always a deviation from zero. The ovality is always
positive and is therefore outputted as an absolute value.
0 = Deviation +/- 10V, actual value "Actual" - nominal value "Nominal"
1 = Absolute value 0 - 10V
a061 Selection of output value for the analog output
0 = No output
1 = RMS: Root mean square value (X or average of XY or XYZ)
2 = Average: arithmetic average value (X or average of XY or XYZ)
3 = X
4 = Y
5 = Z
6 = Ovality: absolute difference between the larger and the smaller
value of XY or XYZ
a070 Range of analog output (range for 0 – 10V or +/- 10V)
a075 Update rate of analog output
0 = Normal. The output value is updated at the end of the selected
averaging time (see parameter b030)
1 = Fast. The output value is updated 10 times per second (10 Hz)
a120 Measuring unit for the connected measuring head
0 = Metric (mm)
1 = Inch (in.)
a137 Measuring mode
0 = The actual value is the average over the selected
averaging time (Select code 000)
1 = The actual value is the minimum during the set time
(Select code 000)
2 = The actual value is the maximum during the set time
(Select code 000)
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a220 Value on the bar graph display
Selection of the value to be displayed on the main LCD display
0 = No display
3 = X
4 = Y
5 = Z
6 = Ovality: absolute difference between the larger and the smaller
value of XY or XYZ
7 = Large: the larger value of XY or XYZ
12 = SRD factor: display of the correction factor, the ratio between
"Input and Output" of the SRD controller. The bar graph is completely
extinguished when the ratio is 1. The display looks as followed:
a230 Range of the bar graph display
a320 Selection of the value for statistic no. 1
3 = X
4 = Y
5 = Z
The selections are the same as for parameter a320
The selections are the same as for parameter a320
a400 Header for printer output, line no. 1
Format: String up to 40 alphanumerical characters
a401 Header for printer output, line no. 2
a435 Tolerance alarm when measuring field is empty
0 = No tolerance monitoring
1 = The tolerance control is always active
a475 Update rate of tolerance outputs
0 = Normal. The output value is updated at the end of the selected
averaging time (see parameter b030)
1 = Fast. The output value is updated 10 times per second (10 Hz)
a990 Main program USYS 20
a991 Designation of the internal measuring module
a992 Date of the main program USYS 20
a993 Version of the processor PCB
a994 Actual scan rate of the connected measuring head
Format: xxxx
Unit: scans / s
8.2 GROUP B: LINE AND CONTROL PARAMETERS
b030 Averaging time OR acquisition time of the actual value
Format: xx.x
Range: 0.4 - 99.5 s
b050 Selection of the controlled value
0 = No control
3 = X
4 = Y
5 = Z
6 = Not available
b200 Deadband
Input in % of the wall thickness or as an absolute value (according to
parameter b201). The wall thickness is calculated with the measured
diameter and the inner diameter.
Format: x.xx
Rang: 0 - 9.95 % or 0 - 9.95 mm
b201 Input mode of the deadband and control limits
0 = The input is made in % of the wall thickness
1 = The input is made as an absolute value
b210 Control limits
Input in % of the wall thickness or as an absolute value (according to
parameter b201). The wall thickness is calculated with the measured
diameter and the inner diameter.
Format: xx.x
Range: 0.1 - 99.5 % or 0.1 - 99.5 mm
b220 Minimum averaging time OR averaging time
This value represents the minimum averaging time if the controller is working
on length base OR the averaging time if the controller is working on time base
(according to parameter b280)
Format: xx.x
Range: 0.1 - 99.5 s
b230 Minimum dead time OR dead time
This value represents the minimum dead time if the controller is working on
length base OR the dead time if the controller is working on time base (according
to parameter b280)
Format: xxx.x
Range: 0.1 - 999.5 s
b240 Correction factor
Gain for the internal controller
Format: xxx
Range: 1 - 200 %
b250 Correction factor of the regulating unit
This factor is only used in case of DDC control made trough a motorized
potentiometer (see parameter b260)
Format: xx.x
Range: 0.2 - 99.5 %
b260 Controller operating mode and polarity in case of static SRD control
0 = Static SRD control: the output voltage increases in case of a
positive error
1 = Static SRD control: the output voltage decreases in case of a
positive error
2 = DDC control: control by relays
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b270 Effect of the controller
0 = The controller reacts on the wall thickness (e.g. jacketing)
1 = The controller reacts on the diameter (e.g. Centerless grinding)
b280 Controller mode Length or Time
0 = Length based control. Needs an external length detector
1 = Time based control. Dead time and averaging time must be set
manually (see parameter b220 and b230)
b310 Distance between 2 pulses of the external length detector
Format: x.xxx
Range: 0.04 - 9.995 m or 0.1 - 9.995 ft (see parameter a120)
b340 Distance between extruder and measuring head
Format: xxx.xx
b341 Distance between the measuring head and the line end
Format: xxx.xx
b342 Distance between the event source (e.g. Sparktester, KW) and the line end
Format: xxx.xx
b400 Units for distance and length detection
0 = Meter (m)
1 = Feet (ft)
b450 Length detector function
To define if a length detector is used or not
0 = Off. No external length detector
1 = On. With external length detector
8.3 GROUP C: PRODUCT PARAMETERS

c015 Order number
c020 Product number
c021 Product name
c022 Operator code
c210 Nominal value
c220 Correction value
c228 Upper tolerance limit for X (only for profile measurement)
c229 Upper tolerance limit for Y (only for profile measurement)
c230 Upper tolerance limit
c231 Upper pre-alarm limit
c232 Tolerance limit for Ovality
c238 Lower tolerance limit for X (only for profile measurement)
c239 Lower tolerance limit for Y (only for profile measurement)
c240 Lower tolerance limit
c241 Lower pre-alarm limit
c250 Inner diameter
c275 Tolerance limit for lumps (only for KW-Function)
c276 Tolerance limit for neckdowns (only for KW-Function)
c285 Glas logic
0 = Off
1 = On
8.4 GROUP D: MEASUREMENTS AND RESULTS

d000 Actual length
Format: xxxxxx
Unit: m or ft (according to parameter b400)
Range: 0 – 999’999
d010 Statistic: Total produced length
Format: xxxxxx
Unit: m or ft (according to parameter b400)
Range: 0 – 999’999
d015 Actual line speed
Format: xxxx
Unit: m/min or ft/min (according to parameter b400)
d020 Statistic: Total number of events
Format: xxxx
Range: 0 – 9999
d021 Actual number of events
Format: xxxx
Range: 0 – 9999
d050 Statistic: Total number of lumps (only for KW-Function)
Format: xxxxx
Range: 0 – 99999
d051 Actual number of lumps (only for KW-Function)
Format: xxxxx
Range: 0 – 99999
d060 StatistiC: Total number of neckdowns (only for KW-Function)
Format: xxxxx
Range: 0 – 99999
d061 Actual number of neckdowns (only for KW-Function)
Format: xxxxx
Range: 0 – 99999
d090 Statistic: Period number / Reel number
Format: xxxxx
Range: 0 – 99999
Remark: When reading this parameter, the number of the last concluded
period is given back. With the writing this parameter, the number of the running
period can be set.
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d200 Controlled value (according to parameter b050)
d201 Actual RMS average (Root mean square value of XY or XYZ)
d202 Actual X
d203 Actual Y
d204 Actual Z
d205 Actual Ovality (absolute difference between the larger and the smaller
value of XY or XYZ)
d206 Actual average (arithmetic average value of XY or XYZ)
d210 Deviation between controlled value (d200) and nominal (c210)
Statistic:
The selection of the values for the statistics is made with parameters a320, a321 und a322.
All statistical results are available by reading the parameters shown in the table below.
Statistic 1 (a320) Statistic 2 (a321) Statistic 3 (a322)

Average d120 d220 d320
Maximum d130 d230 d330
Minimum d140 d240 d340
Standard deviation d150 d250 d350
Range Max-Min d160 d260 d360
CpK d165 d265 d365
Format according to the selected measuring unit and resolution.
8.5 GROUP E: ALARM MESSAGES AND DEVICE STATUS

e010 State of length detector
0 = Working
1 = Faulty
e200 General Alarm
0 = No alarm
1 = General Alarm is present
e220 System Alarm
000 = No alarm
xxx = Alarn number xxx is present
e230 Upper tolerance alarm / For profile measurement: Upper alarm on Y
0 = Limit not exceeded
1 = Limit is exceeded
e231 Upper pre-alarm / For profile measurement: Upper alarm on X
e232 Tolerance alarm on ovality
e240 Lower tolerance alarm / For profile measurement: Lower alarm on Y
e241 Lower pre-alarm / For profile measurement: Lower alarm on X
e250 Control limit
e260 Stored upper tolerance alarm / For profile measurement: Upper alarm on Y
The state shows if there has been an excess since last interrogation of
the parameter (automatic reset to 0 after interrogation of parameter)
e261 Stored upper pre-alarm / For profile measurement: Upper alarm on X
e262 Tolerance alarm on ovality
e270 Stored lower tolerance alarm / For profile measurement: Lower alarm on Y
e271 Stored lower pre-alarm / For profile measurement: Lower alarm on X
e730 Neckdowns were detected (only for KW-Function)
Displays if since the last reading any neckdown has been detected.
After ever reading this Parameter will be internally reset to zero.
0 = No fault
1 = Fault detected
e740 Lumps were detected (only for KW-Function)
Displays if since the last reading any lump has been detected.
After ever reading this Parameter will be internally reset to zero.
0 = No fault
1 = Fault detected
e780 Static SRD controller
The computed output factor is > 2 or zero
0 = No error
1 = Error is present
e790 Static SRD controller
The input or output voltage is greater 10 V
0 = No error
1 = Error is present
8.6 GROUP F: CONTROL FUNCTIONS

f010 Statistic "Pause"
0 = Pause end
1 = Pause begin
f020 Statistic "Start/Stop"
0 = No function
1 = Stops the running statistics and starts a new period
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f110 Controller On/Off
0 = Controller is switched off
1 = Controller is switched on
f250 Reset of the static controller
0 = No function
1 = The input/output ration is set to 1 (correction factor = 1)
8.7 GROUP G: MEASURING HEAD INPUT VALUES

Fast values. Acquisition time 0.1 s:
g200 Value X
g201 Value Y
g202 Value Z
g205 Value Y (the same as g201)
g210 RMS average (Root mean square value of XY or XYZ)
g211 Average (arithmetic average value of XY or XYZ)
g225 Ovality (absolute difference between the larger and the smaller
g230 Position X: position of the measured object on the X axes
g231 Position Y: position of the measured object on the Y axes
g232 Position Z: position of the measured object on the Z axes
Averaged values. Acquisition time according to parameter b030:
g240 Position X: position of the measured object on the X axes
g241 Position Y: position of the measured object on the Y axes
g242 Position Z: position of the measured object on the Z axes
g250 Value X
g251 Value Y
g252 Value Z
g255 Value X (the same as g250)
g260 RMS average (Root mean square value of XY or XYZ)
g261 Average (arithmetic average value of XY or XYZ)
g275 Ovality (absolute difference between the larger and the smaller
9 MAINTENANCE
• Maintenance must be carried out only by qualified personnels.

• Instruct the maintenance personnel on the proper maintenance and the
prevention of risks in the maintenance of the USYS 20.
• If the USYS 20 processor unit must be opened, e.g. for changing the configuration
or repair purposes, the device must be switched off by means of the "Power"
mains switch 1 (position "0"), the mains plug and all other plug connections
on the rear panel must be removed.
9.1 REGULAR MAINTENANCE

Cleaning:
• When using alcohol for cleaning purposes make sure that this work take place
in well ventilated areas or by an open window.
• At the same time avoid exposure to hot surfaces or naked flames which can
cause an explosion!
Cables and plugs:

• All cables and plugs must be inspected regularly for any kind of damage and, if
necessary, be replaced. Use only original spare parts. A spare parts list is in chapter
10.4.
9.2 DIAMETER CALIBRATION

Calibrating the instrument means adjusting the parameters related to the connected
measuring head. These parameters are the head type, the measurement units, the
measurement resolution and, finally, the calibration based on a calibration standard
of exactly known diameter.
9.2.1 Select Code 901: Head type

A current list of all available measuring heads is to be found in Chapter "7
Example:
ODAC 60 J.DT. The number of this measuring head is 40 according to the list of
Select Code 901.
Please note:
It may well happen that an error message will be displayed until the calibration is
completed. This, however, won't affect the calibration process. The display of an error
message of type "ERROR 3xx" only becomes significant after the whole procedure
has been completed.
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9.2.2 Select Code 900: Measurement unit
Measurement unit for diameter measurement
0 = metric (mm)
1 = inch (in.)
9.2.3 Select Code 001: Measurement resolution

Measurement Resolution
(the selection between metric/inch is performed with Select Code 900).
0 = 0.1 m
m oder 0.005 in.
1 = 0.05 m
m 0.002 in.
2 = 0.02 m
m 0.001 in.
3 = 0.01 m
m 0.0005 in.
4 = 0.005 m m 0.0002 in.
5 = 0.002 m m 0.0001 in.
6 = 0.001 m m 0.00005 in.
7 = 0.0005 m
m 0.00002 in.
8 = 0.0002 m
m 0.00001 in.
9 = 0.0001 m
m 0.000005 in.
9.2.4 Select Code 902: Head calibration

Head Calibration
During the calibration, the processor evaluates the operation of the measuring head
based on the measured and entered diameter of the calibration standard. To achieve
this aim, it is necessary to place the calibration standard in the middle of the measuring
zone and to enter its diameter under Select Code 902.
Example: Diameter of the calibration standard = 12.004 mm
The internal calibration procedure starts as soon as the entry has been confirmed with
"Enter". The internal calibration procedure can take up to 15 seconds according to the
connected measuring head. All entries are disabled during this time. The message
"CALIBRATION ..." is displayed on the screen
The end of the calibration procedure is signalled by the display of the positive
acknowledgement "CALIBRATION OK" or of the error message "CALIBRATION
ERROR". After three seconds, the system automatically switches back to the Main
screen "Actual".
If the displayed actual value does not match the calibration simple or if
"CALIBRATION ERROR" is displayed, the following items should be checked:
– Measuring head connection
– Measuring head type
– Selected measurement unit
– Positioning of the calibration sample
– Both calibration sample and measuring head must be clean
– The measuring head must have been operating for at least 10 minutes
– Ambient temperature. The calibration standard is designed for a temperature of
20° C. The temperature correction of a calibration sample made of suitable steel
(ZUMBACH standard) can be computed with the following formula:
Corrected diameter = nom. diameter x (1 + 12 x 10-6 x [temperature - 20° C])
Repeat the calibration with the corrected value.
9.3 INITIALISATION OF THE INSTRUMENT

This function erases the internal data memory and sets it back to the default values.
This is e.g. needed when the software is replaced by a newer version.
The initialisation is carried out as follows:

– Switch on the instrument
– Enter the security code when the "Actual" screen is displayed.
Confirm with "Enter". The security code set at the factory is 954 728.
Please note:
If the security code has been changed by the user, enter the new code.
– The screen then displays the "System utilities" (system programs) page.
The initialisation can be started by entering 3 and then pressing "Enter".
To leave the page without activating any function, enter 0 and then press "Enter".
– Initializing .....
The whole procedure can take up to three
minutes. All entries are disabled during this time.
The default values are then set ("Setting
defaults...") and the system is restarted
("Restarting...").
– The procedure ends with a reconfiguration of the parameters: Head type,

Distances, Controller parameters, Statistics configuration, etc.
Please note:
Following every initialisation of the device,
it is essential to select (Select Code 901)
and to calibrate (Select Code 902) again
the measuring head!
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10 REPAIRING
Repairs must be carried out only by qualified personnels.
Instruct the repair personnel on the proper repair and the prevention of risks in
the repair of the USYS 20.
Warning: Dangerous voltages inside. Be sure to disconnect the device from the
power supply before working inside the device: Pull the power plug! It is the
responsibility of qualified personnels to recognise the resulting dangers and
Chapter 10.4 contains a list of spare parts that can be replaced by the user.
10.1 RETURN FOR REPAIRS

• Enclose an exact description of the failure, including the operational mode in
which the failure or breakdown first occurred.
• Indicate clearly the person that should be contacted in your firm and telephone
number.
• For transportation, please use the original packing material (as far it is still
available). Should this no longer be available, please make sure that the package
protects the equipment adequately.
• Assuming it is necessary and possible, send the entire equipment back (with
cables, peripheral devices etc.).
►Our service and sales subsidiaries can of course also contacted by phone,
fax or email. The addresses are listed in chapter 1.2.
10.2 CONDITIONS APPLYING TO SPARE PARTS

Only use original spare parts from Zumbach. To use products from another source
could harm safety, reliability and performance.
Chapter 7.3 contains a list of standard spare parts. Additional spare parts are available
on request.
To replace the mains cable, use a mains cable that meets the requirements of IEC
60227 or IEC 60245, i.e. rated voltage at least 300 VAC, three wires with cross section
at least 1 mm2 and conductors coloured brown, blue and green-and-yellow, operating
temperature at least 70 °C.
10.3 HOW TO MOUNT THE HOOD OF THE TABLETOP MODEL
If the unit is opened for repair or for installing an optional expansion PCB, it is important
to note the following point about the reassembly!
The hood can only be properly set up if one first lightly adjusts the three front screws
[1] and only then the two rear screws [2]. Otherwise, the hood is submitted to too
great a stress and cannot be placed into the correct position.
10.4 LIST OF SPARE PARTS FOR

USYS 20
Photocopy this page, enter the desired quantities, and send it to one of the Zumbach
addresses in chapter 1.2 of this instruction manual.
When ordering spare parts, please make sure to always note the order number and
serial number from the technical label.
Order Serial
No.: No.:
Company .............................................................
Name .............................................................
Title .............................................................
Adress .............................................................
Phone .............................................................
Fax .............................................................
E-mail .............................................................
Website www. ...................................................
List of spare and wearing parts

The parts listed within the following table are intended for eventual trouble shooting, which
can be achieved by the customer.
All other parts of the appliance must mandatory be accomplished by Zumbach service
engineers or corresponding staff, especially trained by Zumbach.
20190423_USYS.050.0020.EN
Order
Illustration Part number Description Qty.
qty.
Plug-in terminal, housing

A08 415 0070 1
7pol/cable output KGG-MSTB2,5/7
Plug-in terminal block

A08 413 2070 1
7pol SF MSTB2,5/ 7-STF-5,08
Plug-in terminal, housing

A08 415 2151 1
15pol/cable output KGG-MC 1,5/15
Plug-in terminal block

A08 413 6151 1
15pol Schr. MC 1,5/15-STF-3,81
Rocker switch
A11 600 0430 1
Type 1901.1102 1pol 6A250VAC
Front plate
B.USY.0002.1010 1
LCD mounted (complete), USYS 20
Ribbon cable , grey

F10 1030 77C 1
10p 2xMicro-Match 10p 300mm C
CP PCB, equipped
N6.CP.305.A_ 1
Coldfire PCB for J signal
IA PCB, equipped
N6.IA.165.A_ 1
Interface USYS 20
IA PCB, equipped
N6.IA.173.A_ 1
Option SRD Interface USYS 200
Option
USY.9401.00100 1
Real-time clock USYS 20
Cable, Amphenol
USY.0002.F101 1
(for USYS 20 with plug Amphenol 10 )
Cable, Lemo L6
USY.002.F101 1
(for USYS 20 with plug Lemo 10 )
• Technical specifications are subject to change without notice
10.5 CHECK LIST BEFORE CONTACTING THE SERVICE
Error-Message
No display
No keyboard reaction
No control
Err 300
Err 301
Err 302
Err 303
Err 304
Calibration Err
Check the following points Err 310
Err 400
Unit switched on
Mains cable connected
Power mains supply
Internal supply voltage o.k.
Measuring head connected with USYS 20
Measuring head connection cable o.k.
Laser-Light available
Select-Code 901 on right head type
Calibrage completed correctly
Measuring head windows clean
Meas. object lead without vibrations
Meas. object in the middle of meas. field
Measuring object surface clean
Just one meas. object in meas. field
Length detector connected
Select-Code 100 on "1"
Is the line running
Dist. between length detect. and metal o.k.
Controller switched on
External regulating unit connected
Control limits not exceeded
Product not in deadband
20190423_USYS.050.0020.EN
11 DECOMMISSIONING / DISPOSAL
Decommissioning must be carried out only by qualified electricians.
WARNING
Dangerous voltages inside. Be sure to disconnect the device from the power
supply before working inside the device: Pull out the mains connector! It is the
responsibility of qualified electricians to recognise the resulting dangers and
11.1 DECOMMISSIONING
The device can be removed from the line and disposed of without taking any additional
measures.
11.2 GENERAL DISPOSAL

The USYS 20 is an electrical and electronic equipment without dangerous substances.
The disposal must be done in accordance with the directives on waste electrical and
electronic equipment (WEEE), i.e.:
– Separate collection of electrical and electronic equipment
– Return of the material according to national directives for recycling according to
national directives
► For disposal or recycling information please contact your local authorities.
12 PROTOCOLS OF COMMUNICATION
12.1 OVERVIEW
This document gives an overview over the serial communication protocols available
in the latest ZUMBACH electronics units. A Host computer (communication "Master")
may upload or download data to the devices via a serial interface, e.g. RS 232. The
ZUMBACH devices are all implemented as communication "Slave".
There are usually two communication protocols implemented, a protocol consisting
of ASCII characters only, and a multidrop protocol to link multiple devices.
12.1.1 ASCII protocol

This communication protocol is a simple ASCII protocol. It is the standard ZUMBACH
ASCII protocol implemented in almost all ZUMBACH electronics units. The protocol
is well suited for point to point connections. Some of the advantages of this protocol
are:
– A simple terminal or terminal program may be used (no block check character
must be calculated)
– It can be used by service personnel to trouble-shoot or inspect the system
without special software.
– It's very easy to implement on a Host computer. Debugging of the communication
link is easy.
– Automatic output of measuring data without request from Master is possible.
12.1.2 Multidrop protocol

The implemented protocol corresponds to the ANSI standard ANSI X 3.28 rev. 1976,
subcategories 2.5 and A4. It is a simple and safe Fieldbus Master-Slave protocol.
Some of the advantages of this protocol are:
The safety of the messages is guaranteed due to a Block Check Character. This Block
Check Character is calculated easily and fast with just a few XOR operations.
Up to 99 Slave devices may be connected via a single RS 422 or EIA 485 bus.
Any future expansion of the installation with other ZUMBACH devices like METREX5,
USYS, CI-CS/485 or CI-xJ/RS is no problem.
The protocol is easy to implement on the Host, compared with more complex Fieldbus
standards.
The protocol runs on cheap Host hardware, there is no heavy load for the Host processor
nor the need for large buffers in the data memory.
The messages are the same as those of the ZUMBACH ASCII protocol, just a frame
with the network address and the Block Check Character is added.
The following pages contain a description of these two protocols, beginning with some
general definitions, followed by the easier to understand ZUMBACH ASCII protocol.
These specifications concern the layers 2 and 7 of the ISO-OSI model for data
communications.
20190423_USYS.050.0020.EN
12.2 COMMUNICATION SYNTAX
For the purposes of the following explanations the names of single non printable ASCII
characters are indicated by placing the name of the character between "["and "]". The
following non printable characters are used in the descriptions:
Character Function Decimal Hex

[ACK] Acknowledge 6 06
[LF] Line Feed 10 0A
[CR] Carriage return 13 0D
[X-ON] Software Handshake (device on) 17 11
[X-OFF] Software Handshake (device off) 19 13
[NAK] Negative Acknowledge 21 15
[SP] Space 32 20
[EOT] End of Transmission 4 04
[ENQ] End of Inquire 5 05
[STX] Start of Text 2 02
[ETX] End of Text 3 03
Representations of a group of ASCII characters, such as an address or a command,

are placed between "<" and ">".
12.3 GENERAL DEFINITIONS

Download -> Data transmitted from the Master to the Slave.
Upload -> Data transmitted from the Slave to the Master.
Master -> Host Computer.
Slave -> ZUMBACH device.
Command Format
A command tells the Slave to either supply data to, or accept data from the Host
computer.
A command is identified in the following explanations by <CMD>.
Group
Transmitted parameters and data are divided into groups. Each group is designated
with a letter.
Letter
An upper case (capital) letter is used for a download sequence.
A lower case letter is used for an upload sequence.
Number
Each member of a group is designated with a three digit number. The numbers range
from 000 to 999. Leading zeros are mandatory.
Data Format
The data may be a value, a string, a selection or nothing at all. Data is identified in
the following explanations as <DATA>.
Value
A value consists only of numbers, sign prefixes, and a decimal point.
String
A string is a series of characters. Any printable ASCII character is allowed. The maximum
length of a downloaded string depends on the definition.
Selection
A selection from a list can be made by sending a number that corresponds to the
placement of the desired selection in the list. The first selection is 0.
Multiple (Selection)
A multiple selection is used when more than one selection may be selected at one
time. The selections are made by summing the values of the choices desired.
Example
e060 Hardware Self test Alarm Multiple R
0 = No Alarm
1 = WATCHDOG
2 = DUART
4 = EEPROM
8 = EPROM
16 = RAM
32 = ZUMBUS
256 = N6.IO.011 not present
If the watchdog does not work and there is a failure within the EEPROM, an Upload
of code e060 shows the value 5.
01 WATCHDOG
+ 04 EEPROM
———
05
Function
Does not have a value (although any value must be downloaded to conform with the
protocol). Triggers an action.
12.3.1 Communication errors

If an error is detected in the format or the content of a transmission from the Host, the
Slave will return a [NAK].
In addition the cause of the error may be requested using the upload code e040[CR].
The code returned will be one of the following:
e040 0 No Error
e040 200 The received value was invalid
e040 202 The received parameter code was invalid
e040 203 Download is not possible for this parameter
e040 204 Upload is not possible for this parameter
e040 205 Telegram too long
e040 206 Telegram too short
e040 207 Protocol error
e040 208 Block check failure
e040 209 Block aborted, ETX missing
e040 210 Communication time-out
NOTE: The error status register e040 is not implemented in all devices (refer to
manual!). Any error status except 210 will be reset upon the next upload/
download request. If a communication time-out occurs, the error status
210 remains stored until the next upload of the register e040.
20190423_USYS.050.0020.EN
12.3.2 Data and parameter access
Some data or parameters may only be read from the Slave, some may only be written
to the Slave, and some may be read and written.
The Access to the data and parameters is noted in the parameter list as:
R -> Read only
W -> Write only
RW -> Read and Write
12.4 ZUMBACH ASCII PROTOCOL
12.4.1 Upload

Master Slave
<CMD> [CR] [LF] No Reply
( optional )
[NAK]
Wrong <CMD> or
No Message
<CMD> [SP] <DATA> [CR] [LF]
Masters request
<CMD> Four character sequence, C1, C2, C3, C4, representing the parameter
code. For example, the Slave software version number is requested with
the <CMD> of 'a'‚ 9' ‚9' ‚0' (lower case letter!).
[CR] ASCII carriage return terminates the request.
[LF] ASCII Line Feed. (Optional) Ignored by the Slave.
Example - Request for measured value:

g155[CR][LF]
Response from Slave

<CMD> Echo of the four character sequence representing the parameter code.
[SP] ASCII space character.
<DATA> A variable number of characters (D1, D2, D3, ... Dn), representing the
value requested.
[CR] ASCII carriage return. Indicates the end of the data.
[LF] ASCII Line Feed. (Note: The output of this character may be disabled in
some devices, to reduce the telegram length. Refer to manual)
Example - Slave response to request for measured value:

g155[SP]2.65103[CR][LF]
12.4.2 Download

Master Slave
<CMD> [SP] <DATA> [CR] [LF] No Reply
( optional )
[NAK]
[ACK]
Masters request
code. For example, the Slave network address is downloaded with the
<CMD> ‚A'’9'’8'’0' (upper case letter!).
<DATA> A variable number of characters (D1, D2, D3, ... Dn), representing the value
downloaded.
[CR] ASCII carriage return terminates the request.
[LF] ASCII Line Feed. (Optional) Ignored by the Slave.
Example - Set the network address to 01:

A980[SP]01[CR][LF]
Response from Slave

[ACK] ASCII Acknowledge. Sent if data is accepted.
or
[NAK] ASCII Negative Acknowledge. Sent if data is not accepted due to an error.
Example - Slave response to downloaded address:

[ACK]
12.5 ANSI X3.28-2.5-A4 STANDARD PROTOCOL
12.5.1 Upload

Master Slave Master
[EOT] <ADD> <CMD> [ENQ] No Reply [EOT]
[NAK]
[EOT]
(Wrong <CMD> or no Message)
[STX] <CMD> [SP] <DATA> [ETX] <BCC> [ACK]
20190423_USYS.050.0020.EN
Masters request
[EOT] ASCII control character. Resets the communication link passing control
back to the control station (Master). Alerts all devices on the link to examine
the next four characters to see if they correspond with their group/unit
address identifier.
<ADDR> Four character sequence representing the address of the instrument. The
address is broken down into a most significant digit (MSD) and a least
significant digit (LSD). Each digit is repeated for security. The format of the
address, is MSD MSD LSD LSD. For example, the "<ADDR>" for device
number 10 is ‚1' ‚1' ‚0' ‚0'.
code. For example, the Slave software version number is requested with
the <CMD> of ‚a' ‚9' ‚9' ‚0' (lower case letter!).
[ENQ] ASCII control character. Indicates the end of an inquire message.
Response from Slave

[EOT] ASCII control character. If the <CMD> is not recognized or if the Slave has
no value to send, the Slave will send an [EOT] to return control to the control
station (your PCB).
or
[STX] ASCII control character indicating the Start of Text.
<CMD> Echo of the four character sequence representing the parameter code.
<DATA> A variable number of characters (D1, D2, D3, ... Dn), representing the value
requested.
[ETX] ASCII control character. Indicates the end of the message.
[BCC] Block Check Character. Generated by taking the Exclusive OR of the
values of the ASCII characters following and excluding [STX] up to and
including [ETX].
i.e.: [BCC] = C1 XOR C2 XOR C3 XOR C4 XOR SP XOR D1 XOR D2 XOR
D3 XOR D4...XOR Dn XOR ETX.
Response from Master

[EOT] ASCII control character. Returns control to the Master station. This may
be in response to a valid response from the Slave or to a "Time Out" if
no reply was received.
or
[NAK] ASCII control character. Used to indicate an unsuccessful receipt of a
message. This will cause the Slave to repeat the transmission.
or
[ACK] ASCII control character. Used to indicate a successful receipt of a
message.
This will cause the Slave to repeat the transmission (with updated value).
12.5.2 Download

Master Slave Master
[EOT] <ADD> [STX] <CMD> [SP] <DATA> [EXT] <BCC> No reply [EOT]
[ACK]
[NAK]
Masters Message
back to the control station (your PCB). Alerts all devices on the link to
examine the next four characters to see if they correspond with their group/
unit address identifier.
<ADDR> Four character sequence representing the address of the instrument. The
address is broken down into a most significant digit (MSD) and a least
significant digit (LSD). Each digit is repeated for security. The format of the
address, is MSD MSD LSD LSD. For example, the "<ADDR>" for device
number 10 is ‚1' ‚1' ‚0' ‚0'.
[STX] ASCII control character indicating the Start of Text.
code. For example, the diameter averaging time is downloaded with the
<CMD> of ‚B' ‚0' ‚3' ‚0' (upper case letter!).
<DATA> A variable number of characters (D1, D2, D3, ... Dn), representing the
value downloaded.
[ETX] ASCII control character. Indicates the end of the message.
[BCC] Block Check Character. Generated by taking the Exclusive OR of the
values of the ASCII characters following and excluding [STX] up to and
including [ETX].
Response from Slave

[ACK] ASCII control character. Used to indicate a successful receipt of a
message.
or
[NAK] ASCII control character. Used to indicate an unsuccessful receipt of a
message. This may cause the Master to repeat the transmission.
Response from Master

back to the control station (itself).
or
The Master repeats the transmission (e.g. after a [NAK]).
or
The Master sends another message to the same device (same address).
20190423_USYS.050.0020.EN
12.6 EXAMPLES: UPLOAD/DOWNLOAD WITH IBM COMPATIBLE PC
The following example programs are written in QBasic, which is part of MS-DOS. The
examples shows how to communicate with a ZUMBACH USYS device. The examples
may be applied to other devices, just the Upload/Download code used for the parameter
must be adjusted.
The programs read a parameter stored in a USYS and display it on the computer screen.
The user is then prompted for a new value for this parameter. The download string with
the value is built and sent to the USYS. These examples include extensive error checking.
12.6.1 Example with ZUMBACH ASCII protocol

The following example shows how to use the ZUMBACH ASCII Upload/Download
protocol. The parameter code used in this example is c210.
REM ———————————————————————————————————
REM PROGRAM : DEMOUPDN.BAS
REM VERSION : 1.0
REM DATE : 17.5.93
REM LANGUAGE: QBASIC VERSION 1.1 / MS-DOS 6.0
REM ———————————————————————————————————
DECLARE SUB UDLOAD (MESSAGE$, RET$)‚DECLARATION OF SUBROUTINES
DECLARE SUB ERRORMSG (ERR$)
DECLARE SUB TRANSFER (MESSAGE$, RET$)
REM - SETUP FOR COM PORT. IF HARDWARE CHECK NOT NEEDED (NO MS-DOS TIMEOUT),
REM - USE STRING „COM2:4800,E,7,1,CD0,CS0,DS0“
COMSET$ = „COM2:4800,E,7,1“ ‚WITH CHECK
REM - CODE FOR NOMINAL VALUE, SEE MANUAL USYS

PARAMETER$ = „C210“
CLS ‚CLEAR SCREEN

PRINT STRING$(80, „-“) ‚DISPLAY TITLE
PRINT „ZUMBACH ELECTRONIC“
PRINT „DEMO PROGRAM UP/DOWNLOAD IBM PC <—> USYS“
PRINT STRING$(80, „-“)
PRINT „“
PRINT „OPEN COM PORT WITH: „; COMSET$
PRINT „—————————————————“
PRINT „NOTE: THE WIRING OF THE COM PORT MUST BE CORRECT, OTHERWISE A“
PRINT „TIMEOUT WILL OCCUR (FROM MS-DOS).“
PRINT „“
OPEN COMSET$ FOR RANDOM AS #1‚INITIALISE COM PORT AS DEVICE 1
PRINT „READ PARAMETER „; PARAMETER$; „ (UPLOAD)“
PRINT „——————————————“
LOAD$ = LCASE$(PARAMETER$)‚MAKE SURE CODE IS LOWER-CASE
PRINT „SEND TO USYS: „; LOAD$‚DISPLAY CODE TO SEND TO USYS
CALL UDLOAD(LOAD$, ANSWER$)‚CALL SUBROUTINE UDLOAD
REM - CHECK IF UPLOAD WAS POSSIBLE
IF (ANSWER$ = „NAK“) OR (ANSWER$ = „ACK“) OR (ANSWER$ = „TIMEOUT“) THEN
CALL ERRORMSG(ANSWER$)‚CALL SUBROUTINE TO DISPLAY ERROR MESSAGE
ELSE‚PROCEED ONLY IF UPLOAD OK
PRINT „RECEIVED FROM USYS: „; ANSWER$ ‚DISPLAY RECEIVED STRING
VALUE = VAL(MID$(ANSWER$, 5)) ‚RECEIVED VALUE
PRINT „-> CURRENT VALUE IS: „; VALUE ‚DISPLAY CONVERTED VALUE
PRINT „“

PRINT „WRITE PARAMETER „; PARAMETER$; „ (DOWNLOAD)“
PRINT „———————————————“
PRINT „ENTER NEW VALUE FOR „; PARAMETER$; „: „; ‚ASK FOR NEW VALUE
LINE INPUT VALUE$
REM - BUILD MESSAGE STRING. PARAMETER CODE MUST BE UPPER-CASE AND

REM - CONTAIN A [SPACE].
LOAD$ = UCASE$(PARAMETER$) + „ „ + VALUE$
PRINT „SEND TO USYS: „; LOAD$ ‚DISPLAY CODE TO SEND
CALL UDLOAD(LOAD$, ANSWER$) ‚CALL SUBROUTINE UDLOAD
IF (ANSWER$ = „ACK“) THEN ‚POSITIVE RESPONSE

PRINT „RECEIVED FROM USYS: [ACK]“
PRINT „-> DOWNLOAD DONE CORRECTLY“
ELSE
CALL ERRORMSG(ANSWER$) ‚CALL SUBROUTINE TO DISPLAY ERROR MESSAGE
END IF
END IF ‚UPLOAD POSSIBLE
CLOSE ‚CLOSE DEVICES
END
REM ———————————————————————————————————
SUB ERRORMSG (ERR$)

REM ———————————————————————————————————
REM DISPLAYS AN ERROR MESSAGE ON SCREEN
REM ———————————————————————————————————
IF (ERR$ = „NAK“) THEN
PRINT „ERROR: COMMUNICATION ERROR OR WRONG DATA. USYS RETURNED [NAK].“
ELSEIF (ERR$ = „ACK“) THEN
PRINT „ERROR: DOWNLOAD INSTEAD OF UPLOAD. USYS RETURNED [ACK].“
ELSEIF (ERR$ = „TIMEOUT“) THEN
PRINT „ERROR: TIMEOUT, USYS DID NOT RESPOND.“
ELSE
PRINT „ERROR: UPLOAD INSTEAD OF DOWNLOAD. USYS RETURNED MESSAGE: „; ERR$;
END IF
REM ———————————————————————————————————
END SUB
SUB TRANSFER (MESSAGE$, RET$)
REM ———————————————————————————————————
REM SENDS A MESSAGE USING DEVICE #1 TO USYS AND WAITS FOR A RESPONSE
REM RETURNS: - STRING WITHOUT [CR] (UPLOAD)
REM - „ACK“ (DOWNLOAD)
REM - „TIMEOUT“ OR „NAK“ IN CASE OF AN ERROR
REM ———————————————————————————————————
REM INITIALISATIONS
REM ———————————————————————————————————
TRUE = 1
FALSE = 0
CR$ = CHR$(&HD) ‚POSITIVE RESPONSE UPLOAD
ACK$ = CHR$(&H6) ‚POSITIVE RESPONSE DOWNLOAD
NAK$ = CHR$(&H15) ‚NEGATIVE RESPONSE
IF NOT EOF(1) THEN RCV$ = INPUT$(LOC(1), #1) ‚CLEAR INPUT BUFFER
RCV$ = „“ ‚CLEAR INPUT STRING
TIMEOUT = 1000 ‚SET TIMEOUT VALUE
TIMCNT = 0 ‚CLEAR TIMEOUT COUNTER
RCVEND = FALSE ‚CLR RECEIVE COMPLETED FLAG
REM ———————————————————————————————————
REM - SEND MESSAGE TO USYS. COMMAND „PRINT“ APPENDS [CR] TO MESSAGE
PRINT #1, MESSAGE$
REM ———————————————————————————————————
WHILE (RCVEND = FALSE) AND (TIMCNT < TIMEOUT) ‚WAIT FOR ANSWER OR TIMEOUT
WHILE NOT EOF(1) ‚GET DATA FROM INPUT BUFFER
IN$ = INPUT$(1, #1) ‚READ NEXT CHARACTER
IF (IN$ <> CR$) THEN ‚IF NOT [CR]
RCV$ = RCV$ + IN$ ‚APPEND TO INPUT STRING
END IF
IF (IN$ = CR$) OR (IN$ = ACK$) OR (IN$ = NAK$) THEN
RCVEND = TRUE
END IF
TIMCNT = 0 ‚RESET TIMEOUT COUNTER
20190423_USYS.050.0020.EN
WEND
TIMCNT = TIMCNT + 1 ‚TIMEOUT COUNTER + 1
WEND
REM ———————————————————————————————————
REM - BUILD STRING TO RETURN
IF (RCV$ = ACK$) THEN
RET$ = „ACK“
ELSEIF (RCV$ = NAK$) THEN
RET$ = „NAK“
ELSEIF (TIMCNT >= TIMEOUT) THEN
RET$ = „TIMEOUT“
ELSE
RET$ = RCV$
END IF
REM ———————————————————————————————————
END SUB
SUB UDLOAD (LOAD$, ANSWER$)
REM ———————————————————————————————————
REM SENDS A MESSAGE TO SUBROUTINE „TRANSFER“ AND WAITS FOR A RESPONSE.
REM IF THE RESPONSE IS NEGATIVE, THE MESSAGE IS SENT A SECOND TIME.
REM RETURNS THE MESSAGE RECEIVED FROM SUBROUTINE „TRANSFER“.
REM ———————————————————————————————————
CALL TRANSFER(LOAD$, ANSWER$) ‚CALL SUBROUTINE
IF (ANSWER$ = „NAK“) OR (ANSWER$ = „TIMEOUT“) THEN ‚TRY AGAIN IF ERROR
FOR I = 1 TO 5000: NEXT I ‚DELAY BEFORE CALL
CALL TRANSFER(LOAD$, ANSWER$) ‚CALL SUBROUTINE
END IF
REM ———————————————————————————————————
END SUB
12.6.2 Example with ANSI X3.28-2.5-A4 protocol

The following example shows how to use the ANSI X3.28-2.5-A4 Upload/Download
protocol. The parameter code used in this example is c210, the device address of
the USYS is 10.
REM ———————————————————————————————————
REM PROGRAM : DEMOANSI.BAS
REM VERSION : 1.1
REM DATE : 17.1.94
REM LANGUAGE : QBASIC VERSION 1.1 / MS-DOS 6.0
REM ATTENTION : THE VALUE „TIMEOUT“ IN FUNCTION „TRANSFER“ MUST BE
REM ADJUSTED TO THE PCs PERFORMANCE
REM (E.G. 386DX33: 2000; 486DX266: 4000)
REM ———————————————————————————————————
DECLARE FUNCTION UPLOAD$ (ADDR$, MESSAGE$) ‚DECLARATION OF SUBROUTINES
DECLARE FUNCTION DNLOAD$ (ADDR$, MESSAGE$)
DECLARE SUB ERRORMSG (ERR$)
DECLARE FUNCTION TRANSFER$ (MESSAGE$)
DECLARE FUNCTION GETBCC (CHECK$)
CONST TRUE = 1 ‚CONSTANTS

CONST FALSE = 0
COMMON SHARED STX$, ETX$, EOT$, ENQ$, ACK$, NAK$ ‚GLOBALS
STX$ = CHR$(&H2) ‚START OF TEXT DOWNLOAD

ETX$ = CHR$(&H3) ‚END OF TEXT UPLOAD MESSAGE
EOT$ = CHR$(&H4) ‚END OF TRANSMISSION
ENQ$ = CHR$(&H5) ‚END OF UPLOAD MESSAGE
ACK$ = CHR$(&H6) ‚POSITIVE RESPONSE DOWNLOAD
NAK$ = CHR$(&H15) ‚NEGATIVE RESPONSE DOWNLOAD
REM ———————————————————————————————————
REM - SETUP FOR COM PORT. IF HARDWARE CHECK NOT NEEDED (NO MS-DOS TIMEOUT),
REM - USE STRING „COM2:4800,E,7,1,CD0,CS0,DS0,RB2048“ ‚WITH INPUT BUFFER !
COMSET$ = „COM2:4800,E,7,1,RB2048“
ADDRESS$ = „1100“ ‚DEVICE ADDRESS OF USYS IS SET TO „10“

PARAMETER$ = „C210“ ‚CODE FOR NOMINAL VALUE, SEE MANUAL USYS
REM ———————————————————————————————————
CLS ‚CLEAR SCREEN

PRINT STRING$(80, „-“) ‚DISPLAY TITLE
PRINT „ZUMBACH ELECTRONIC“
PRINT „DEMO PROGRAM UP/DOWNLOAD IBM PC <—> USYS“
PRINT „WITH PROTOCOL ANSI X3.28 - 2.5 - A4“
PRINT STRING$(80, „-“)
PRINT „“
PRINT „OPEN COM PORT WITH: „; COMSET$
PRINT „—————————————————“
PRINT „NOTE: THE WIRING OF THE COM PORT MUST BE CORRECT, OTHERWISE A“
PRINT „TIMEOUT WILL OCCUR (FROM MS-DOS).“
PRINT „“
OPEN COMSET$ FOR RANDOM AS #1 ‚INITIALISE COM PORT AS DEVICE 1
PRINT „READ PARAMETER „; PARAMETER$; „ (UPLOAD)“

PRINT „——————————————“
LOAD$ = LCASE$(PARAMETER$) ‚MAKE SURE CODE IS LOWER-CASE
ANSWER$ = UPLOAD$(ADDRESS$, LOAD$) ‚CALL SUBROUTINE UPLOAD
REM - CHECK IF UPLOAD WAS POSSIBLE

SELECT CASE ANSWER$
CASE „NAK“, „ACK“, „EOT“, „TIMEOUT“, „BCC ERROR“
CASE ELSE ‚PROCEED ONLY IF UPLOAD OK
PRINT „RECEIVED FROM USYS: „; ANSWER$ ‚DISPLAY RECEIVED STRING

VALUE = VAL(MID$(ANSWER$, 6)) ‚RECEIVED VALUE
PRINT „-> CURRENT VALUE IS: „; VALUE ‚DISPLAY CONVERTED VALUE
PRINT „“
PRINT „WRITE PARAMETER „; PARAMETER$; „ (DOWNLOAD)“

PRINT „———————————————“
PRINT „ENTER NEW VALUE FOR „; PARAMETER$; „ (0..99): „; ‚ASK NEW VALUE
LINE INPUT VALUE$
REM - BUILD MESSAGE STRING. PARAMETER CODE MUST BE UPPER-CASE AND

REM - CONTAIN A [SPACE].
LOAD$ = UCASE$(PARAMETER$) + „ „ + VALUE$
ANSWER$ = DNLOAD$(ADDRESS$, LOAD$) ‚CALL SUBROUTINE UDLOAD

IF (ANSWER$ = „ACK“) THEN ‚POSITIVE RESPONSE
PRINT „RECEIVED FROM USYS: [ACK]“
PRINT „-> DOWNLOAD DONE CORRECTLY“
ELSE
END IF
END SELECT ‚UPLOAD POSSIBLE
REM - END OF MAIN PROGRAM
CLOSE ‚CLOSE DEVICES
END
REM ———————————————————————————————————
20190423_USYS.050.0020.EN
FUNCTION DNLOAD$ (ADDR$, MESSAGE$)
REM ———————————————————————————————————
REM IF THE RESPONSE IS NEGATIVE, THE MESSAGE IS SENT A SECOND TIME.
REM RETURNS THE MESSAGE RECEIVED FROM SUBROUTINE „TRANSFER“.
REM ———————————————————————————————————
BCC = GETBCC(MESSAGE$ + ETX$)

DNMSG$ = EOT$ + ADDR$ + STX$ + MESSAGE$ + ETX$ + CHR$(BCC)
ANSWER$ = TRANSFER$(DNMSG$) ‚CALL SUBROUTINE

IF (ANSWER$ = „NAK“) OR (ANSWER$ = „TIMEOUT“) THEN ‚TRY AGAIN IF ERROR
§ANSWER$ = TRANSFER$(DNMSG$) ‚CALL SUBROUTINE
END IF
DNLOAD$ = ANSWER$ ‚DEFINE RETURN VALUE
REM ———————————————————————————————————
END FUNCTION
SUB ERRORMSG (ERR$)
REM ———————————————————————————————————
REM DISPLAYS AN ERROR MESSAGE ON SCREEN
REM ———————————————————————————————————
IF (ERR$ = „NAK“) THEN
PRINT „ERROR: COMMUNICATION ERROR OR WRONG DATA. USYS RETURNED [NAK].“
ELSEIF (ERR$ = „EOT“) THEN
PRINT „ERROR: CODE DOES NOT EXIST. USYS RETURNED [EOT].“
ELSEIF (ERR$ = „ACK“) THEN
PRINT „ERROR: DOWNLOAD INSTEAD OF UPLOAD. USYS RETURNED [ACK].“
ELSEIF (ERR$ = „TIMEOUT“) THEN
PRINT „ERROR: TIMEOUT, USYS DID NOT RESPOND.“
ELSEIF (ERR$ = „BCC ERROR“) THEN
PRINT „ERROR: BLOCK CHECK FAILED.“
ELSE
PRINT „ERROR: UPLOAD INSTEAD OF DOWNLOAD. USYS RETURNED MESSAGE: „; ERR$;
END IF
REM ———————————————————————————————————
END SUB
FUNCTION GETBCC (CHECK$)

REM ———————————————————————————————————
REM CALCULATES BLOCK CHECK CHARACTER OF A STRING
REM ———————————————————————————————————
BCC = 0
IF LEN(CHECK$) > 0 THEN
FOR I = 1 TO LEN(CHECK$)
BCC = BCC XOR ASC(MID$(CHECK$, I, 1))
NEXT I
END IF
GETBCC = BCC
END FUNCTION
FUNCTION TRANSFER$ (MESSAGE$)
REM ———————————————————————————————————
REM SENDS A MESSAGE USING DEVICE #1 TO USYS AND WAITS FOR A RESPONSE
REM RETURNS: - STRING WITH ALL CONTROL CHARACTERS (UPLOAD)
REM - „ACK“ (DOWNLOAD)
REM - „TIMEOUT“, „EOT“ OR „NAK“ IN CASE OF ANY ERROR
REM ———————————————————————————————————
REM INITIALISATIONS
REM ———————————————————————————————————
IF NOT EOF(1) THEN RCV$ = INPUT$(LOC(1), #1) ‚CLEAR INPUT BUFFER
RCV$ = „“ ‚CLEAR INPUT STRING
TIMEOUT = 1000 ‚SET TIMEOUT VALUE
TIMCNT = 0 ‚CLEAR TIMEOUT COUNTER
RCVEND = FALSE ‚CLR RECEIVE COMPLETED FLAG
NXTEND = FALSE ‚CLR ALMOST COMPLETED FLAG
REM ———————————————————————————————————
REM - SEND MESSAGE TO USYS. COMMAND „PRINT“ MUST NOT APPEND [CR] TO MESSAGE
PRINT #1, MESSAGE$;
REM ———————————————————————————————————
WHILE (RCVEND = FALSE) AND (TIMCNT < TIMEOUT) ‚WAIT FOR ANSWER OR TIMEOUT
WHILE NOT EOF(1) ‚GET DATA FROM INPUT BUFFER
IN$ = INPUT$(1, #1) ‚READ NEXT CHARACTER
RCV$ = RCV$ + IN$ ‚APPEND TO INPUT STRING
IF (NXTEND = TRUE) THEN
RCVEND = TRUE ‚NOW WE GOT BCC
ELSEIF (IN$ = ETX$) THEN
NXTEND = TRUE ‚WAIT FOR BCC
ELSEIF (IN$ = EOT$) OR (IN$ = ACK$) OR (IN$ = NAK$) THEN
RCVEND = TRUE
END IF
TIMCNT = 0 ‚RESET TIMEOUT COUNTER
WEND
TIMCNT = TIMCNT + 1 ‚TIMEOUT COUNTER + 1
WEND
REM ———————————————————————————————————
REM - BUILD STRING TO RETURN
IF (RCV$ = ACK$) THEN
TRANSFER$ = „ACK“
ELSEIF (RCV$ = NAK$) THEN
TRANSFER$ = „NAK“
ELSEIF (RCV$ = EOT$) THEN
TRANSFER$ = „EOT“
ELSEIF (RCVEND = FALSE) THEN
TRANSFER$ = „TIMEOUT“
ELSE
TRANSFER$ = RCV$
END IF
REM ———————————————————————————————————
END FUNCTION
FUNCTION UPLOAD$ (ADDR$, CMD$)
REM ———————————————————————————————————
REM CHECKS IF THE RECEIVED BLOCK IS OK.
REM IN CASE OF AN ERROR, THE MESSAGE IS SENT A SECOND TIME.
REM
REM RETURNS THE MESSAGE RECEIVED FROM SUBROUTINE „TRANSFER“ (WITHOUT CONTROL
REM CHARACTERS STX, ETX, BCC) OR ERROR MESSAGE „BCC ERROR“.
REM
REM ATTENTION: MULTIPLE EXITS
REM ———————————————————————————————————
UPMSG$ = EOT$ + ADDR$ + CMD$ + ENQ$ ‚BUILD MESSAGE FRAME
RECEIV$ = TRANSFER$(UPMSG$) ‚CALL SUBROUTINE

IF (RECEIV$ = „TIMEOUT“) THEN ‚TRY AGAIN IF ERROR
RECEIV$ = TRANSFER$(UPMSG$) ‚CALL SUBROUTINE
END IF
‚——————————
20190423_USYS.050.0020.EN
UPLOAD$ = RECEIV$ ‚DEFINE RETURN VALUE
IF MID$(RECEIV$, 1, 1) <> STX$ THEN EXIT FUNCTION ‚RETURN IF NOT STX
‚——————————
RECEIV$ = MID$(RECEIV$, 2, LEN(RECEIV$) - 1) ‚STRIP OF STX
BCC = GETBCC(RECEIV$)
‚CALCULATE BCC
IF (BCC <> 0) THEN ‚TRY AGAIN IF ERROR
RECEIV$ = TRANSFER$(NAK$) ‚CALL SUBROUTINE
‚——————————
UPLOAD$ = RECEIV$ ‚DEFINE RETURN VALUE
IF MID$(RECEIV$, 1, 1) <> STX$ THEN EXIT FUNCTION ‚RETURN IF NOT STX
‚——————————
RECEIV$ = MID$(RECEIV$, 2, LEN(RECEIV$) - 1) ‚STRIP OF STX
BCC = GETBCC(RECEIV$) ‚CALCULATE BCC
END IF
‚——————————
IF (BCC <> 0) THEN ‚DEFINE RETURN VALUE
UPLOAD$ = „BCC ERROR“
ELSE
UPLOAD$ = MID$(RECEIV$, 1, LEN(RECEIV$) - 2) ‚STRIP OF ETX / BCC
END IF
REM ———————————————————————————————————
END FUNCTION
12.7 ANNEX: CONNECTING AN IBM COMPATIBLE PC

The following diagrams show how an IBM compatible PC could be connected to a
ZUMBACH device. The standard interfaces of the units correspond with the RS-
232 standard, and allow therefore only a point to point connection. If more than one
ZUMBACH device should be connected to the PC, interface converters must be used
(RS 422 or EIA 485).
IBM PC ZUMBACH DEVICE

Sub D, 25 pin, m Sub D, 25 pin, f
2 2
3 3
7 7
4
5
6
8
20
Sub D, 9 pin, m Sub D, 25 pin, f
2 2
3 3
5 7
7
8
4
1
6
13 TECHNICAL APPENDIX
13.1 WIRING DIAGRAM USYS 20 (LEMO) STANDARD
20190423_USYS.050.0020.EN
13.2 WIRING DIAGRAM USYS 20 (LEMO) STANDARD 19"
13.3 WIRING DIAGRAM USYS 20 (AMPHENOL) STANDARD
20190423_USYS.050.0020.EN
13.4 WIRING DIAGRAM USYS 20 (AMPHENOL) STANDARD 19"
13.5 SN6.CP.305.A31/2
20190423_USYS.050.0020.EN
13.6 SN6.CP.305.A3 2/2
13.7 SCHEMATIC DIAGRAM SN6.CP.305.3

20190423_USYS.050.0020.EN
13.8 INTERFACE PCB SN6.IA.165.A1
13.9 SCHEMATIC DIAGRAM SN6.IA.165.2
20190423_USYS.050.0020.EN
13.10 SRD INTERFACE PCB SN6.IA.173.A3
20190423_USYS.050.0020.EN
13.12 INTERFACE FOR KEYBOARD AND DISPLAY SN6.IA.175.A2
20190423_USYS.050.0020.EN
14 ZUMNET
14.1 GENERAL DESCRIPTION

The ZUMNET definition describes how to connect ZUMBACH devices to a host
computer through a RS-485 network.
Please note that only devices supporting the ANSI X3.28-1976 protocol can be
interconnected in this way.
14.2 CABLING
Up to 8 devices per host interface are normally connected (theoretical max. 31).
The devices are wired in a bus structure. Long stub cables are to be avoided. To
prevent reflections, the line must be terminated with a 120 ohm resistor at the first and
last device. The maximal length of the bus should not exceed 500 m (theoretical
maximal length: 4000 ft / 1219 m. We recommend to use the signal cable LIY-TPC-Y
2 x 2 x 0.25 mm2 (ZUMBACH Item No. A13 252 0160, wave impedance: 120 ohm,
twisted conductor pairs, shielded).
The following connectors are available (screw connections):

For 25pin D-Sub, female: ZUMBACH Item. No.: RS.4859.99900
For 9pin D-Sub, male: ZUMBACH Item. No.: A09 400 1095
14.3 SHIELD / GROUND

The bus cable must be shielded on its whole length. For every device, the shielding
must be connected to the casing ground through the connector casing. (This is
automatically taken care of with the recommended D-Sub connectors.)
The shielding should never be used for potential equalization between different ground
connections. A potential equalization line should link ground connections together if
potential differences are present.
The signal ground should be connected, although this is not always necessary. As in the
case of the shielding, there shouldn‘t be any current flow due to potential equalization.
14.4 ELECTRICAL STANDARD

The electrical characteristics of the interface must fulfil the EIA485 (formerly RS485)
standard. All ZUMBACH devices also dispose of an electrically separated interface.
14.5 FAIL-SAFE INTERFACE

ZUMBACH devices dispose of a special interfacing component that receives a particular
signal even in the absence of any active emitter on the bus. In the case of third-party
interfaces, the voltage difference of the data lines is often too low when the bus is
terminated with 120 ohm on both sides. Faults and disturbances may occur. In this
case, it is necessary to equip the lines with 560-ohm resistors (see figure).
+5 V S E S E S E
560 Ohm
T+/R+
120 Ohm 120 Ohm

T-/R-
560 Ohm
GND
14.6 ZUMNET APPLICATION EXAMPLE
20190423_USYS.050.0020.EN
15 INDEX
A
About this Manual.............................................................................................................................................. 2.
Acquisition of additional parameters............................................................................................................... 80.
Actuation by relays.......................................................................................................................................... 34.
Additional values............................................................................................................................................. 81.
Adresses - the ZUMBACH-Group....................................................................................................................11.
Alarm lamps............................................................................................................................................... 50,62.
Analog output.................................................................................................................................................. 33.
Analogue input SRD (optionally)..................................................................................................................... 43.
Analogue output SRD (optionally)................................................................................................................... 43.
Annex: Connecting an IBM compatible PC................................................................................................... 125.
ANSI X3.28-2.5-A4 standard protocol............................................................................................................116.
ASCII protocol................................................................................................................................................112.
C
Cabling.......................................................................................................................................................... 139.
Care at handling.............................................................................................................................................. 17.
Changing the security code............................................................................................................................. 60.
Character format............................................................................................................................................. 71.
Check list before contacting the service.........................................................................................................110.
Check the power supply voltage..................................................................................................................... 26.
Communication errors....................................................................................................................................114.
Communication syntax...................................................................................................................................113.
Components of the processor unit USYS 20................................................................................................... 27.
Computation of the statistical values............................................................................................................... 79.
Conditions applying to spare parts................................................................................................................ 107.
Configuration and operational check............................................................................................................... 32.
Configuration of statistics and reports............................................................................................................. 78.
Configuration of the controller parameters................................................................................................. 34,37.
Connecting the SRD Static Regulating Unit.................................................................................................... 36.
Connection (2-Wire NAMUR).......................................................................................................................... 32.
Connection to mains........................................................................................................................................ 30.
Connection to the USYS 20 processor unit..................................................................................................... 70.
Contents............................................................................................................................................................ 3.
Control key "Controller ON/OFF"...................................................................................................... 34,36,50,65.
Controller (Option)........................................................................................................................................... 65.
Control of the statistics.................................................................................................................................... 33.
Control with motor potentiometer (DDC-Controlling)....................................................................................... 34.
Correction effects............................................................................................................................................ 34.
Cyclical output of the actual values................................................................................................................. 73.
D
Data and parameter access...........................................................................................................................115.
Dear customer................................................................................................................................................. 10.
Decommissioning........................................................................................................................................... 111.
Decommissioning / Disposal.......................................................................................................................... 111.
Delay of actual values and events................................................................................................................... 80.
Delivery extend of the standard execution...................................................................................................... 18.
Description of the hardware............................................................................................................................ 22.
Diameter calibration...................................................................................................................................... 104.
Digital inputs "DIN3" to "DIN7"........................................................................................................................ 40.
Digital outputs "DOUT1" to "DOUT5".............................................................................................................. 42.
Dimensions...................................................................................................................................................... 19.
"DIN1" and "DIN2" Counter inputs................................................................................................................... 38.
Display field..................................................................................................................................................... 56.
Display of date and time.................................................................................................................................. 78.
Display of the correction factor........................................................................................................................ 65.
Download................................................................................................................................................ 116,118.
Dual-measuring heads with synchrobox CI-1JS/1J "large diameter".............................................................. 76.
E
Electrical standard......................................................................................................................................... 139.
Entering date and time.................................................................................................................................... 78.
Entry field........................................................................................................................................................ 49.
Entry of controller settings............................................................................................................................... 66.
Error messages............................................................................................................................................... 74.
EU Declaration of conformity........................................................................................................................... 15.
Examples: Upload/Download with IBM compatible PC..................................................................................119.
Example with ANSI X3.28-2.5-A4 protocol.................................................................................................... 121.
Example with ZUMBACH ASCII protocol.......................................................................................................119.
Exit from configuration mode........................................................................................................................... 59.
F
Factory settings............................................................................................................................................... 70.
Fail-Safe Interface......................................................................................................................................... 139.
Formatted Output of the reports...................................................................................................................... 64.
Front panel...................................................................................................................................................... 27.
Functional description........................................................................................................................... 45,72,80.
Function key "Nominal"................................................................................................................................... 51.
Function keys.................................................................................................................................................. 50.
function keys - parameter entry....................................................................................................................... 51.
Function key "Statistic".................................................................................................................................... 53.
Function key "Tolerance"................................................................................................................................. 52.
Function key "User"......................................................................................................................................... 54.
Function of front panel elements..................................................................................................................... 47.
20190423_USYS.050.0020.EN
G
Gauge.............................................................................................................................................................. 30.
General Definitions.........................................................................................................................................113.
General description........................................................................................................................ 23,24,25,139.
General disposal............................................................................................................................................ 111.
General precautions........................................................................................................................................ 16.
Group 0xx: Measurement and display............................................................................................................. 82.
Group 1xx: Distances and length detector...................................................................................................... 84.
Group 2xx: Controller...................................................................................................................................... 84.
Group 3xx: Analog output................................................................................................................................ 86.
Group 4xx: Tolerance control........................................................................................................................... 86.
Group 5xx: Digital and relay outputs – digital inputs....................................................................................... 87.
Group 6xx: Serial communication................................................................................................................... 89.
Group 7xx: Statistics and reports.................................................................................................................... 92.
Group 9xx: System parameters and measuring head..................................................................................... 93.
Group A: System parameters.......................................................................................................................... 96.
Group B: Line and control parameters............................................................................................................ 98.
Group C: Product parameters......................................................................................................................... 99.
Group D: Measurements and results............................................................................................................ 100.
Group E: Alarm messages and device status............................................................................................... 101.
Group F: Control functions............................................................................................................................ 102.
Group G: Measuring head input values......................................................................................................... 103.
H
Host Interface: List of data and parameters.................................................................................................... 96.
How to mount the hood of the tabletop model............................................................................................... 108.
I
Inadmissible use.............................................................................................................................................. 17.
Initialisation of the instrument........................................................................................................................ 106.
Inner Diameter................................................................................................................................................. 66.
Inspection of goods upon arrival..................................................................................................................... 10.
Installation....................................................................................................................................................... 31.
Installation / Commissioning............................................................................................................................ 26.
Intended use.................................................................................................................................................... 17.
Interface for keyboard and display SN6.IA.175.A2....................................................................................... 137.
Interface PCB SN6.IA.165.A1....................................................................................................................... 133.
Introduction...................................................................................................................................................... 10.
K
Key "Select"..................................................................................................................................................... 55.
Key "Select" - Configuration mode................................................................................................................ 55.
L
"Large Diameter" Calibration of dual ODAC JSxK with synchrobox CI-1JS/1J............................................... 77.
LCD Display.................................................................................................................................................... 47.
LED additional display..................................................................................................................................... 70.
Length counter................................................................................................................................................ 81.
Length detector............................................................................................................................................... 31.
List of select-codes for parameter input.......................................................................................................... 82.
List of spare parts.......................................................................................................................................... 108.
M
Mains connection............................................................................................................................................ 70.
Maintenance.................................................................................................................................................. 104.
Modifications at the system............................................................................................................................. 17.
Multidrop protocol...........................................................................................................................................112.
N
N6.IA.165 multifunction I/O board................................................................................................................... 24.
Navigation....................................................................................................................................................... 58.
O
Operating manual............................................................................................................................................ 45.
Operating precautions..................................................................................................................................... 26.
Operation......................................................................................................................................................... 63.
Optimizing measurement acquisition.............................................................................................................. 72.
Option: DDC/SRD control module B.USY.002.8010 (N6.ia.173.a).................................................................. 24.
Option: real-time clock..................................................................................................................................... 78.
Option: RTC USYS 20 - USY.9401.00100 (M 1093.A2).................................................................................. 25.
Output similar.................................................................................................................................................. 43.
Overview........................................................................................................................................................112.
P
Parameter entry............................................................................................................................................... 56.
Parameter identification................................................................................................................................... 56.
Pause function "Pause"................................................................................................................................... 81.
Penetration depth measurement or height measurement............................................................................... 75.
Penetration depth measurement principle....................................................................................................... 75.
Period number................................................................................................................................................. 81.
Pin assignment "ST2"...................................................................................................................................... 37.
Polarity of the SRD input voltage.................................................................................................................... 36.
"Port 1" and "Port 2" Serial ports..................................................................................................................... 29.
"Port 3" Ethernet connection........................................................................................................................... 30.
Power-On relay............................................................................................................................................... 36.
Printer initialization string................................................................................................................................ 63.
Printer interface............................................................................................................................................... 63.
Printouts and parameter definitions................................................................................................................. 46.
Processor board N6.CP.305............................................................................................................................ 23.
Protected entry................................................................................................................................................ 58.
Protocols of communication...........................................................................................................................112.
20190423_USYS.050.0020.EN
R
Rear panel....................................................................................................................................................... 28.
Regular maintenance.................................................................................................................................... 104.
Relay outputs.................................................................................................................................................. 33.
Relays and digital outputs............................................................................................................................... 63.
Repairing....................................................................................................................................................... 107.
Report layout................................................................................................................................................... 63.
Return for repairs.......................................................................................................................................... 107.
Risks and transportation.................................................................................................................................. 10.
S
Safety.............................................................................................................................................................. 16.
Schematic diagram SN6.CP.305.3................................................................................................................ 132.
Schematic diagram SN6.IA.165.2................................................................................................................. 134.
Security code................................................................................................................................................... 59.
Select Code 001: Measurement resolution................................................................................................... 105.
Select Code 080: Selection of date format...................................................................................................... 78.
Select Code 081: Selection of time format...................................................................................................... 78.
Select Code 200: Dead band.......................................................................................................................... 66.
Select Code 201: Control limits....................................................................................................................... 66.
Select Code 202: Averaging............................................................................................................................ 67.
Select Code 203: Deadtime............................................................................................................................ 67.
Select Code 204: Correction factor................................................................................................................. 68.
Select Code 205: Selection of the control value.............................................................................................. 68.
Select Code 210: Entry mode of the dead band............................................................................................. 68.
Select Code 211: Control action...................................................................................................................... 68.
Select Code 212: Length-based or time-based control................................................................................... 68.
Select Code 213: Controller type and control polarity..................................................................................... 69.
Select Code 214: Actuator constant................................................................................................................ 69.
Select Code 220: Manual reset of the static controller.................................................................................... 70.
Select Code 400: Output rate of tolerances.................................................................................................... 60.
Select Code 403: Tolerance in empty measuring field.................................................................................... 60.
Select Code 404: Absolute or relative tolerance limits.................................................................................... 60.
Select Code 405: Mode of tolerance monitoring............................................................................................. 61.
Select Code 406: Extended tolerance monitoring........................................................................................... 61.
Select Code 407: Tolerance monitoring of the ovality..................................................................................... 61.
Select Code 408: Fault detection.................................................................................................................... 62.
Select Code 409: Acquisition period for KW function...................................................................................... 62.
Select Code 900: Measurement unit............................................................................................................. 105.
Select Code 901: Head type......................................................................................................................... 104.
Select Code 902: Head calibration................................................................................................................ 105.
Select Code 910: Relative fault monitoring..................................................................................................... 72.
Select Code 911: Absolute monitoring............................................................................................................. 73.
Select Code 912: Position monitoring............................................................................................................. 73.
Select Code 913: Error suppression............................................................................................................... 73.
Select Code 918: Acquisition interval of internal preprocessing...................................................................... 73.
Select Code 922: Resetting the ground penetration depth............................................................................. 76.
Select Code 922: "Zeroing" a ground penetration depth................................................................................. 75.
Setting the device address.............................................................................................................................. 71.
Shield / Ground............................................................................................................................................. 139.
SN6.CP.305.A3.............................................................................................................................................. 130.
SRD Interface PCB SN6.IA.173.A3............................................................................................................... 135.
"ST1" Relay of outputs.................................................................................................................................... 44.
"ST2": Digital and analog in- and outputs........................................................................................................ 37.
"Start/Stop" Evaluation period......................................................................................................................... 80.
Static control SRD (Option)............................................................................................................................. 35.
Statistics.......................................................................................................................................................... 79.
Symbols........................................................................................................................................................... 14.
System configuration printout..................................................................................................................... 59,65.
System overview USYS 20............................................................................................................................. 18.
T
Table top.......................................................................................................................................................... 20.
Technical appendix........................................................................................................................................ 126.
Technical data....................................................................................................................................... 21,23,25.
Technical description....................................................................................................................................... 18.
Text fields........................................................................................................................................................ 81.
Text format....................................................................................................................................................... 63.
Tolerance monitoring and fault detection......................................................................................................... 60.
Trim mode....................................................................................................................................................... 35.
U
Upload..................................................................................................................................................... 115,116.
V
Version as 19" rack.......................................................................................................................................... 19.
Version as table top......................................................................................................................................... 19.
W
Wall mounting............................................................................................................................................. 19,20.
Warranty.......................................................................................................................................................... 10.
Wiring diagram USYS 20 (Amphenol) Standard........................................................................................... 128.
Wiring diagram USYS 20 (Amphenol) Standard 19"..................................................................................... 129.
Wiring diagram USYS 20 (LEMO) Standard................................................................................................. 126.
Wiring diagram USYS 20 (LEMO) Standard 19"........................................................................................... 127.
Wiring references for "ST2"............................................................................................................................. 37.
Z
ZUMBACH ASCII Protocol.............................................................................................................................115.
ZUMBACH Product overview.......................................................................................................................... 12.
ZUMNET........................................................................................................................................................ 139.
ZUMNET Application example....................................................................................................................... 140.
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PROCESSOR UNIT

Document INSTRUCTION MANUAL

The translation of the original instruction manual

Registration, or Update Date of this Manual 23.04.2019

Read the chapters 2, 3 and 4 before starting the installation.

5 Operating instructions (Software)

4A DESCRIPTION OF THE HARDWARE 22

7 LIST OF SELECT-CODES FOR PARAMETER INPUT 82

11 DECOMMISSIONING / DISPOSAL 111

12 PROTOCOLS OF COMMUNICATION 112

13 TECHNICAL APPENDIX 126

1.1 DEAR CUSTOMER

1.1.1 Risks and transportation

1.1.2 Inspection of goods upon arrival

France ZUMBACH Bureau France

ODAC® 1, 2 and 3 axis Laser

MSD Diameter and Ovality

ODEX® Non-contact Eccentricity,

USYS Multitasking Data

RAYEX® X-Ray Measuring System

CELLMASTER® Foam and Foam Skin

CAPAC® Capacitance Measuring

PROFILEMASTER® In-Line Profile

SIMAC® Surface Quality

LSV Speed and Length

WST TEMPMASTER Conductor Preheaters

CALIBRATOR SP Spark Tester Calibrator

Warning, possibility of electrical shock!

General warning sign!

Disposal of old devices: This symbol indicates that this product

CAUTION Safety warning: A note with the heading CAUTION indicates

WARNING Safety warning: A warning with the heading WARNING indicates

This instruction manual provides information on existing residual risks and

Installation, operation, maintenance and repairing as well as decommissioning

2.2 GENERAL PRECAUTIONS

► Further, specific safety aspects are listed in the corresponding chapters.

2.4 INADMISSIBLE USE

2.5 CARE AT HANDLING

Avoid inappropriate handling!

2.6 MODIFICATIONS AT THE SYSTEM

3.1 SYSTEM OVERVIEW USYS 20

All important parameters can be evaluated statistically and printed. It is of course

3.2 DELIVERY EXTEND OF THE STANDARD EXECUTION

3.3.1 Version as table top

3.3.1.1 Wall mounting 5

3.3.2 Version as 19" rack

3.3.2.2 Only 19" rack

3.3.4 Table top

SRD In/Out (Option)

4A.1.2 Technical data

4A.2.1 General description

4A.3 OPTION: DDC/SRD CONTROL MODULE B.USY.002.8010 (N6.IA.173.A)

4A.3.1 General description

4A.4.1 General description

4A.4.2 Technical data

Installation activities must be carried out only by qualified personnels.

The hood can only be properly set up if one first lightly

4B.1 OPERATING PRECAUTIONS

• Preventing electric shock and fire hazards